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General Precautions for Installation/Servicing/Maintenance for the Finisher MJ-1021 The installation and service should be done by a qualified

service technician. 1. When installing the Finisher MJ-1021 to the Plain Paper Copier, be sure to follow the instructions described in the Unpacking/Set-Up Procedure for the MJ-1021 booklet which comes with unit of the MJ-1021. 2. The MJ-1021 should be installed by an authorized/qualified person. 3. Before starting installation, servicing or maintenance work, be sure to turn off and unplug the copier first. 4. When selecting the installation site, avoid placing the Finisher/Inserter and copier on different levels or inclined floors. 5. When servicing or maintaining the MJ-1021, be careful about the rotating or operation sections such as gears, pulleys, sprockets, cams, belts, etc. 6. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise noted in this manual or other related materials. Be careful not to reassemble small parts such as screws, washers, pins, E-rings, toothed washers to the wrong places. 7. Basically, the machine should not be operated with any parts removed or disassembled. 8. Delicate parts for preventing safety hazard problems (such as breakers, thermofuses, fuses, door switches, sensors, etc. if any) should be handled/installed/adjusted correctly. 9. When servicing the machines with the main switch turned on, be sure not to touch live sections and rotating/operating sections. Avoid exposure to laser radiation. 10. Be sure not to touch high-voltage sections such as the high-voltage transformer and power supply unit. Especially, the board of these components should not be touched since the electirc charge may remain in the condensers, etc. on them even after the power is turned OFF. 11. Use suitable measuring instruments and tools. 12. During servicing or maintenance work, be sure to check the serial No. plate and other cautionary labels (if any) to see if they are clean and firmly fixed. If not, take appropriate actions. 13. The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband, because the ICs on it may be damaged due to static electricity. Before using the wrist band, pull out the power cord plug of the copier and make sure that there is no uninsulated charged objects in the vicinity. 14. For the recovery and disposal of used MJ-1021, consumable parts and packing materials, it is recommended that the relevant local regulations/rules. 15. After completing installation, servicing and maintenance of the MJ-1021, return the MJ-1021 to its original state, and check operation.

16. 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.

[A]

2002 TOSHIBA TEC CORPORATION All rights reserved

INTRODUCTION
This Service Manual contains basic data and figures for the Finisher (MJ-1021) needed to service the machine in the field. This manual comprises the following chapters: Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 General Description introduces the finishers features, specifications, and names of parts, and shows how to operate the finisher. Finisher Unit Basic Operation discusses the principles of operation used for the finisher mechanical and electrical systems. It also explains the timing at which these systems are operated. Saddle Finisher Unit Basic Operation discusses the principles of operation used for the saddle stitcher units mechanical and electrical systems. It also explains the timing at which these systems are operated. Mechanical System discusses how the finisher is constructed mechanically, and shows how it may be disassembled/assembled and adjusted. Maintenance and Inspection provides tables of periodically replaced parts and consumables and durables, together with a scheduled servicing chart. Troubleshooting shows how to troubleshoot possible faults and gives electrical parts arrangement diagrams, LED/check pin diagrams by PCB, and self diagnosis tables. Appendix contains diagrams showing tables of signals, overall circuit diagrams and tables of solvents/oils. Descriptions regarding installation are not mentioned in this Service Manual as the Finisher (MJ-1021)s packing boxes contain Installation Procedures. The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins. All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins, and be able to identify and isolate faults in the machine.

ii

CONTENTS
CHAPTER 1 GENERAL DESCRIPTION
I. II. FEATURES ................................. 1-1 SPECIFICATIONS ....................... 1-2 A. Specifications ........................... 1-2 B. Cross Section ........................... 1-7 III. Using the Machine ....................... 1-9 A. Removing Paper Jams from the Finisher Unit ............................. 1-9 B. Supplying the Finisher Unit with Staples ................................... 1-10 C. Removing Staple Jams from the Finisher Unit ........................... 1-12 D. Removing Paper Jams fron the Saddle Stitcher Unit ............... 1-13 E. Supplying the Saddle Stitcher Unit with Staples .................... 1-15 F. Removing Staple Jams from the Saddle Stitcher Unit ......... 1-16 IV. MAINTENANCE BY THE USER ........................................ 1-18 A. Maintenance by the User ....... 1-18

CHAPTER 2 FINISHER UNIT BASIC OPERATION


I. BASIC OPERATION .................... 2-1 A. Outline ...................................... 2-1 B. Outline of Electrical Circuitry .... 2-2 C. Inputs to and Outputs from the Finisher Controller PCB ........... 2-4 II. FEED/DRIVE SYSTEM ............. 2-12 A. Outline .................................... 2-12 B. Type of Delivery Paths ............ 2-17 C. Feeding and Delivering .......... 2-20 D. Job Offset ............................... 2-23 Staple Operation .................... 2-26 Stapler Unit ............................ 2-34 Tray Operation ........................ 2-40 Detecting the Height of Stack on the Tray .................... 2-42 I. Shutter Operation ................... 2-44 J. Buffer Path Operation ............. 2-48 K. Detecting Jams ...................... 2-53 III. POWER SUPPLY SYSTEM ...... 2-58 E. F. G. H.

iii

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION


I. BASIC OPERATION .................... 3-1 A. Outline ...................................... 3-1 B. Electrical Circuitry .................... 3-2 C. Inputs to and Outputs from the Saddle Stitcher Controller PCB .... 3-3 II. FEEDING/DRIVE SYSTEM ........ 3-8 A. Outline ...................................... 3-8 III. PAPER OUTPUT MECHANISM ............................ 3-14 A. Outline .................................... 3-14 B. Controlling the Inlet Flappers ................................. 3-17 C. Controlling the Movement of Sheets .................................... 3-21 D. Aligning the Sheets ................ 3-23 E. Controlling the Phase of the Crescent Roller ...................... 3-26 IV. STITCHING SYSTEM ............... 3-28 V. FOLDING/DELIVERY SYSTEM ................................... 3-31 VI. CHECKING FOR A JAM ........... 3-38 VII. POWER SUPPLY ...................... 3-43

CHAPTER 4 MECHANICAL CONSTRUCTION


I. FINISHER UNIT .......................... 4-1 A. Externals and Controls ............. 4-1 B. FEEDING SYSTEM ................. 4-9 C. PCBs ...................................... 4-13 D. Caution when removing MJ-1021 ................................. 4-13 II. SADDLE STITCHER UNIT ....... 4-14 A. Externals and Controls ........... 4-14 B. SADDLE UNIT ....................... 4-17 C. PCBs ...................................... 4-27 D. Power supply unit ................... 4-27 E. Accessory .............................. 4-28

CHAPTER 5 MAINTENANCE AND INSPECTION


I. PERIODICALLY REPLACED PARTS ......................................... 5-1 A. Finisher Unit ............................. 5-1 B. Saddle Stitcher Unit ................. 5-1 II. CONSUMABLES AND DURABLES ................................ 5-2 A. Finisher Unit ............................. 5-2 B. Saddle Stitcher Unit ................. 5-2 III. PERIODICAL SERVICING .......... 5-2

iv

CHAPTER 6 TROUBLESHOOTING
I. ADJUSTMENTS ......................... 6-1 A. Electrical System (finisher unit) ............................ 6-1 B. Electrical System (saddle stitcher unit) ................. 6-6 II. ARRANGEMENT OF ELECTRICAL PARTS ................. 6-8 A. Finisher Unit ............................. 6-8 B. Saddle Stitcher Unit ............... 6-15 C. Light-Emitting Diodes (LED) and Check Pins by PCB......... 6-21 III. TROUBLESHOOTING .............. 6-23 A. Finisher Unit ........................... 6-23 B. Saddle Stitcher Unit ............... 6-33

APPENDIX
A. FINISHER UNIT GENERAL TIMING CHART ......................... A-1 B. SADDLE STITCHER UNIT GENERAL TIMING CHART ....... A-2 C. SIGNAL AND ABBREVIATIONS....................... A-3 D. FINISHER UNIT CIRCUIT DIAGRAM ................................... A-4 E. SADDLE STITCHER UNIT CIRCUIT DIAGRAM ................. A-18 F. SOLVENTS AND OILS ............. A-26

vi

CHAPTER 1 GENERAL DESCRIPTION

I. FEATURES ................................. 1-1 II. SPECIFICATIONS ....................... 1-2 A. Specifications ............................ 1-2 B. Cross Section ............................ 1-7 III. Using the Machine ....................... 1-9 A. Removing Paper Jams from the Finisher Unit ............................... 1-9 B. Supplying the Finisher Unit with Staples ..................................... 1-10 C. Removing Staple Jams from the Finisher Unit ............................ 1-12

D. Removing Paper Jams fron the Saddle Stitcher Unit ................. 1-13 E. Supplying the Saddle Stitcher Unit with Staples ............................. 1-15 F. Removing Staple Jams from the Saddle Stitcher Unit ................. 1-16 IV. MAINTENANCE BY THE USER ........................................ 1-18 A. Maintenance by the User ......... 1-18

CHAPTER 1 GENERAL DESCRIPTION

I.
1.

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 The finisher is capable of handling papers between 60 and 256 gm/m2. Offers a job offset function The finisher has a job offset function for sorting non-stapled stacks of copies. Offers four types of auto stapling The finisher offers a choice of four stapling modes (1-point stapling at rear, diagonal stapling at front, diagonal stapling at rear, 2-point stapling). Uses a buffer roller The use of a buffer roller enables the finisher to accept copies without interruption from the host machine even during stapling or offset operation. Has a saddle stitch function The finisher can staple along the center of paper and fold it in two (up to 15 sheets). Offers a punch function (option: MJ-6003) The use of the puncher unit enables the finisher to punch sheets for binders before they are output. (The puncher unit is capable of handling papers between 60 and 256 gm/m2. It cannot handle special paper, postcards and transparencies.) Insert function (option: MJ-7001) Enable the use of special type of paper and printed paper in addition to the staple sorting or the hole punching mode (Available when the optional staple sorting and the hole punching mode units are installed.) This paper is not run through fuser (heat).

2.

3. 4. 5.

6.

7.

8.

9.

1-1

CHAPTER 1 GENERAL DESCRIPTION

II.
A.
1.

SPECIFICATIONS
Specifications
Finisher Unit
Item Description Trays 1 and 2: by lifting tray Face-down AB: A3, A4, A4-R, A5-R, B4, B5, B5-R, FOLIO Inch: LD, LG, LT, LT-R, ST-R, COMPUTER A3, A4, A4-R, B4, B5, LD, LG, LT, LT-R, FOLIO, COMPUTER 60 to 256 g/m2 Trays 1 and 2 Non-sort: Sort: Staple sort: Non sort trays 1 and 2 trays 1 and 2 trays 1 and 2 Small-size (1) Small-size (2) Large-size(1)(2) Sort Staple sort Small-size (1) Large-size (1) Small-size (1) Large-size (1) 250 mm (2000 sheets) 140 mm (1000 sheets) 140 mm (1000 sheets) 250 mm (2000 sheets) 140 mm (1000 sheets)
(Note 2) (Note 2) (Note 2) (Note 2)

Stacking method Stacking orientation Stacking size Sortable size Basis weight Bins Modes

Stacking capacity
(Note 1)

110 mm or 750 sheets or 100 sets 74 mm or 500 sheets or 50 sets

Size mixing
(Note 1)

Non-sort/sort mixing: 74 mm or less (500 sheets) Staple mixing: 74 mm or less (500 sheets) or 50 sets Mode mixing: 22 mm or less (150 sheets) or 50 sets Face-down

Stacking direction
Note 1: Note 2: Note 3:

Approximate when computed with reference to 80 g/m2 paper. Alignment may not be correct if 750 or more small-size sheets are stacked. The accuracy of the stack height is 7 mm/0.28 in.

Table 1-201 Reference: The term Small-size (1) stands for A4, B5 and LT, the term Small-size (2) stands for A5-R and ST-R, while the term Large-size(1) stands for A3, B4, A4-R, LD, LG, LT-R, FOLIO and COMPUTER, Large-size (2) stands for B5-R. Non-sort/sort mixing means stacking different sized paper with non-sort mode, Staple mixing means stacking different sized papers with staple mode, and Mode mixing mean stacking nonstapled papers and stapled papers.

1-2

CHAPTER 1 GENERAL DESCRIPTION

Item Stapling Stapling position Stapling capacity


(Note 4)

Description By rotating cam See Figure 1-201. 60 ~ 80 g/m2 Exclusive staple (100 sheets stapling) Option staple (50 sheets stapling) Small-size (1) Large-size (1) Small-size (1) Large-size (1) 100 sheets 50 sheets 50 sheets 30 sheets 90 g/m2, 105 g/m2 ----(Note 5) (Note 5)

30 sheets 15 sheets

Staple supply Staples


(Note 6)

Exclusive staple cartridge (5000 staples) STAPLE-1700 : Exclusive (100 sheets stapling) : 3 cases of 5000 staples in a package STAPLE-1800 : Option (50 sheets stapling) : 3 cases of 5000 staples and one exclusive cartridge in a package STAPLE-1900 : Option (50 sheets stapling) : 3 cases of 5000 staples in a package

Staple detection Manual stapling Stapling size

Provided Not provided 1-point diagonal Front stapling (diagonal) Rear 1-point 2-point Rear
A3, B4, A4, A4-R, B5, LD, LG, LT, LT-R, FOLIO, COMPUTER

A3, B4, A4, B5, LD, LT, COMPUTER A4-R, LT-R, LG, FOLIO

A3, B4, A4, B5, A4-R, LD, LG, LT, LT-R, FOLIO, COMPUTER

Paper detection Control panel Display Dimensions Weight Power supply Maximum power consumption

Provided Not provided Not provided 740 630 1023 mm/29.13 24.80 40.28 in 66 kg/145.5 lb AC115-127V (50/60Hz), AC220-240V(50/60Hz) 160 W or less (W D H)

Note 4: Including two sheets of thick stock or cover (200 ~ 256 g/m2) Note 5: Use the staple for 50 sheets when stapling 90g/m2 and 105g/m2 paper. Note 6: 1 cartridge for 100 sheets stapling and 1 case (5000 staples) for 100 sheets stapling are co-packed in the product.

Table 1-202

1-3

CHAPTER 1 GENERAL DESCRIPTION

Stapling Positions (finisher unit)

1-point stapling (rear)

1-point stapling (diagonal; front)

1-point stapling (diagonal; rear)

30 52.5mm/ 0.20.1in Specified paper width 52.5mm/ 0.20.1in

30

62.5mm/ 0.240.1in

52.5mm/ 0.20.1in

2-point stapling A3 and A4 B4 and B5 COMPUTER LD and LT

64mm/ 0.240.16in

64mm/ 0.240.16in

81.84mm/ 3.220.16in 201.84mm/ 7.940.16in

61.84mm/ 2.430.16in 181.84mm/ 7.160.16in

64mm/ 0.240.16in

734mm/ 2.870.16in 1934mm/ 7.60.16in

A4-R and FOLIO

LT-R and LG

64mm/ 0.240.16in

64mm/ 0.240.16in

48.34mm/ 1.900.16in 148.34mm/ 5.840.16in

51.24mm/ 2.020.16in 151.24mm/ 5.950.16in

Figure 1-201

1-4

52.5mm/ 0.20.1in

Specified paper width 62.5mm/ 0.240.1in

CHAPTER 1 GENERAL DESCRIPTION

2.

Saddle Stitcher Unit


Item Description Center binding (double folding) See Figure 1-202. A3, B4, A4-R, LD, LT-R W/binding: 1 sheet (including single cover page) W/out binding:2 to 15 sheets 60 to 105 g/m2 (cover page up to 256 g/m2)
(Note 1)

Stapling method Folding position Paper size Capacity Paper weight Stacking capacity Stapling

10 sets (stack of 11 to 15 sheets), 20 sets (stack of 6 to 10 sheets), 25 sets (stack of 5 sheets or less) Stapling position Staple accommodation Staple supply Staples Staple detection Manual stapling 2 points (center distribution; fixed interval) 2000 staples Special cartridge Special staples (STAPLE-600: 3 cartridges of 2000 staples in a package) Provided Not provided Roller contact Double folding Paper center Provided

Folding

Folding method Folding mode Folding position Position adjustment

Power supply Power consumption

From finisher unit DC24V, DC5V 160 W or less

Note1: Special paper, postcards, transparencies, reproducibles, label paper and hole-punched paper cannot be handled.

Table 1-203

1-5

CHAPTER 1 GENERAL DESCRIPTION

Staple and Folding Position (saddle stitcher unit)

A3

B4

A4-R

Staple position
2101mm/ 8.270.04in

Edge Edge of of staple staple


832mm/ 3.480.08in 2032mm/ 8.210.08in

632mm/ 2.70.08in 1832mm/ 7.420.08in

148.51mm/ 5.850.04in

1821mm/ 7.170.04in

39.52mm/ 1.770.08in 159.52mm/ 6.50.08in

Stack front edge

LD

LT-R

742mm/ 3.140.08in 1942mm/ 7.860.08in

139.71mm/ 5.50.04in

2161mm/ 8.50.04in

42mm/ 1.890.08in 1622mm/ 6.610.08in

Figure 1-202

1-6

CHAPTER 1 GENERAL DESCRIPTION

B.
1.

Cross Section
Finisher Unit
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11]

[16]

[17]

[15]

[14] [13] [12]

[1] [2] [3] [4] [5] [6] [7] [8] [9]

Tray 1/2 Shutter Delivery roller Swing guide Feed roller 2 Height sensor Wrap flapper Buffer roller Buffer inlet flapper

[10] [11] [12] [13] [14] [15] [16] [17]

Saddle stitcher flapper Inlet feed roller Feed roller 1 Vertical path Stapler Knurled belt Tray lift motor Saddle stitcher unit

Figure 1-203

1-7

CHAPTER 1 GENERAL DESCRIPTION

2.

Saddle Stitcher Unit

[6]

[7] [8]

[5] [9] [4] [3] [2] [11] [12] [1]

[10]

[1] [2] [3] [4] [5] [6]

Guide plate Paper folding roller Delivery guide plate Holding roller Stitcher (front, rear) Inlet roller

[7] [8] [9] [10] [11] [12]

No.1 flapper No. 2 flapper Stitcher mount Paper pushing plate Crescent roller Paper positioning plate

Figure 1-204

1-8

CHAPTER 1 GENERAL DESCRIPTION

III. Using the Machine


A. Removing Paper Jams from the Finisher Unit

3) Open the upper cover, and check the inside of the finisher.

If the host machine indicates the finisher paper jam message, perform the following to remove the jam. 1) Pushing the finisher unit as shown, move it to detach it from the host machine. Figure 1-303 4) Lift the buffer roller cover, and remove the jam.

Figure 1-301 2) Remove any jam visible from the outside.

Figure 1-304 5) Lift the buffer roller, and remove the jam.

Figure 1-302

Figure 1-305

1-9

CHAPTER 1 GENERAL DESCRIPTION

6) Return the buffer roller and the buffer roller cover to their original positions, and close the upper cover.

B.

Supplying the Finisher Unit with Staples

If the host machine indicates the finisher unit staple supply message, perform the following to supply it with staples. 1) Open the front cover.

Figure 1-306 7) Connect the finisher to the host machine. Figure 1-308 2) Lift up and pull the blue lever in the stapler, and slide out the staple cartridge.

Figure 1-307 8) Operate as instructed on the display.

Figure 1-309 3) Push the buttons to open the cover of the staple cartridge.

Figure 1-310

1-10

CHAPTER 1 GENERAL DESCRIPTION

4) Remove the empty staple case upward from the staple cartridge, and push in a new staple case into the cartridge until a click is heard. Do not remove the seal holding the staples until the staple case is set in the cartridge.

6) Return the staple cartridge to its original position until it is caught by the claw and fixed with a click sound, and slightly push the lever down.

Figure 1-313 Figure 1-311 Reference: You may set no more than one staple cartridge at a time. Make sure that the new cartridge is one specifically designed for the finisher unit. 7) Close the front cover of finisher.

5) Pull out the seal holding the staples straight upward, and close the cover manually.

Figure 1-314 Note: After the type of staple cartridge is switched, be sure to turn off the power then turn it on.

Figure 1-312

1-11

CHAPTER 1 GENERAL DESCRIPTION

C.

Removing Staple Jams from the Finisher Unit

4) Shift down the tab on the staple cartridge.

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.

Figure 1-318 5) Remove all staples that have slid out of the staple case.

Figure 1-315 2) Open the front cover.

Figure 1-319 6) Return the tab on the staple cartridge to its original position. Figure 1-316 3) Lift up and pull the blue lever in the stapler, and slide out the staple cartridge.

Figure 1-320

Figure 1-317

1-12

CHAPTER 1 GENERAL DESCRIPTION

7) Return the staple cartridge to its original position until it is caught by the claw and fixed with a click sound, and close the front cover of finisher.

D.

Removing Paper Jams from the Saddle Stitcher Unit

If the host machine indicates the saddle stitcher unit paper jam message, perform the following to remove the jam. 1) Holding the saddle stitcher unit as shown, move it to detach it from the host machine.

Figure 1-321 Reference When the cover has been closed, the stapler unit will automatically execute idle punching several times to advance the staples. Figure 1-322 2) Open the front lower cover.

Figure 1-323

1-13

CHAPTER 1 GENERAL DESCRIPTION

3) Turn the knob in the counter clockwise.

6) Open the inlet cover, and remove the jam.

Figure 1-324 4) Turn the knob in the clockwise while pushing it in.

Figure 1-327 7) Close the front lower cover.

Figure 1-328 Figure 1-325 8) 5) Remove the jam. 9) Operate as instructed on the display. Connect the finisher unit.

Figure 1-326

1-14

CHAPTER 1 GENERAL DESCRIPTION

E.

Supplying the Saddle Stitcher Unit with Staples

3) Pull the stitcher unit to the front once, and then shift it up.

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.

Figure 1-331 4) Hold the empty cartridge on its sides, and remove it.

Figure 1-329 2) Slide out the stitcher unit.

Figure 1-332 5) Set a new cartridge.

Figure 1-330

Figure 1-333 Reference You must always replace both cartridges at the same time.

1-15

CHAPTER 1 GENERAL DESCRIPTION

6) Pull the stitcher to the front once, and then return it to its original position.

F.

Removing Staple Jams from the Saddle Stitcher Unit

If the host machine indicates the saddle stitcher unit staple jam message, perform the following to remove the jam. 1) Open the front lower cover.

Figure 1-334 7) Push in the stitcher unit, and close the front cover.

Figure 1-336 2) Slide out the stitcher unit.

Figure 1-335

Figure 1-337 3) Pull the stapler of the stitcher unit to the front once, and then shift it up.

Figure 1-338 1-16

CHAPTER 1 GENERAL DESCRIPTION

4) Hold the cartridge on its sides, and remove it.

7) Return the cartridge to its original position.

Figure 1-342 Figure 1-339 5) Push down on the area identified as A, and pull up the tab identified as B. 8) Pull the stitcher of the stitcher unit to the front once, and then return it to its original position.

Figure 1-340 Figure 1-343 6) Remove the staple jam, and return the tab B to its original position. 9) Push the stitcher unit back to its original position, and close the front lower cover.

Figure 1-341 Figure 1-344 Reference Whenever you have removed a staple jam, be sure to execute staple edging.

1-17

CHAPTER 1 GENERAL DESCRIPTION

IV. MAINTENANCE BY THE USER


A.
No. 1 2

Maintenance by the User


Item Replacing the staple cartridge (finisher unit) Replacing the staple cartridge (saddle stitcher unit) Timing When the appropriate indication is made on the host machines display.

Caution: 1. Use different type of staple cartridge for the finisher unit and the saddle stitcher unit. 2. There are two types of staple cartridge for 50 sheets and 100 sheets in the finisher unit. 3. After the type of staple cartridge is switched in the finisher unit, be sure to turn off the power then turn it on. Table 1-401

1-18

CHAPTER 1 GENERAL DESCRIPTION

1-19

CHAPTER 2 FINISHER UNIT BASIC OPERATION


1. This chapter discusses the purpose and role of each of the finishers functions, and the principles 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 flow of electrical signals.
2. In descriptions of digital circuits on the finisher, 1 indicates a high signal voltage level, while 0 indicates a low signal voltage level. Voltage values differ according to circuit. A microprocessor is used on the finisher. A description of microprocessor operation is omitted in this chapter as it is practically impossible to check internal operation of the microprocessor. Descriptions in this chapter also assume that PCBs will not be repaired at user sites. For this reason, descriptions of circuits on PCBs is limited to block diagrams. Two types of block diagrams are provided for separate functions: diagrams indicating details from sensors up to input sections of major PCBs, and diagrams indicating details from the output sections of major PCBs up the loads.

I.

BASIC OPERATION .................... 2-1 A. Outline ....................................... 2-1 B. Outline of Electrical Circuitry...... 2-2 C. Inputs to and Outputs from the Finisher Controller PCB ............. 2-4 II. FEED/DRIVE SYSTEM ............. 2-12 A. Outline ..................................... 2-12 B. Type of Delivery Paths ............. 2-17 C. Feeding and Delivering ............ 2-20 D. Job Offset ................................ 2-23

Staple Operation ...................... 2-26 Stapler Unit .............................. 2-34 Tray Operation.......................... 2-40 Detecting the Height of Stack on the Tray...................... 2-42 I. Shutter Operation .................... 2-44 J. Buffer Path Operation .............. 2-48 K. Detecting Jams ........................ 2-53 III. POWER SUPPLY SYSTEM ....... 2-58

E. F. G. H.

CHAPTER 2 FINISHER UNIT BASIC OPERATION

I.
A.

BASIC OPERATION
Outline

The finisher is designed to deliver copies arriving from its host machine, and its modes of delivery 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. In the case of the saddle stitch mode, copies from the host machine may be routed to the saddle stitcher unit.

Swing guide drive system

Control system

Alignment drive system Stapler drive system Delivery drive system Feeder drive system Shutter drive system

Tray drive system

Saddle stitcher unit control system Tray drive system

Figure 2-101 Note:


The term job offset refers to shifting each sorting job, separating a single stack into several stacks.

2-1

CHAPTER 2 FINISHER UNIT BASIC OPERATION

B.

Outline of Electrical Circuitry

The finishers 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 finishers 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. In addition, it communicates the finishers various states (information on sensors and switches) to the host machine through a serial communications circuit. The finisher controller PCB not only communicates with the saddle stitcher controller PCB but also communicates the saddle stitcher units various states (information on sensors and switches) to the host machine. The ICs used on the finisher controller PCB are designed for the following: IC1 (CPU) Controls sequence of operations. IC2 (EP-ROM) Backs up adjustment values. IC3 Contains sequence programs. IC6/IC7 (RAM) Backs up initial setting data. IC4 (communications IC) Communicates with the host machine and the saddle stitcher unit. IC9 (regulator IC) Generates PWM. Figure 2-102 shows the flow of signals between the finisher and the options controller.

2-2

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Saddle stitcher controller PCB

Finisher controller PCB communication


IC1 CPU IC2 EEP-ROM IC4 IC IC3 EP-ROM IC6/IC7 RAM IC9

Motor Solenoid Switch Sensor

Punch driver PCB (Puncher unit (option))

Host machine (DC controller PCB CPU)

Inserter driver PCB (Inserter unit (option))


Connecting with inserter

Regulator IC
Not connecting with inserter

Figure 2-102

2-3

CHAPTER 2 FINISHER UNIT BASIC OPERATION

C.
1.

Inputs to and Outputs from the Finisher Controller PCB


Inputs to the Finisher Controller PCB
Finisher controller PCB

PI1

Inlet sensor
PI3

J106-3 -1 -2 J134-3 -1 -2 J122-3 -1 -2

-7 -9 -8 -1 -3 -2 -4 -6 -5

-3 -1 -2 -4 -2 -3 -6 -4 -5

J17-7 -9 -8 J12A-10 -12 -11 J12B-4 -6 -5

J202

+5V PENT

When the sensor detects paper, 1.

Delivery sensor

+5V PDEL

J222

When the sensor detects paper, 1.

PI4

Stapling tray sensor

Rear alignment plate home position sensor

PI6

J137-3 -1 -2

J205

Shutter open sensor

PI5

J118-3 -1 -2

J561

+5V STPTY

When the sensor detects paper, 1.

-1 -3 -2

-3 -1 -2

J6B-1 +5V -3 STOPN -2

When the shutter opens, 1.

-4 -6 -5

-3 -1 -2

J12A-4 -6 -5

Stapler shift home position sensor

J210

PI7

J129-3 -1 -2

J121

+5V JOGRHP

When the rear alignment plate is at the home position, 1.

-2 -4 -3

-3 -1 -2

J6B-7 +5V -9 STPHP -8

When the stapler is at the home position, 1.

Tray 1 home position sensor

PI8

J130-3 -1 -2

J14A-1 -3 -2

+5V TRYHP 1

When the tray 1 is at the home position, 1.

Figure 2-103

2-4

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2.

Inputs to the Finisher Controller PCB


Finisher controller PCB
PI10 J120-1 -2 -3 J2011-3 -1 -2 J8011-3 -1 -2 J110-3 -1 -2 J117-3 -1 -2 J147-3 -1 -2 J105-3 -1 -2 J127-3 -1 -2 J6011-3 -4 -1 -6 -2 -5
J6010

Delivery motor clock sensor


PI11

-9 -8 -7 -1 -3 -2 -1 -3 -2 -3 -1 -2 -3 -1 -2

-1 -2 -3 -1 -3 -2 -7 -9 -8

J12B-9 +5V -8 DELCLK -7

While the delivery motor is rotating, alternately between 0 and 1.

J561

J2010

PI12

J201 J801

Tray 1 paper sensor

-3 J14A-4 +5V -1 -6 FSTTRAY* When paper is present on tray 1, 0. -2 -5 -3 J14B-7 +5V -9 SNDTRAY* When paper is present on -1 tray 2, 0. -8 -2 J24-4 +5V -6 BUFPASS -5 J6A-5 +5V -7 JOINT -6

PI14

Buffer path paper sensor


PI15

J8010

Tray 2 paper sensor

When paper is in the buffer path, 1.

Joint sensor

When the finisher is joined with the host machine, 1.

PI16

PI17

J113

Door open sensor

-1 -3 -2

-3 -1 -2

J6B-4 +5V -6 DROPN -5

When the front door is open, 0.

Buffer path inlet paper sensor


PI18

J24-1 +5V -3 BUFENTR When paper is present at the buffer path inlet, 1. -2 -1 -3 -2 -3 -1 -2 J12A-13 +5V -15 SWGOPN -14

PI9

J204

Swing guide open sensor

When the swing guide is open, 1.

Tray 1 lift motor clock sensor 1


PI19

-3 -4 -1 -6 -2 -5
J601

-3 J14A-10 +5V -12 SFTCLK11 When the tray 1 lift motor -1 is rotating, alternately -11 -2

between 1 and 0.

Tray 1 lift motor clock sensor 2


PI23

J6011-6 -1 -4 -3 -5 -2

-6 -1 -4 -3 -5 -2

-6 J14A-7 +5V -9 SFTCLK12 When the tray 1 lift motor -4 is rotating, alternately -8 -5

between 1 and 0.

Tray 2 lift motor clock sensor 1


PI24

J8021-3 -4 -1 -6 -2 -5
J8020

-3 -4 -1 -6 -2 -5
J801

-6 J14B-4 +5V -6 SFTCLK21 When the tray 2 lift motor -4 is rotating, alternately -5 -5

between 1 and 0.

Tray 2 lift motor clock sensor 2

-6 -1 -4 -3 -5 -2

-6 -1 -4 -3 -5 -2

-9 J14B-1 +5V When the tray 2 lift motor -3 SFTCLK22 -7 is rotating, alternately -2 -8

between 1 and 0.

Figure 2-104 2-5

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3.

Inputs to the Finisher Controller PCB

Finisher controller PCB


PI20

Swing motor clock sensor

J125-1 -2 -3

-3 -2 -1

-4 -5 -6

J12A-3 +5V -2 SWGCLK -1

When the swing motor is rotating, alternately between 0 and 1.

PI25

Tray 2 home position sensor

J135-3 -1 -2

J121

J14B-10 +5V -12 TRYHP2 -11

When the tray 2 is home position, 1.

PI26

Paddle home position sensor

J560-3 -1 -2

-1 -3 -2

-3 -1 -2

J12B-10 +5V -12 PDLHP -11

When the paddle is home position, 1.

PI28

Knurled belt home position sensor

J555-3 -1 -2

J221

-1 -3 -2

-3 -1 -2

J12A-7 +5V -9 RBHP -8

When the knurled belt is home position, 1.

PI29

Front alignment plate home position sensor

J139-3 -1 -2

J554

-1 -3 -2

-9 -7 -8

J12B-1 +5V -3 JOGFHP -2

When the front alignment plate is home position, 1.

PS1

Height sensor

J114-3 -4 -2 -1

J561

-2 -1 -3 -4

-3 -4 -2 -1

J6A-2 +5V -1 Height -3 PWR -4

Measures the distance between the sensor and the top of the stack on the tray.

Figure 2-105

2-6

J212

CHAPTER 2 FINISHER UNIT BASIC OPERATION

4.

Inputs to and Outputs from the Finisher Controller PCB

Finisher controller PCB Door switch


N. O. MS1 C. +24V J148-1 -2 J148-1 -1
J112

-1 -2

J5-1 +24VMOVE -2 DRSW

-2 -2

Swing guide closed detecting switch 1


N. O. MS2 C. -1
J209

When the front door and the upper cover are closed, 1.

-1 -2

J5-7 +24V SHIFT -6

-2

Swing guide closed detecting switch 2


N. O. MS6 C. -3
J209

-3 -4

J5-8 +24VSTPL -9 SWGGCLD

-4

When the swing guide is closed, 1.

Safety zone switch


C. N. C. N. O. MS3 J131-1 -3 -2 J5-3 -4 -5 +24VSHIFT TRAYSAF

When the tray is at the delivery slot, 1.

Shutter closed detecting switch


N. C. N. O. MS4 C. J140-3 -2 -1 J206-1 -2 -3 J206-1 -2 -3 J7-5 -6 -7 SHUTCLD

When the shutter is closed, 1.

Tray coming close detection switch


J138-3 N. C. N. O. MS9 C. J1151-3 -2 -1 -1 J1151-3 -2 -1 J115-4 -3 J115-4 J5-11 -3 TRYLMT +24VSHIFT -10

When the tray 1 gets close to the tray 2: "0"

Figure 2-106

2-7

CHAPTER 2 FINISHER UNIT BASIC OPERATION

5.

Outputs from the Finisher Controller PCB


Stapler unit Finisher controller PCB

Staple edging sensor

When a staple is at the edge of the stapler, 0.

Staple home position sensor

When the stapler is at the home position, 0.

Cartridge discrimination sensor

When a 100 sheets staple cartridge is present, 0.

Staple sensor

When staples are present in the cartridge, 0.

When the stapler is connected, 0.

CONNECT
J400-9 -8 -7 -6 -5 -4 J400-1 -2 -3 -4 -5 -6

Communication line

Saddle stitcher controller PCB

J2-1 J15-3 -4 -1 -2 -8 -9 J31-1 -2 -3 -4 -5

Communication line

Host machine

1 2

J33-1 -2

J32-1 -3

Power supply

-5 -3 -4

Figure 2-107 2-8

CHAPTER 2 FINISHER UNIT BASIC OPERATION

6.

Outputs from the Finisher Controller PCB


Finisher controller PCB Flapper solenoid
-1
J107

+24V -2 -1 -1
J701

-2 -1

J4-1

SL1

When "0", the solenoid turns on.


-2 FLPSL* +24V J4-3

-2

-2

Buffer inlet solenoid


-1
J108

-3 -2

SL2

When "0", the solenoid turns on.


-4 ENTSL* +24V

-2

Buffer outlet solenoid


-1
J109

-2 -1

J24-7

SL3

When "0", the solenoid turns on.


-8 EXITSL* +24V

-2

Drop solenoid
-1
J128

-2 -1

-4
J207

-2 -1

J11-5

SL4

When "0", the solenoid turns on.


-6 DRPSL*

-2

-5

+24V

First feed motor J146-6


-1 -2 -4 -3 -5

M1

J146-6 -1 -2 -4 -3 -5

J10-1 -2 -3 -4 -5 -6

B* A* B A

According to rotation direction/speed, changes between + and - in sequence.

Delivery motor
-1
J119

-2 -1

J11-1 -2

-2

According to rotation direction/speed, changes between + and -.

Rear alignment motor

J208

According to rotation direction/speed, changes between + and - in sequence.

Figure 2-108 2-9

CHAPTER 2 FINISHER UNIT BASIC OPERATION

7.

Outputs from the Finisher Controller PCB


Stapler shift motor Finisher controller PCB

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 -2 -1 -2

According to rotation direction/speed, changes between + and -.

Tray 2 lift motor According to rotation direction/speed, changes between + and -. Swing motor According to rotation direction/speed, changes between + and -. Second feed motor

According to rotation direction/speed, changes between + and -.

Inlet feed motor

According to rotation direction/speed, changes between + and - in sequence.

Figure 2-109

2-10

CHAPTER 2 FINISHER UNIT BASIC OPERATION

8.

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 between + and -.

Figure 2-110

2-11

CHAPTER 2 FINISHER UNIT BASIC OPERATION

II.
A.

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 delivery

Method of delivery

Simple stacking Job offset Staple Front diagonal Rear 1-point Rear diagonal 2-point

Saddle stitch deliver

Figure 2-201

Normal delivery tray

Normal delivery tray

To saddle stitcher unit

Figure 2-202

2-12

CHAPTER 2 FINISHER UNIT BASIC OPERATION

1. a.

Normal Delivery Simple Stacking The finisher delivers copies directly to the tray.
Tray Copies Tray Copies

Delivery roller

Feed roller 1

Feed roller 2

Figure 2-203

2-13

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 delivered without being shifted. Whether the first copy or the last copy of a sort job should be shifted is determined by the host machine.

b.

Tray

Each sort job is stacked alternately.

Figure 2-204
Swing guide

Stapling tray

Stopper Delivery roller Feed roller 1

Figure 2-205
Results of Delivering 4 Sets

Copies handled by job offset

Direction of delivery

Figure 2-206

2-14

CHAPTER 2 FINISHER UNIT BASIC OPERATION

c.

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

Stapling tray Delivery roller

Stopper Feed roller 1

Figure 2-207

Paper width/2 Front diagonal stapling 2-point stapling

Rear 1-point stapling Rear diagonal stapling

Figure 2-208

2-15

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2.

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.

To saddle stitcher

Figure 2-209

2-16

CHAPTER 2 FINISHER UNIT BASIC OPERATION

B.

Type of Delivery Paths

The finisher has three different paper paths for delivery, each selected to suit paper size and delivery mode. 1. Straight Path When stacking copies shown in Table 2-201, the copies pass under the buffer roller.
Length or width 182 mm or less A5-R, ST-R, thick paper

Copy size Typical copy examples

Table 2-201
Delivery roller Buffer roller

Figure 2-210 2. Buffer Paper Path 1 When stacking copies shown in Table 2-202, the copies pass over the buffer roller, increasing the distance between copies.
Copy size Typical copy examples Length and width 182 mm or more A3, B4, A4, A4-R, B5, B5-R, LD, LG, LT, LT-R, (excluding transparencies and thick paper)

Table 2-202
Buffer roller

Feed roller 2 Delivery roller

Figure 2-211

2-17

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3.

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.
Copy size Typical copy examples Length 182 to 232mm, and width 182 to 297mm A4, B5, LT, (excluding transparencies and thick paper)

Table 2-203 The following shows paper delivery operation in the case of three originals in the staple mode. 1) The first copy is moved in the direction of the buffer roller.
Buffer roller

First copy

Figure 2-212 2) The first copy wraps around the buffer roller and, at the same time, the second copy arrives from the host machine.

First copy

Second copy

Figure 2-213

2-18

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

Figure 2-215 Caution:


The third copy as explained here is moved through buffer paper path 1. This fact is omitted from the discussion to avoid interrupting the sequence of operations.

2-19

CHAPTER 2 FINISHER UNIT BASIC OPERATION

C.
1.

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. The first feed motor (M1), second feed motor (M8) and inlet feed motor (M9) are stepping motors, and delivery motor (M2) is a DC motor. These motors are controlled by the microprocessor (CPU) on the finisher controller PCB, and rotate either clockwise or counterclockwise. The paper paths are equipped with the following four sensors for detection of paper (arrival, passage): Inlet sensor (PI1) Delivery sensor (PI3) Stapling tray sensor (PI4) Buffer path paper sensor (PI14) In addition, each delivery tray is equipped with a sensor designed to detect the presence/absence of paper on it. No.1 tray paper sensor (PI11) No.2 tray paper sensor (PI12) If a copy fails to reach or move past each sensor within a specific period of time, the finisher controller PCB identifies the condition as a jam, and stops the ongoing operation, and at the same time, informs the host machine of the condition. When all doors are closed after the paper jam is removed, the buffer path inlet paper sensor (PI17) checks whether or not copies are being detected in addition to the above four sensors (inlet sensor, delivery sensor, stapling tray sensor and buffer path paper sensor). If the sensors detect a copy, the finisher unit judges that paper jams have not completely been removed, and sends the paper jam removal signal to the host machine again.

2-20

Tray 2 lift motor drive signal Shift motor clock detection signal 1 SFTCLK 21 Shift motor clock detection signal 2 SFTCLK 22 Front alignment motor drive signal Rear alignment motor drive signal Delivery motor drive signal Delivery motor clock signal DELCLK Swing motor drive signal Swing motor clock signal SWGCLK Paddle motor drive signal Shift motor clock detection signal 1 SFTCLK11 Shift motor clock detection signal 2 SFTCLK12

PI10

PI20

M11 M2 M7
M14

M3

PI23 PI19 PI9 M5


SL4

PI24 M8

M10

Finisher controller PCB


Tray 1 lift motor drive signal Drop solenoid drive signal DRPSL

Figure 2-216
M4 SL3 SL2 SL1
M13

Second feed motor drive signal

M1
First feed motor drive signal

M9
Inlet feed motor drive signal

CHAPTER 2 FINISHER UNIT BASIC OPERATION

M6

Buffer outlet solenoid drive signal EXITSL Buffer inlet solenoid drive signal EXTSL Flapper solenoid drive signal FLPSL Knurled belt motor drive signal Stapler motor drive signal Stapler shift motor drive signal

2-21

2-22
No. 2 tray paper detection signal SNDTRAY No. 1 tray paper detection signal FSTTRAY
CHAPTER 2 FINISHER UNIT BASIC OPERATION

PI12 PI4 PI3

PI11

Stapling tray paper detection signal STPTY Buffer path paper detection signal BUFPASS Delivery detection signal PDEL

Finisher controller PCB

Figure 2-217
PI14 PI17 PI1

Buffer path inlet paper detection signal BUFENTR Inlet paper detection signal PENT

CHAPTER 2 FINISHER UNIT BASIC OPERATION

D.
1.

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. The alignment plate is checked by the alignment plate home position sensor (PI6, PI29) to find out whether it is at the home position. The finisher controller PCB drives the front and rear alignment motors (M3, M11) at power-on to return the alignment plate to its home position. The finisher controller PCB stops the delivery motor (M2) when the trailing edge of the copy has moved past the feed roller 2. Then, the finisher controller PCB rotates the delivery motor counterclockwise, and drives the swing motor (M7). As a result, the drive of the delivery motor is transmitted to the swing guide to move up the guide. When the swing guide open sensor (PI18) detects the swing guide, the delivery motor stops, and the swing guide is held at the up position. When the swing guide has moved up, the feed belts attached to the feed roller 2 move the copy to the stapling tray. The presence of paper on the stapling tray is monitored by the stapling tray sensor (PI4). (The first sheet is fed to the stapling tray while the swing guide is moving up.) The finisher controller PCB drives the alignment motor (M3, M11) in advance, and keeps the alignment plate in wait at a waiting position of the trailing edge of a sheet. Whenever one sheet is moved to the stapling tray, each sheet is aligned, and the fifth or last sheet in a sort job/group is fed to the stapling tray. Then the alignment motor shifts the sheets front or rear by 15 mm. When the copy has been shifted, the finisher controller PCB rotates the alignment motor counterclockwise to move the alignment plate to a waiting position of the trailing edge of the sheet. This alignment operation is repeated until alignment of the fifth or last sheet in a sort job is completed. At this time, the swing guide is moved down and is closed, and the delivery motor rotates clockwise to deliver the sheet.

2-23

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) 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) Front alignment motor (M11) Alignment plate home position sensor (PI6, PI29) Swing motor (M7) Swing guide open sensor (PI18) Swing guide closed detecting switch 1 (MS2)

: Motor CW rotation

: Motor CCW rotation

Figure 2-219 2-24

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2.

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 Stapling tray Stopper

Figure 2-220 2) The alignment plate shifts the sheet to the front.
Existing stack Alignment plate

Offset sheet

Figure 2-221 3) The swing guide moves down and, at the same time, the delivery roller delivers the sheet.
Offset sheet Swing guide

Feed roller 2

Knurled belts Tray 1/2 Delivery roller Stapling tray Stopper

Figure 2-222 2-25

CHAPTER 2 FINISHER UNIT BASIC OPERATION

E.
1.

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. When starting operation after power-on, the finisher controller PCB drives the stapler shift motor (M4) to return the stapler unit to the home position. If the stapler is already at the home position, it is kept as it is in wait.

Stapler shift motor (M4)

Sheets

Stapler

Stapler shift home position sensor (PI7)

Figure 2-223

2-26

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

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2.

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. The finisher controller PCB stops the delivery motor (M2) as soon as the trailing edge of the first sheet has moved past the feed roller 2. Then, it rotates the delivery motor clockwise to switch the gear drive to the swing motor (M7), causing the swing guide to move up. When the swing guide open sensor (PI18) finds the swing guide at the up position, the swing motor stops, maintaining the swing guide at the up position. When the swing guide has moved up, the knurled belts of the feed roller 2 move the sheet to the stapling tray. (The first sheet is fed to the stapling tray while the swing guide is moving up.) The presence of paper on the stapling tray is detected by the stapling tray sensor (PI4). The finisher controller PCB drives the alignment motors (M3, M11) when the stapling tray paper sensor has detected paper to put sheets in order. The alignment plate is kept in wait in advance at a point 10 mm behind the trailing edge of the paper. The swing guide is kept in wait at the up position until the last sheet is output onto the stapling tray.
Swing guide

Drop lever arm First sheet

Feed roller 2

Knurled belts Tray 1/2 Delivery roller

Stapling tray Stapler

Figure 2-225

2-28

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

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. When the sheet outputs onto the stapling tray, the finisher controller PCB rotates the alignment motors (M3, M11) to put the sheets in order. When the 11th, 21st, 31st or 41st sheet of paper is fed on the stapling tray, the finisher controller PCB turns on the knurled belt motor (M13) to transfer the knurled belts for proper feeding of the sheet.

3.

Swing guide Second and subsequent sheets Paddles

Feed roller 2 Knurled belts


M13

Tray 1/2

Delivery roller Stapling tray Stapler

Knurled belt motor

Figure 2-227

2-30

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

CHAPTER 2 FINISHER UNIT BASIC OPERATION

4.

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). Then, the finisher controller PCB rotates the swing motor (M7) counterclockwise to move down the swing guide. The finisher controller PCB moves the stapler according to the staple mode for stapling. From then on, it rotates the delivery motor (M2) clockwise to deliver the stack to the tray.
Swing guide Sheets Feed roller 2

Knurled belts Tray 1/2 Delivery roller Stapling tray Stapler

Figure 2-230

2-32

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

CHAPTER 2 FINISHER UNIT BASIC OPERATION

F.

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. The stapler motor is controlled by the microprocessor (IC1) on the finisher controller so that it is rotated clockwise or counterclockwise. When the stapling home position sensor is off, the finisher controller PCB rotates the stapler motor clockwise until the sensor turns on so as to return the stapling cam to its initial state. The staple cartridge is judged as Absence when both staple edging sensor (PI21) and staple sensor (PI31) indicate 1. The presence/absence of staples inside the staple cartridge is detected by the staple sensor (PI31). The staple edge sensor (PI21) is used to find out whether a staple has been edged out to the end of the cartridge. The finisher controller PCB does not drive the staple motor (M6) unless the swing guide closed detecting switch 2 (MS6) is on (i.e., the swing guide is closed). This is to protect against injuries that could occur when a finger is stuck inside the stapler. Also, this finisher detects the type of staple cartridge when turning on the power. After the cartridge for stapling 100 sheets is switched to that for stapling 50 sheets or vice versa, be sure turn off the power then turn it on. Note:
When displaying Set stapler cartridge even though the staple cartridge is installed, it may not be installed correctly. If you move the gear of stapler unit manually, the cartridge cannot be detected due to the dislocation of gear because it is not correctly installed. In this case, move the gear to the position as shown below and reinstall the cartridge.

Gear Figure 2-232

2-34

Staple edge detection signal

Staple motor drive signal


M6

Finisher controller PCB

Figure 2-233
Stapling home position detection signal Cartridge detection signal Staple detection signal

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2-35

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Start signal Host machine delivery signal First sheet Stacking Second sheet Stapling Delivery

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) Front alignment motor (M11) Alignment guide home position sensor (PI6, PI29) Swing guide open sensor (PI18) Swing guide closed detecting switch 1 (MS2) Drop solenoid (SL4) Paddle motor (M14) Staple motor (M6) Staple home position sensor (PI22) Stapler shift motor (M4)

: Motor CW rotation

: Motor CCW rotation

Figure 2-234

2-36

CHAPTER 2 FINISHER UNIT BASIC OPERATION

5.

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. This movement occurs regardless of the selected mode of delivery, as no specific mode is recognized at this point in time. When the command for stapling arrives from the host machine after the first sheet has reached the host machine pre-registration sensor, the stapler moves to the staple wait position to suit the appropriate stapling position and paper size. See Figures 2-235 and later for an idea of the wait position according to the stapling mode. a. Front Diagonal Stapling The position is the same as the stapling position.

Stopper

Stapling tray delivery direction

Stopper

Guide plate Stapler

Figure 2-235

2-37

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

b.

Wait position

Stapling tray delivery direction Stapler Stopper

Guide plate

Figure 2-236 Rear Diagonal Stapling For A4, LT and B5 sizes, the stapler is kept in wait toward the rear away from the stapling position. The stapler is moved to and from the stapling position for each stapling operation.
Stapler Wait position Stapling position

c.

Stopper

Stapling tray delivery direction Stopper

Guide plate

Figure 2-237 2-38

CHAPTER 2 FINISHER UNIT BASIC OPERATION

d.

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

Stopper

Guide plate

Figure 2-238

2-39

CHAPTER 2 FINISHER UNIT BASIC OPERATION

G.

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). The tray 1 position is detected by counting the clock pulses of tray 1 lift motor clock sensors 1 and 2 (PI9 and PI19) in relation to the tray 1 home position sensor (P18). The tray 2 position is detected by counting the clock pulses of tray 2 lift motor clock sensors 1 and 2 (PI23 and PI24) in relation to the tray 2 home position sensor (PI25). When the tray is already at the home position, it is moved away from the home position once, then returned to that position. When both tray 1 and tray 2 are at the home position, the above operation is performed for tray 1 and tray 2 in this order. The finisher controller PCB moves up and down the tray selected by the host machine so that it is positioned at the delivery slot. The upper limit of the tray is detected by the tray coming close detecting switch (MS9). The finisher controller PCB stops the drive (up) of the tray 1 lift motor (M5) as soon as the tray upper limit detecting switch turns on. The height of the stack on the tray is identified by the height sensor (PS1), which measures its distance from the top of the stack. The tray is moved down when the distance between the top of the stack and the delivery assembly drops to a specific measurement. The finisher controller PCB cuts off the +24V power of the tray 1 lift motor (M5) as soon as the safety zone switch (MS3) turns on while the shutter and the swing guide are open, stopping the operation of the finisher.

2-40

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Tray 1 lift motor

One way gear Tray 1 lift motor clock sensor / and 2 Tray coming close detection switch

Rack

Tray 2 lift motor

One way gear Tray 2 lift motor clock sensor / and 2

Figure 2-239

2-41

CHAPTER 2 FINISHER UNIT BASIC OPERATION

H.
1.

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 operations) are stored in memory by the finisher controller PCB. The height of the stack is checked by the height sensor (PS1). See Table 2-204 for the maximum loading capacity of each tray. The finisher controller PCB stops operation when the conditions in Table 2-204 occur, informing the host machine that the tray is full.
Stacking mode Non-staple mode Small-size (1) Small-size (2) Size mixing Sort mode Staple sort mode Small-size (1) Large-size (1) Small-size (1) Large-size (1) Size mixing Mode mixing
Notes: 1. 2. 3. 4. 5.

Height 250 mm high (2000 sheets) 140 mm high (1000 sheets) 74 mm high (500 sheets) 250 mm high (2000 sheets) 140 mm high (1000 sheets) 110 mm high (750 sheets or 100sets) 74 mm high (500 sheets or 50 sets) 74 mm high (500 sheets or 50 sets) 22 mm high (150 sheets or 50 sets)

Large-size (1)(2) 140 mm high (1000 sheets)

The capacity for the non-staple sort mode is approximate and computed based on 80 g/m2 paper. Alignment for stacks containing 750 sheets or more is not guaranteed. Stacking height precision is 7 mm. Mode mixing means stacking non-stapled papers and stapled papers. The term Small-size (1) stands for A4, B5 and LT, the term Small-size (2) stands for A5-R and ST-R, while the term Large-size (1) stands for A3, B4, A4-R, LD, LG, LT-R, FOLIO and COMPUTER, Largesize (2) stands for B5-R.

Table 2-204

2-42

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Height sensor (PS1) Paper

Figure 2-240

2-43

CHAPTER 2 FINISHER UNIT BASIC OPERATION

I.

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. The shutter moves up (to close) when the second feed motor (M8) rotates counterclockwise, and is held in position when the motor stops. When the second feed motor rotates counterclockwise once again, it moves down (to open) to enable delivery. When the shutter is held at the up position, claws slide out of the swing guide to engage the back of the shutter. This way, the existing slack and the swing guide engage while the tray is moved, preventing the guide from opening. The claws slide in when the shutter is moved down to release the engagement. The upward movement of the shutter is monitored by the shutter closed detecting switch (MS4), and the downward movement is monitored by the shutter open sensor (PI5). See the following diagrams for how these operations take place. 1) The second feed motor rotates counterclockwise to move the shutter up.

M8

Second feed motor

Figure 2-241

2-44

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).

Tray 1 lift motor M5

M10

Tray 2 lift motor

Figure 2-242 3) The second feed motor rotates counterclockwise, and the shutter moves down.

M8

Second feed motor

Figure 2-243

2-45

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)

M10

Tray 2 lift motor

Figure 2-244

Claw Shutter

Claw Shutter closed detecting switch (MS4) Shutter open sensor (PI5)

M8

One-way cam

Second feed motor

Figure 2-245 2-46

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Sequence Operations (shutter drive)


Move from Tray 1 to Tray 2 Tray moved Shutter opened

Shutter closed Second feed motor (M8) Tray 1 lift motor (M5) Tray 2 lift motor (M10) Shutter closed detecting switch (MS4) Shutter open sensor (PI5) Height sensor (PS1)

Correct height detected Motor CW rotation Motor CCW rotation

Figure 2-246

2-47

CHAPTER 2 FINISHER UNIT BASIC OPERATION

J.
1.

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. During this time, job offset and stapling are performed on the stapling tray. The following shows operation on the buffer paper path. 1) When the first sheet arrives, the buffer inlet solenoid (SL2) remains off. The first sheet enters the buffer path.

OFF

First sheet

SL2

Buffer inlet solenoid

Figure 2-247 2) When the leading edge of the sheet has moved past the buffer path inlet paper sensor (PI17), the buffer outlet solenoid (SL3) turns on so as to cause the sheet to wrap around the buffer roller.

Buffer outlet solenoid


ON SL3

Buffer path inlet paper sensor (PI17)

Figure 2-248

2-48

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 roller starts to operate once again.

First sheet

Second sheet Inlet sensor (PI1)

Figure 2-250

2-49

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.

Second sheet First sheet

Third sheet Buffer path paper sensor (PI14)

Figure 2-252

2-50

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 solenoid (SL3) turns off so that the path is directed in the direction of delivery. (The actual switchover will occur after the trailing edge of the first sheet has moved past the flapper.)
Second sheet First sheet

Buffer outlet solenoid


OFF

SL3

Third sheet Inlet sensor (PI1)

Figure 2-254

2-51

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

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. When the CPU identifies a jam, it suspends the finishers delivery operation and informs the host machine DC controller of the presence of a jam. After the paper jam is removed, the buffer path inlet paper sensor (PI17) checks whether or not copies are being detected in addition to the above four sensors (inlet sensor, delivery sensor, stapling tray sensor and buffer path paper sensor). If the sensors detect a copy when all doors are closed, the finisher unit judges that paper jams have not completely been removed, and sends the paper jam removal signal to the host machine again. The tray 1 paper sensor (PI11) and tray 2 paper sensor (PI12) are not used to detect jams.

PI3

PI14 PI1 PI4

No. PI1 PI3 PI4 PI14

Sensor names Inlet sensor Delivery sensor Stapling tray sensor Buffer path paper sensor

Figure 2-256

Table 2-205

2-53

CHAPTER 2 FINISHER UNIT BASIC OPERATION

1.

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 Jam check Inlet sensor (PI1) Inlet feed motor (M9) Normal Jam check Inlet sensor (PI1) Inlet feed motor (M9)

Equivalent of 400 mm

Jam

Figure 2-257 2. Inlet Sensor Stationary Jam The sheet does not move past the 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 Jam check Inlet sensor (PI1) Inlet feed motor (M9) Normal Jam check Inlet sensor (PI1) Inlet feed motor (M9)

Equivalent of size x 2

Jam

Figure 2-258 3. Buffer Path Paper Sensor Delay Jam The buffer inlet sensor does not detect paper when an equivalent of 550 mm has been fed after the inlet sensor turned on.

Equivalent of 550 mm Jam check Inlet sensor (PI1) Buffer path paper sensor (PI14) First feed motor (M1) Normal Jam check Inlet sensor (PI1) Buffer path paper sensor (PI14) First feed motor (M1)

Equivalent of 550 mm

Jam

Figure 2-259

2-54

CHAPTER 2 FINISHER UNIT BASIC OPERATION

4.

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 Jam check Buffer path paper sensor (PI14) First feed motor (M1) Normal Jam check Buffer path paper sensor (PI14) First feed motor (M1)

Equivalent of size x 2

Jam

Figure 2-260 5. a. Delivery Sensor Delay Jam Straight Path The delivery sensor does not detect paper when an equivalent of 476 mm has been fed after the inlet sensor turned on.

Equivalent of 476 mm Jam check Inlet sensor (PI1) Delivery sensor (PI3) First feed motor (M1) Second feed motor (M8) Normal Jam check Inlet sensor (PI1) Delivery sensor (PI3) First feed motor (M1) Second feed motor (M8)

Equivalent of 476 mm

Jam

Figure 2-261

2-55

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.

b.

Equivalent of 772 mm Jam check Inlet sensor (PI1) Delivery sensor (PI3) First feed motor (M1) Second feed motor (M8) Normal Jam check Inlet sensor (PI1) Delivery sensor (PI3) First feed motor (M1) Second feed motor (M8)

Equivalent of 772 mm

Jam

Figure 2-262 6. Delivery Sensor Stationary Jam The sheet does not move past the delivery sensor when an equivalent of twice the feeding length of the sheet has been fed after the delivery sensor turned on.

Equivalent of size x 2 Jam check Delivery sensor (PI3) Second feed motor (M8) Delivery motor (M2) Normal Jam check Delivery sensor (PI3) Second feed motor (M8) Delivery motor (M2)

Equivalent of size x 2

Jam

Figure 2-263

2-56

CHAPTER 2 FINISHER UNIT BASIC OPERATION

7. on.

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 Jam check Stapling tray sensor (PI4) Delivery motor (M2) Normal Jam check Stapling tray sensor (PI4) Delivery motor (M2)

1 sec Jam

Figure 2-264 8. Timing Jam The inlet sensor (PI1) detects a sheet before the delivery signal is received from the host machine. 9. Staple Jam When the staple motor (M6) is rotating clockwise, the staple home position sensor (PI22) does not turn on within 0.5 sec. after it has turned off. However, the sensor turns on within 0.5 sec. after the motor has been rotated counterclockwise. 10. Power-On Jam One of the inlet sensor (PI1), delivery sensor (PI3), buffer path paper sensor (PI4) or buffer path inlet paper sensor (PI17) detects paper at power-on. 11. Door Open Jam One of the joint sensor (PI15), door open sensor (PI16) or door switches (MS1) detects the cover open during operation (including front door switch (MS2P) when the optional puncher unit is mounted). 12. Punch Jam The punch home sensor (PI3P) does not turn on again within 200 msec after turning off. 13. Stay Jam Caused By Finisher Start Signal OFF The finisher start signal is turned OFF in the host machine while paper is being fed in the finisher.

2-57

CHAPTER 2 FINISHER UNIT BASIC OPERATION

III. POWER SUPPLY SYSTEM


1. 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. The power is turned on due to this operation, and 24VDC power is supplied to the finisher controller PCB. 24VDC power is used to drive the motors and the solenoids, while 5VDC power is used for sensors and ICs on PCB. Both lines are also used to feed power from the finisher controller PCB to the saddle stitcher controller PCB. Power is also supplied to the punch driver PCB when the optional puncher unit is mounted. Some of the 24 VDC power used to drive motors is cut off when the door switch (MS1) is open. However, the power to the saddle stitcher controller PCB and the punch driver PCB will not be cut off. Figure 2-301 is a block diagram showing the power supply system.
Door switch (MS1) Motor

Saddle stitcher controller PCB

Motor J1-1,2 Power supply Circuit breaker (CB1) Solenoid

J1-5

Finisher controller PCB Sensors Host machine J2-6 Logic

Punch driver PCB (Puncher Unit (option))

Figure 2-301 2. Protection Functions The 24 VDC power line used to drive motors and solenoids is equipped with a circuit breaker (CB1) for protection against overcurrent. The 24 V line used to drive the first feed motor (M1), alignment motors (M3, M11), and stapler shift motor (M4) are equipped with a fuse, which is designed to blow when an overcurrent occurs.

2-58

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2-59

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION


1. This chapter discusses the purpose and role of each of the stitchers 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. The symbol in drawings indicates transmission of mechanical drive, and signals marked by together with the signal name indicates the flow of electrical signals.

2. In descriptions of digital circuits on the stitcher, 1 indicates a high signal voltage level, while 0 indicates a low signal voltage level. Voltage values differ according to circuit. A microprocessor is used on the stitcher. A description of microprocessor operation is omitted in this chapter as it is practically impossible to check internal operation of the microprocessor. Descriptions in this chapter also assume that PCBs will not be repaired at user sites. For this reason, descriptions of circuits on PCBs is limited to block diagrams. Two types of block diagrams are provided for separate functions: diagrams indicating details from sensors up to input sections of major PCBs, and diagrams indicating details from the output sections of major PCBs up the loads.

I.

BASIC OPERATION .................... 3-1 A. Outline ....................................... 3-1 B. Electrical Circuitry ...................... 3-2 C. Inputs to and Outputs from the Saddle Stitcher Controller PCB ........................................... 3-3 II. FEEDING/DRIVE SYSTEM ........ 3-8 A. Outline ....................................... 3-8 III. PAPER OUTPUT MECHANISM ............................ 3-14 A. Outline ..................................... 3-14 B. Controlling the Inlet Flappers ................................... 3-17

C. Controlling the Movement of Sheets...................................... 3-21 D. Aligning the Sheets .................. 3-23 E. Controlling the Phase of the Crescent Roller ........................ 3-26 IV. STITCHING SYSTEM ............... 3-28 V. FOLDING/DELIVERY SYSTEM ................................... 3-31 VI. CHECKING FOR A JAM ........... 3-38 VII. POWER SUPPLY ...................... 3-43

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

I.
A.

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.

Finisher unit control system

Guide plate drive system Paper positioning plate drive system Alignment drive system

Control system

Stitcher drive system Delivery drive system Feed drive system Paper pushing plate drive system Paper folding roller drive system

Figure 3-101

3-1

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

B.

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 finisher controller PCB. The saddle stitcher controller PCB is also used to communicate the state of various sensors and switches to the finisher controller PCB in serial. The functions of the major ICs mounted on the saddle stitcher controller PCB are as follows: Q1 Controls the sequence of operations. Q2 Contains the sequence program. Q3 Controls the sequence of operations. Q4 Handles IPC communications. Electrical circuitry block diagram

Sensors

Saddle stitcher controller PCB


Q1 CPU

Motors Solenoids

Switches

Q2 ROM Q3 RAM
Communications IC

Q4

Finisher controller PCB

Host machine

Figure 3-102

3-2

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

C.
1.

Inputs to and Outputs from the Saddle Stitcher Controller PCB


Inputs to the Saddle Stitcher Controller PCB
Saddle stitcher controller PCB

Paper pushing plate motor clock sensor Front door open/closed sensor

PI1S

J107-1 -2 -3 J104-3 -1 -2 J103-3 -1 -2

J11-15 -14 -13 J11-10 -12 -11 J11-7 -9 -8

+5V LUNGECLK

When the paper pushing plate motor is rotating, alternately between 1 and 0. When the front door is open, 0.

PI2S

+5V FDR

PI3S

Delivery cover sensor


PI4S

J303-1 -3 -2

J203-3 -1 -2

+5V EJCVR

When the delivery cover is open, 0.

Paper folding motor clock sensor Alignment plate home position sensor

J102-1 -2 -3

J11-6 -5 -4

+5V FLDCLK

When the paper folding motor is rotating, alternately between 1 and 0. When the alignment plate is at home position, 1.

PI5S

J101-3 -1 -2

J309-1 -3 -2

J209-3 -1 -2

J11-1 -3 -2

+5V JOGHP

PI6S

Tray paper sensor


PI7S

J502 J402A J402

J100-3 -1 -2

-1 -3 -2

-3 -4 -1 -6 -2 -5
J302 J202A J202

-3 -1 -2

J6-7 -9 -8

+5V TRYPAR

When paper is present on the tray, 1.

Paper positioning plate home position sensor

J106-3 -1 -2

-1 -3 -2

-6 -4 -5

J6-4 -6 -5

+5V PAPPOS

When the paper positioning plate is at the home position sensor, 1.

Figure 3-103

3-3

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

2.

Inputs to the Saddle Stitcher Controller PCB


Saddle stitcher controller PCB

PI8S

J301 J301A J201

Paper positioning plate paper sensor


PI9S

J105-3 -1 -2

-1 -3 -2

-3 -1 -2

J6-1 +5V -3 PPOSPAR -2

When paper is present at the paper positioning plate, 1.

Inlet cover sensor

J124-3 -1 -2 J525-3 -1 -2 -2 -4 -3 -3 -1 -2 -2 -4 -3

J10-6 +5V -8 INLTCVR -7 -3 J9-1 +5V -1 -3 DELV -2 -2

When the inlet cover is closed, 1.

PI12S

Crescent roller phase sensor

J126-3 -1 -2

J425 J425 J325

J225 J225 J125

Delivery sensor

PI11S

When paper is present in the delivery sensor unit, 1.

J9-4 +5V -6 FDRLHP -5

When the flag of the crescent roller is at the sensor, 1.

Guide home position sensor

PI13S

J127-3 -1 -2

J9-7 +5V -9 GIDHP -8

When the guide is at home position, 1.

PI14S

Paper pushing plate home position sensor


PI15S

J128-3 -1 -2

J9-10 +5V -12 LUNGEHP When the paper pushing plate is at home position, 1. -11

Paper pushing plate top position sensor


PI16S

J129-3 -1 -2

J9-13 +5V -15 LUNGETOP When the paper pushing plate is at the leading edge, 1. -14

Stitcher unit IN sensor

J131-3 -1 -2

J13-1 +5V -3 STPLHP* -2

When the stitcher unit is housed, 0.

PI17S

Vertical path paper sensor

Paper folding home position sensor

PI21S

J130-3 -2 -1

J308 J308A J208

J132-3 -1 -2

-1 -3 -2

-4 -2 -3

J13-4 +5V -6 VPJM -5

When paper is present in the vertical path, 1.

J18-1 +5V -3 PAFLDHP* When the paper folding roller is at home position, 0. -2

Figure 3-104

3-4

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

3.

Inputs to the Saddle Stitcher Controller PCB


Saddle stitcher controller PCB Paper sensor PCB
PI18S

No.1 paper sensor


J304 J304A J204

PI19S

No.2 paper sensor


PI20S

J123-5 -4 -3 -2 -1

-1 -2 -3 -4 -5

-5 -4 -3 -2 -1

J10-1 -2 -3 -4 -5

+5V 1STPA 2NDPA 3RDPA

When paper is present at the No.1 paper sensor, 1. When paper is present at the No.2 paper sensor, 1. When paper is present at the No.3 paper sensor, 1.

No.3 paper sensor Stitcher unit (front) Stitcher home position sensor (front) Staple sensor (front)

MS7S

J315-5

-3
J305 J120

-5

J8-3

STCHHP1*

MS6S

-7 -6

-1 -2

-7 -6

-1 -2 HKEMP1

When the stitcher unit is at the home position for stitching, 0. When no staple is present, 0.

Stitcher unit (rear) Stitcher home position sensor (rear) Staple sensor (rear)

MS5S

J316-5

-3
J306 J121

JD2 JD1

-5

J8-10

STCHHP2*

MS4S

-7 -6

-1 -2

-7 -6

-8 HKEMP2 -9

When the stitcher unit is at the home position for stitching, 0. When no staple is present, 0.

Inlet door switch


N.O. MS1S J109-3 -2 J4-1 -2

+24V

INLTCVRMS When the inlet door is

Front door switch


N.O. MS2S J110-3 -2 J4-3 -4 FDROPN

closed, 1.

Delivery door switch


N.O. MS3S J111-2 -3 -1
J305 J205

When the front door is closed, 1.

-1 -2

J4-5 -6 +24U DELVMS

-2

When the delivery door is closed, 1.

Figure 3-105

3-5

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

4.

Outputs from the Saddle Stitcher Controller PCB


Saddle stitcher controller PCB No.1 paper deflecting solenoid
-1 -2 J15-1 +24V

J118

SL1S

When 0, the solenoid turns ON.


-1 -2 FLPSL1* +24V -2 J15-3

-2

No.2 paper deflecting solenoid


-1

J117

SL2S

When 0, the solenoid turns ON.


-1 -4 FLPSL2* +24V -2 J15-5

-2

Feed plate contact solenoid


-1

J116

SL4S

When 0, the solenoid turns ON.


-1 -6 RLNIPSL*

-2

Feed motor

-1

-4

J5-1 A -2 A* -3 B -4 B*

J115A

-2 M1S -3 -4

-3 -2 -1

The pulse signals change according to the rotation of the motor.

Paper folding motor


J112-2 M2S -1 -7 J4-8

The states (+ and -) change according to the rotation of the motor.


+24V

Guide motor
M3S

J119-5 -4 -3 -2 -1

J12-1 -2 B* -3 A* -4 -5 J7-6 -7 B* -8 A* -9 B -10 A J7-1 -2 B* -3 A* -4 B -5 A B A

The pulse signals change according to the rotation of the motor.


+24V

Paper positioning plate motor

J114-5 -4 -3 -2 -1

M4S

The pulse signals change according to the rotation of the motor.


+24V

Alignment motor

J113-5 -4 -3 -2 -1

M5S

The pulse signals change according to the rotation of the motor.

Figure 3-106 3-6

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

5.

Outputs from the Saddle Stitcher Controller PCB


Saddle stitcher controller PCB
J315-4 -3 -2 -1 -4 -5 -6 -7 -4 -3 -2 -1 J8-4 -5 -6 -7

Stitcher unit (front)

J305

Stitcher motor (front) Stitcher unit (rear)


J316-4 -3 -2 -1 -4 -5 -6 -7
JD2 JD1

J120

M7S

The states (+ and -) change according to the rotation of the motor.

J306

Stitcher motor (rear) Paper pushing plate motor


J108-1 M8S -2 J4-9 -10

J121

M6S

-4 -3 -2 -1

J8-11 -12 -13 -14

The states (+ and -) change according to the rotation of the motor.

The states (+ and -) change according to the rotation of the motor.

Finisher controller PCB


J3-6 -5 -4 -3 -2 -1 J400-1 -2 -3 -4 -5 -6 J400-9 -8 -7 -6 -5 -4 J2-1 -2 -3 -4 -5 -6

Communication line
+5V

+24V J19-1 -2 J401-1 -2 J401-1 -2 J1-1 -2

Figure 3-107

3-7

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

II.
A.

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. The machines operation consists of the following: 1. Receive sheets. 2. Aligns the sheets 3. Stitches the stack. 4. Feeds the stack. 5. Folds and delivers the stack.

1) Receive sheets

3) Stitches the stack

2) Aligns the sheets

5) Folds and delivers the stack

4) Feeds the stack

Figure 3-201

3-8

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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. Sheets coming later are output closer to the delivery slot, and the volume of paper that may be output is as follows: 15 sheets (maximum of 14 sheets of 80 g/m2 + 1 sheet of 256 g/m2)

Direction of delivery

Second sheet First sheet

Paper positioning plate

Figure 3-202

3-9

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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 assembly. The alignment plates also operate after stapling to prepare the stack for delivery.
Sheets

Alignment plate

Alignment plate

Paper positioning plate

Figure 3-203

3-10

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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 between two staples and to limit the load on the power supply. If only one sheet of paper arrives from the host machine, stitching does not take place and the sequence goes to the next operation (stack feeding).

Stitcher

Staple

Figure 3-204

3-11

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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. The stack is moved forward by operating the paper positioning plate. When the plate is operated, the guide plate which has been covering the paper folding rollers, also moves down so that the paper folding rollers directly face the stack.

Paper folding roller

Paper pushing guide

Paper positioning plate Guide plate

Figure 3-205

3-12

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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. The paper folding rollers together with the delivery roller then move the stack along to output it on the delivery tray.

Paper folding roller

Delivery roller

Figure 3-206

3-13

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

III. PAPER OUTPUT MECHANISM


A. 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 configure the paper path to suit the size of paper. The paper positioning plate is kept in wait at a predetermined location to suit the size of paper. The paper positioning plate is driven by the paper positioning plate motor (M4S), and the position of the plate is identified in reference to the number of motor pulses coming from the paper positioning plate home position sensor (PI7S). A sheet moved by the inlet roller is handled by the feed rollers and the crescent roller and held in a predetermined position. The feed plate serve to move sheets by coming into contact with or moving away from sheets as needed. The alignment plates put the stack into order each time a sheet is output. The alignment plates are driven by the alignment motor (M5S), whose position is identified in reference to the number of motor pulses coming from the alignment plate home position sensor (PI5S). To prevent interference between paper and the paper folding rollers when the paper is being output, the folding rollers are designed to be covered by a guide plate. The guide plate moves down before paper is folded so as to expose the paper folding rollers. The inlet is equipped with the No.1, No.2 and No.3 paper sensors (PI18S, PI19S, PI20S) each suited to a specific paper size, and the paper positioning plate is equipped with a paper positioning plate paper sensor (PI8S).

3-14

.AA@

J H @HELA IEC =

/KE@A

J H @HELA IEC =

!5 5

5JEJ?DAH J H @HELA IEC = BH J HA=H

) EC

A J

J H @HELA IEC =

#5 $5 %5

5=@@ A IJEJ?DAH ? JH AH 2+* 


J H @HELA IEC = J H

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

Figure 3-301
"5 &5 5 21"5 215 5 "5
J H ? ? IEC = 7 /-+

2=FAH FKIDE C F =JA

2=FAH B @E C

J H @HELA IEC =

2=FAH F IEJE E C F =JA @HELA IEC =

 F=FAH @AB A?JE C I A E@ @HELA IEC = . 25 

5 5 5 5

F=FAH @AB A?JE C I A E@ @HELA IEC = . 25 .AA@ F =JA ? J=?J I A E@ @HELA IEC = 4 125

5=@@ A IJEJ?DAH ? JH AH 2+*  

2=FAH B @E C

J H ? ? IEC = . ,+

2=FAH FKIDE C F =JA

3-15

3-16
Paper positioning plate home position detection signal PAPPOS Paper positioning plate paper detection signal PPOSPAR Tray paper detection signal TRYPAR Guide plate home position detection signal GIDHP Crescent roller position detection signal FDRLHP Delivery detection signal DELV Paper folding home position detection signal PAFLDHP

PI21S

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

Saddle stitcher controller PCB (1/2)


Vertical path paper detection signal VPJM

Figure 3-302
PI15S PI14S

Paper pushing plate top position detection signal LUNGETOP

PI19S

Saddle stitcher controller PCB (2/2)

Paper pushing plate home position detection signal LUNGEHP

PI20S

No.3 paper detection signal 3RDPA

PI18S

No.2 paper detection signal 2NDPA

No.1 paper detection signal 1STPA

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

B.
1.

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. To detect the passage of the trailing edge of the paper being moved by an appropriate sensor. 2. To prevent the following sheet from butting against the top of the existing stack, Table 3-301 shows the relationship between sensors and paper sizes.
Sensor No.1 paper sensor (PI18S) No.2 paper sensor (PI19S) No.3 paper sensor (PI20S) A3/LD Used Not used Not used B4 Used Used Not used A4-R/LT-R Used Used Used

Table 3-301 Each flapper is driven by its own solenoid. Table 3-302 shows the relationship between solenoids and paper sizes.
Solenoid No.1 paper deflecting solenoid (SL1S) No.2 paper deflecting solenoid (SL2S) A3/LD OFF OFF B4 ON OFF A4-R/LT-R ON ON

Table 3-302

3-17

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

2.

A3/LD Paper Path (3 sheets)

 F=FAH IA I H 2=II=CA B F=FAH 21&5  F=FAH @AB A?JE C 5 5 .. I A E@ F=II=CA B F=FAH F=FAH IA I H .. 21'5 F=FAH @AB A?JE C 5 5 F=II=CA B F=FAH I A E@ ! F=FAH IA I H 21 5 6 F A@CA 21&5 21'5 21 5

21&5 21'5 21 5 - JHO B .EHIJ IDAAJ

- JHO B 5A? @ IDAAJ

- JHO B 6DEH@ IDAAJ

Figure 3-303

3-18

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

3.

B4 Paper Path (3 sheets)

No.1 paper sensor PI18S


SL1S

Passage of paper

ON
Passage of paper

No.2 paper sensor PI19S

SL2S No.3 paper sensor Non-passage of paper

OFF

PI20S

PI18S PI19S Top edge PI20S

PI18S PI19S

PI20S Entry of First sheet

Entry of Second sheet

Entry of Third sheet

Figure 3-304

3-19

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

4.

A4-R/LT-R Paper Path (3 sheets)

No.1 paper sensor PI18S


SL1S

Passage of paper

ON
Passage of paper

No.2 paper sensor PI19S PI20S

SL2S Passage of paper No.3 paper sensor

ON

PI18S PI19S

PI20S

Top edge

PI18S PI19S

PI20S Entry of First sheet

Entry of Second sheet

Entry of Third sheet

Figure 3-305

3-20

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

C.

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. The contact is broken as soon as the leading edge of the sheet reaches the paper positioning plate. This series of operations is executed each time a sheet arrives. When the leading edge of the first sheet reaches the paper positioning plate, the paper positioning plate paper sensor (PI8S) turns ON. The arrival of the second and subsequent sheets will not be checked since the first sheet will still be over the sensor. The crescent roller keeps rotating while sheets are being output, butting the leading edge of each sheet against the paper positioning plate, and ultimately, keeping the leading edge of the stack in order. The alignment plate motor (M5S) drives the alignment plates for each sheet so as to put both left and right edges of the sheet in order. 1) The solenoid turns ON while paper is being moved so that the feed plate comes into contact.
Intermediate feed roller Feed motor M1S ON SL4S Feed plate contact solenoid

Figure 3-306

3-21

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.

M1S OFF SL4S

Figure 3-307 3) The solenoid turns ON when the next sheet arrives, and the feed plate comes into contact.

M1S ON SL4S

Figure 3-308

3-22

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

D.

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. The position of the alignment plate is identified in reference to the number of motor pulses from the alignment plate home position sensor (PI5S). The following briefly describes what takes place when the saddle stitching mechanism operates on two sheets. 1) When the first sheet has been output, the alignment plates butt against the left and right edges of the stack (first alignment). The alignment plates leave the home position in advance and remain in wait at points 10 mm from the edges of the stack.
Sheets Alignment plate Alignment plate

Paper positioning plate

Alignment plate home position sensor (PI5S)

Figure 3-309 2) The alignment plates move away from the edges of the stack over a short distance and then butt against the edges once again (Second alignment).

Figure 3-310

3-23

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.

Figure 3-313 7) When the first sheet of the following stack reaches the No.1 paper sensor, the guide moves to a point 10 mm from the edge of the stack to be ready for the next alignment operation.

Figure 3-314

3-24

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

In case of 2 sheets:
Entry of Entry of 1st sheet of follow1st sheet 2nd sheet ing stack entry

Alignment plate home position sensor (PI5S) Alignment motor (M5S) Paper positioning plate motor (M4S)

[1]

[2] [3] [4]

: Alignment : Escape [1]: Move to wait position [2]: Stapling period [3]: Paper folding/delivery period [4]: Move to following stack size wait position

Figure 3-315
Alignment plate Alignment motor M5S

Alignment plate

Stack

Alignment plate home position sensor (PI5S) Paper positioning plate

Figure 3-316

3-25

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

E.
1.

Controlling the Phase of the Crescent Roller

Outline If alignment was executed with the crescent roller in contact with the stack of sheets, the resulting 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. The phase of the crescent roller is identified by the crescent roller phase sensor (PI12S). The flag for the crescent roller phase sensor is mounted to the crescent roller shaft. The flag will leave the sensor while the roller shaft rotates, turning the sensor ON or OFF, enabling the assumption that the crescent roller is positioned at the opposite side of the stack (Figure 3-319). The alignment plates are operated to correspond with this change in the state of the sensor.

Crescent roller phase sensor (PI12S) Alignment plates Flag

Crescent roller M1S Feed motor Stack

Figure 3-317

3-26

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 operation could be obstructed.

Figure 3-318

Alignment operation is started when the flag has covered the sensor and the crescent roller is away from the stack.

Figure 3-319
First sheet Second sheet Feed motor stops

Crescent roller phase sensor (PI12S) Alignment operation Feed motor (M1S)

Figure 3-320 3-27

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

IV. STITCHING SYSTEM


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 (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. The stitcher base is designed so that it may be drawn out to the front from the saddle stitcher for replacement of the staple cartridge or removal of a staple jam. The stitcher unit in sensor (PI16S) is used to make sure that the stitcher base is properly fitted to the saddle stitcher. Safety switches are not mounted for the stitcher unit (front, rear), as the location does not allow access by the user.

Stitcher (rear)

Stitcher (front)

Stack

Figure 3-401

3-28

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

2.

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. (A time delay for initiating the stitcher motor startup current helps decrease the load on the power supply.) The stitcher home position sensor (MS7S, MS5S) is used to monitor the movement of the rotary cam, enabling identification of individual stitcher operations. The presence/absence of staples inside the staple cartridge fitted to the stitcher is detected by the staple sensor (MS6S, MS4S). The alignment plates keep both edges of the stack in place while stitching takes place.

Figure 3-402
Stitcher home position sensor (front) (MS7S) Stitcher motor (front) (MS7) Stitcher home position sensor (rear) (MS5S) Stitcher motor (rear) (M6S) No.1 paper sensor (PI18S) Alignment motor (M5S) Alignment Escape

Figure 3-403

3-29

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

Cam

Mount

Figure 3-404

3-30

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

V.
1.

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. Before the stack is folded, the guide plate moves down to enable the folding rollers to operate. The folding rollers are driven by the paper folding motor (M2S), and the drive of the motor is monitored by the paper folding motor clock sensor (PI4S). The mechanism is also equipped with a paper folding home position sensor (PI21S) for detecting the position of the paper folding rollers. The paper pushing plate is driven by the paper pushing plate motor (M8S), and the drive of the paper pushing plate motor is monitored by the paper pushing plate motor clock sensor (PI1S). The paper pushing plate home position sensor (PI14S) and the paper pushing plate top position sensor (PI15S) are used to detect the position of the paper pushing plate. After being folded into two by the paper folding rollers, a stack is moved ahead by the delivery roller for delivery. The delivery roller is driven by the paper folding motor. The delivery sensor (PI11S) is mounted to the delivery assembly to detect delivery of paper. The tray paper sensor (PI6S) is used to detect the presence/absence of paper on the tray, but does not detect jams. The vertical path paper sensor (PI17S) serves to detect the presence of paper after jam removal.

3-31

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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 paper pushing plate is located. The position of the paper positioning plate is controlled in reference to the number of motor pulses coming from the paper positioning home position sensor (PI7S). At the same time as the paper positioning plate operates, the guide plate lowers so that folding may take place.
Stitching ends Paper positioning plate motor Guide motor Guide home position sensor (PI13S) Equivalent of specific number of pulses

Figure 3-501

3-32

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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. When the paper folding roller has gripped the stack for a length of about 10 mm, the paper pushing plate motor starts to rotate once again, and the paper pushing plate returns to its home position. The stack gripped in this way by the paper folding roller is drawn further by the paper folding roller and then is moved by the delivery roller to the paper tray. Half of the peripheral area of the paper folding rollers excluding the center part is punched out. This punched out area only feeds the paper as the paper feeding roller (lower) contacts the paper feeding roller (upper) only at the center of the roller to prevent the paper from wrinkling. As the paper feeding roller (lower) contacts the paper feeding roller (upper) at their entire surfaces on the remaining half of the peripheral area, paper folding starts from this half of the peripheral area, and paper is fed while it is being folded. The stop position of the paper folding rollers is in this half of the peripheral area. The paper folding start and stop positions on the paper folding rollers is controlled according to the motor clock signals from the paper folding home position sensor (PI21S).

Paper pushing plate top position sensor (PI15S) Paper folding roller (upper) Sensor flag Paper folding home position sensor (PI21S)

Paper pushing plate home position sensor (PI14S)

Paper pushing plate

Paper folding roller (lower)

M8S M2S Paper pushing plate motor

Stack of sheets

Paper folding motor

Figure 3-502

3-33

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

Paper pushing plate top position sensor


(PI15S)

Paper pushing plate home position sensor (PI14S)

Sensor flag Paper folding home position sensor (PI21S) Paper pushing plate

M8S M2S

Paper pushing plate motor

Paper folding motor

Figure 3-503 [Paper folding start position]

Stack of sheets

Paper pushing plate Delivery outlet Paper feed inlet

Sensor flag Paper folding home position sensor (PI21S) Paper folding/feeding is performed. Paper feeding is performed.

Figure 3-504

3-34

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 position sensor (PI14S) Paper pushing plate top position sensor (PI15S) Delivery sensor (PI11S) Tray paper sensor (PI6S) Paper folding home position sensor (PI21S) : Motor CW : Motor CCW
Equivalent of 10mm by paper folding motor

Figure 3-506

3-35

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

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. Then, the paper folding rollers rotate normally, and the paper pushing plate returns to its home position while the stack is being delivered. This way, a stack requiring a large force may properly be folded with less pressure. 1) The paper pushing plate pushes the stack in the direction of the paper folding rollers.

Paper pushing plate

M2S M8S Paper folding motor Paper folding roller Paper pushing plate motor

Figure 3-507 2) The paper folding rollers grip the stack for a length of about 20 mm.

20 m (approm x.)

M2S Paper folding motor

Figure 3-508

3-36

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).
20 m (appr m ox.)

M2S 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.

M2S Paper folding motor M8S Paper pushing plate motor

Figure 3-510
Gripping of paper stack Equivalent of 20 mm Paper folding motor (M2S) Paper pushing plate motor (M8S) Paper pushing plate home position sensor (PI14S) Paper pushing plate top position sensor (PI15S) Delivery sensor (PI11S) Tray paper sensor (PI6S) Paper folding home position sensor (PI21S) : Motor CW : Motor CCW Equivalent of 20 mm (reverse feeding)

Figure 3-511 3-37

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

VI. CHECKING FOR A JAM


1. 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.

PI18S PI19S PI20S

PI8S

Figure 3-601
No. PI8S PI11S PI14S PI15S PI17S PI18S PI19S PI20S Delivery sensor Paper pushing plate home position sensor Paper pushing plate top position sensor Vertical path paper sensor No.1 paper sensor No.2 paper sensor No.3 paper sensor Sensor Paper positioning plate paper detection sensor

Table 3-601

3-38

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

2.

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) No.1 paper (PI18S) sensor Feed motor Inlet sensor (PI1) No.1 paper sensor (PI18S) Feed motor Jam
Load stops

Delivery speed (mm/sec)

Delivery speed (mm/sec)

Figure 3-602 3. Inlet Stationary Jam The No.1 paper sensor (PI18S), No.2 paper sensor (PI19S), and No.3 paper sensor (PI20S) on the paper sensor PCB do not turn OFF when the stack has been fed for a specific period after the No.1 paper sensor (PI18S) turns ON. The paper sensor used varies according to the paper size. a. A3/LD Stack
Normal No.1 paper sensor (PI18S) Feed motor T: feeding of (paper length x 1.5) mm Jam Load stops T: feeding of (paper length x 1.5) mm

No.1 paper sensor (PI18S) Feed motor

Figure 3-603

3-39

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

b.

B4 Stack
Normal Normal No.1 paper sensor (PI18S) No.2 paper sensor (PI19S) 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. Single detection, however, uses only one sensor. Jam Jam

No.1 paper sensor (PI18S) No.2 paper sensor (PI19S) Feed motor

Figure 3-604 c. A4-R/LT-R Stack


Normal Normal Normal No.1 paper sensor (PI18S) No.2 paper sensor (PI19S) No.3 paper sensor (PI20S) 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 three sensors checking for jams. Single detection, however, uses only one sensor. Jam Jam Jam

No.1 paper sensor (PI18S) No.2 paper sensor (PI19S) No.3 paper sensor (PI20S) Feed motor

Figure 3-605

3-40

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

4. a.

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 position sensor Delivery sensor Paper folding motor Paper pushing plate top position sensor Delivery sensor Paper folding motor Load stops T: Equivalent of 180 mm T: Equivalent of 180 mm

Normal

Jam

Figure 3-606 5. a. Delivery Stationary Jam By vertical path paper sensor The vertical path paper sensor (PI17S) does not turn OFF within a specific period of time (feeding) after the delivery sensor (PI11S) has turned ON, i.e., the trailing edge of the stack does not leave the vertical path paper sensor.
Vertical path paper sensor (PI17S) Delivery sensor Paper folding motor Normal Vertical path paper sensor (PI17S) Delivery sensor Paper folding motor Jam

T: Feeding of

Paper length

-130

+ 50 mm

T: Feeding of

Paper length

-130

+ 50 mm

Note: The length 130 mm is the length of the feeding path from the vertical path paper sensor to the delivery paper sensor, while the length 50 mm is a margin.

Figure 3-607

3-41

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 Jam Load stops

b.

Delivery sensor Paper folding motor

Delivery sensor Paper folding motor

T: Feeding of

Paper length

1.5 mm

T: Feeding of

Paper length

1.5 mm

Figure 3-608 6. Power-ON Jam Any of the No.1 paper sensor (PI18S), No.2 paper sensor (PI19S), No.3 paper sensor (PI20S), Vertical path paper sensor (PI17S) or delivery sensor (PI11S) on the paper sensor PCB detects paper at power-ON. 7. Door Open Jam The front door open/closed sensor (PI2S), outlet cover sensor (PI3S), or inlet cover sensor (PI9S) finds that the respective cover is open during operation. 8. Stitcher Staple Jam When the stitcher motor (M7S/M6S) is rotating clockwise, the stitcher home position sensor (MS7S/MS5S) does not turn ON within 0.5 secs after it has turned OFF. In addition, the sensor turns ON within 0.5 secs after the motor has been rotated counterclockwise. 9. Saddle Feeding Delay Jam (by the paper sensor for the paper positioning plate) The paper sensor for the paper positioning plate is not turned ON at the start of the push (folding) operation. Reference:
When all doors are closed after the user has removed the jam, the saddle stitcher unit checks whether the vertical path paper sensor (PI17S) has detected the presence of paper. If the sensor has detected paper, the unit will identify the condition as being faulty jam removal and send the jam signal to the host machine once again.

3-42

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

VII. POWER SUPPLY


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). The 24V power to motors, on the other hand, will not be supplied if any of the three door switches is open. The 5V power is used to drive sensors and ICs.
Inlet door switch Front door switch Delivery door switch

J19-1

J1-1 Motor systems Circuit breaker Solenoids

Finisher controller PCB

Saddle stitcher controller PCB

Sensors

J3-2

J2-5 Logic

Figure 3-701 2. Protective Mechanisms The 24 VDC power supply used for motors and solenoids is equipped with a circuit breaker (CB1). The 24V power supply used to drive the feed motor (M1S), alignment motor (M5S), and the paper positioning plate motor (M4S) is equipped with a fuse designed to blow when an overcurrent flows.

3-43

CHAPTER 4 MECHANICAL CONSTRUCTION


This chapter describes the mechanical features and operations, and disassembly and assembly procedures. Be sure to observe the following points when disassembling and assembling the machine: 1. Before performing disassembly and assembly, be sure to unplug the power plug for safetys sake.

2. Assemble parts by following the disassembly procedure in reverse unless otherwise mentioned. 3. Assemble screws, etc., making sure that their type (length and diameter) and location of use are correct. 4. In principle, do not operate the machine with any parts removed.

I.

FINISHER UNIT .......................... 4-1 A. Externals and Controls .............. 4-1 B. FEEDING SYSTEM ................... 4-9 C. PCBs ....................................... 4-13 D. Caution when removing MJ-1021 ................................... 4-13

II. A. B. C. D. E.

SADDLE STITCHER UNIT ....... 4-14 Externals and Controls ............ 4-14 SADDLE UNIT......................... 4-17 PCBs ....................................... 4-27 Power supply unit..................... 4-27 Accessory ................................ 4-28

CHAPTER 4 MECHANICAL CONSTRUCTION

I.
A.
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13]

FINISHER UNIT
Externals and Controls
Upper door End cap Front door Front lower door Tray 1 Tray 2 Grate-shaped upper guide (6) Grate-shaped lower guide (6) Saddle delivery tray Sub-support upper cover (2) Sub-support lower cover (2) Rear cover (3) Rear lower cover (4) Figures in parenthese ( ) indicate the number of mounting screws.
[7] [5] [2] [1]

[8] [6]

[3]

[4]

[9]

Figure 4-101

[12]

[10]

[13]

[11]

Figure 4-102

4-1

CHAPTER 4 MECHANICAL CONSTRUCTION

1.

Removing the Front Door Assembly 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the bushing [3] (center). 3) Remove the screw [4], and remove the bushing (top) [5]. Then, remove the front door assembly.

[5]

[4]

[1]

[3]

[2]

Figure 4-103

2. Removing the Rear Cover 1) Open the upper door assembly [1]. 2) Remove the three screws [2], and lift the rear cover [3] to remove.

[1]

[3]

[2]

[1] Upper door assembly [2] Screws [3] Rear cover

Figure 4-104

4-2

CHAPTER 4 MECHANICAL CONSTRUCTION

3.

Removing the Upper Door Assembly 1) Open the upper door assembly [1]. 2) Remove the two claws [2], and remove the upper door assembly.

[1]

[2]

Figure 4-105

4. Removing the Front Cover 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the front cover [3].

[1]

[2]

[3]

Figure 4-106

4-3

CHAPTER 4 MECHANICAL CONSTRUCTION

5. How to Lower the Tray 1/2 Unit 1) Insert a screwdriver or similar object into the hole [2] while supporting the tray assembly [1]. 2) Release the tray lift motor one-way gear, and lower the tray 1/2 unit.

[1] [2]

Figure 4-107 6. Removing the Tray 1 Unit 1) Open the upper cover and remove the end caps [1]. 2) Remove the prop upper cover [2] and the prop lower cover [3].
[1]

[2]

[3]

Figure 4-108 3) Remove the harness [1] from the bracket [2]. 4) Disconnect the three connectors [3]. Remove the screw [4], and remove the bracket. 5) Lift the tray 1 unit to remove.
[3]

[2]

[4]

[1]

Figure 4-109

4-4

CHAPTER 4 MECHANICAL CONSTRUCTION

7. 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.

[3]

[1] [2]

Figure 4-110 8. Removing the Tray 1/2 Lift Motor 1) Remove the tray 1/2. 2) Remove two screws [1], and two lift blocks [2]. 3) Remove the five screws [3], and remove the tray from the tray unit.
[2] [2]

[1]

[3]

[3]

Figure 4-111 4) Release the two harness stops [1]. Remove the four screws [2], and remove the tray frame [3]. Release the claws [4] to remove.

[2]

[3]

[2]

[1] [4] [4]

Figure 4-112

4-5

CHAPTER 4 MECHANICAL CONSTRUCTION

5) Disconnect the connector [1], and remove the two screws [2].

[2]

[1]

Figure4-113 6) Pull out the motor slightly, and remove the parallel pin [1] and the motor.

[1]

Figure 4-114

9. 1) 2)

3) 4)

Removing the Grate-Shaped Upper Guide Remove the slide guide [1] and end caps [2]. Release the tray lift motor gear clutch [6] with a screwdriver or similar object while supporting the tray assembly, and gently lower the tray assembly down to its lowest position. Remove the five screws [3] (M4). Remove the screw [4] (M3), and remove the grate-shaped upper guide [5].

[2]

[5]

[1]

[2]

[3] [3]

[4]

[6]

Figure 4-115

4-6

CHAPTER 4 MECHANICAL CONSTRUCTION

10. Removing the Grate-Shaped Lower Guide 1) Remove the tray assembly. 2) Remove the five screws [1] (M4), and remove 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. Caution:
To remove a sub-support, remove the front sub-support [2]. The rear sub-support [6] is adjustable. If the rear sub-support [6] has been removed, be sure to adjust the rear subsupport screw to the marking at which it was set prior to the removal, or adjust parallelism referring to "11. Installing the Rear SubSupport."

[1]

[3] [2] [4] [5] [6]

Figure 4-116 5) Free the harness [9] from the harness stop [8]. 6) Disconnect the two connectors [10], and remove the grate-shaped lower guide [7].

[10] [8]

[9]

[7]

Figure 4-117

4-7

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. 3) Move tray 2 by hand and check that it moves smoothly.

[4] [2] [3]

[1]

Figure 4-118 12. Removing the Right Guide Assembly 1) Remove the four screws [5] to take out the latch unit [4] 2) Remove the rear cover (see I-A-2). 3) Open the front door assembly [1]. 4) Remove the one screw [2], and remove the right guide assembly [3].

[3] [1]

[2]

[4]

[5]

Figure 4-119

4-8

CHAPTER 4 MECHANICAL CONSTRUCTION

B.

FEEDING SYSTEM

1. 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). Caution:
When removing the swing unit, make sure the stapler assembly unit is at its home position in front side (at the front-end position). If not, shift it to the home position manually. Be sure to escape the front paper stopper to rear side before moving the stapler assembly unit.

[1]

[1]

[2]

[1] [2] [1] [2] [2]

Figure 4-120
[7]

6) Remove the harness from the six harness clamps [1], and disconnect the seven connectors [2]. 7) Push and shift the stapler assembly unit to the center. 8) Release the stopper of the knurled belt escape roller [3] at front side, and remove two flanges [4] and one roller [5]. (same for the rear side) Caution:
1. Be sure not to drop the roller and flange when installing or removing them. 2. Make sure the direction of flange when installing the flange and the roller.

[5]

[4] [6]

[3]

Figure 4-122

Figure 4-121

9) Remove the front knurled belt [6] from the shaft [7]. (same for the rear side)

Figure 4-123 4-9

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.

[8]

[9]

[8]

[8]

Figure 4-124

Caution:
Install the swing unit to the machine so that the black plastic of swing unit is overlaid on the plate.

Figure 4-125

2. Removing the Feed Drive Unit 1) Remove the finisher controller PCB (see IC-1). 2) Remove the three screws [1] and pull down PCB base [2].

[2]

[1]

[1]

Figure 4-126 4-10

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 the feed drive unit. The move gear attachment must be adjusted also when removing and attaching the swing unit. If you forget to fasten the screw, the gear teeth may disengage, resulting in defective feed.

[6]

[5] [4]

[7]

[5]

[3]

[5]

Figure 4-127
[3]

3.

Removing the Buffer Roller Assembly 1) Remove the finisher controller PCB (see IC-1). 2) Remove the feed drive unit (see I-B-2). 3) Remove the screw [1], and remove the guide support plate assembly [2] to slide out the harness leads [3] towards the buffer roller assembly side.

[1]

[2]

Figure 4-128 4) Remove the front cover (see I-A-4). 5) Remove the screw [4], and remove the guide support plate assembly [5]. Then, remove the buffer roller assembly [6].

[6]

[4]

[5]

Figure 4-129

4-11

CHAPTER 4 MECHANICAL CONSTRUCTION

4. Removing the Stapler 1) Open the front cover. Remove two screws [1], and remove the stapler cover [2].
[1]

[2]

Figure 4-130

2) Move the stapler assembly unit [3] to the front. 3) Remove two connectors [4] and one screw [5]. 4) Turn the stapler assembly unit clockwise, and pull it out upward.
[5]

[3]

[4]

Figure 4-131

Caution:
When displaying Set stapler cartridge even though the staple cartridge is installed, it may not be installed correctly. If you move the gear of stapler unit manually, the cartridge cannot be detected due to the dislocation of gear because it is not correctly installed. In this case, move the gear to the position as shown below and reinstall the cartridge.

Gear

Figure 4-132

4-12

CHAPTER 4 MECHANICAL CONSTRUCTION

C.
1.

PCBs

[2]

Removing the Finisher Controller PCB 1) Remove the rear cover. 2) Disconnect the 19 connectors [1]. 3) Remove the four screws [2], and remove the finisher controller PCB [3].

[3]

[2] [2]

[1]

Figure 4-133

D.
1.

Caution when removing MJ-1021

After removing MJ-1021, make sure to install BLIND-FINCABLE (6LA01294000). 1) Install the BLIND-FIN-CABLE [1] with two screws.

[1]

Figure 4-134

4-13

CHAPTER 4 MECHANICAL CONSTRUCTION

II.
A.
1.

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 bushing [3], and then remove the front lower door assembly.

[3] [1]

[2]

Figure 4-201 2. Removing the Rear Lower Cover 1) Remove the four screws [1], and remove the rear lower cover [2].

[1] [1]

[2]

Figure 4-202

4-14

CHAPTER 4 MECHANICAL CONSTRUCTION

3. Removing the Front Inside Cover 1) Open the front lower door assembly [1]. 2) Remove the screw [2], and remove the folding roller knob [3]. 3) Remove the five screws [4], and remove the front inside cover [5].
[1]

[4]

[5]

[4] [2] [3] [4]

Figure 4-203 4. Removing the Saddle Delivery Tray Assembly 1) Lift up the open/close lever [2] of the saddle delivery tray assembly [1], and open the saddle delivery tray assembly.
[1] [2]

Figure 4-204 2) Remove the door shaft [3] in the direction of the arrow, and slide out towards the front of the saddle delivery tray assembly [4].
[4]

[3]

Figure 4-205 4-15

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 remove the saddle delivery tray assembly [8].

[5]

[7]

[6]

[8]

Figure 4-206 5. Removing Upper Delivery Guide Assembly 1) Remove the grate-shaped lower guide (see I-A-10). 2) Remove the two screws [1] and ground lead [2], and remove the upper delivery guide assembly [3].
[2]

[1] [3] [1]

Figure 3-207 6. Removing the PCB Cover 1) Remove the four screws [1], and remove the PCB cover [2].
[1]

[2]

[1]

Figure 4-208 4-16

CHAPTER 4 MECHANICAL CONSTRUCTION

B.

SADDLE UNIT

1. Removing the Saddle Unit 1) Remove the grate-shaped lower guide (see I-A-7). 2) Remove the right guide assembly (see I-A8). 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). 6) Remove the saddle delivery tray assembly (see II-A-4).

[1]

[2]

Figure 4-209

7) Remove the harness from the harness clamp [3] and harness lead [4]. 8) Remove the upper delivery guide (see II-A5). 9) Remove the PCB cover (see II-A-6). 10) Disconnect two connectors [1] and remove the two screws [2].

[4]

[3]

Figure 4-210

4-17

CHAPTER 4 MECHANICAL CONSTRUCTION

11) Remove the screw [5].

[5]

Figure 4-211
[6] [6]

12) Remove the two screws [6], and remove the saddle stitcher unit [7] by moving it in the pick-up direction.

[7]

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].

[8] [9]

Figure 4-213 4-18

CHAPTER 4 MECHANICAL CONSTRUCTION

2. 1) 2) 3) 4) 5)

Removing the Paper Folding Roller Remove the front lower door assembly (see II-A-1). Remove the front inside cover (see II-A-3). Remove the upper delivery guide assembly (see II-A-5). Remove the PCB cover (see II-A-6). Disconnect the two connectors [1].

[1]

Figure 4-214

6) Disconnect two connectors [2], remove the three screws [3], and remove the paper pushing motor mount [4].

[4]

[2]

[3]

[2]

Figure 4-215

4-19

CHAPTER 4 MECHANICAL CONSTRUCTION

7) Remove the tension springs (front [5], rear [6]).

[5]

Figure 4-216

[6]

Figure 4-217

4-20

CHAPTER 4 MECHANICAL CONSTRUCTION

8) Remove the two C-rings [7], and remove the sensor flag [8] and two bearings [9] at the rear.

[9] [7]

[8]

Figure 4-218 9) Remove the two C-rings [10], and remove the two gears [11] at the front.

[11] [10]

Figure 4-219

4-21

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.
[ 14] [ 14]

[ 15]

[ 13]

Figure 4-221 3. Installing the Paper Folding Roller 1) Attach the gear [2] so that the grooved section [1] on the gear is facing the grooved section [1] on the paper folding roller to align the phases.

[2]

[1]

Figure 4-222 4-22

CHAPTER 4 MECHANICAL CONSTRUCTION

4. 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].

[2] [1]

[3]

Figure 4-223 3) Pull out the stitcher mount unit [4] to the front.
[4]

Figure 4-224

5. Adjusting the Stitcher Position 1) Remove the front lower door assembly (see II-A-1). 2) Remove the front inside cover (see II-A-3). 3) Open the front door assembly. 4) Pull out the stitcher mount unit to the front, then pull out the stitcher towards you and then pull the stitcher down. 5) Remove the three screws [1], and remove the stitcher mount unit cover [2].

[1]

[2]

Figure 4-225

4-23

CHAPTER 4 MECHANICAL CONSTRUCTION

6) Remove the stitcher positioning tool [3] from the back of the cover.

[3]

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 adjust the rear stitcher, remove the center guide plate [5] and the rear guide plate [6] (one screw each).

[6]

[5]

[4]

Figure 4-227 8) If you must adjust the front stitcher, loosen the two screws [8] on the stitcher mount [7]. If you must adjust the rear stitcher, loosen the two screws [9].
[9]

[8]

[7]

Figure 4-228

4-24

CHAPTER 4 MECHANICAL CONSTRUCTION

9) Insert the tool [10] into the staple slot of the stitcher [9].

[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. Then, tighten the screws [12] on the mount to fix the two in place.
[11]

[12]

Figure 4-230

6.

Removing the Positioning Plate Unit 1) Remove the saddle stitcher controller PCB (see II-C-1). 2) Disconnect the two connectors [1], remove the three harness clamps [2], and remove the harness leads [3] from the two edge saddles [4]. 3) Remove the two screws [5], slide the positioning plate unit [6] once towards the front and remove from the rear side.

[2] [3] [6] [1]

[5]

[4]

Figure 4-231

4-25

CHAPTER 4 MECHANICAL CONSTRUCTION

7.

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 deflecting plate bushing, and pull out the No.1 paper deflecting plate shaft [2] toward the rear. (The procedure is the same for the No.2 paper deflecting plate.)

[1]

[2]

Figure 4-232 4) After detaching the front shaft of the No.1 paper deflecting plate [3] from the front side plate, remove the No.1 paper deflecting plate.
[3]

Figure 4-233

4-26

CHAPTER 4 MECHANICAL CONSTRUCTION

C.
1.

PCBs

[1]

[2] [3]

[2] [2]

[1]

Removing the Saddle Stitcher Controller PCB 1) Remove the PCB cover (see II-A-6). 2) Remove the four screws [1] and 14 connectors [2], and remove the saddle stitcher controller PCB [3].

[1]

[2]

[1]

Figure 4-234

D.

Power supply unit

[1]

1. Removing the Power Supply Unit 1) Remove the rear lower cover (see II-A-2). 2) Remove one connector [1] and two screws [2] to remove the power supply unit [3].

[2]

[3]

Figure 4-235

4-27

CHAPTER 4 MECHANICAL CONSTRUCTION

E.
1.

Accessory
[2]

Support tray Install the support tray (accessory) to the suddle delivery tray when the paper stacking on the saddle delivery tray is significantly deteriorated, 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. 1) Take off the saddle delivery tray assembly (see II-A-4). 2) Install the support tray [2] to the saddle delivery tray [1] with 2 screws[3].

[3] [1]

Figure 4-236

3) Install the saddle delivery tray.

Figure 4-237

4-28

CHAPTER 4 MECHANICAL CONSTRUCTION

4-29

CHAPTER 5 MAINTENANCE AND INSPECTION

I.

PERIODICALLY REPLACED PARTS......................................... 5-1 A. Finisher Unit .............................. 5-1 B. Saddle Stitcher Unit ................... 5-1

II.

CONSUMABLES AND DURABLES ................................ 5-2 A. Finisher Unit .............................. 5-2 B. Saddle Stitcher Unit ................... 5-2 III. PERIODICAL SERVICING .......... 5-2

CHAPTER 5 MAINTENANCE AND INSPECTION

I.
A.

PERIODICALLY REPLACED PARTS


Finisher Unit
The finisher unit does not have parts that must be replaced on a periodical basis.

B.

Saddle Stitcher Unit


The saddle stitcher unit does not have parts that must be replaced on a periodical basis.

5-1

CHAPTER 5 MAINTENANCE AND INSPECTION

II.

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 machines warranty period. Replace them as necessary.

A.
1 2 3

Finisher Unit
No. Name Stapler Knurled belt Paddle Qty 1 2 2 4 Estimated Life 500,000 operations 1,000,000 copies 1,000,000 copies Paddle unit Paddle rubber only Remarks 5,000 operations/cartridge

B.
1

Saddle Stitcher Unit


No. Name Stitcher Qty 2 Estimated Life 200,000 operations Remarks 2,000 operations/cartridge

III. PERIODICAL SERVICING


Item Knurled belt Paddle Host machine minimum servicing interval Cleaning Use moist cloth Interval Work Remarks

5-2

CHAPTER 5 MAINTENANCE AND INSPECTION

5-3

CHAPTER 6 TROUBLESHOOTING

I.

ADJUSTMENTS ......................... 6-1 A. Electrical System (finisher unit) .............................. 6-1 B. Electrical System (saddle stitcher unit) ................... 6-6 II. ARRANGEMENT OF ELECTRICAL PARTS ................. 6-8

A. Finisher Unit .............................. 6-8 B. Saddle Stitcher Unit ................. 6-15 C. Light-Emitting Diodes (LED) and Check Pins by PCB .......... 6-21 III. TROUBLESHOOTING .............. 6-23 A. Finisher Unit ............................ 6-23 B. Saddle Stitcher Unit ................. 6-33

CHAPTER 6 TROUBLESHOOTING

I.
A.
1.

ADJUSTMENTS
Electrical System (finisher unit)

2.

Adjusting the Height Sensor (PS1) Perform the following adjustments whenever you have replaced the finisher controller PCB or the height sensor (PS1). 1) Set SW3 on the finisher controller PCB as indicated.
ON

Adjusting the Rear Alignment Position If you have replaced the finisher controller PCB or if an alignment fault occurs, adjust as follows. Performing the steps will affect all paper sizes. 1) Remove the rear cover of the finisher unit. 2) Set SW3 of the finisher controller PCB as indicated.
ON

Figure 6-102
1 2 3 4 5 6 7 8

Figure 6-101 2) Place a paper on the tray. 3) Press SW1 on the finisher controller PCB. This causes the finisher to execute automatic adjustment, in which the tray unit will shift. At the end of adjustment, trays will return to their home positions. During adjustment, LED1 flashes. At the end of adjustment, LED1 turns and remains ON. If automatic adjustment fails, the mechanism stops while the tray in question is being adjusted (at the same time, LED1 turns OFF). 4) Shift all bits on SW3 to OFF, and turn OFF the host machine once.

3) If you are using A4 paper, press SW1 on the finisher controller PCB. If you are using LT paper, press SW2 on the finisher controller PCB. Pressing SW1/2 will open the swing guide and cause the rear alignment plate to move to A4/LT positions. 4) Place 10 sheets of A4/LT paper between the front and rear alignment plate, butting them against the stoppers. 5) Press SW1 or SW2 on the finisher controller PCB, and butt the rear alignment plate against the sheets. Pressing SW1 will shift the rear alignment plate to the front in 0.35 mm increments. Pressing SW2 will shift the rear alignment plate to the rear in 0.35 mm increments.

6-1

CHAPTER 6 TROUBLESHOOTING

3.
Rear alignment plate Shift by SW2 A4/LT paper Shift by SW1

Adjusting the Staple Position (stapler movement range) Adjust as follows if you have replaced the finisher controller PCB. Performing this one step adjusts the position of all paper sizes in front and rear side of staple. 1) Remove the rear cover from the finisher unit. 2) Set SW3 on the finisher controller PCB as indicated. In case of use A4 paper:
ON

Stopper

Stopper

Figure 6-104
Front alignment plate

In case of use LT paper:


ON

Figure 6-103 6) Press SW1 and SW2 simultaneously to store the adjustment value (this will lower the swinging guide). 7) Shift all bits of SW3 to OFF, and install the rear cover of the finisher unit.
1 2 3 4 5 6 7 8

Figure 6-105 3-a) Press the SW1 (finisher controller PCB) for adjusting the rear side of staple position. 3-b) Press the SW2 (finisher controller PCB) for adjusting the front side of staple position. Pressing SW1/2 will open the swing guide and cause the knurled belt to rotate. Before adjusting either front or rear side of staple after another, turn off the power then turn it on, or turn off all switches (bits) of SW3. 4) Within 5 secs after pressing the switch, place one sheet of paper between the front and rear alignment plate, butting it against the stoppers. When the finisher detects the paper, it will lower the swing guide and execute stapling (rear, 1-position). Take out the stapled paper manually as delivery will not be executed.

6-2

CHAPTER 6 TROUBLESHOOTING

2922mm (A4)/ 2742mm (LT)

Stapler Rear alignment plate

Staple Paper

Shift by SW2

Shift by SW1 Feeding direction

Stopper

Figure 6-107 7) Press SW1 and SW2 simultaneously. This will open the swing guide, and cause the knurled belt to rotate. Placement of one sheet of paper will cause the finisher to start stapling. 8) Check the stapling position. If good, set all bits of SW3 to OFF. If re-adjustments are necessary, go back to Step 6. Caution:
The settings held by the finisher controller PCB are changed as soon as SW1 or SW2 is pressed. As such, to recover the previous settings after the press, you must press the other of the two switches as many times as you pressed previously.

Stopper

Front alignment plate

Figure 6-106 5) If the stapling position is correct, set all bits on SW3 to OFF to end the adjustments. If you need to change the stapling position, on the other hand, go to the next step. 6) To suit the position of the staple on the paper, press SW1 or SW2 on the finisher controller PCB as many times as necessary. Pressing SW1 will shift the stapling position to the front in 0.3 mm increments. Pressing SW2 will shift the stapling position to the rear in 0.3 mm increments.

6-3

CHAPTER 6 TROUBLESHOOTING

4.

Adjusting the Buffer Roller Winding Amount Perform this adjustment in the following instances: a. When the finisher controller PCB or the EEPROM (Q2) on the finisher controller PCB has been replaced b. When something causes the winding amount to fluctuate The "winding amount" is the amount of difference between the First and Second sheets wound onto the buffer roller device in the feed direction.

6) Measure the winding amount (shift) of the stack of sheets, and compare this amount with the standard amounts. This amount should be measured at the center of the paper leading edge.

First sheet and Second sheet: 0 1mm First sheet and Third sheet: 4mm or less Second sheet and Third sheet: 4mm or less Paper delivery direction

Third sheet Second sheet First sheet

Paper delivery direction

Second sheet Third sheet

Figure 6-110 7) If the amount is within the standard, turn the host machine OFF, and then set all bits of SW3 to OFF. If the amount is outside the standard, perform the following. 8) Turn the host machine OFF, and set SW3 on the finisher controller PCB as indicated. If EEPROM (Q2) on the finisher controller PCB has been replaced, proceed to step 10).
ON

Winding amount

First sheet

Figure 6-108 1) Set SW3 on the finisher controller PCB as indicated.


ON

Figure 6-111
1 2 3 4 5 6 7 8

Figure 6-109 2) Turn the host machine OFF then back ON again. 3) Set the mode setting on the host machine to "1" and the number of originals (A4 or LT) to "3" in the staple mode. 4) Press the copy start key. Copying starts, three sheets for the first copy are output as a stack on the staple tray, and copying stops with the copies held at the delivery roller. 5) Remove the stack of sheets from the finisher delivery taking care to prevent the offset of the output sheets from changing. 6-4

9) Turn the host machine ON, and then press SW2 on the finisher controller LCB. The current setting values are displayed at LED1.
Adjustment value 0 Lights for 1 second (once)

Adjustment value +N Blinks (lights for 0.2 second) for N times. Adjustment value -N Lights for 1 second (once), and blinks (lights for 0.2 second) for N times. The adjustment width is 0.72mm for each N=1.

Table 6-101

CHAPTER 6 TROUBLESHOOTING

10) Turn the host machine OFF, and then set SW3 on the finisher controller PCB as indicated.
ON

Figure 6-112 11) Press SW1 or SW2 on the finisher controller PCB as necessary. Each press of SW1 increments the winding amount in 0.72mm increments. Each press of SW2 decrements the winding amount in 0.72mm increments.

Paper delivery direction

Third sheet Second sheet First sheet Movement of Movement of direction of direction of 1st sheet by SW2 1st sheet by SW1

Figure 6-113 12) Repeat steps 1) though 6) twice. Check that the winding amount is within the standard in both times. 13) Turn the host machine OFF, and set all bits of SW3 to OFF. This completes the adjustment.

6-5

CHAPTER 6 TROUBLESHOOTING

B.
1.

Electrical System (saddle stitcher unit)

Mark

Adjusting the Folding Position The folding position is adjusted by changing the settings of bits 6 through 8 of DIPSW1 on the saddle stitcher controller PCB to match the stitching position (i.e., adjusting the distance over which the paper positioning plate is moved to the folding position from the stitching position.) If you have replaced the saddle stitcher controller PCB, be sure to set the new DIPSW1 so that the settings will be the same as those on the old DIPSW1. If, for any reason, you must change the following position, perform the following steps: 1) Remove the PCB cover, and set bits 1 through 4 of DIPSW1 on the saddle stitcher controller PCB as indicated.
ON

A3/LD paper

Insert direction

Figure 6-115 4) Press SW2 on the saddle stitcher controller PCB so that the feed motor (M1S) starts to rotate. (Press SW2 three seconds or more if LD paper is used). 5) Open the inlet cover, and insert two sheets of paper (push them in by hand until the leading edge of the sheets butts against the paper positioning plate).

Do not change bits 5 through 8. Figure 6-114 2) Remove the rear cover of the saddle stitcher unit, and tape the actuator of the inlet cover open sensor (PI9S) and the inlet cover open detection switch (MS1S) of the saddle stitcher unit in place. 3) Before inserting the paper, mark the top of the paper (you will be using two sheets of A3 or LD paper).

Sheets Mark

Figure 6-116 6) Close the inlet door while holding it down with your hand. 7) Press SW2 on the saddle stitcher controller PCB. The saddle stitcher unit will stitch the sheets, and fold and deliver the stack automatically.

6-6

CHAPTER 6 TROUBLESHOOTING

8) Measure the distance (L) between the stitching position and the folding position. Then, perform positive width adjustment or negative width adjustment to suit the relationship between the stitching position and the folding position. If the stitching position is below the folding position, perform positive width adjustment. If the stitching position is above the folding position, perform negative width adjustment.
Mark Positive Width Adjustment

9) Change the settings of bits 6 through 8 on DIPSW1 referring to Table 6-102 below. If the width adjustment is 0, The stitching position and the folding position match, requiring no change. If for positive width adjustment, Set DIPSW1 so that the difference resulting from subtraction of the interval from the appropriate setting in Table 6-102 is provided. For instance, if the DIPSW1 is currently set to +2 and the interval is +1 mm, set DIPSW1 to reflect -2. If for negative width adjustment Set DIPSW1 so that the sum resulting from addition of the interval from the appropriate setting is provided. For instance, if the DIPSW1 is currently set to -1 and the interval is +0.5 mm, set DIPSW1 to reflect +1.
DIPSW1 bit settings bit 6 OFF OFF OFF OFF bit 7 ON ON OFF OFF OFF ON ON bit 7 OFF bit 8 ON OFF ON OFF ON OFF ON bit 8 OFF Settings (in units of 0.5 mm) +3 +2 +1 0 1 2 3

Folding position Stitching position

Unit: mm Example: If L is 1 mm, provide +1 mm.

ON ON ON

Mark Negative Width Adjustment

Do not touch the following: bit 6 ON

Table 6-102 10) Set bits 1 through 4 on DIPSW1 to OFF.


Stitching position Folding position

2.

Stitching Position (adjusting center stitching) Use the host machine adjustment mode to perform the following:

Unit: mm Example: If L is 0.5 mm, provide -0.5 mm.

Figure 6-117 6-7

CHAPTER 6 TROUBLESHOOTING

II.
A.
1.

ARRANGEMENT OF ELECTRICAL PARTS


Finisher Unit
Sensors

PI9 PI19

PI23 PI24

PI18 PI17 PS1 PI10 PI6 PI14 PI20 PI8 PI3 PI4 PI29 PI28 PI16 PI26 PI12 PI11 PI1 PI15

PI5

PI21 PI22 PI30 PI31

PI7

PI25

Figure 6-201

6-8

CHAPTER 6 TROUBLESHOOTING

Name Photointerrupter

Notation PI1 PI3 PI4 PI5 PI6 PI29 PI7 PI8 PI10 PI11 PI12 PI14 PI15 PI16 PI17 PI18 PI9 PI19 PI20 PI21 PI22 PI23 PI24 PI25 PI26 PI28 PI30 PI31

Function 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 Detects front alignment plate at home position Detects the stapler at home position Detects the tray at home position Detects delivery motor clock pulses Detects paper on tray 1 Detects paper on tray 2 Detects paper in the buffer path Detects the finisher joint Detects the state (open) of the door Detects paper at the inlet to the buffer path Detects the state (open) of the swing guide Detects tray 1 lift motor clock pulses 1 (on sensor PCB) Detects tray 1 lift motor clock pulses 2 (on sensor PCB) Detects swing guide clock Detects edging of staples (inside stapler) Detects staple drive home position (inside stapler) Detects tray 2 lift motor clock pulses 1 (on sensor PCB) Detects tray 2 lift motor clock pulses 2 (on sensor PCB) Detects tray home position Detects paddle home position Detects knurled belt home position Detects the cartridge discrimination (inside stapler) Detects the staple (inside stapler) Detects the height of the stack on the tray

Height sensor

PS1

Table 6-201

6-9

CHAPTER 6 TROUBLESHOOTING

2.

Microswitches

MS9

MS2 MS6 MS1 MS3

MS4

Figure 6-202
Name Microswitches Notation MS1 MS2 MS3 MS4 MS6 MS9 Function 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

6-10

CHAPTER 6 TROUBLESHOOTING

3.

Motors

M5

M10

M7 M14 M3 M11 M2 M13

M8 M1 M9 M4

M6

Figure 6-203

6-11

CHAPTER 6 TROUBLESHOOTING

Name Motor

Notation M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M13 M14

Function 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

6-12

CHAPTER 6 TROUBLESHOOTING

4.

Solenoids

SL4 SL2 SL3 SL1

Figure 6-204
Name Solenoid Notation SL1 SL2 SL3 SL4 Flapper solenoid Buffer inlet solenoid Buffer outlet solenoid Paddle solenoid Function

Table 6-204

6-13

CHAPTER 6 TROUBLESHOOTING

5.

PCBs

[4]

[4]

[1] [3]

[4] [2]

[5]

Figure 6-205
Reference [1] [2] [3] [4] [5] Finisher controller PCB Relay PCB 4 Relay PCB 3 Sensor PCB Power supply unit Name

Table 6-205 6-14

CHAPTER 6 TROUBLESHOOTING

B.
1.

Saddle Stitcher Unit


Photointerrupters

PI18S PI19S PI20S

PI16S PI9S

PI21S PI2S PI11S PI6S PI5S PI3S PI17S

PI14S PI15S

PI12S PI13S

PI8S PI7S

PI4S PI1S

Figure 6-206

6-15

CHAPTER 6 TROUBLESHOOTING

Name Photointerrupter

Notation PI1S PI2S PI3S PI4S PI5S PI6S PI7S PI8S PI9S PI11S PI12S PI13S PI14S PI15S PI16S PI17S PI18S PI19S PI20S PI21S

Function Detects clock pulses from the paper pushing plate motor Detects the state (open) of the front door Detects the state (open) of the delivery cover Detects clock pulses from the paper folding motor Detects the alignment plates at home position Detects paper on the tray Detects paper positioning plate at home position Detects paper on the paper positioning plate Detects the state (open) of the inlet cover Detects paper in the delivery area Detects the phase of the crescent roller Detects the guide at home position Detects the paper pushing plate at home position Detects the paper pushing plate at top position Detects the state (in) of the stitcher unit Detects paper in the vertical path Detects paper (No. 1; on paper sensor PCB) Detects paper (No. 2; on paper sensor PCB) Detects paper (No. 3; on paper sensor PCB) Detects the paper folding at home position

Table 6-206

6-16

CHAPTER 6 TROUBLESHOOTING

2.

Microswitches

MS1S MS4,5S MS6,7S MS2S

MS3S

Figure 6-207
Name Microswitches Notation MS1S MS2S MS3S MS4S MS5S MS6S MS7S Detects Detects Detects Detects Detects Detects Detects Function the state (open) of the inlet door the state (open) of the front door the state (open) of the delivery door the presence of staples (rear) stitching home position (rear) the presence of staples (front) stitching home position (front)

Table 6-207 6-17

CHAPTER 6 TROUBLESHOOTING

3.

Motors

M6S M7S M4S M3S M1S M2S M5S

M8S

Figure 6-208
Name Motor Notation M1S M2S M3S M4S M5S M6S M7S M8S Feed motor Paper folding motor Guide motor Paper positioning plate motor Alignment motor Stitcher motor (rear) Stitcher motor (front) Paper pushing plate motor Function

Table 6-208 6-18

CHAPTER 6 TROUBLESHOOTING

4.

Solenoids

SL1S

SL2S

SL4S

Figure 6-209
Name Solenoid Notation SL1S SL2S SL4S Function No. 1 paper deflecting plate solenoid No. 2 paper deflecting plate solenoid Feed plate contact solenoid

Table 6-209

6-19

CHAPTER 6 TROUBLESHOOTING

5.

PCBs

[2]

[1]

Figure 6-210
Reference [1] [2] Paper sensor PCB Name Saddle stitcher controller PCB

Table 6-210

6-20

CHAPTER 6 TROUBLESHOOTING

C.

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. Do not touch them in the field.

1.

Finisher Controller PCB

12 1 1 A 15 15 B 1

A B J14

1 12

1 J3

8 1 J2

10 1

A B J6

1 10

1 J17

12 1 J16 7 1 J24 9 1 J4

LED1 LED2 SW1 SW2

J12

1 A 14 4 1 8

14 SW3 B 1 J21

J9

10 1 7 1

J10 6 1

J23 J11 11 J8 J1 J18 6 1 J22 2 1 7 J7 1 11 J5 1 J19 2 1 1 5

Figure 6-211
Switch SW1 SW2 SW3 Function Adjust the height sensor/alignment plate position/stapling position and move the trays up, etc. Adjust the alignment plate position/staple position and move the trays down, etc. Adjust the height sensor/alignment plate position and stapling position, etc.

Table 6-211

6-21

CHAPTER 6 TROUBLESHOOTING

2.

Saddle Stitcher Controller PCB


SW1 15 J11 1 10 J7 1 1 10 J9 J4 1 CB1 15 1 J6 2 1 14 J1 J8 1 8 J15 1 4 J5 1 5 J12 1 9 J18 1 3 1 SW2 J13 7 1 J2 6

1 J10 8

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. SW2 Starts correction of discrepancy between stitching position and folding position.

Table 6-212

6-22

CHAPTER 6 TROUBLESHOOTING

III. TROUBLESHOOTING
A.
1.

Finisher Unit
Fault in communication with host machine
Cause Step 1 Checks Turn the host machine OFF then ON. Is the problem corrected? Is the wiring between the finisher controller PCB and the host machine controller PCB normal? Replace the finisher controller PCB and the host machine DC controller PCB. Is the problem corrected? Yes/No Yes End. Action

Finisher controller PCB, Host machine DC controller PCB Wiring

No

Correct it.

Finisher controller PCB, Host machine DC controller PCB

Yes No

End. Mulfunction of the host machine.

2.

Fault in communication with saddle stitcher unit


Cause Step 1 Checks Turn the host machine OFF then ON. Is the problem corrected? Is the wiring between the finisher controller PCB and the saddle stitcher controller PCB normal? Measure the voltage between J19-1 (+) and J19-2 () on the finisher controller PCB. Is it 24 VDC? Yes/No Yes End. Action

Finisher controller PCB, Saddle stitcher controller PCB Wiring

No

Correct it.

Power supply Saddle stitcher controller PCB

No Yes

Replace the finisher controller PCB. Replace the saddle stitcher controller PCB.

6-23

CHAPTER 6 TROUBLESHOOTING

3.

Faulty height sensor (communication)


Cause Step 1 Checks Turn the host machine OFF then ON. Is the problem corrected? Is the wiring between the finisher controller PCB and the sensors normal? Measure the voltage between J6-2 (+) and J6-4 () on the finisher controller PCB. Is it 5 VDC? Yes/No Yes End. Action

Finisher controller PCB

Wiring

No

Correct the wiring.

Power supply Height sensor (PS1)

No Yes

Replace the finisher controller PCB. Adjust the height sensor once again. If an error occurs again, replace the height sensor.

4.

Faulty height sensor (disconnection)


Cause Step 1 Checks Is J6 on the finisher controller PCB, J114 on the height sensor, or the relay connector J212 disconnected? Measure the voltage between J6-2 (+) and J6-4 () on the finisher controller PCB. Is it 5 VDC? Is the wiring between the finisher controller PCB and sensors normal? Yes/No Yes Action Connect the connector.

Connector

Power supply

No

Replace the finisher controller PCB.

Height sensor (PS1) Wiring

Yes No

Replace the height sensor. Correct the wiring.

6-24

CHAPTER 6 TROUBLESHOOTING

5.

Faulty height sensor (adjustment)


Cause Step 1 Checks Try making adjustments using the DIP switch once again. Is the problem corrected? Is the wiring between the finisher controller PCB and sensors normal? Measure the voltage between J6-2 (+) and J6-4 () on the finisher controller PCB. Is it 5 VDC? Yes/No Yes End. Action

Adjustment

Wiring

No

Correct the wiring.

Power supply Height sensor (PS1)

No Yes

Replace the finisher controller PCB. Replace the height sensor.

6.

Faulty back-up RAM


Cause Step 1 Checks Turn the host machine OFF then ON. Is the problem corrected? Replace the finisher controller PCB and punch driver PCB. Is the problem corrected? Yes/No Yes End. Action

Finisher controller PCB, punch drive PCB

Yes

End.

7.

Faulty delivery motor


Cause Step 1 2 3 Checks Turn the delivery roller by hand. Does it turn smoothly? Check the delivery motor clock sensor. Is the sensor normal? Does the voltage between J11-1 and J11-2 on the finisher controller PCB change to 24 VDC as soon as the delivery motor starts to rotate? Yes/No No No No Yes Action Correct mechanical operation. Replace the sensor. Replace the finisher controller PCB. Check the wiring from the motor to the controller PCB. If normal, replace the motor.

Deliver roller Delivery motor clock sensor (PI10) Finisher controller PCB

6-25

CHAPTER 6 TROUBLESHOOTING

8.

Faulty alignment motor


Cause Step 1 Checks Check the alignment plate home position sensor. Is it normal? Is the wiring between the finisher controller PCB and the alignment plate motor normal? Is there any mechanical obstacle in the path of the alignment plate? Replace the alignment motor. Is the problem corrected? Yes/No No Action Replace the sensor.

Alignment plate home position sensors (PI6, PI29) Wiring

No

Correct the wiring.

Alignment plate

Yes

Remove the mechanical obstacle. End. Replace the finisher controller PCB.

Alignment motors (M3, M11) Finisher controller PCB

Yes No

9.

Faulty staple motor


Cause Step 1 Checks Is the wiring between the stapler and the finisher controller PCB normal? Replace the stapler. Is the problem corrected? Yes/No No Action Correct the wiring.

Wiring

Stapler Finisher controller PCB

Yes No

End. Replace the finisher controller PCB.

6-26

CHAPTER 6 TROUBLESHOOTING

10. Faulty stapler shift motor


Cause Stapler shift home position sensor (PI7) Wiring Step 1 Checks Check the stapler shift home position sensor. Is the sensor normal? Is the wiring between the finisher controller PCB and the stapler shift motor normal? Is there any mechanical obstacle in the path of the stapler shift base? Replace the stapler motor. Is the problem corrected? Yes/No No Action Replace the sensor.

No

Correct the wiring.

Stapler shift base

Yes

Remove the mechanical obstacles. End Replace the finisher controller PCB.

Stapler shift motor (M4) Finisher controller PCB

Yes No

11. Faulty swing motor (related to MS6)


Cause Swinging mechanism Step 1 Checks Turn the swing motor in reverse by hand. Does the swing guide move up and down? Is the swing guide closed detection switch 2 normal? Does the swing motor rotate in reverse at a specific timing? Yes/No No Action Correct the swing mechanism.

Swing guide closed detection switch 2 (MS6) Swing motor (M7) Finisher controller PCB

2 3

No No Yes

Replace the microswitch. Replace the motor. Replace the finisher controller PCB.

6-27

CHAPTER 6 TROUBLESHOOTING

12. Faulty swing motor (related to PI18)


Cause Swinging mechanism Step 1 Checks Turn the delivery motor in reverse by hand. Does the swing guide move up and down? Is the swing guide open sensor normal? Does the swing motor rotate in reverse at a specific timing? Yes/No No Action Correct the swinging mechanism.

Swing guide open sensor (PI18) Swing motor (M7) Finisher controller PCB

2 3

No No Yes

Replace the sensor. Replace the motor. Replace the finisher controller PCB.

13. Faulty swing motor (related to MS3)


Cause Safety zone switch (MS3) Step 1 2 Swing guide closed detection switch 2 (MS6) 3 Checks Check the safety zone switch. Is the switch normal? Is the safety zone detection switch pressed correctly? Check the swing guide closed detection switch 2. Is the switch normal? Is the swing guide closed detection switch 2 pressed correctly? Yes/No No No No Action Replace the switch. Correct mechanical operation. Replace the switch.

4 Finisher controller PCB

No Yes

Correct mechanical operation. Replace the finisher controller PCB.

6-28

CHAPTER 6 TROUBLESHOOTING

14. Faulty swing motor (related to PI20)


Cause Swing motor clock sensor (PI20) Finisher controller PCB Step 1 2 Checks Check the swing motor clock sensor. Is the sensor normal? Does the voltage of the swing motor between J9-6 and -7 on the finisher controller PCB reach 24 V at a specific rotation timing? Yes/No No No Yes Action Replace the sensor. Replace the finisher controller PCB. Check the wiring from the motor to the finisher controller PCB. If normal, replace the motor.

15. Faulty tray 1 lift motor (related to PI8)


Cause Tray 1 home position sensor (PI8) Tray 1 lift mechanism Step 1 2 Checks Check the tray 1 home position sensor. Is it normal? Check the tray 1 lift mechanism. Is the mechanism normal? Is the tray 1 lift motor supplied with 24 VDC by the finisher controller PCB as soon as the tray is driven? Check the wiring from the finisher controller PCB to the tray 1 lift motor. Is the wiring normal? Yes/No No No Action Replace the sensor. Correct the mechanism. Replace the finisher controller PCB.

Finisher controller PCB

No

Wiring Tray 1 lift motor (M5)

No Yes

Correct the wiring. Replace the tray 1 lift motor.

16. Faulty tray 2 lift motor (related to PI25)


Cause Tray 2 home position sensor (PI25) Tray 2 lift mechanism Step 1 2 Checks Check the tray 2 home position sensor. Is it normal? Check the tray 2 lift mechanism. Is the mechanism normal? Is the tray 2 lift motor supplied with 24 VDC by the finisher controller PCB as soon as the tray is driven? Check the wiring from the finisher controller PCB to the tray 2 lift motor. Is the wiring normal? Yes/No No No Action Replace the sensor. Correct the mechanism. Replace the finisher controller PCB.

Finisher controller PCB

No

Wiring Tray 2 lift motor (M10)

No Yes

Correct the wiring. Replace the tray 2 lift motor.

6-29

CHAPTER 6 TROUBLESHOOTING

17. Faulty tray 1 motor (related to PI9/PI19)


Cause ___ Step 1 Checks Does the tray 1 move up/ down? Yes/No No Yes 2 Finisher controller PCB Tray 1 lift mechanism Tray 1 lift motor (M5) Tray 1 lift motor clock sensor 1/2 (PI9/19) Finisher controller PCB 4 Is the tray 1 lift motor clock sensor 1/2 normal? 3 Is the motor supplied with power by the finisher controller PCB as soon as the tray 1 moves up/down? Is there a fault in the tray 1 lift mechanism? Yes No Yes No No Yes Action Go to step 2. Go to step 4. Go to step 3. Replace the finisher controller PCB. Correct the tray 1 lift mechanism. Replace the tray 1 lift motor. Replace the sensor PCB. Replace the finisher controller PCB.

18. Faulty tray 2 motor (related to PI23/24)


Cause ___ Step 1 Checks Does the tray 2 move up/ down? Yes/No No Yes 2 Finisher controller PCB Tray 2 lift mechanism Tray 2 lift motor (M10) Tray 2 lift motor clock sensor 1/2 (PI23/24) Finisher controller PCB 4 Is the tray 2 lift motor clock sensor 1/2 normal? 3 Is the motor supplied with power by the finisher controller PCB as soon as the tray 2 moves up/down? Is there a fault in the tray 2 lift mechanism? Yes No Yes No No Yes Action Go to step 2. Go to step 4. Go to step 3. Replace the finisher controller PCB. Correct the tray 2 lift mechanism. Replace the tray 2 lift motor. Replace the sensor PCB. Replace the finisher controller PCB.

6-30

CHAPTER 6 TROUBLESHOOTING

19. Faulty second feed motor (related to PI5)


Cause Second feed motor (M8) Step 1 Checks Does the second feed motor in reverse at a specific timing? Yes/No No Action Replace the second feed motor or the finisher controller PCB. Engage them correctly.

Shutter mechanism

Are the shutter and the shutter upper/lower bar engaged correctly? Turn the feed roller 2 in reverse by hand. Does the shutter upper/lower bar move up/down? Is the shutter open detection sensor normal?

No

No

Correct mechanism from the shutter upper/ lower bar to the gear of the feed roller 2. Replace the sensor. Replace the finisher controller PCB.

Shutter open detection sensor (PI5) Finisher controller PCB

No Yes

20. Faulty second feed motor (related to MS4)


Cause Second feed motor (M8) Step 1 Checks Does the second feed motor rotate in reverse at a specific timing? Are the shutter and the shutter upper/lower bar engaged correctly? Turn the feed roller 2 in reverse by hand. Does the shutter upper/lower bar move up/down? Is the shutter closed detection switch normal? Yes/No No Action Replace the second feed motor or the finisher controller PCB. Engage them correctly.

Shutter mechanism

No

No

Correct the mechanism from the shutter upper/lower bar to the gear of the feed roller 2. Replace the switch. Replace the finisher controller PCB.

Shutter closed detection switch (MS4) Finisher controller PCB

No Yes

6-31

CHAPTER 6 TROUBLESHOOTING

21. Faulty second feed motor (related to MS3)


Cause Safety zone switch (MS3) Step 1 2 Shutter closed detection switch (MS4) 3 Checks Check the safety zone switch. Is the switch normal? Is the safety zone detection switch passed correctly? Check the shutter closed detection switch. Is the switch normal? Is the shutter closed detection switch pressed correctly? Yes/No No No No Action Replace the switch. Correct mechanical operation. Replace the switch.

4 Finisher controller PCB

No Yes

Correct the mechanism. Replace the finisher controller PCB.

6-32

CHAPTER 6 TROUBLESHOOTING

B.
1.

Saddle Stitcher Unit


Faulty paper positioning plate
Cause Step 1 Checks Check the paper positioning plate home position sensor. Is the sensor normal? Do the paper positioning plates operate at a specific timing? Yes/No No Action Replace the sensor.

Paper positioning plate home position sensor (PI7S) Saddle stitcher controller PCB Paper positioning plate motor (M4S)

Yes

Replace the saddle stitcher controller PCB. Check the positioning plate drive mechanism. If a fault is found, correct it. Otherwise, go to step 3. End. Replace the saddle stitcher controller PCB.

No

3 Saddle stitcher controller PCB

Replace the paper positioning plate motor. Is the problem corrected?

Yes No

2.

Faulty paper folding motor


Cause Step 1 Checks Check the paper folding motor clock sensor. Is the sensor normal? Check the paper folding home position sensor. Is the sensor normal? Does the paper folding motor operate at a specific timing? Yes/No No Action Replace the sensor.

Paper folding motor clock sensor (PI4S) Paper folding home position sensor (PI21S) Saddle stitcher controller PCB Paper folding motor (M2S)

No

Replace the sensor.

Yes

Replace the saddle stitcher controller PCB. Check the paper folding roller drive mechanism. If a fault is found, correct it. Otherwise, go to step 4. End. Replace the saddle stitcher controller PCB.

No

4 Saddle stitcher controller PCB

Replace the paper folding motor. Is the problem corrected?

Yes No

6-33

CHAPTER 6 TROUBLESHOOTING

3.

Faulty guide motor


Cause Step 1 Checks Check the guide home position sensor. Is the sensor normal? Does the guide motor operate at a specific timing? Yes/No No Action Replace the sensor.

Guide home position sensor (PI13S) Saddle stitcher controller PCB Guide motor (M3S)

Yes

Replace the saddle stitcher controller PCB. Check the guide plate drive mechanism. If a fault is found, correct it. Otherwise, go to step 3. End. Replace the saddle stitcher controller PCB.

No

3 Saddle stitcher controller PCB

Replace the guide motor. Is the problem corrected?

Yes No

4.

Faulty alignment motor


Cause Step 1 Checks Check the alignment plate home position sensor. Is the sensor normal? Does the alignment motor operate at a specific timing? Yes/No No Action Replace the sensor.

Alignment plate home position sensor (PI5S) Saddle stitcher controller PCB Alignment motor (M5S)

Yes

Replace the saddle stitcher controller PCB. Check the alignment plate drive mechanism. If a fault is found, correct it. Otherwise, go to step 3. End. Replace the saddle stitcher controller PCB.

No

3 Saddle stitcher controller PCB

Replace the alignment motor. Is the problem corrected?

Yes No

6-34

CHAPTER 6 TROUBLESHOOTING

5.

Faulty stitcher
Cause Step 1 Checks Are the front and rear stitchers and bases installed correctly? Is the stitching home position switch of the front and the rear stitchers normal? Do the front and the rear stitchers operate at a specific timing? Yes/No No Action Install them correctly.

Stitcher (installation)

Stitching home position switch (MS7S/MS5S) Saddle stitcher controller PCB

No

Replace the front or rear stitcher. Check the wiring between the stitcher and the saddle stitcher controller PCB. If normal, replace the controller PCB. Replace the front or the rear stitcher.

Yes

Stitcher motor (M7S/ M6S)

No

6.

Faulty paper pushing plate motor (related to PI14S)


Cause Step 1 Checks Check the paper pushing plate home position sensor. Is the sensor normal? Check the paper pushing plate top position sensor. Is the sensor normal? Does the paper pushing plate motor operate at a specific timing? Yes/No No Action Replace the sensor.

Paper pushing plate home position sensor (PI14S) Paper pushing top position sensor (PI15S) Saddle stitcher controller PCB Paper pushing plate motor (M8S)

No

Replace the sensor.

Yes No

Replace the saddle stitcher controller PCB Check the paper pushing plate drive mechanisms. If a fault is found, correct it. Otherwise, go to step 3. End. Replace the saddle stitcher controller PCB.

4 Saddle stitcher controller PCB

Replace the paper pushing plate motor. Is the problem corrected?

Yes No

6-35

CHAPTER 6 TROUBLESHOOTING

7.

Faulty paper pushing plate motor (related to PI15S)


Cause Step 1 Checks Check the paper pushing plate top position sensor. Is the sensor normal? Does the paper pushing plate motor operate at a specific timing? Yes/No No Action Replace the sensor.

Paper pushing top position sensor (PI15S) Saddle stitcher controller PCB Paper pushing plate motor (M8S)

Yes

Replace the saddle stitcher controller PCB. Check the paper pushing plate drive mechanism. If a fault is found, correct it. Otherwise, go to step 3. End. Replace the saddle stitcher controller PCB.

No

3 Saddle stitcher controller PCB

Replace the paper pushing plate motor. Is the problem corrected?

Yes No

8.

Faulty paper pushing plate motor (related to PI1S)


Cause Step 1 Checks Check the paper pushing plate motor clock sensor. Is the sensor normal? Does the paper pushing plate motor operate at a specific timing? Yes/No No Action Replace the sensor.

Paper pushing plate motor clock sensor (PI1S) Saddle stitcher controller PCB Paper pushing plate motor (M8S)

Yes

Replace the saddle stitcher controller PCB. Check the paper pushing plate drive mechanism. If a fault is found, correct it. Otherwise, go to step 3. End. Replace the saddle stitcher controller PCB.

No

3 Saddle stitcher controller PCB

Replace the paper pushing plate motor. Is the problem corrected?

Yes No

6-36

CHAPTER 6 TROUBLESHOOTING

9.

Disconnected sensor connector (related to PI13S)


Cause Step 1 Checks Are the connectors of the guide home position sensor and the saddle stitcher controller PCB connected correctly? Is the wiring between the sensor and the saddle stitcher broken? Is 5 VDC present at J9-7 on the saddle stitcher controller PCB? Is J9-8 on the saddle stitcher controller PCB grounded correctly? Yes/No No Action Connect the connectors.

Guide home position sensor (PI13S; disconnected)

Wiring

Yes

Correct the wiring.

Power supply

No

Replace the saddle stitcher controller PCB.

Ground

No

10. Disconnected sensor connector (related to PI14S)


Cause Paper pushing plate home position sensor (PI14S; disconnected) Step 1 Checks Are the connectors of the paper pushing plate home position sensor and the saddle stitcher controller PCB connected correctly? Is the wiring between the sensor and the saddle stitcher broken? Is 5 VDC present at J9-10 on the saddle stitcher controller PCB? Is J9-11 on the saddle stitcher controller PCB grounded correctly? Yes/No No Action Connect the connectors.

Wiring

Yes

Correct the wiring.

Power supply

No

Replace the saddle stitcher controller PCB.

Ground

No

6-37

CHAPTER 6 TROUBLESHOOTING

11. Disconnected sensor connector (PI15S)


Cause Paper pushing plate home position top position sensor (PI15S; disconnected) Wiring Step 1 Checks Are the connectors of the paper pushing plate top position sensor and the saddle stitcher controller PCB connected correctly? Is the wiring between the sensor and the saddle stitcher broken? Is 5 VDC present at J9-13 on the saddle stitcher controller PCB? Is J9-14 on the saddle stitcher controller PCB grounded correctly? Yes/No No Action Connect the connectors.

Yes

Correct the wiring.

Power supply

No

Replace the saddle stitcher controller PCB.

Ground

No

12. Faulty microswitch


Cause Switch actuator Step 1 Checks Check the switch actuator of the inlet door. Do the switch and the sensor operate correctly? Check the inlet door switch. Is the switch normal? Measure the voltage at J10-8 on the saddle stitcher controller PCB with the inlet cover open. Is it 5 V? Measure the voltage between J19-1 (+) and J19-2 () on the finisher controller PCB. Is it 24 V? Yes/No No Action Correct the mechanism.

Inlet door switch (MS1S) Inlet cover sensor (PI9S)

2 3

No Yes

Replace the switch. The sensor is faulty. Replace the sensor.

Power supply, wiring

No Yes

Replace the finisher controller PCB. Check the wiring between J19 on the finisher controller PCB and J1 on the saddle stitcher controller PCB. If a fault is found, correct it. Otherwise, replace the saddle stitcher controller PCB.

6-38

CHAPTER 6 TROUBLESHOOTING

13. Faulty microswitch (related to MS2S)


Cause Switch actuator Step 1 Checks Check the switch actuator of the front door. Do the switch and the sensor operate correctly? Check the front door switch. Is the switch normal? Measure the voltage at J11-12 on the saddle stitcher controller PCB with the front door open. Is it 5 V? Yes/No No Action Correct the mechanism.

Front door switch (MS2S) Front door open/closed sensor (PI12S)

2 3

No Yes No

Replace the switch. The sensor is faulty. Replace the sensor. Replace the saddle stitcher controller PCB.

14. Faulty microswitch (related to MS3S)


Cause Switch actuator Step 1 Checks Check the delivery door switch actuator. Do the switch and the sensor operate correctly? Check the delivery door switch. Is the switch normal? Measure the voltage at J11-9 on the saddle stitcher controller PCB with the delivery door open. Is it 5 V? Yes/No No Action Correct the mechanism.

Delivery switch (MS3S) Delivery cover sensor (PI3S)

2 3

No Yes No

Replace the switch. The sensor is faulty. Replace the sensor. Replace the saddle stitcher controller PCB.

6-39

APPENDIX

A. FINISHER UNIT GENERAL TIMING CHART ......................... A-1 B. SADDLE STITCHER UNIT GENERAL TIMING CHART ....... A-2 C. SIGNAL AND ABBREVIATIONS....................... A-3

D.

FINISHER UNIT CIRCUIT DIAGRAM ................................... A-4 E. SADDLE STITCHER UNIT CIRCUIT DIAGRAM ................. A-18 F. SOLVENTS AND OILS ............. A-26

A. FINISHER UNIT GENERAL TIMING CHART


A4, 2 Sheets, 1-Point Stapling (rear), 1 Set

Operation start signal Host machine delivery signal Operation 1 Inlet sensor (PI1) 2 Delivery sensor (PI3) 3 Inlet feed motor (M9) 4 First feed motor (M1) 5 Second feed motor (M8) 6 Delivery motor (M2) 7 Staple tray sensor (PI4) 8 Rear alignment motor (M3) 9 Front alignment motor (M11) 10 Alignment position home position sensor (PI6)

11 Swing motor (M7) 12 Swing guide open sensor (PI18) 13 Swing guide closed detecting switch (MS2)

14 Staple motor (M6) Staple home position sensor 15 (PI22) 16 Stapler shift motor (M4) 17 Height sensor (PS1) 18 Tray 1 lift motor (M5) 19 Drop solenoid (SL4) 20 Paddle motor (M14) 21 Paddle home position sensor (PI26)

22 Knurled belt motor (M13) 23 Knurled belt home position sensor (PI28)

: Motor CW rotation

: Motor CCW rotation

Note) When the 11th, 21st, 31st or 41st sheet of paper is fed on the stapling tray, the finisher controller PCB turns on the knurled belt motor (M13).

A-1

B. SADDLE STITCHER UNIT GENERAL TIMING CHART


A4R, 3 Sheets, Stitching, 1 Set
Copy Start Key ON Operation 1 Inlet feed motor (M9) 2 Finisher unit flapper solenoid (SL1) Initialize Delivery signal 1st sheet delivery 2nd sheet delivery 3rd sheet delivery Stitching
Stack feeding

Folding,/delivery

3 Feed motor (M1S) 4 No. 1 paper sensor (PI18S) 5 No. 2 paper sensor (PI19S) 6 No. 3 paper sensor (PI20S) 7 8 No. 1 paper deflecting solenoid (SL1S)

No. 2 paper deflecting solenoid (SL2S) Feed plate contact solenoid 9 (SL4S) 10 Alignment plate home position sensor (PI5S)

11 Alignment motor (M5S) 12 Crescent roller phase sensor (PI12S)

13 Stitcher motor (front) (M7S) 14 Stitcher home position sensor (front) (MS7S)

15 Stitcher motor (rear) (M6S) 16 17 Stitcher home position sensor (rear) (MS5S) Guide home position sensor (PI13S)

18 Guide motor (M3S) 19 20 21 22 23 Paper positioning plate paper sensor (PI8S) Paper positioning plate home position sensor (PI7S) Paper positioning plate motor (M4S) Paper pushing plate home position sensor (PI14S) Paper pushing plate top position sensor (PI15S)

24 Paper pushing plate motor (M8S) 25 Paper folding motor (M2S) 26 Delivery sensor (PI11S) 27 Tray paper sensor (PI6S) 28 Paper folding home position sensor (PI21S)

: Motor CW rotation

: Motor CCW rotation

A-2

C. SIGNAL AND ABBREVIATIONS


The following presents the abbreviations of signals used in this manual and in drawings, and the meanings of each signal. Reference:
Signals enclosed by brackets [ ] are electrical signals. However, the state 1 or 0 of these analog signals cannot be indicated. Otherwise, the state of digital signals 1 or 0 can be indicated. Finisher unit BUFENTR BUFPASS CRTSIZE DELCLK DROPN DRSW ENTSL EXITSL FLPSL FSTTRAY HOOKEMP HOOKTOP JOGRHP JOINT PDEL DRPSL PENT SFTCLK11 SFTCLK12 SFTCLK21 SFTCLK22 SHUTCLD SNDTRAY STOPN STPCON STPDRHP STPHP STPTY SWGCLK SWGGCLD SWGOPN TRAYSAF TRYHP1, TRYHP2 TRYLMT PDLHP RBHP JOGFHP Saddle stitcher unit 1STPA 2NDPA 3RDDPA DELV DELVMS EJCVR FDR FDRLHP FDROPN FLDCLK FLPSL1 FSPSL2 GIDHP HKEMP1 HKEMP2 INLTCVR INLTCVRMS JOGHP LUNGECLK LUNGEHP LUNGETOP PAFLDHP PAPPOS PPOSPAR RLNIPSL STCHHP1 STCHHP2 STPLHP TRYPAR VPJM

BUFFER PATH INLET PAPER DETECT Signal BUFFER PATH PAPER DETECT Signal CARTRIDGE TYPE DETECT Signal DELIVERY MOTOR CLOCK DETECT Signal DOOR OPEN DETECT Signal DOOR SWITCH Signal BUFFER INLET SOLENOID DRIVE Signal BUFFER OUTLET SOLENOID DRIVE Signal FLAPPER SOLENOID DRIVE Signal TRAY 1 PAPER DETECT Signal HOOK EMPTY DETECT Signal HOOK STOP POSITION DETECT Signal REAR ALIGNMENT PLATE HP DETECT Signal JOINT DETECT Signal DELIVERY DETECT Signal DROP SOLENOID DRIVE Signal INLET PAPER DETECT Signal TRAY LIFT MOTOR CLOCK DETECT Signal 11 TRAY LIFT MOTOR CLOCK DETECT Signal 12 TRAY LIFT MOTOR CLOCK DETECT Signal 21 TRAY LIFT MOTOR CLOCK DETECT Signal 22 SHUTTER CLOSED DETECT SWITCH Signal TRAY 2 PAPER DETECT Signal SHUTTER OPEN DETECT Signal STAPLER CONNECT DETECT Signal STAPLER DRIVE HP DETECT Signal STAPLER SHIFT HP DETECT Signal STAPLE TRAY PAPER DETECT Signal SWING MOTOR CLOCK DETECT Signal SWING GUIDE CLOSED DETECT SWITCH Signal SWING GUIDE OPEN DETECT Signal TRAY SAFETY ZONE SWITCH Signal TRAY HOME POSITION DETECT Signal TRAY UPPER LIMIT DETECTING SWITCH Signal PADDLE HOME POSITION DETECT Signal KNURLED BELT HOME POSITION DETECT Signal FRONT ALIGNMENT PLATE HP DETECT Signal

No.1 PAPER SENSOR DETECT Signal No.2 PAPER SENSOR DETECT Signal No.3 PAPER SENSOR DETECT Signal DELIVERY DETECT Signal DELIVERY DOOR OPEN DETECT SWITCH Signal DELIVERY DOOR OPEN DETECT Signal FRONT DOOR OPEN DETECT Signal CRESCENT ROLLER PHASE DETECT Signal FRONT DOOR OPEN DETECT SWITCH Signal FOLD MOTOR CLOCK Signal FLAPPER DRIVE Signal 1 FLAPPER DRIVE Signal 2 PAPER GUIDE HOME POSITION DETECT Signal HOOK EMPTY DETECT Signal 1 HOOK EMPTY DETECT Signal 2 INLET COVER OPEN DETECT Signal INLET COVER OPEN SWITCH Signal ALIGNMENT HP DETECT Signal LUNGE MOTOR CLOCK Signal LUNGE HOME POSITION DETECT Signal LUNGE TOP POSITION DETECT Signal PAPER FOLD HOME POSITION DETECT Signal PAPER POSITION PLATE HP DETECT Signal PAPER POSITIONING GUIDE PAPER DETECT Signal FEED PLATE CONTACT SOLENOID DRIVE Signal STITCHING HP DETECT Signal 1 STITCHING HP DETECT Signal 2 STITCHER IN DETECT Signal TRAY PAPER DETECT Signal VERTICAL PATH PAPER DETECT Signal

A-3

D. FINISHER UNIT CIRCUIT DIAGRAM (1/2)


7 6 5 4 3 2 1

SWING_UNIT M7
SWING_MOT

M3
R_ALIGNMENT_MOT
M

M2
DELIVERY_MOT
M
4 4 5 5 1 2

M14
PADDLE_MOT
M

SL4
DROP_SOL

M11
F_ALIGNMENT_MOT
M

PI3
DELIVERY_SENS
MT5

PI6
R_ALIGNMENT_ HP_SENS

PI20
SWING_MOT_ CLK_SENS

PI26
PADDLE_HP_SENS

PI10
DELIVERY_MOT_ CLK_SENS

PI4
STAPLING_TRAY_ SENSOR

PI29
F_ALIGNMENT_ HP_SENS F

MS3
SAFETY_ZONE_SW
NC

M
2 1 1 1 2 2

SL
1 3 3 1 2 1 2 5 5 4 4 3 3 2 2 1 1 2 2 3 3 2 2 3 3 1 2 2 3 3 1 2 2 3 3 1 2 2 3 3 1 2 2 3 3 1 2 2 3 3 1

3 2
NO

J137

J131

12

11

10

12

11

10

15

14

10

11

J12B_[0:15] J11_[0:11] J9_[0:7] J12A_[0:15]

J12A_[0:15]

11

J12WH

A15

B15
J12B

13

J5_[0:11] J5_[0:11]

J6A_[0:10]

J6B_[0:10]

10

COM

J134 J124 J552 MT3


1 2 3

J125

J560

J120

J122

J139

J557H J501H J501


1 2

J128H
2 1

J119H J119
2 1

J557

J128

MT4 MT2

E
J208L J208LH J208D
1 2 3 4 5 5 4 3 2 1

J207L J207LH J207D

J558L J558LH

J222L J222LH

J121L J121LH

J221L
6 5 4 3 2 1

J561L J561LH

J221LH
1 2 3 4 5 6

J558D

J222D

J121D

J221D

J561D

J12A

J9

J11

J12

DC CONTROLLER
J5
11
J6B

J6
B10 A10
J6A
J6WH

J4
10

J17
1

J10
2 3 4 5 6 1 2

J16
3 4 5 6 7

12
J12A_[0:15]

J4_[0:10]

J6B_[0:10]

J551D J551LH J551L


4 3 2 1 10 9 8 7 6 5

J554D J554LH

J554L

J17_[0:12]
5 6 4 1 2

4 2 1

10

11

12

J553D J553H

J212D
2 2 1 1

J701D J112F J112M J212DH J212L


4 3 2 1

J202D J202LH

J146 J555
1 2 3 4 5 6

J113D J113LH J113L

J108 J108H

J145

J701LH J701L
1 2

J202L

1 1

2 2

3 3

M M 4G1-2190

KNURLED_BELT_MOT

KNURLED_BELT_ HP_SENS

FIRST_FEED_MOT

SECOND_FEED_MOT

M13
J107 J107H
2 2 1 1 2 1

PI28

M1 FEED_DRIVE_UNIT

M8

KNURLED_BELT_UNIT

J148F J148M J502

FF3-4074

J106 J114
1 2 3 4

SOLD2

J117 J147
1 1 2 2 3 3 2 1

1 1 1 2 2 3 3 1 2 1

2 2

3 3

4 4

5 5

6 3 6 3 2 2 1 1

NO

2 1
COM

SOLD1

SL SL
1 4

3
NC

DOOR_SW

JOINT_SENS HEIGHT_SENS DOOR_OPEN_SENS BUFFER_INLET_SOL

FLAPPER_SOL

INLET_FEED_MOT

INLET_SENS

MS1 FEED_UNIT

PS1

PI16

SL2

PI15 INLET_FEED_UNIT

SL1

M9

PI1

A-4

D. FINISHER UNIT CIRCUIT DIAGRAM (2/2)


7 6 5 4 3 2 1
MT7 MT9

SWING_UNIT

SHATTER_UNIT

TRAY1
LIFT_MOT_CLK_SENS2 LIFT_MOT_CLK_SENS1

TRAY2

MS6
SWING_GUIDE_ CKOSE_SW2
SOLD3

MS2
SWING_GUIDE_ CKOSE_SW1
SOLD5
1
COM

PI18
SWING_GUIDE_ OPEN_SENS

PI5
SHUTTER_OPEN_SENS
COM

MS4
SHUTTER_CLOSE_SW
NC NC

MS9
TRAY_COMING_CLOSE_SW
3 2
NO COM

M5
LIFT_MOT
M
2 1

MT6

PI9 PI19

PI11
PAPER_SENS

PI8
TRAY1_HP_SENS

M10
LIFT_MOT
M

LIFT_MOT_CLK_SENS2

LIFT_MOT_CLK_SENS1

MT8

PI24 PI23

PI12
PAPER_SENS

3 2
NO

1 1 2 3

1 3 2 1

2 2

3 3

COM

2 2

3 3

2 2

1 1

PI25
TRAY2_HP_SENS

1
NO NC

2 2

3 3

2 2

3 3

J140

J138

J2011

J130

J8011

J127

NO

NC

J118

J6011
SOLD6

J8021
1 2

1 3 2 2 1 1 3

SOLD4

J1150
FF3-4020

J135

J1160

FF3-4080
3 3 2 2 1 1

J1151M J1151F J6010L


6 5 4 3 2 1

J2010L J2010LH J2010D

FF3-4021

J8010L J8010LH

J8020L J8020LH

J8010D

J204L J209M J209F


4 4 3 3 2 2 1 1

J205L J205DH

J6010LH J206M
1 1 2 2 3 3

E
6 5 4 3 2 1

J204LH J204D
1 2 3

J6010D

J8020D

J205D

J206F

15

14

13

J5_[0:11]

J601L J601LH
4 4 3 3 2 2 1 1

J201L J201LH

J801L J116F
1 1 2 2 3 3

J12A_[0:15]

J115M J115F J601D


1 2 3 4 5 6

J801DH J801D
9 8 7 6 5 4 3 2 1

J201D

J116M
J6B_[0:10]
11 10

12

11

10

10

11

J14A_[0:12]
4 3 1 2

J7_[0:7] J14B_[0:12]

J14WH

J14A

A12

B12

J14B

J7 J22
2 1 1 2 3

J14 J18

J8
4 5 6 7 8 6 5

DC CONTROLLER
J24
2 1 1 2

J1
3 4 5

J19
1 2 8 7 6 5

J3
4 3 2 1

J2
C

J6B_[0:10]

10

J24_[0:9]

J2F_[0:7]

J210D J210LH J210L

J31

MT1

SWR
1 4 5 2 3 6 7

12

J32 J307 J308


1 2 1 2 3 4 5 6 7

B
MT10

J306

FF3-4022

J401 J109 J129


1 1 1 2 2 3 1 3 2 1 2 3 4 5 6 2 3 1 2 3 2 1

J400

10 11 12

J15 MT11

J109H J33
1 2

SADDLE_UNIT

PPC

STAPLE_HP_SENS

STAPLE_SENS

PI22 STAPLE_SHIFT_HP_SENS
STAPLE_MOT
1 2 3

PI31
1 2 3

J105

3 3

2 2

1 1

J110

3 3

2 2

1 1 1 2

STAPLE_SHIFT_MOT

PI7

M6
STAPLE_EDGE_SENS CARTIDGE_DISCRIMINATION_SENS

M4
BUFFER_PATH_ INLET_ENT_SENS BUFFER_PARH_ PAPER_SENS

SL

BUFFER_OUTLET_SOL

PI21

PI30

PI17

PI14

SL3

STAPLE_UNIT

BUFFER_PATH_UNIT

A-5

1. Finisher Controller PCB (A501)


+5V

[A505] STPLMM[1:0] FEED2M[1:0] [A510] [A507]


RJOGM1 STPLMM1 STPLMM0 RJOGM0
+5V
2

C4
ADDRESS0 ADDRESS1 ADDRESS2 ADDRESS3 ADDRESS4 ADDRESS5 ADDRESS6

DATA10

DATA11

DATA12

DATA13

DATA14

PREGS5

PREGS4

PREGS3

PREGS2

PREGS1

FEED2M1

FEED2M0

64

63

62

61

60

59

58

57

56

55

54

53

52

R342

DQ2

DQ3

DQ4

DQ5

DQ6

DQ7

VCC

A0

A1

A2

A3

A4

A5

10K,1/16W

BUF_PS0 ENTRANS_S0 STPLHP0


+5V

[A509] [A508] [A510]


128 127 126

10K,1/16W

+5V

+5V

DATA9 DATA8 ADDRESS24

1 2 3 4 5 6 7

A6

EJECT_S0

[A506]

R341

51

BUF_EP0

[A509]

PREGS0

[A512]

DUST0

ENTM[3:0]

[A509]

DATA15

24VS0

DQ1 DQ0 W R S BM INTR RXD3

A7 PA0 PA1 PA2 PA3 PA4 PA5 PA6

50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 [A502] [A502] [A510] PWMG_WRB PWMG_CSB STPL_CON0 [A505] [A505] [A503] [A505]

[A508]

ADDRESS23 ADDRESS20

125

124

123

122

121

120

119

118

117

116

115

114

113

112

111

110

109

108

107

106

105

104

103

R340

10K,1/16W

R339

P10/PO8/TIOCA0/_DACK0

P11/PO9/TIOCB0/_DACK1

P12/PO10/TIOCC0/TCLKA

P13/PO11/TIOCD0/TCLKB

P15/PO13/TIOCB1/TCLKC

P17/PO15/TIOCB2/TCLKD

P14/PO12/TIOCA1

P16/PO14/TIOCA2

PG0/_CAS/_OE

P47/AN7/DA1

P46/AN6/DA0

PG1/_CS3

0.1U,50V

1 2 3 4 5

PG3/_CS1

P53/_ADTRG

102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87

C1

10K,1/16W

P45/AN5

P44/AN4

P43/AN3

P42/AN2

P41/AN1

P40/AN0

0.1U,50V

VSS16

AVSS

MD2

MD1

MD0

C2

VREF

PG2/_CS2

AVCC

PG4/_CS0

P52/SCK2 VSS15 VSS14 P51/RXD2 P50/TXD2 PF0/_BREQ PF1/_BACK PF2/_WAIT/_BREQO PF3/_LWR PF4/_HWR PF5/_RD PF6/_AS VCC5 PF7/FAI VSS13

SERIAL4 SERIAL5 SERIAL2

8 9 10 11 12 13

VSS1 VSS2 VCC1 PC0/A0 PC1/A1 PC2/A2 PC3/A3 VSS3 PC4/A4 PC5/A5 PC6/A6 PC7/A7 PB0/A8 PB1/A9 PB2/A10 PB3/A11 VSS4 PB4/A12 PB5/A13 PB6/A14 PB7/A15 PA0/A16 PA1/A17 PA2/A18 PA3/A19 VSS5 PA4/A20/_IRQ4 PA5/A21/_IRQ5 PA6/A22/_IRQ6 PA7/A23/_IRQ7 P67/_CS7/_IRQ3 P66/_CS6/_IRQ2 VSS6 VSS7
P65/_IRQ1

IC4
TXD3 RXD2 TXD2 RXD1 TXD1 CTS3 CTS2 CTS1 CLK P12
CNVSS XOUT RST INT P10 XIN VSS P07 P06 P05 P04 P03 P02 P01

M38881M2-010GP

PA7 PB0 PB1 PB2 PB3 PB4 PB5 PB6 PB7 P00

ADDRESS7

[A512]

PREGS[5:0]

1U,16V

PADOL_CW PADOL_CCW REMORT_ON STEPMOFF1

ENTM1 ENTM0 EEPROM3 EEPROM2 EEPROM1 ADDRESS25 ADDRESS24 ADDRESS23

SERIAL3 SERIAL0 SERIAL1 +5V

ADDRESS0 ADDRESS1 ADDRESS2 ADDRESS3

6 7 8 9 10

R312
10K,1/16W
1 2 1 2

14 15 16 17 18

ADDRESS4 ADDRESS5 ADDRESS6 ADDRESS7 ADDRESS8 ADDRESS9 ADDRESS10 ADDRESS11

11 12 13 14 15 16 17 18 19

R313
10K,1/16W

SHIFTM2_0 SHIFTM2_1 [A504] EEPROM0

19

20

21

22

23

24

25

26

27

28

29

30

31

32

[A510] [A510]

CARTRIDGE0 STPL_READY0 HOOK0 FJOG_HP_S TRAYS0 TRAYS1 PADOL_HP_S SERIAL[5:0]

X2
2
30P,50V 1 2

[A510] [A506]
30P,50V

1
2

IC1
HD6432655A00F

EXTAL XTAL VCC4 STBY NMI RES WDTOVF P20/PO0/TIOCA3 P21/PO1/TIOCB3 P22/PO2/TIOCC3/TMRI0 P23/PO3/TIOCD3/TMCI0 P24/PO4/TIOCA4/TMRI1 P25/PO5/TIOCB4/TMCI1 P26/PO6/TIOCA5/TMO0 P27/PO7/TIOCB5/TMO1 P63/_TEND1 P62/_DREQ1 P61/_TEND0/_CS5 VSS12 VSS11
P60/_DREQ0/_CS4

86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68

C6

C7

EXTAL0 [A503]
1000P,50V

C5
1

[A504] [A504] [A506]


CSA12.2MTZ12.288MHZ

ADDRESS12 ADDRESS13 ADDRESS14 ADDRESS15 ADDRESS16 ADDRESS17 ADDRESS18 ADDRESS19

20 21 22 23 24 25 26 27 28 29

[A502]

1 2

IC35
4 2 S00

IC30
4 S14
2

[A502]

[A507]

[A509] +5V

RESET0

SHIFTM_PWM0 EJECTM_PWM0 SWINGM_PWM0 PUNCHM_PWM0 PREGM1 PREGM0 PWMG_SCLK PWMG_SIN FEEDM1 FEEDM0
PUNCH_CLK0

[A504] [A505] [A505]

R1
10K,1/16W
1

IC8
1
VOUT M-RST GND VCC

[A512] [A512] [A512] [A502] [A502]

ADDRESS20 ADDRESS21 ADDRESS22

4 3

HC138

SHIFTCK1 SWINGM_CK0 EJECTM_CK0 FEEDM_STEP0

[A504] [A506] [A506] [A507]

31 32 33 34 35 36

PST591DMT
Y7 Y6 Y5 Y4 Y3

ADDRESS19
[A507]

3 2 1

C B A

7 9 10
10K,1/16W 10K,1/16W

ADDRESS18
[A507]

ADDRESS17
[A512]

11

12 13 14 15

67
Y2

ENTM0
FEED2M_STEP0 [A507]

[A508]

37 38

66 65

IC2S IC2
1 2 3 1 2 3 4
CS SK DI DO VCC NC TEST GND

R2

R3

+5V

STPL_TRAY0 [A506]

8 7 6 5

8 7 6 5
2 0.1U,50V

Y1 Y0

P30/TXD0

P31/TXD1

P32/RXD0

PD2/D10

PD3/D11

PD4/D12

PD5/D13

PD6/D14

PD7/D15

P34/SCK0

P35/SCK1

PE1/D1

PE2/D2

PE3/D3

PE4/D4

PE5/D5

PE6/D6

PE7/D7

PD0/D8

PD1/D9

P64/_IRQ0

VSS10

P33/RXD1

VCC2

VSS8

VSS9

VCC3

SHIFTCK0

[A504]

30

IC16

0.1U,50V
2

C8

+5V [A508] [A509]

G1

G2A

G2B

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

HIGHT1
EEPROM1 EEPROM3 EEPROM2

+5V

64

LAMP0 HIGHT0
+5V
EEPROM[3:0]

EEPROM0

S-93C46ADP

RA4

[A508]
1 3 5 7

RA2

DICF-8CS-E

R280
10K,1/16W
1 2

100,0.0625

RA1

100,0.0625

100,0.0625

RA3

PWMG_OCB
[A502]

100,0.0625

DATA10

DATA11

DATA12

DATA13

DATA14

DATA15

DATA0

DATA1

DATA2

DATA3

DATA4

DATA5

DATA6

DATA7

DATA8

DATA9

DATA[15:0] [A502]

C3
2 1 1U,16V

+5V
ADDRESS[25:0]

[A502]

A-6

C10

C9
0.1U,50V

PE0/D0

1. Finisher Controller PCB (A502)


ADDRESS[25:0]

IC42 C150
+5V +5V
2

1 HC14 2

SHIFTM2_PWM0

IC36 IC6
ADDRESS15 ADDRESS13

0.1U,50V

[A504]

R336

1U,16V

C11

PWMG_CSB

[IPC PB7] [A501] [IPC PB6] [CPU P27] [CPU P26] [CPU P31]

1 2 3 4 5 6 7

CSB RB WRB SIN SCLK OCB GND

VCC PWM1 PWM2 PWM3 PWM4 XOUT XIN

14 13 12 11 10 9 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14

A14 A12 A7 A6 A5 A4 A3 A2 A1 A0 I/O0 I/O1 I/O2 VSS

VCC WE A13 A8 A9 A11 OE A10 CS I/O7 I/O6 I/O5 I/O4 I/O3

28 2 1U,16V 27 26 25 24 23 22 21 20 19 18 17 16 15
ADDRESS25 ADDRESS14 ADDRESS9 ADDRESS10 ADDRESS12 ADDRESS23 ADDRESS11 ADDRESS21 DATA7 DATA6 DATA5 DATA4 DATA3

ADDRESS15 ADDRESS13

1 2 3 4 5 6 7 8 9 10 11 12 13 14

A14 A12 A7 A6 A5 A4 A3 A2 A1 A0 I/O0 I/O1 I/O2 VSS

VCC WE A13 A8 A9 A11 OE A10 CS I/O7 I/O6 I/O5 I/O4 I/O3

28 1U,16V 27 26 25 24 23 22 21 20 19 18 17 16 15
ADDRESS24 ADDRESS14 ADDRESS9 ADDRESS10 ADDRESS12 ADDRESS23 ADDRESS11 ADDRESS21

RESET0

IC3S

DICF-40CS-E

+5V

IC7

+5V

10K,1/16W 3

IC42
4 HC14
PADOL_PWM0

1
ADDRESS19 DATA7 DATA6 DATA5 DATA4 DATA3 DATA2 DATA1 DATA0

40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21
ADDRESS9 ADDRESS8 ADDRESS7 ADDRESS18 ADDRESS17 ADDRESS16 ADDRESS15 ADDRESS14 ADDRESS13 ADDRESS12 ADDRESS11 ADDRESS10

PWMG_WRB PWMG_SIN PWMG_SCLK PWMG_OCB

C12

2 3 4 5 6 7 8 9 10 11

R337

ADDRESS7 ADDRESS6 ADDRESS5 ADDRESS4 ADDRESS3 ADDRESS2 ADDRESS1 DATA0 DATA1 DATA2

ADDRESS7 ADDRESS6 ADDRESS5 ADDRESS4 ADDRESS3 ADDRESS2 ADDRESS1 DATA8 DATA9 DATA10

ADDRESS8

ADDRESS8

C13

[A505]
2

EXTAL0

10K,1/16W 5

IC42
6 HC14

M66242FP
DATA15 DATA14 DATA13

R338

SERIAL[5:0] [A501]

DATA15 DATA14 DATA13 DATA12 DATA11 DATA10 DATA9 DATA8 ADDRESS23

12 13 14 15 16 17 18 19 20

DATA12 DATA11

10K,1/16W

+5U 1

+5U

PPC OUT
1
J7P

R6
1SS270A 4.7K,1/16W

UPD43256BGU-70LL
ADDRESS5 ADDRESS4

UPD43256BGU-70LL
SERIAL0
2

D1

ADDRESS6

J2 J2 J2 J2 J2

R4
1

R5
2 1

2
J7P

+5V
ADDRESS3

+5V OPEN6

1K,1/16W

C16
1 100P,50V

1K,1/16W 3
J7P

RB_HP_S

STPPOS_S

ADDRESS2 ADDRESS1

IC42
TRAY_HP2 SHIFTCK2_1 SHIFTCK2_0 HC14
2

SERIAL1

R7
1 2

4
J7P

R105

10K,1/16W

Q1
1 2SC3735
J7P

1K,1/16W

10K,1/16W

R8
1 2

10K,1/16W

DATA[15:0]
2

4.7K,1/16W

SADDLE OUT
+5V

DATA14

DATA13

DATA12

DATA11

DATA15

DATA10

DATA9

DATA8

R332

[A505] [A505] [A505]


79 78 77 76

RBMT1 RBMT0

1
J8P

J3 J3

97 [A506]

96 [A510]

93 [A504]

92 [A504]

91 [A504]

ADDRESS22 100 99 98

90 [A504]

R323

RESET0

SOLOUT4

J8P

+5U 1

+5U
1

95

94

89

88

87

86

85

84

83

82

81

P87/D15

P86/D14

P85/D13

P84/D12

P83/D11

P82/D10

RESETB

P81/D9

P80/D8

GND8

GND7

CSB

DBS

80

P77

P76

P75

P74

D7

D6

D5

D4

D3

D2

D1

D0

1SS270A

ADDRESS23 ADDRESS24 ADDRESS0 ADDRESS1 ADDRESS2 ADDRESS3

D2

R11
2

3
J8P

J3 J3 J3 J3 J3 J3

1 2 3 4 5 6 7 8 9 10 11 12 13

RDB WRB A0/HWRB A1 A2 A3 P00 P01 P02 P03 GND1 GND2 VDD1 P04 P05 P06 P07 P10 P11 P12 P13 P14 P15 P16 P17

P73 P72 P71 P70 P67 P66 P65 P64 P63 P62 P61

75 74 73 72 71 70 69 68 67 66 65 64 63

[A509] [A509] [A509] [A509] [A505] [A510] [A508] [A504] [A504] [A512] [A512] [A512]

SOLOUT3 SOLOUT2 SOLOUT1 SOLOUT0 RJOGM_I0 STPLMM_I0 HIGHT_ON0 SHIFTM_0 SHIFTM_1 EEPSK0 SS_CONNECT0 EEPCS0
+5V
SERIAL3 SERIAL2
2

R9
1

470,1/10W
2 1

4
J8P

1K,1/16W

C17
1 100P,50V

R10
1K,1/16W

+5U
2

R14 IC42
HC14 11 10 4.7K,1/16W
1

5
J8P

DIP_SW[7:0] [A509]

DIP_SW0 DIP_SW1 DIP_SW2 DIP_SW3


+5V

R12
1 2

6
J8P

Q2
1 2SC3735
J8P

1K,1/16W

R13
1 2

7 +5U

4.7K,1/16W

R15
2 1
J8P

10K,1/16W

IC5
UPD65625GC-052-7EA

P60 VDD3 GND6 GND5 P57 P56 P55 P54 P53 P52 P51 P50 P47 P46

EEPDO0
2 2

+5V

DIP_SW4 DIP_SW5 DIP_SW6 DIP_SW7 PUSH_SW1 [A509] PUSH_SW[1:0] EEPDI0 STPLMM_HP0 RJOG_HP0 TRAY_HP0 SHATER_S0 SWING_S0 PUSH_SW0 [A512] [A510] [A506] [A504] [A508] [A506]

14 15 16 17 18 19 20 21 22 23 24 25

62 61 60 59 58 57 56 55 54 53 52 51

C14
0.1U,50V 1

C15
0.1U,50V
SERIAL4
2

R16
1

[A507] [A509] [A507] [A506] [A508] [A506] [A512] [A510] [A511] [A511]

FEEDM_I0 LAMP1 FEED2M_I0 RBMT_I0 ENTM_I0 FJOGM_I0 PREG_I0 STEPMOFF0 STPLM_W0 STPLM_W1

10K,1/16W

IC42
HC14
SERIAL5

13

12

GND3

GND4

VDD2

P20

P21

P22

P23

P24

P25

P26

P27

P30

P31

P32

P33

P34

P35

P36

P37

P40

P41

P42

P43

P44

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

P45

FJOGM0

FJOGM1

PUNCH_U[3:0] FJOGM[1:0]
+5V

[A512] [A506] R343


2

+5V

UPPERC_S0

R344
2

10K,1/16W
1

JOINT0

10K,1/16W

SS_CONNECT0

[A505] [A505] [A512] [A512] [A505] [A505] [A503] [A512]

EJECTM_W0 EJECTM_W1 PUNCHM0 PUNCHM1 SWINGM_W0 SWINGM_W1 OPEN[3:0] PUNCH_U4

PUNCH_U0

PUNCH_U1

PUNCH_U2

PUNCH_U3

[A508]

[A508]

[A502]

OPEN3

OPEN2

OPEN1

OPEN0

A-7

1. Finisher Controller PCB (A503)


J2
6
J7P

+5V

J2

7
J7P

+24R

+24U

R17
2
1 2

2.2,1W

C19
1
470U,35V

C22
2 2 4.7U,50V 0.1U,50V

C25

C24

2 1 15P,50V

IC10
AT-51 16MHZ
1 XIN
VDD 8

J2P

R20

R18

3.83K,1/10W

IC9
3.83K,1/10W 1 2
N.IN1 ININ1 FB TCON CT RT GND C1 N.IN2 ININ2 ROUT OCON VCC C2 E2 E1

R24
1 2

2 1SS270A

J2P

J19

10K,1/16W 16 15 14 13 12 11

2 1 15P,50V

2 XOUT REFOUT/RS0 7 3 REF_OFF MODOUT/RS1 6 4 LF


VSS 5
1 2

KE1-8012

J1
J5P

51K,1/10W

4 5 6

Q3
2SJ527(L) 1 2

ICP9
ICP-N25 2 1 1

CB1
TBC6011-21-0941 2 1 2
2 2 2

L1
2
ELC-12E001/FH3-0613

R27
0.56,1W
1 2

JNT1
1 2

2.2K,1/16W

FS741BZB

C27
680P,50V

C26
22P,50V

+5V

J5P

330,1/4W

J1

7 8

10

R26

7.5K,1/10W

R277

33,2W

C152

CP1
AK04

10K,1/16W

2K,1/10W

2K,1/10W

470U,35V

2200P,50V

R21

R19

C20

R29

J1 J1 J1

J5P

C18
4
J5P

2 3

820,1W

check

IC17 ETH1
E

R28
EXTAL0 [A501]
2 1

S08 4

2 1

560U,35V

R97
5
J5P

+5V

2 3

100,1/16W

REMORT0

1K,1/16W

PWM0 [A505] DOOR_SW [A506]

ICP10
ICP-N70 2 1

J5

1
J11P

+24VSHIFT [A504]

+5V
2

C33 R35
4.7K,1/16W

ZD1
HZS18-2

Q4
RT1N141C

+24VMOVE

10U,50V

OPEN2
2

Q53
2SA1015Y 2 1

+5U

J5

2
J11P

1
2

P35
1

SAFETY_ZONE_SW
1

J5

3
J11P

4.7K,1/4W

100,1/4W

100P,50V

6.8,1/4W

R34

+5V
2

R283

C28

R285

R37
4.7K,1/16W

J11P

ZD2
HZS18-2

Q5
RT1N141C

OPEN3
2

P34 OPEN3 REMORT_ON [IPC PB2]

R282 Q52
3
2 1

R284
2 1

J5

Q54
2SA1020Y

J5

4
J11P

1
2

SWING_GUIDE_SW1

R36
4.7K,1/4W
1

C29
100P,50V

RT1N141C

220,1/4W

560,1/10W

R346
2 1

J5 J5

7
J11P

REMORT0

120,1/4W 6
J11P

+5V
2

SWING_GUIDE_SW2
1

R39
4.7K,1/16W

J5

8
J11P

+24VSTPL

Q6 ZD4
HZS18-2 RT1N141C

OPEN0
2

P37 OPEN0
11 12 HC02

IC22
13

5 6

IC22
4 HC02 2 3

IC22
1 HC02

J5

9
J11P

SHUTTER_CLOSE_SW

C31 R38
4.7K,1/4W
2

J7

5
J7P

C30
10U,50V
1

100P,50V

SHIFT_BREAK [A504]

+5V

R40
4.7K,1/16W

ZD3
HZS18-2

J7

6
J7P

Q7
RT1N141C

OPEN1
2

P36 OPEN1
8 9 HC02

IC22
10

J7

7
J7P

JP2
1 2 KE1-8012/NOTMNT

C32
100P,50V

OPEN[3:0] [A502]

A-8

UPC494C

R25

R30

ETH2

R23

D4

TICPIN-1

100U,35V

2K,1/16W

C21

R33

POWER_SUPPLY

JP1

R22
1 2

+5V

+5U

+24V

R31

2K,1/16W

J19

D3

C23

X1

10,1/16W

R32

3 3
1 2

1 2

1. Finisher Controller PCB (A504)


+5U +5U

TRAY1_HP_SENS

R168
1 2
WJ24P

A1 A2
WJ24P

J14 J14 J14

+24VSHIFT [A503] TRAY_HP0 TRAY_COMING_CLOSE_SW


[65625 P15]

R167
1

220,1/4W

R165
1 2

R166
1 2

22K,1/16W
2

A3

10K,1/16W

J5 J5

10
J11P

C108
1000P,50V

10K,1/16W +5U
2

C109
1000P,50V

WJ24P

+5U
1

TRAY1_SENS

11
J11P

R160 C34
0.01U,50V 2 1 2

C35
0.01U,50V 1

2
WJ24P

A4 A5
WJ24P

R159
22K,1/16W

J14 J14 J14

220,1/4W

TRAYS0
[IPC P05]
2

R157
1 2

R158
1 2

A6
2
WJ24P

R46
+5V
2

R47
2 1

10K,1/16W

C104
1

10K,1/16W +5U
2

C105
1000P,50V +5U

1000P,50V

TRAY1_LIFT_CLK2

1K,1/10W

1K,1/10W

R58
1 2
WJ24P

R42
10K,1/16W
1

A7 A8
WJ24P

R48
2.4K,1/4W 2 3 HC02
1

Q10
1 1

Q11
2SJ529(L) 3

J14 J14 J14

2SJ529(L)
2

IC25
TRAY1_LIFT_MOTOR
4
J7P

R57
22K,1/16W 13
2

220,1/4W

SHIFTM_PWM0
[CPU P20]

IC24
1 3

SHIFTCK1
[CPU PA6]

12

R56
1 2

3
2

HC14

A9
2

Q8
RT1N141C
J7P

J7 J7

10K,1/16W

C58
1000P,50V

WJ24P

SHIFT_BREAK
[A503]

C57
1000P,50V +5U
2

+5U

TRAY1_LIFT_CLK1

SHIFTM_0
[65625 P64]
2

IC23
3 HC00

Q12
2SK2925(L) 3
1 1 2

Q13
2SK2925(L) 3

R61
1 2
WJ24P

A10 A11
WJ24P

J14 J14 J14

IC25
HC14

R60
22K,1/16W 11
2

220,1/4W

R44
10K,1/16W
1

SHIFTCK0
[CPU PA5]

10

R59
1 2

A12
2
WJ24P

10K,1/16W

C59
1000P,50V +5U

1000P,50V

C60

SHIFTM_1
[65625 P63]
2

IC23
6 HC00

+5U

TRAY2_LIFT_CLK2

R45
10K,1/16W

5 5 6
1

R63
22K,1/16W

R64
1 2
WJ24P

B1 B2
WJ24P

J14 J14 J14

IC24
4 HC02 3

R49
2
1 2

IC25
SHIFTCK2_1
[65625 P82]
2

220,1/4W

2.4K,1/4W

Q9
RT1N141C

R62
1 2

HC14

B3
WJ24P

10K,1/16W

C62
1000P,50V
1

+5V
2

C61
1000P,50V +5U
2

TRAY2_LIFT_CLK1
+5U

R276
4.7K,1/16W

R67
1 2
WJ24P WJ24P

B4 B5 B6
WJ24P

J14 J14 J14

OPEN6
[65625 P83]

ZD5
3 2 HZS18-2 1

IC25
HC14

R66
3
2

220,1/4W

RT1N141C

[65625 P81]

10K,1/16W

Q51
1

SHIFTCK2_0
2

R65 C63
1000P,50V

22K,1/16W

C64
1000P,50V

100P,50V

+24VSHIFT [A503]

C151

C36
0.01U,50V 2 1 2

C37
0.01U,50V 1

+5U
2

+5U

TRAY2_SENS

R164
1 2
WJ24P

B7 B8
WJ24P

J14 J14 J14

R163
22K,1/16W

220,1/4W

+5V

R52
1 2

R53
1 2

TRAYS1
[IPC P06]

R161
1 2

R162
1 2

B9
2
WJ24P

1K,1/10W

1K,1/10W

10K,1/16W

C106
1000P,50V
1

10K,1/16W

C107
1000P,50V
1

R43
10K,1/16W
1

R54
2.4K,1/4W 8 9
1

Q16
1

Q17
1

2SJ529(L)
2

2SJ529(L) 3

SHIFTM2_PWM0
[A502]

IC24
10 HC02 3

3
2 2

TRAY2_LIFT_MOTOR
2
J7P

+5U
2

+5U
1

TRAY2_HP_SENS

Q14
RT1N141C
J7P

J7 J7
TRAY_HP2
[65625 P80]

R172
2
WJ24P

B10 B11
WJ24P

SHIFT_BREAK
[A503]

R171
22K,1/16W

J14 J14 J14

220,1/4W

Q18
9
2

Q19
2

SHIFTM2_0
[IPC CLK]

IC23
8 HC00

R169
1 2

R170
1 2
WJ24P

2SK2925(L) 3

2SK2925(L) 3

B12

C111
1000P,50V

10K,1/16W
1

1000P,50V

SHIFTM2_1
[IPC P12]
2

12

IC23
11 HC00

R51
10K,1/16W
1

13 11 12 HC02
1

IC24
13 3

R55
2
1 2

2.4K,1/4W

Q15
RT1N141C

R50

10

C110

2 1

10K,1/16W

10K,1/16W

A-9

1. Finisher Controller PCB (A505)


+5V

Q69
RT1P141C
1

+24V 1
2

ICP12
ICP-N38 2

STEPMOFF1
[IPC PB3]

3 +5V +5V +24V +5V


1
2 2 2

C157
2 1 0.01U,50V 2

C158
1 0.01U,50V

STEPMR1
[A506]

RJOGM0
[CPU P17]
47K,1/16W 47K,1/16W

R299
1 2

R300
1 2

R295 ICP3
ICP-N25
2

R95

R96

+5V

IC11
SMA7029M

10K,1/16W

R298
2

1K,1/10W

1K,1/10W

Q32
RT1P141C
1

[A502]

+5V
1

C76

[65625 P67]

2.4K,1/16W

2200P,50V
2

3 5

TDA REFA GNDA INA OUTA RSA VS RSB OUTB TDB GNDB REFB INB OUTB

2 4 6 8 10

330P,50V

RJOGM_I0

R91 R92
1,1W
1 2 1 2

C73

1
J7P

2
J7P

3.3K,1/16W

CP2
2 2

3
J7P

7 9

J9 J9 J9 J9 J9

R296
10K,1/16W
2

HC02

REAR_ALIGNMENT_MOTOR

PADOL_PWM0

IC38
1 3

2.4K,1/4W
2
1 2

Q57
3 2SJ527(L)

Q58
3 2SJ527(L)

1 2

PADDLE_MOTOR
3
J11P

OUTA

Q56
RT1N141C

J11 J11

4
J11P

PADOL_CW
[IPC P15 CW]

5 +5V
1

IC38
4 HC02

Q59
3 2SK2796(L)

Q60
3 NC 2SK2796(L)

270,1/4W

TICPIN-1
1

R88

R89

R93 R94
1 2

4
J7P

check

1,1W

C74
2

11 13 15

12
J7P

R297
10K,1/16W
2

2.4K,1/16W

2200P,50V

14

R90
33,1/16W
1

PADOL_CCW
[IPC P14 CCW]

8 9

IC38
10
2

C75
330P,50V
1

HC02 11

IC38
13 3 HC02

R301
1 2

2.4K,1/4W
1

RJOGM1 [CPU P16]

12

Q61
RT1N141C

ICP2
ICP-N50 1 2

+24V

C69
+5V
2

C70
1

DROP_SOL +24SOL
J11P

1 0.01U,50V

1 0.01U,50V

J11

D8
AK04 6
J11P

R81
1 2

R82
1 2

R80
10K,1/16W
1

R83
2

1K,1/10W
1

1K,1/10W

SOL_PWM0 SWING_MOTOR SOLOUT4


[65625 P74]

12 13

SWINGM_PWM0 [CPU P22]


+5V
1

IC27
1 3 HC02

2.4K,1/4W
2
1 2

Q28
3 2SJ527(L)

Q29
3 2SJ527(L) 6
J7P

11 HC08

470,1/10W
1 2

3
1

Q36
2SK3065

3
1

Q26
RT1N141C

J9 J9

10K,1/16W
2

R78

7
J7P

SWINGM_W1
[65625 P40 CW]

5 +5V
1

IC27
4 HC02

Q30
3 2SK2796(L)

Q31
3 2SK2796(L)

FJOGM[1:0]
+5V +5V +24V

10K,1/16W

R79

FJOGM0
10
1

SWINGM_W0
[65625 P41 CCW]

8 9

IC27
HC02 11 12 HC02

[65625 P24]
2

IC28

R104

J11

1 2 2 1

R309

47K,1/16W

R310

RT1N141C

[65625 P52]

REFA GNDA INA OUTA RSA VS RSB OUTB TDB GNDB REFB INB OUTB

+24V 1

ICP1
ICP-N50 2
3.3K,1/16W

4 6 8 10

2.4K,1/16W

2200P,50V

3 5

TDA

C162

330P,50V

FJOGM_I0

R305 R307
1,1W
1 2 1 2

C159

OUTA

Q27

RT1P141C
1

13

2.4K,1/4W

Q62

SMA7029M

IC27

R84
1 2

47K,1/16W

STEPMR1
+5V

270,1/4W

R302

R304

C67
+5V 2 1 0.01U,50V 2

C68
1 0.01U,50V

TICPIN-1
check

10K,1/16W
1

EJECTM_PWM0 [CPU P21]


+5V
1

2 3

IC26
1 HC02

RT1N141C
2
1 2

3 2SJ527(L)
2 2

3 2SJ527(L)

330P,50V

3
1

R76
2.4K,1/4W

DELIVERY_MOTOR
1
J11P

FJOGM1
[65625 P25]

R71 10K,1/16W
2

J11 J11

2 5
2

EJECTM_W1
[65625 P44 CW]

IC26
4 HC02

J11P

Q24
3 2SK2796(L)

Q25
3 2SK2796(L)

+5V
1

10K,1/16W
2

R72

EJECTM_W0
[65625 P45 CCW]

8 9

IC26
10 HC02 11 12 HC02

IC26
13 3

R77
2
1 2

2.4K,1/4W
1

Q21
RT1N141C

A-10

Q20

1K,1/10W

1K,1/10W

33,1/16W

2200P,50V

Q22

Q23

C161

IC39

ICP13
ICP-N25

FRONT_ALIGNMENT_MOTOR
7
J11P

8
J11P

CP11

9
J11P

7 9 11 13 15

J11 J11 J11 J11 J11

R308 R306
1 2

10
J11P

1,1W

12
J11P

11

R73

R74
1 2 1

R75

2.4K,1/16W

R303

C160

14

1. Finisher Controller PCB (A506)

+5U +5U
2

+5U

FRONT_ALIGNMENT_HP_SENS

SWING_MOTOR_CLK_SENS
2

R327 R328
1 2
WJ30P

B1 B2
WJ30P

IC41
HC14

R193 R194
2 1 2 1

R195
22K,1/16W

A1
WJ30P

J12 J12 J12


FJOG_HP_S [IPC P04]
8

J12 J12 J12

IC41
HC14 9 2

10K,1/16W 13
1

10K,1/16W
1 2

SWINGM_CK0 [CPU PA7]

12

A2 2
WJ30P

R329

22K,1/16W

220,1/4W

B3 2
WJ30P

C121
1000P,50V

10K,1/16W

C122
1000P,50V 1

+5U A3
WJ30P

C171
1000P,50V

C172
1000P,50V

+5U +5U
2

REAR_ALIGNMENT_HP_SENS

R189
1 2
WJ30P

A4 A5
WJ30P

J12 J12 J12


STPL_TRAY0 [CPU P60]
12 HC14

+5U
2

+5U

STAPLE_TRAY_SENS

R186
1 2
WJ30P

R188
22K,1/16W

220,1/4W

B4 B5
WJ30P

J12 J12 J12

R185 IC21
13 2

220,1/4W

IC41
RJOG_HP0 [65625 P14]
10 HC14 11 2

R187
1 2

10K,1/16W

A6 2
WJ30P

R184
1 2

B6 2
WJ30P

10K,1/16W

C118
1000P,50V 1

10K,1/16W

C117
1000P,50V 1

C115

C116
1 1000P,50V

+5U +5U
2

KNURLED_BELT_HP_SENS

R318
1 2
WJ30P

1000P,50V

A7 A8
WJ30P

J12 J12 J12


EJECTM_CK0 [CPU P67]
4

CP8
1

+5U
2

DELIVERY_MOTOR_CLK_SENS

check

IC25
HC14

220,1/4W

R320
10K,1/16W
1 1 2

R319
22K,1/16W 2

IC41
HC14 3

TICPIN-1

R192
4.7K,1/16W
1 1 2

B7
WJ30P

J12 J12 J12

C166
1000P,50V 1

1000P,50V

C119
1 1000P,50V

R191
10K,1/16W

C120
1000P,50V

RB_HP_S [65625 P87]

A9
WJ30P

R190
1 2

B8
WJ30P

C165

10K,1/16W

+5U B9
WJ30P

+5U

+5U

DELIVERY_SENS

R345 R70
22K,1/16W
1 2
WJ30P

A10 A11

J12
+5U +5U

220,1/4W
1
WJ30P

PADDLE_HP_SENS

IC41
EJECT_S0 [CPU PG1]
6 HC14 5

J12
2

R324
1 2
WJ30P

B10 B11
WJ30P

R68
1 2 1 2
WJ30P

A12 2

R325 J12
PADOL_HP_S
2

J12 J12 J12 J12 J12 J12

IC41
HC14 1 2

220,1/4W

C65
1000P,50V 1

10K,1/16W

10K,1/16W
1 2
WJ30P

10K,1/16W

R69

R326

22K,1/16W

B12

C66
1000P,50V

[IPC P07]

C169
1000P,50V 1
WJ30P WJ30P

C170
1 1000P,50V

B13 B14 B15

+5U
2

+5U

WJ30P

R87
1 2

SWING_OPEN_SENS
A13
WJ30P

R86 IC21
HC14 22K,1/16W

J12 J12 J12

220,1/4W A14
WJ30P

SWING_S0 [65625 P17]

10

11 2

R85
1 2
WJ30P

A15

C72
1000P,50V

1000P,50V

C71

10K,1/16W

A-11

1. Finisher Controller PCB (A507)


+5V

10
PR

IC18
Q

12 11

D K

9 +24V

FEEDM_STEP0
CLR

ICP5
ICP-N50 +5V
1

RESET0 [A501] FEEDM0 [CPU P62]


STEPMR0 [A509] +5V
2

13

[CPU P66]

HC74

+5V

R119

47K,1/16W

R120

47K,1/16W

SMA7029M

IC12

FIRST_FEED_MOTOR
1
J6P

Q38
RT1P141C
1

J10 J10 J10 J10 J10 J10

2.4K,1/16W
2
1 2

C84

1000P,50V
2

3 5

TDA REFA GNDA INA OUTA RSA VS RSB OUTB TDB GNDB REFB INB OUTB

2 4 6 8 10

330P,50V

FEEDM_I0 [65625 P57]

R115 R116
3.3K,1/16W

C81

OUTA

2
J6P

3
J6P

1,1W
1 2 1 2

4
J6P

R112

R113

CP5
TICPIN-1
1
check

130,1/4W

7 9

R117 R118
1 2

5
J6P

1,1W

C82

11 13 15
2

12 14
J6P

R114
33,1/16W
1

2.4K,1/16W

1000P,50V

C83
330P,50V
1

FEEDM1 FEED2M_STEP0 [A501]

[CPU P63]

[CPU P64]
+5V
10

IC19
PR

12 11

HC74
D K Q Q

CLR

RESET0 FEED2M[1:0]

[A501]

13

+5V

+5V

+24V

FEED2M0
2

R128

STEPMR0 [A509]
+5V

47K,1/16W

R129

[A501]

47K,1/16W

[CPU P13]

ICP6
ICP-N50

IC13
SMA7029M

SECOND_FEED_MOTOR
1
J7P

Q39
RT1P141C
1

[65625 P55]

REFA GNDA INA OUTA RSA VS RSB OUTB TDB GNDB REFB INB OUTB

1000P,50V

3 5

TDA

C88

2.4K,1/16W

2 4 6 8 10

330P,50V

FEED2M_I0

OUTA

4
PR

R124 R125
3.3K,1/16W

C85

2
J7P

J16 J16 J16 J16 J16 J16 J16


2 3
D K

IC19
Q

3
J7P

HC74

1,1W
1 2

4
J7P

130,1/4W

7 9

R121

R122

R127
1 2

R126
1,1W

5
J7P

C86

11 13 15
2

12
J7P

6 7
J7P

CLR

check

TICPIN-1

CP6

2.4K,1/16W

1000P,50V

14

R123
33,1/16W
1

C87
330P,50V
1

[CPU P12]

FEED2M1

A-12

1. Finisher Controller PCB (A508)


CP3
1

+5U
1

+5U

HEIGHT_SENS TICPIN-1
check

+5U +5U
2

JOINT_SENS

D9 R106
1K,1/16W
2 1

R108
10K,1/16W A1
WJ20P

1SS270A
2

R145
1 2
WJ20P

A5 A6
WJ20P

J6 J6 J6

HIGHT0 [CPU P33]

R107
2 1

J6
JOINT0
[65625 P30]

R144
22K,1/16W

D10
1SS270A

1K,1/16W +5U

220,1/4W

C77
1000P,50V
2

R142
1 2

R143
1 2

A7
WJ20P

10K,1/16W

10K,1/16W

WJ20P

IC20
Q0 Q1 9

1000P,50V

C78
10U,50V

R111
4.7K,1/16W +5U +5U A3

A2

J6

C96

C97
1000P,50V

7 6 5 3 2 4 5

IC29
2

STP_POS_SENS

HC32 6 3

WJ20P

J6
2

R333 R334
1 2
WJ20P

IC29
1 HC32 3 10 CP

Q2 Q3 Q4 Q5 Q6

A8 A9
WJ20P

C79
1

J6 J6 J6

Q37
RT1N141C

1000P,50V

IC43
HC14 A4
WJ20P

22K,1/16W

220,1/4W

PWM0 [A503] HIGHT_ON0 [65625 P65]

J6

4 13 12 14 15 1 12
2 1

C176
1000P,50V
1

STPPOS_S [65625 P86]

12

13

R335
1 2
WJ20P

A10

10K,1/16W

C175
1000P,50V
1

11
1

MR

Q7 Q8 Q9

IC29
9 HC32 8 10

R109
1K,1/16W
2

R110
4.7K,1/16W

Q10 Q11
1

IC29
HC32 11 13

CP4
TICPIN-1 HIGHT1 [CPU P35]

check

IC43
HC14 8 9 HC4040

SHUTTER_OPEN_SENS
+5U +5U
2

C80
1000P,50V

R156
1 2
WJ20P

B1 B2 B3

J6 J6 J6

R153
10K,1/16W

R155
22K,1/16W

220,1/4W

SHATER_S0
1 2 1 2

WJ20P

INLET_FEED_MOTOR ENTM0 [A501] ENTM[1:0] ENTM0 [A501] STEPMR0 [A509]


47K,1/16W 2
2 2

[65625 P16]

C102
1000P,50V
1

R154
10K,1/16W
1

C103
1000P,50V

+24V
[CPU P65]

[CPU P50]
+5V +5V
2

C93
10U,50V/NOTMNT

+5U +5U
2

DOOR_OPEN_SENS

R152
1 2
WJ20P

B4 B5
WJ20P

ICP7
ICP-N50

J6 J6 J6

+5V

R151
22K,1/16W

220,1/4W

R137

RT1P141C
1

IC14
SMA7029M

Q40
ENTM_I0 [A502]
[65625 P53]

47K,1/16W

R138

UPPERC_S0
1

R149
1 2

R150
1 2

B6
WJ20P

[65625 P31] 1
J12P

10K,1/16W

10K,1/16W

C100
1

C101
1000P,50V
1

R133
2.4K,1/16W
1 2

REFA GNDA INA OUTA RSA VS RSB OUTB TDB GNDB REFB INB OUTB

3.3K,1/16W

R134
1

4 6 8

C92

1000P,50V

3 5

TDA

330P,50V

C89

OUTA

2
J12P

3
J12P

1,1W
1 2

4
J12P

7 9

J17 J17 J17 J17 J17 J17


STPLMM_HP0
[65625 P13] 10

1000P,50V

+5U +5U
2

STAPLE_SHIFT_HP_SENS

R131

130,1/4W

R130

R148 R147
1 2
WJ20P

B7 B8
WJ20P

R135 R136
1 2

10
J12P

5 6
J12P

J6 J6 J6

CP7
TICPIN-1

13 15
2

HC14 11
2

check

2.4K,1/16W
2

1000P,50V

14

R146
1 2

1,1W

C90

11

12

IC43

22K,1/16W

220,1/4W

B9
2

R132
33,1/16W
1

10K,1/16W

C98
1000P,50V
1 1

C99
1000P,50V B10
WJ20P

C91
330P,50V
1

J6

ENTM1

[CPU P51] INLET_SENS


+5U +5U
2

R141
1 2
J12P

7 8
J12P

J17 J17 J17

IC43
ENTRANS_S0 [CPU PG3]
2 1

R140
22K,1/16W

220,1/4W

R139
1 2

HC14
2

9
2

10K,1/16W

C95
1000P,50V

J12P

1000P,50V

C94

10
J12P

J17 J17 J17

11
J12P

12
J12P

A-13

1. Finisher Controller PCB (A509)


+5V +5V
2

R98
10K,1/16W
1

ICP4
+24SOL
1 2

+24V

LAMP1 [65625 P56]


1
J10P

LED2
1 2 LT1P40A

R196
1 2

SOLOUT0
[65625 P70]

ICP-N38
1

IC25
HC14 9 8

3.3K,1/16W

J4

IC18
2
Q

D5
AK04

LAMP0 [CPU P34]

LED1 1

2 LT1P40A

R197
1 2

FLAPPER_SOL
2
J10P

1K,1/16W

PR

D K

470,1/10W
1 2

3
1

PWM0 [A503]

SOLOUT1
[65625 P71] Q

2 HC08

HC74

IC28

R101 Q33
2SK3065

J4 J4

3
J10P

D6
AK04

BUFFER_INLET_SOL
4
J10P

CLR

SOLOUT2 RESET0 [A501] SOL_PWM0


[65625 P72]

6 5 HC08

470,1/10W
1 2

3
1

Q34
2SK3065

IC28

R102

J4

+5V +5V

+24V

RBMT0
[65625 P75]

R293

47K,1/16W

R294

STEPMR1
+5V

KNURLED_BELT_MOTOR

47K,1/16W

IC37
SMA7029M

ICP11
ICP-N25
2

+5V
1

Q55
RT1P141C
1

+24U

D11
5
J10P

R180 R179
1K,1/16W
1 2

C156

[65625 P54]

2.4K,1/16W
1 2

2200P,50V
2

3 5

TDA REFA GNDA INA OUTA RSA VS RSB OUTB TDB GNDB REFB INB OUTB

2 4 6 8 10 12

330P,50V

6
J10P

J4 J4 J4

24VS0 [CPU P41]


2

3.3K,1/16W

CP10
2 2

R291
1,1W
1 2 1 2

7
J10P

C114
100P,50V
1

R181
1

7 9

2.4K,1/16W

330,1/4W

R286

R288

TICPIN-1
1
check

8
J10P

R292 R290
1 2

11
1

1,1W

+5V 9
J10P

13 15
2

J4 J4
2

2.4K,1/16W

R287
33,1/16W
1

C154
2200P,50V

14 10
J10P

PUSH_SW[1:0] [A502]
[65625 P11] PUSH_SW0

R182
10K,1/16W

R183
10K,1/16W

C155
330P,50V

SW1
1 B3F-1000 2

RBMT1
[65625 P76] [65625 P10] PUSH_SW1

SW2
1 B3F-1000 2

+5V

DIP_SW[7:0]
2 4 6 2 4 6

RA6
10K,0.0625
[65625 P07] [65625 P06]

[A502]
+5U +5U

RA5
10K,0.0625
1 3 5 1 3 5 7 7

BUFFER_INLET_SENS

R175
1 2
J9P

SW3
8 9 10 11 12 13 14 15 16 ADE08C 7

1 2
J9P

R174 IC43
HC14
1

J24 J24 J24

DIP_SW7 DIP_SW6 DIP_SW5

220,1/4W

22K,1/16W

[65625 P05] [65625 P04] [65625 P03]

BUF_EP0 [CPU PG0]

5
2

R173
1 2
J9P

6 3

DIP_SW4
5

10K,1/16W

DIP_SW3
4

C112
1000P,50V
1

+5U
2

+5U

[65625 P02]

DIP_SW2
3

R178
1 2

BUFFER_PAPER_SENS
4
J9P

R177 IC43
HC14 22K,1/16W

J24 J24 J24

[65625 P01] [65625 P00]

DIP_SW1
2

220,1/4W 5
J9P

DIP_SW0
1

BUF_PS0 [CPU PG2]

3
2

R176
1 2
J9P

10K,1/16W

C113
1000P,50V
1

BUFFER_OUTLET_SOL +24SOL
1
J9P

J24

SOL_PWM0
2

D7
AK04 8

IC28
8 HC08

R103
470,1/10W
1 2

J9P

J24 J24

SOLOUT3
[65625 P73]

3
1

10

Q35
2SK3065

9
J9P

A-14

RBMT_I0

R289

C153

J4

1SS270A

OUTA

10K,1/16W

1. Finisher Controller PCB (A510)


+5U 1
J8P

J8

+5U
2

R200
10K,1/16W

STPL_READY0 [IPC P02]

R198
1 2

R199
1 2

2
J8P

10K,1/16W

10K,1/16W

C123
1000P,50V
1

J8

READY

+5U
2

R208
4.7K,1/16W 3
J8P

CARTRIDGE0 [IPC P01]

R206
1 2

R207
1 2

10K,1/16W

C126
1000P,50V
1

10K,1/16W

J8

50/100 CARTRIDGE

+5U
2

R203
1K,1/16W

STPL_CON0 [IPC P00]

R201
1 2

R202
1 2

4
J8P

C124
1000P,50V
1

10K,1/16W

10K,1/16W

J8

CONNECT

+5U
2

IC21
HC14

R205
10K,1/16W 5
J8P

C125
1000P,50V
1

STPLHP0 [CPU PG4]

R204
1 2

10K,1/16W

J8

STAPLE H.P

+5U
2

IC21
HC14

R210
4.7K,1/16W 6
J8P

C127
1000P,50V
1
J8P J8P

HOOK0 [IPC P03]

R209
1 2

10K,1/16W 7 8

J8 J8 J8

HOOK SENSE

+5V

Q42 RT1P141C

STEPMOFF0 [65625 P50]

STEPMR0 [A505][A506] [A507] STPLMM[1:0] [A501] STPLMM0


2 2

+5V

+5V +24VMOVE

R218

47K,1/16W

R219

+5V

IC15
SMA7029M

47K,1/16W

[CPU P15]

SATPLER_SHIFT_MOTOR

ICP8
ICP-N50
2

Q41
RT1P141C
1

STPLMM_I0 [65625 P66]

2.4K,1/16W
2

REFA GNDA INA OUTA RSA VS RSB OUTB TDB GNDB REFB INB OUTB

4 6 8 10

2200P,50V

3 5

TDA

C131

R214
3.3K,1/16W

330P,50V

C128

1
J6P

OUTA

2
J6P

3
J6P

130,1/4W

CP9
R211
1

R215
1 2

4
J6P

7 9

J18 J18 J18 J18 J18 J18

TICPIN-1

R212

1,1W

R216
1 2

check

R217
2.4K,1/16W
1 2

1,1W

5
J6P

11

C129
2

12 14
1

13 15

2200P,50V

C132
10U,50V/NOTMNT

J6P

R213
33,1/16W
1

C130
330P,50V
1

STPLMM1 [CPU P14]

A-15

1. Finisher Controller PCB (A511)


+5V

VCC GND

16 8

VCC GND

5 3

VCC

14 7

VCC

14 7

VCC

16 8

VCC

14 7

VCC GND

14 7

VCC

14 7

GND

GND

GND

GND

GND

HC138

C38

S08

C39

HC74

C40

HC74

C41

HC4040

C42

HC14

C43

HC02

C44

HC00

C45

0.1U,50V

0.1U,50V

0.1U,50V

0.1U,50V

0.1U,50V

0.1U,50V

0.1U,50V

0.1U,50V

+5V

IC24
VCC GND

IC25
14 7
VCC GND

IC26
14 7
VCC GND

IC27
14 7
VCC GND

IC28
14 7
VCC GND

IC29
14 7
VCC GND

IC30
S14 14 7
VCC GND

5 3 1

HC02

HC14

HC02

HC02

HC08

C46
0.1U,50V

C47
0.1U,50V

C48
0.1U,50V

C49
0.1U,50V

C50
0.1U,50V

HC32

NC1

C51

C52
0.1U,50V

0.1U,50V

+5V

IC32
VCC GND

IC33
14 7
VCC GND

IC35
14 7
VCC GND

IC38
5 3
VCC GND

IC41
14 7
VCC GND

IC42
14 7
VCC GND

IC43
14 7
VCC GND

14 7

HC02

HC08

S00

HC02

HC14

HC14

HC14

C54
0.1U,50V

C55
0.1U,50V

C56
0.1U,50V

C177
0.1U,50V

C179
0.1U,50V

C180
0.1U,50V

C53
0.1U,50V

+24VSTPL

C138
0.01U,50V +5V 2
1

C139
0.01U,50V 2 1

+5V

R221
3.3K,1/16W
1 2

Q43
RT1P141C

R226
1 2

R227
1 2

Q44
RT1N141C
2

1.5K,1/10W

1.5K,1/10W

10K,1/16W

R222
2

2
2

IC32
1 HC02

R228
1 2

Q47
3 2SJ553L

Q48
3 2SJ553L 1
J2P

10K,1/16W
1

3
1

3.3K,1/4W

3
2

R220

J22 J22
STAPLE_MOTOR

C133
1

2
J2P

0.01U,50V

STPLM_W1 [65625 P46] [CW]


+5V

3 2 HC08
2

3 +24U
1SS270A 1 1

IC33

Q49
2SK2869
2

Q50
2SK2869 3

D12

IC34
BA10358F 3 1 2
8

R235 IC34
BA10358F 7
1

C136
1

39K,1/16W 6 5

0.1U,50V 1 2

R231
1 2

10K,1/16W
2

R223

10K,1/16W

R234

C135

33K,1/16W

0.01U,50V

R230

1SS270A
2

R237
1 2

1SS270A

D13

R233
1 2

R232
1 2

STPLM_W0 [65625 P47] [CCW]

100K,1/16W

R236
1 2

C137
2 1000P,50V 1

200K,1/16W

10K,1/16W

R224
10K,1/16W
1 2

4 5

IC33
6 HC08 +5V 4

4.7K,1/16W

Q46
3
1 2

R229
1 2

C134
0.01U,50V 5 6
1

IC32
HC02
1

RT1N141C

3.3K,1/4W

R225
3.3K,1/16W
1 2

Q45
RT1P141C
2

IC32
10 HC02

IC33 9
8 10 HC08

IC33 12
11 13 HC08

11 12

IC32
13 HC02

A-16

0.02,2W

D14
2

IC16

IC17

IC18

IC19

IC20

IC21

IC22

IC23

2 1

1 2

8 4

1. Finisher Controller PCB (A512)


PUNCH_U[3:0]
+5U

PREGS[5:0]
2

R240
[A501] [CPU P42] PREGS0
22K,1/16W +5U

R238
1 2

R239
1 2

A4
WJ28P

B1

J21 IC21
[65625 P21]

10K,1/16W

10K,1/16W +5U
1

R267
22K,1/16W

C140
1000P,50V
1

PUNCH_U1

6 HC14

5
2

R266
1 2

P_HP
WJ28P

B7

R243
22K,1/16W

J21

10K,1/16W

[CPU P43]

PREGS1

R241
1 2

R242
1 2

C146
B4
WJ28P

+5U
1
2

B2

J21 IC21
[65625 P22]

1000P,50V

10K,1/16W

10K,1/16W +5U
1

R269
22K,1/16W

C141
1000P,50V
1

PUNCH_U2

8 HC14

9
2

R268
1 2

REG_HP
WJ28P

B8

R246
22K,1/16W B3
WJ28P

J21

10K,1/16W

J21

[CPU P44]

PREGS2

R244
2

R245
10K,1/16W +5U
1

C147
A4R
1000P,50V

+5U

R272
2

10K,1/16W

4.7K,1/16W
1

C142
1000P,50V

R249
22K,1/16W
1

[65625 P23]

PUNCH_U3

R270
1 2

R271
1 2

PUNCH_F_COVER
WJ28P

B9

J21

10K,1/16W

10K,1/16W

2
WJ28P

J21

10K,1/16W

10K,1/16W +5U

C143
1000P,50V
1

[CPU P45]

PREGS3

R247

R248

B5R

C148
B4 1000P,50V

R252
22K,1/16W

B10
WJ28P

J21

[CPU P46]

PREGS4

R250
1 2

R251
1 2

+5U

R_EDGE
WJ28P

B5

J21

10K,1/16W

10K,1/16W
1

R275
4.7K,1/16W

C144
1000P,50V
1

PUNCH_CLK0
[CPU P61]

R273
1 2

R274
1 2

PUNCH_CLK
WJ28P

B11

J21

10K,1/16W

10K,1/16W

[CPU P47]

PREGS5

R253
1 2

EDGE_LED
WJ28P

B6

J21

C149
1000P,50V
1

4.7K,1/16W +5U

+5U

6 5

RA9
22K,0.0625
1

R254
22K,1/16W A1
WJ28P

RA11
10K,0.0625
1 3

PUNCHM1 PUNCHM_PWM0 PUNCHM0 PREGM0

[65625 P42] [CPU P23] [65625 P43] [CPU P25]

RA7
1 3 5 7 2 4

A2
WJ28P

6
WJ28P

A3 A4
WJ28P

8 1K,0.0625

J21 J21 J21 J21

[65625 P20] [65625 P33]

PUNCH_U0 PUNCH_U4

RA10
1 3 5 7 2 4 6

PUNCH_U_UMU
WJ28P

B12 B13
WJ28P

PUNCH_U_COVER

B14
WJ28P

8
WJ28P WJ28P

A13 A14

1K,0.0625 A5
WJ28P

PREG_I0 PREGM1 STEPMOFF0 EEPDO0

[65625 P51] [CPU P24] [65625 P50] [65625 P60]

RA8
1 3 5 7 2 4
WJ28P

J21 J21 J21 J21 J21

A6 A7
WJ28P

6 8
WJ28P

A8
2

J21 J21 J21 J21

+5V
J4P

J23 J23 J23 J23

1K,0.0625

R256
22K,1/16W +5U
J4P

R255 22K,1/16W
1

2 +24VMOVE 3
J4P

EEPCS0
[65625 P61]

R257
1 2

470,1/10W
WJ28P

A9

J21
J4P

R258
EEPSK0
[65625 P62]
1

470,1/10W
2
WJ28P

A10

J21 J21

EEPDI0
[65625 P12]

R259
1

470,1/10W
2
WJ28P

A11
2 2

+5U
2

R262
22K,1/16W
1

R261
22K,1/16W
1

R260
22K,1/16W
1

R265
22K,1/16W

DUST0
[65625 P80]

R263
1 2

R264
1 2

A12
WJ28P

J21

C145
1000P,50V
1

10K,1/16W

10K,1/16W

A-17

E.

SADDLE STITCHER UNIT CIRCUIT DIAGRAM


12
PI1S Paper pushing plate motor clock sensor
1 2 3

11
J107 1 2 3 J11-15 J11-14 J11-13

10

PI2S Front door open/closed sensor

J131-3 J131-2 J131-1 J208-4 J208-3 J208-2

J701-8 J701-7 J701-6 J701-5 J701-4 J701-3

PI3S Delivery cover sensor

+5V G STPLHP +5V G VPJM

1 2 3

J103 1 2 3

J303 3 2 1

PI5S PI4S Alignment plate Paper folding home position motor clock sensor sensor

1 2 3

J101 1 2 3

J309 3 2 1

J209 1 2 3

J11-3 J11-2 J11-1

J9-12 J9-11 J9-10

J128 1 1 2 2 3 3

PI6S Tray paper sensor

J100 1 1 2 2 3 3

J502 3 2 1

J402 1 2 3

J302 6 5 4 3 2 1

J202 1 2 3 4 5 6 J6-9 J6-8 J6-7 J6-6 J6-5 J6-4

PI8S PI7S Paper positioning Paper positioning plate sensor plate home position sensor

J106 1 2 3 1 2 3

J105 1 2 3 1 2 3

J301 3 2 1

J201 1 2 3

J6-3 J6-2 J6-1

PI16S Stitcher unit home position sensor

MS7S Stitcher home position switch (front)

MS6S Staple sensor (front)

INLTCVRMS +24V

Stitcher unit (front)

J131 1 1 2 2 3 3 J208 1 2 3 4

J13-3 J13-2 J13-1

J108-2 J108-1 J112-2 J112-1 J205-2 J205-1 J110-2 J110-1 J109-2 J109-1

J4 10 9 8 7 6 5 4 3 2 1

J4 10 9 8 7 6 5 4 3 2 1

J6 FDROPN +5V G PPOSPAR +5V G PAPPOS +5V G TRYPAR


J12 J12 5 A 5 4 B 4 3 A 3 2 B 2 1 +24V 1

J6 1 2 3 4 5 6 7 8 9 J201-3 J201-2 J201-1 J202-6 J202-5 J202-4 J202-3 J202-2 J202-1

PI17S Vertical path sensor

STCHHP2 G HKEMP2

STCHHP1 G HKEMP1

J15 J15 8 8 7 7 6 6 RLNIPSL 5 5 +24V 4 4 FSPSL2 3 3 +24V 2 2 FLPSL1 1 1 +24V

STICHMT1

STICHMT1

STICHMT1

STICHMT2

STICHMT2

STICHMT2

STICHMT2

STICHMT1

1 2 3

J132 1 2 3

J308 4 3 2 1

J13-6 J13-5 J13-4

J702-2 J702-1

J1 2 1

J1 2 G 1 +24V

1 2 3 4 5 6 7 8 9

J8-7 J8-6 J8-5 J8-4 J8-3 J8-2 J8-1

1 2 3 4 5 6 7

1 2 3 4 5 6 7

7 6 5 4 3 2 G 1

M7S Stitcher motor (front)

DELVMS

J120

J305

J315 7 6 5 4 3 2 1

MS5S Stitcher home position switch (rear)

MS4S Staple sensor (rear)

Stitcher unit (rear)

J114-1 J114-2 J114-3 J114-4 J114-5 J113-1 J113-2 J113-3 J113-4 J113-5

J7 10 9 8 7 6 5 4 3 2 1

J7 10 9 8 7 6 5 4 3 2 1

A B A B +24V A B A B +24V

J9 +5V G DELV +5V G FDRLHP +5V G GIDHP +5V G LUNGEHP +5V G LUNGETOP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

J9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 J125-3 J125-2 J125-1 J126-3 J126-2 J126-1 J127-3 J127-2 J127-1 J128-3 J128-2 J128-1 J129-3 J129-2 J129-1

J9-15 J9-14 J9-13

J121 J8-14 J8-13 J8-12 J8-11 J8-10 J8-9 J8-8 1 2 3 4 5 6 7

J306 1 2 3 4 5 6 7

Saddle stitcher controller PCB

J316 7 6 5 4 3 2 1

7 6 5 4 3 2 G 1

Stitcher motor

M6S

PI15S Paper pushing plate top position sensor

J129 1 1 2 2 3 3

PI14S Paper pushing plate home position sensor

1 2 3

J102 1 2 3

J11-6 J11-5 J11-4

J107-1 J107-2 J107-3 J104-1 J104-2 J104-3 J203-1 J203-2 J203-3 J102-1 J102-2 J102-3 J209-1 J209-2 J209-3

J14

J17

1 2 3 4 +5V 5 G 6

J203 1 2 3

J11-9 J11-8 J11-7

J13 J11 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 J11 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 J16 +5V LUNGECLK G FDR G +5V EJCVR G +5V +5V FLDCLK G JOGHP G +5V
1 2 3 4 5 6 7 8 9 10 11 12 13 14

J2 J2
1 2

J13

1 +5V 2 PAFLDHP 3 G

J9-9 J9-8 J9-7

PI13S Guide home position sensor

J18 J18 1 J130-3 2 J130-2 3 J130-1 J10 J10

J10-1 J10-2 J10-3 J10-4 J10-5

J204 5 4 3 2 1

J304 1 2 3 4 5

J123 5 4 3 2 1 1 G 2 3RDPA 3 2NDPA 4 1STPA 5 +5V

PI20S PI19S PI18S No. 3 paper No. 2 paper No. 1 paper sensor sensor sensor

J18-3 J18-2 J18-1

1 2 3

1 2 3 4 5 6 7

1 2 3 4 5 6 7

1 2 3 4 5 6

1 2 3

J9-6 J9-5 J9-4

1 2 3

1 2 3

J127 1 1 2 2 3 3

PI12S Crescent roller phase sensor

PI18S Paper folding home position sensor

1 2 3

J104 1 2 3

J11-12 J11-11 J11-10

J130 1 2 3

PI9S Inlet cover sensor

J10-8 J10-7 J10-6

J124 1 2 3

PI11S Delivery sensor

1 2 3

J9-3 J9-2 J9-1

J125 1 2 3 4

J225 4 3 2 1

J325 1 2 3 4

J425 4 3 2 1

J525 1 1 2 2 3 3

J126

+5V 1STPA 2NDPA 3RDPA G +5V G INLTCVR

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

J204-5 J204-4 J204-3 J204-2 J204-1 J124-3 J124-2 J124-1

M8S Paper pushing plate motor

M2S Paper folding motor

SL

MS1S Inlet door switch

NO

MS2S Front door switch

NO

J110 1 2 3

J4-3 J4-4

Finisher unit
J305 J205 1 1 2 2 J4-5 J4-6

M5S Alignment motor

MS3S Delivery door switch

NO

J111 1 2 3

M1S Feed motor

1 +5V 2 3 4 5 6 7 8

J2-6 J2-5 J2-4 J2-3 J2-2 J2-1 J7-5 J7-4 J7-3 J7-2 J7-1 J1-1 J1-2

J113 1 2 3 4 5 1 2 3 4 5

J5-4 J5-3 J5-2 J5-1

J115 1 2 3 4

4 3 2 1

SL

J3

1 2 3 4 5 6 7 8

J15-5 J15-6

SL4S Feed plate contact solenoid

J109 1 2 3

J4-1 J4-2

J400 8 7 6 5 4 3 2 1

J701

M4S Paper positioning plate motor

3 2 1

J112 3 2 1

J121-1 J121-2 J121-3 J121-4 J121-5 J121-6 J121-7 J120-1 J120-2 J120-3 J120-4 J120-5 J120-6 J120-7

J116-1 J113-2 J117-1 J117-2 J118-1 J118-2

J115-1 J115-2 J115-3 J115-4

J119-1 J119-2 J119-3 J119-4 J119-5

J4-8 J4-7

J7-10 J7-9 J7-8 J7-7 J7-6

J114 1 2 3 4 5 1 2 3 4 5

J15-3 J15-4

J117 2 1

J117a 1 2

SL

2 1

J4-10 J4-9

J8

J5 4 3 2 1

J15-1 J15-2

J118 2 1

J118a 1 2

SL2S SL1S No. 2 deflecting No. 1 deflecting plate solenoid plate solenoid

J108 2 1

J12-5 J12-4 J12-3 J12-2 J12-1

J119 1 2 3 4 5

1 2 3 4 5

B B A A

14 13 12 11 10 9 8 7 6 5 4 3 2 1

M3S Guide motor

J8

14 13 12 11 10 9 8 7 6 5 4 3 2 1

J5 4 3 2 1

J116 2 1

J116a 1 2

J19 +24V 1 2

J500 J702 1 1 2 2

A-18

1.
+5C

Saddle Stitcher Unit PCB (A501)


2

+5v

L4

2 +5C

+5V

<A507>

R448

1 ABUS16 2 ABUS15 3 ABUS12 4 ABUS7 5 ABUS6 6 ABUS5 7 ABUS4 8 ABUS3 9 ABUS2 10 ABUS1 11 ABUS0 12 DBUS0 13 DBUS1 14 DBUS2 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

VPP A16 A15 A12 A7 A6 A5 A4 A3 A2 A1 A0 00 01 02 GND

DBUS0 DBUS1

DBUS2 DBUS3 DBUS4 DBUS5 DBUS6 DBUS7

ABUS0 ABUS1 ABUS2 ABUS3 ABUS4 ABUS5 ABUS6

Q2

VCC PGN NC A14 A13 A8 A9 A11 OE A10 CE 07 06 05 04 03

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

C1

+5v

C2 L6 2 1 2

LED3

C9

ABUS14 ABUS13 ABUS8 ABUS9 ABUS11 ABUS20 ABUS10 ABUS17 DBUS7 DBUS6 DBUS5 DBUS4 DBUS3

1 ABUS12 2 ABUS7 3 ABUS6 4 ABUS5 5 ABUS4 6 ABUS3 7 ABUS2 8 ABUS1 9 ABUS0 10 DBUS11 11 DBUS12 12 DBUS13 13 14

NC A12 A7 A6 A5 A4 A3 A2 A1 A0 1/01 1/02 1/03 GND

Q3

VCC WE CS2 A8 A9 A11 OE A10 CS1 1/08 1/07 1/06 1/05 1/04

28 27 26 25 24 23 22 21 20 19 18 17 16 15

+5V R3

HOOKS[1:0] DOORSW[2:0]
A7 PA0 PA1 PA2 PA3 PA4 PA5 PA6 PA7

<A503> <A502> <A505>

ABUS21 ABUS8 ABUS9 ABUS11 ABUS20 ABUS10 ABUS18 DBUS7 DBUS6 DBUS5 DBUS4 DBUS3

DG2

DG3

DG4

DG5

DG6

DG7

A0

A1

A2

A3

A4

A5

Q5
1 2
VOUT N-RST GND VCC

4 3

C10 1 2

C11 1 2

ABUS21 ABUS20 ABUS19

<A504>

BUS0 BUS1

<A501><A504> <A504> <A504> <A505> <A504> SLOUT2 PAPERPOSM[2:0] SENS5[2:0]

RESET NUKE6 NUKE5 NUKE3 NUKE1 NUKE4 NUKE2 HARI-KEN1 HARI-KEN0 <A505> <A506> <A505> <A507> <A506> <A505> <A503> <A503> +5V

CNVSS

HMT

KEY

VSS

PQ7

PQ6

PQ5

PQ4

PQ3

PQ2

19 20 21 22 23 24 25 TRAY-P-SENS231 26 TRAY-P-SENS230 27 28 29 30 PULLOUTS43 PULLOUTS42 31 PULLOUTS41 32

PQ1

P10

XIN

P12

XOUT

TRAY-M2 TRAY-M1 TRAY-M0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

VCC

A6

64 63 62 61 60 59 58 57 56 55 54 53 52 51

DG1 DG0 W R S DN

INTR RXD3 TXD3 RXD2 TXD2 RXD1 TXD1 CTS3 CTS2 CTS1 CLK

Q4

PD0 PD1 PD2 PD3 PD4 PD5 PD6 PD7 PO0

50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33

ABUS7 HOOKS0 HOOKS1 DOORSW0 DOORSW1 DOORSENS0 DOORSENS1 DOORSW2 DIPSW0 DIPSW1 DIPSW2 DIPSW3 DIPSW4 DIPSW5 DIPSW6 DIPSW7

DOORSENS[1:0]

COVER

<A506>

R4

FEEDM1 FEEDM0 FEEDM2 TUKIPWM PAPERPOSM1 PAPERPOSM0 TRAY-HP SENS52 SENS51 TUKE-CLK SENS50

FEEDM[2:0]

PAPERPOSM2 SOLTMR

TUKICW +5V JOGM[2:0] <A504> 5VB JOGM0 JOGM1 ORIPWN TUKICCW GAIDOM0 GAIDOM1 GAIDOM2 JOGM2 SENS40 SENS41 STPLHPS50 STPLHPS51 SENS42 SENS43 <A501><A504> <A506> <A506> <A506> <A506> RESET PPHP SUHP PUSHSW HAHS SENS30 SENS31 SENS3[1:0] <A505> STPLM0 STPLM1 1 L2 2

PULLOUTS40

DIPSW[7:0]

<A506>

LED1

PULLOUTS4[3:0] ORI-NUKE TRAY-M[2:0] <A507> <A507> <A507> <A507>

C3

112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85

<A505> <A506> <A503>

GAIDOM[2:0] SENS4[3:0] STPLHP3[1:0]

<A505>

PC5 PC6 PC7 RES0 PD0 PD1 PD2 PD3 PD4 PD5 VSS2 D0 VSS5 VSS2 VSS4 D1 D2 D3 D4 D5 D6 D7 D10 D11 D12 D13 D14 D15 A10

CLK PO2 PO1 PO0 A19 A18 A17 A16 A15 A14 A13 A12 A11 A8 A9 D8 D9 A0 A1 A2 A3 A4 A5 A6 A7

EJCT-SENS <A505> ORITOP 24VDOWN <A506> 1 2 ABUS16 ABUS15 ABUS14 ABUS13 ABUS12 ABUS11 3 ABUS19 <A505> Q7

Q15
BUS1

14

R24

Q23

R23

TRAY-SENS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

VCC PB0 PB1 PB2 PB3 PB4 PB5 PB6 PB7 VSS1 PC0 PC1 PC2 PC3 PC4

AVCC MD2 MD1 MD0 LWR MRW RD AS

VCCS XTAL RXTAL VSS5

DBUS[8:0]

RES STBV

Q1

NM1

9 Q7 10

2 8 ABUS18 ABUS17

1 C6

C7
2 1

ORIDIR0 ORIDIR1 SLOUT0 SLOUT1

ABUS8 ABUS9 ABUS10

ABUS0 ABUS1 ABUS2 ABUS3 ABUS4 ABUS5 ABUS6 ABUS7

C165

C166
Q172

R507

<A503>

STPLM[3:0]

STPLM2 STPLM3

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

1 2 3 4

XIN

VDD XOUT MODOUT/RS0 REF-OFF REFOUT/RS1 LF VSS

8 7 6 5

R505

84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57

C5 1 2

VREF

VSS6

A23

A22

A21

A20

P77

P76

P75

P74

P73

P72

P71

PB4

PB3

PB2

PB1

PB0

AVSS

P70

PA7

PA6

PA5

PA4

PA3

PA2

PA1

PA0

X2 C14
1 2 2

ORI-HP

C15

C16

R449 R450

ABUS21 ABUS20

5VB

TARY-P-SEN23[1:0]

+5U

+5U

BUS[4:0]

BUS0

R22
1

R21
+5U

R20

D1

1 J2 2 J2 3 J2 4 J2

ABUS[22:0]

C8

C17

R504

R25
1 J17 2 J17

4 Q7 5

C6

X1
1

Q173

C163

C164

R506
+5V

R508
LED1

LED1
1 2

R32

R509
5VB

1 2

<A502> <A504>

ORIDIR[1:0] SLOUT[1:0]

DBUS0 DBUS1 DBUS2 DBUS3 DBUS4 DBUS5 DBUS6 DBUS7

Q172

2 1

C162

VCC 5 GND 3

C167

A-19

1.

Saddle Stitcher Unit PCB (A502)


L8 Q7

+5V

Q11 Q8
C65 C66
14 7
VCC GND

Q12
74

02

Q13 08
C69
7
VCC GND

C67

VCC GND

VCC GND

VCC GND

+5U

+5V

+5V

+5U

+5V

C70

1 2

14

14

14

14

Q12
4 2 PR D K Q CLR 6 Q 5

Q15
2

Q16
2

Q17
2

Q117
C120 C74
14 7
VCC

Q168
14 7
VCC

C71

VCC GND

VCC

C72

14 7

14 7

VCC

14 7

GND

GND

GND

GND

OEM_POWER<A507>
+24V

12 13

Q13
11

CB1 J1
1
1 +2

2 1

ICP5

C21

R51 ETH2
1 2 E +5V

R52 C157
1
1 1

J1 J4

ORIDIRO 24S<503> R358 R61


2

11

10

3
1

Q168

Q32

R50

C158
1 2

C148

Q28
3

Q29
3

INLET DOOR J4 J4
2 1

ZD2
2

DOORSW0 PA2 Q118 ORIPWM PB2


+5V

R62

13

12

1 +24R

Q30 3

R359

C122

1 2

FRONT DOOR
2

1 10

11

1 1
4

+ -

R45 DOORSW1 PA3 ZD3


1 2
1

D5

Q117

D6 D7

R63

Q9

+5V 3 2

C27
7
4

Q9

+ -

R56
2

R60

C28

J4

R58

Q26

C29

R55

Q117

2 Q8 3

FOLDING MTR 7 J4 8 J4

3 Q31

R46

C23

1 2

ETH3 R57
1 2 E

+24U

J4

11 12

Q8
13
2

ORIDIR1
+5V

Q168
13 12

Q33
3

R53

R64 R47 DELIVERY COVER DOORSW2 J4


6 1
1 +2

ORIDIR[1:0] PA7

ZD4
2

3
1

Q27

R48

C26

C25

1 2

DOORSW[2:0]

A-20

1.
24S<502> 1 2

Saddle Stitcher Unit PCB (A503)

ICP8

C150 STPLM[3:0]
+5V

C151
1 2

R77
R65

R78

2 1

Q168 D0 STPLM0
2

Q38
2 3

2 1

R76
2

Q34

Q35
3

STITCHER MTR (R)


14 13 12

J8 J8 J8 J8

C31

R69 CP4
1

+5V

R68

5 6

Q11
4

R75

Q36
3 3

Q37

11

STPLHPS[1:0] Q108 R331


1 2

+5U

C114 R333

R332

HOOK[1:0] Q17 STPLHPS0


2 1
2

R97

HARI-KEN0
2

R329

+ -

+5V
1

C113

R98 C38
+5U

STAPLE H.P2
10 J8

R330 C139
1 2

R70

9 J8
1

Q168 D1 STPLM1
1 2

2 3

R79 R80 HOOKS0


24S<502>

R100

D10

Q11

C33

R102
C39
2

HOOK SENS2
8 J8

R101

R74
3

R73

+5V

1 2

ICP9

C154

C155
1 2

D11

Q39

+5U

R93
R81

R94 STPLHPS1 Q17


4 3
1 2

R103

STAPLE H.P1
3 J8

2 1

D2

Q168 STPLM2
2

2 1

R92
2

Q40

Q41
3

6 11 12

Q44 3
1

STITCHER MTR (F) 7 J8


6 5

R104 C40
+5U

C35

R84

CP3
1

Q11

+5V

C126
1 2

R106

D14

R85

13

R91

Q42
3

Q43
2

J8 J8 J8

2 J8

HOOKS1 R337
1 2

R108
C41
1 2

R107

HOOK SENS1 1 J8

R335
2

+5V

C115

R336 C140
1 2

R339

R86

Q168 D3 STPLM3
9 8 9
1 2

Q11
10

R95 R96

C37

R90 Q45

3
1

R89

R338

C116

D15

HARI-KEN1

+ -

Q108

A-21

1.

Saddle Stitcher Unit PCB (A504)


+5V

R428

FEEDM[2:0]

+5V

+24U

ICP1

+5V

SLOUT[1:0]
C133 C131 R119
1 +2 2

+24V

ICP7

1 J15

D17

C132

FLAP SL1
2 J15 3 J15

1 2

SOLTMR
10

Q155
1 MB 2 T
E MA

Q154
16 15 1 2 3
MB T E MA

Q12
9 8

15

R433

C138

C136

C134

8 PH
1

IO

I1 PH

C IO

D19

R429

10

7 8

10 9
1

VCC

VR

R437

6 VCC 7 I1

VR

13

11

R430

3 VMM1 VMM2 14 4 GND1 GND4 13 12 5 GND3


GND2

R431

C137

C135

VMM1 VMM2 GND1 GND4 GND2 GND3

R427

4 5 6

13 12 11

Q CLR

R475

14

SOLPWM <A507>

D K

D18

12 11

16

PR Q

SLOUT0

Q13 R476

Q47

FLAP SL2
4 J15 5 J15

SLOUT1

Q13

Q48

<501> <504> <501>

RESET Q13
8

FEED SL
6 J15

10

+5v

SLOUT2 P55

Q170 R120

1 J5 A 2 J5 A 3 J5 B 4 J5 B FEED MOTOR

NC Q7
FEED POWER UP 11 12 13

7 J15

R435

R436

R434

* *

NC

8 J15

PA4 PA5 PA3

FEEDM0 FEEDM1 FEEDM2


1 +5V

Q15
11 10

+24U

ICP2

2 +5V

JOGM[2:0]
R302
+5V

PAPERPOSM[2:0]
+5V 1 J7

ICP3
1 2

PB0

JOGM0
R301
+5V

R311

Q101
C104
2

PA0

PAPERPOSM0

6 J7

C108

PB7

Q102 JOGM2 3

R303 R304
1

1 OUTA 3 REFA 5 INA 7 RSA 9 RSB 11 TDB 13 REFB 15 OUT/B

JOG MTR
2 J7 B 3 J7 A 4 J7 B

+5V

R310

Q103
OUTA REFA INA RSA RSB TDB REFB OUT/B TDA GA OUT/A VS OUTB GB INB

TDA GA OUT/A VS OUTB GB INB

4 6 8 10 12 14

* *

A23 PAPERPOSM2 3
R317 2 R316

R312
2 1

2 4 6 8 10 12 14

Q104

PAPER POS MTR


7 J7 B 8 J7 A 9 J7 B 10 J7 A

1 5 7 9 11 13 15

R308 2

C101

* *

R307

R313

C105 R314
1 2

R305 R306

C102

R315
5 J7 A

C106
2

R309

C103

R318

C107
1

CP5

CP6

PB1

JOGM1

PA1 PAPERPOSM1

A-22

1.

Saddle Stitcher Unit PCB (A505)


+5U

1
+5U

Q151
3 +5U

PULLOUTS41
1

R151

D35

R411

R150

10 J9 11 J9 12 J9

PUSHING H.P

+5U

+5U

SENS51 R129
1 J9 DELIVERY SENS 2 J9 3 J9

R153
2

R152 C54
1

D36

+5U

R208
+5U

R130

13 J9

NUKE6 R209 ORITOP Q17


12 13

R408
14 J9 +5U 15 J9

Q16 EJCT-SENS
6 5

PUSHING TOP S

R131
2

C49

+5U

+5U

R210
2 1

R134

R135

4 J9

C79 CRESCENT SENS

PULLOUTS4[3:0]
+5U

Q150
3 +5U

Q16 CRESCENT
4 3

5 J9 6 J9

R410

R136
2

PULLOUTS40

R146

R145

1 J11 2 J11 3 J11

C50
+5U

NUKE3
+5U

R128 ALIGNMENT H.P R139


7 J9 8 J9

ALIGNMENT H.P

Q15
6 5

GUIDEHP0

R147
2
+5U

GUIDEHP1 Q16 3
2 1

R140

C53

R154

D37

FOLDING CLK

R156
1

R141
1

GUIDE H.P
9 J9

4 J11

FOLDING CLK
+5U

Q58

C51

R155

D38

Q152
3 +5U

+5U

5 J11 6 J11

C55
+24V

+5U

PULLOUTS42

R158

R159

+5V

D39

ICP4

R412

7 J11

DELIVERY COVER
8 J11 9 J11

R319

GUIDEM[2:0] PB4 GUIDEM0

+5V

DOORSENS0
1 J12

R161
1 2

D40

R320

+5V

Q105
2

C56

1 2
+5U

R160

+5U

Q153
3

C109

GUIDE MTR
2 J12 B 3 J12 A 4 J12 A 5 J12 A

PB6

R326 2

R325

R322

R323
2 1

C112

13 REFB 15 OUT/B

INB

14

C57

D42

R324

C111

9 RSB 11 TDB

VS

OUTB 10 GB 12

DOORSENS1

R166
1

5 INA 7 RSA

R164

D41

C110

GA 4 OUT/A 6

R413

Q106 GUIDEM2 3

R321

1 OUTA 3 REFA

TDA

PULLOUTS43

+5U

*
1

163

10 J11

FRONT DOOR
11 J11 12 J11

R165

+5U

R327

13 R367
TUKI-CLK

J11

R365

R366
+5U

14

J11
TUKI CLK SENS

PB5

GUIDEM1

C125
1

15

J11

A-23

1.

Saddle Stitcher Unit PCB (A506)


+5U +5U +5U

SENS4 [3:0]

R174 Q16
PC6 SENS43 8 9 2 C59 1

1 2

J10 J10 1st P SENS J10 2nd P SENS J10 3rd P SENS J10
SENS42 10

+5U

R175
+5U

R168 R169 Q17


11 2 C58 1

1 2 3

J6 J6 PAPER SENS J6

3 4

R170
+5U +5U

R179

Q16
PC0 SENS40 10 11 2 C60 1

R180
+5U

R198 R199

4 5 6

J6 PAPER POS H.P J6 J6

R184

PPHP

Q17
8 9 2 C64

R200

PC1

SENS41

12

13 C61 1

Q16

R185
+5U

NUKE2
+5U +5U

R123

NUKE4
+5U

R187

R124 J10 J10 TRAY-SENS J10


6

D51

R189 R190

7 8

INLET COVER SENS Q17


5 2

R125

R188
1

7 J6 8 J6 9 J6

COVER PA6(IPC)

R191
2 1 C62 1

R126 C48

TRAY P SENS

D52

NUKE5
+5U +5U

R402
+5V

R403 D117
2

1 2 3

J13 J13 J13

R404 R420

STITCHER IN SENS

SUHP

R405
2 C129 1

R5

R6

R7

R8

R9

R398

R399

R400

D118

R401

DIPSW [7:0]

+5U

+5U

R421 D119
1

4 5 6 7

J13 J13 PATH SENS J13 J13 PUSHSW

R422
2

HANS

R424
2 C130 1

R423 D120
1

DIPSW0 DIPSW1 DIPSW2 DIPSW3 DIPSW4 DIPSW5 DIPSW6 DIPSW7

SW1
1 3 5 7 9 11 13 15 2 4 6 8 10 12 14 16

SW2
1 2

+5V

R14
+24R

24VDOWN
2 C12

Q59
1

ZD1
3 2 1

A-24

1.
ICP10 C160
2 1 +24U

Saddle Stitcher Unit PCB (A507)

C159
2 1 NUKE1

+5V

R374
+5V

R344

R345

TUKICW PA7

Q117
1 2 3

R343
3

Q15
TRAY-HP 12 13 +5V TRAY-P-SEN23 [1:0]

R194

Q111
1

Q113

Q114 9 10 J4 J4

R355 Q8
2

TUKIPWM PA2

R356
3

Q117
4

5 6

4 +24R

FOLDING MTR TRAY-P-SEN2 8

Q15
9 +5V

R464

Q115

Q116

R357
+5V GAIDOHP <A506>

C119
1 2

D22
1 2

D109
2 1 6

Q117
5
2

D108
1 2

D107
2 1 1

+
4

3 2 7

Q109

C118

R353

C117

Q109

R349

R347

R346
TRAY-P-SEN3 4

Q15
3

R460

R348

TRAY-M[2:0] TRAY M0

+5V

R502 R503 R452

8 9

Q8
10

TRAY M1

R351
TUKICCW PB3

TRAY M2

Q117
9 8 3

Q112 J2
1

5
+24R

R354

OEM_POWER <A502>
+5U
1

R33
+2 1

C19
3

R35

Q171
NUKE7

J2

R37

Q6
1 N.IN1 2 ININ1
N.IN2

R40
16

D3

+5U

<501>

JNT1
1 2 J 15 ININ2 14 ROUT

R496
+5U

+5U

R38 R492 J18


FOLDING HP

R34

1 2

R36

3 FB 4 TCON OCON 13 12 5 CT VCC 6 RT 7 GND 11 C2 10 E2 9 E1

Q25
1 2

L1

R43

J18

R42
R801 C20
1

C22

R39

D4

R493
ORI-HP

R41 R207

<501>

R495

R494

J18
+5V

C162

8 C1

CP2

+2 1

+2

CP1
1

ETH1
1 2 E

C161

R44 SOLPWM <A504>

+5V

+5V LED3

LED1
LED1
1 2

R32

R426

A-25

APPENDIX

F.
No. 1

SOLVENTS AND OILS


Name Cleaner Description Cleaning: e.g.,glass, plastic, rubber parts, external covers Drive, friction parts, lead cam Composition Hydrocarbon (fluorine family) Alcohol Surface activating agent Water Silicone oil Remarks Do not bring near fire. Procure locally. Isopropyl alcohol may be substituted.

Lubricant

A-26

APPENDIX

A-27

1-1, KANDA NISHIKI-CHO, CHIYODA-KU, TOKYO, 101-8442, JAPAN

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