Toshiba MJ-1027 Service Manual
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Toshiba MJ-1027 Service Manual

Toshiba MJ-1027 Service Manual

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SERVICE MANUAL
FINISHER
MJ-1027/1028
File No. SME040041A0
R04102169300-TTEC
Ver01_2007-09

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Summary of Contents for Toshiba MJ-1027

  • Page 1 SERVICE MANUAL FINISHER MJ-1027/1028 File No. SME040041A0 R04102169300-TTEC Ver01_2007-09...
  • Page 2 General Precautions for Installation/Servicing/Maintenance for the Finisher MJ-1027/1028 The installation and service should be done by a qualified service technician. 1. When installing the Finisher MJ-1027/1028 to the equipment, be sure to follow the instructions described in the “Unpacking/Set-Up Procedure for the MJ-1027/1028”...
  • Page 3 15. When you move the finisher, do not move it in the direction of the arrow as shown in the figure below otherwise it might fall down. © 2005 TOSHIBA TEC CORPORATION ALL rights reserved...
  • Page 4 INTRODUCTION This Service Manual contains basic data and figures for the Finisher (MJ-1027)/Saddle Stitch Finisher (MJ-1028) needed to service the machine in the field. This manual comprises the following chapters: Chapter 1 “General Description” introduces the finisher’s features, specifications, and names of parts, and shows how to operate the finisher.

  • Page 6: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL DESCRIPTION FEATURES ........1-1 E. Supplying the Saddle Stitcher II. SPECIFICATIONS ....... 1-2 Unit with Staples A. Specifications ......1-2 (Saddle Stitch Finisher) ..1-15 B. Cross Section ......1-7 F. Removing Staple Jams from the III.
  • Page 7 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION BASIC OPERATION ....3-1 C. Controlling the Movement of A. Outline ........3-1 Sheets ........3-21 B. Electrical Circuitry ....3-2 D. Aligning the Sheets ....3-23 C. Inputs to and Outputs from the E.
  • Page 8 CHAPTER 6 TROUBLESHOOTING ADJUSTMENTS ......6-1 A. Finisher Unit ......6-7 A. Electrical System B. Saddle Stitcher Unit ....6-14 (finisher unit) ......6-1 C. Light-Emitting Diodes (LED) B. Electrical System and Check Pins by PCB ..6-20 (saddle stitcher unit) ....6-5 III.
  • Page 10 CHAPTER 1 GENERAL DESCRIPTION FEATURES ........1-1 E. Supplying the Saddle Stitcher II. SPECIFICATIONS ....... 1-2 Unit with Staples A. Specifications ......1-2 (Saddle Stitch Finisher) ... 1-15 B. Cross Section ......1-7 F. Removing Staple Jams from the III. Using the Machine ....... 1-9 Saddle Stitcher Unit A.

  • Page 11: Chapter 1 General Description

    CHAPTER 1 GENERAL DESCRIPTION FEATURES 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/m...

  • Page 12: Specifications

    CHAPTER 1 GENERAL DESCRIPTION SPECIFICATIONS Specifications Finisher Unit Item Description Stacking method Tray-1 and -2: by lifting tray Stacking orientation Face-down Stacking size AB: A3, A4, A4-R, A5-R, B4, B5, B5-R, FOLIO Inch: LD, LG, LT, LT-R, ST-R, COMPUTER Paper weight 60 to 256 g/m (16 lb.
  • Page 13 616 × 630 × 1023 mm/24.25 × 24.88 × 40.38 in (W × D × H) 740 × 630 × 1023 mm/29.25 × 24.88 × 40.38 in (sub-tray extended) Weight Finisher (MJ-1027): 43 kg/94.80 lb Saddle stitch finisher (MJ-1028): 63 kg/138.89 lb Power supply From host machine (DC 24V ±...
  • Page 14 CHAPTER 1 GENERAL DESCRIPTION Stapling Positions (finisher unit) 1-point stapling (rear) 1-point stapling 1-point stapling (diagonal; front) (diagonal; rear) 30˚ 30˚ 4.4±4mm/ Specified paper width 6±4mm/ Specified paper width 6±4mm/ 0.17±0.16in 0.24±0.16in 0.24±0.16in 2-point stapling A3 and A4 B4, B5 and LD and LT COMPUTER 83±4mm/...
  • Page 15 CHAPTER 1 GENERAL DESCRIPTION Saddle Stitcher Unit Item Description Stapling method Center binding (double folding) Folding position See Figure 1-202. Paper size A3, B4, A4-R, LD, LT-R, LG Capacity With binding : 1 sheet Without binding (including single cover page) : 2 to 15 sheets (60 ~ 80 g/m / 16~21.3 lb.
  • Page 16 CHAPTER 1 GENERAL DESCRIPTION Staple and Folding Position (saddle stitcher unit) A4-R Staple position Edge Edge of of staple staple 83±4mm/ 63±4mm/ 39.5±4mm/ 3.27±0.16in 2.48±0.16in 1.56±0.16in 203±4mm/ 183±4mm/ 159.5±4mm/ 8.0±0.16in 7.20±0.16in 6.28±0.16in Stack front edge LT-R 74±4mm/ 42±4mm/ 42±4mm/ 2.91±0.16in 1.65±0.16in 1.65±0.16in 194±4mm/...

  • Page 17: Cross Section

    CHAPTER 1 GENERAL DESCRIPTION Cross Section Finisher Unit [2] [3] [4] [5] [6] [10] [11] [16] [17] [15] [14] [13] [12] [1] Tray -1/-2 [10] Saddle stitcher flapper [2] Shutter [11] Inlet feed roller [3] Delivery roller [12] Feed roller 1 [4] Swing guide [13] Vertical path [5] Feed roller 2...
  • Page 18 CHAPTER 1 GENERAL DESCRIPTION Saddle Stitcher Unit [10] [11] [12] [1] Guide plate [7] No.1 flapper [2] Paper folding roller [8] No. 2 flapper [3] Delivery guide plate [9] Stitcher mount [4] Holding roller [10] Paper pushing plate [5] Stitcher (front, rear) [11] Crescent roller [6] Inlet roller [12] Paper positioning plate...

  • Page 19: Using The Machine

    CHAPTER 1 GENERAL DESCRIPTION 3) Open the upper cover, and check the in- III. Using the Machine side of the finisher. Removing Paper Jams from the Finisher Unit If the host machine indicates the finisher paper jam message, perform the following to remove the jam.

  • Page 20: Supplying The Finisher Unit With Staples

    CHAPTER 1 GENERAL DESCRIPTION 6) Return the buffer roller and the buffer roller Supplying the Finisher cover to their original positions, and close Unit with Staples the upper cover. If the host machine indicates the finisher unit staple supply message, perform the fol- lowing to supply it with staples.
  • Page 21 CHAPTER 1 GENERAL DESCRIPTION 4) Hold the empty staple case on its sides, and 6) Pull the length of tape (used to hold the slide it out. staples in place) straight out. Figure 1-311 Figure 1-313 5) Set a new staple case. 7) Push in the stapler unit until the green le- ver returns to its original position.

  • Page 22: Removing Staple Jams From The Finisher Unit

    CHAPTER 1 GENERAL DESCRIPTION 4) When the staple cartridge has slightly slid Removing Staple Jams out, hold and pull it out. from the Finisher Unit If the host machine indicates the finisher unit staple jam message, perform the follow- ing to remove the jam. 1) Remove the stack waiting to be stapled from the delivery tray.

  • Page 23: Removing Paper Jams From The Saddle Stitcher Unit (Saddle Stitch Finisher)

    CHAPTER 1 GENERAL DESCRIPTION 7) Return the tab on the staple cartridge to its Removing Paper Jams original position. from the Saddle Stitcher Unit (Saddle Stitch Fin- 8) Return the staple cartridge to its original isher) position, and close the front cover. If the host machine indicates the saddle stitcher unit paper jam message, perform the following to remove the jam.
  • Page 24 CHAPTER 1 GENERAL DESCRIPTION 3) Turn the knob on the left side. 6) Open the inlet cover, and remove the jam. Figure 1-325 Figure 1-328 4) Turn the knob on the right side while push- 7) Close the front lower cover. ing it in.

  • Page 25: Supplying The Saddle Stitcher Unit With Staples (Saddle Stitch Finisher)

    CHAPTER 1 GENERAL DESCRIPTION 3) Pull the stitcher unit to the front once, and Supplying the Saddle then shift it up. Stitcher Unit with Staples (Saddle Stitch Finisher) If the host machine indicates the saddle stitcher unit staple supply message, perform the following to supply it with staples.

  • Page 26: Removing Staple Jams From The Saddle Stitcher Unit (Saddle Stitch Finisher)

    CHAPTER 1 GENERAL DESCRIPTION 6) Pull the stitcher to the front once, and then Removing Staple Jams return it to its original position. from the Saddle Stitcher Unit (Saddle Stitch Fin- isher) If the host machine indicates the saddle stitcher unit staple jam message, perform the following to remove the jam.
  • Page 27 CHAPTER 1 GENERAL DESCRIPTION 4) Hold the cartridge on its sides, and remove 7) Return the cartridge to its original position. Figure 1-343 Figure 1-340 8) Pull the stitcher of the stitcher unit to the 5) Push down on the area identified as A, and front once, and then return it to its original pull up the tab identified as B.

  • Page 28: Maintenance By The User

    CHAPTER 1 GENERAL DESCRIPTION IV. MAINTENANCE BY THE USER Maintenance by the User Item Timing Replacing the staple cartridge (finisher unit) When the appropriate indication is made on Replacing the staple cartridge (saddle stitcher the host machine’s display. unit) Caution: The finisher unit and the saddle stitcher unit use different cartridge types.
  • Page 29 CHAPTER 2 FINISHER UNIT BASIC OPERATION 1. This chapter discusses the purpose and role of each of the finisher’s functions, and the prin- ciples of operation used for the finisher mechanical and electrical systems. It also explains the timing at which these systems are operated.The symbol in drawings indicates transmission of mechanical drive, and signals marked by together with the signal name indicates the...

  • Page 30: Chapter 2 Finisher Unit Basic Operation

    CHAPTER 2 FINISHER UNIT BASIC OPERATION BASIC OPERATION Outline The finisher is designed to deliver copies arriving from its host machine, and its modes of (Note) delivery include simple stacking, job offset , and staple. All operations involved in these modes are controlled by the finisher controller PCB, according to the appropriate commands from the host machine.

  • Page 31: Outline Of Electrical Circuitry

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Outline of Electrical Circuitry The finisher’s sequence of operation is controlled by the finisher controller PCB. The finisher controller PCB is a 16-bit microprocessor (CPU), and is used for communication with the host machine (serial) in addition to controlling the finisher’s sequence of operations. The finisher controller PCB responds to the various commands coming from the host machine through a serial communications line to drive solenoids, motors, and other loads.
  • Page 32 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller Motor Saddle stitcher PCB communication controller PCB (Saddle Stitch Finisher) Solenoid Switch EEP-ROM Punch driver PCB (Puncher unit (option)) Sensor EP-ROM Host machine (DC controller PCB CPU) IC6/IC7 Regulator IC Connecting with inserter Finisher controller Motor Saddle stitcher...

  • Page 33: Inputs To And Outputs From The Finisher Controller Pcb

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to and Outputs from the Finisher Controller PCB Inputs to the Finisher Controller PCB Finisher controller PCB J106-3 J17-7 +5V When the sensor detects PENT Inlet sensor paper, “1”. J134-1 J11-3 When the sensor detects Delivery sensor PDEL paper, “1”.
  • Page 34 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to the Finisher Controller PCB Finisher controller PCB PI10 J120-1 J9A-9 +5V Delivery motor While the delivery motor DELCLK is rotating, alternately clock sensor between “0” and “1”. PI11 J201-3 J25-1 +5V Tray-1 paper When paper is present on FSTTRAY* sensor...
  • Page 35 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to the Finisher Controller PCB Finisher controller PCB PI20 J125-1 J9B-5 Swing motor When the swing motor is SWGCLK clock sensor rotating, alternately between “0” and “1”. PI25 J135-3 J14-1 When the tray-2 is home Tray-2 home TRYHP2 position, “1”.

  • Page 36: Inputs To And Outputs From The Finisher Controller Pcb

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to and Outputs from the Finisher Controller PCB Stapler unit Finisher controller PCB When a staple is at the edge of Staple edging the stapler, “0”. sensor Staple home When the stapler is at the home position sensor position, “0”.
  • Page 37 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB +24V Flapper solenoid J12A-7 When "0", the solenoid turns on. FLPSL* +24V Buffer inlet solenoid J12B-9 When "0", the solenoid turns on. ENTSL* +24V Buffer outlet solenoid J24-7 When "0", the solenoid turns on.
  • Page 38 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB Stapler shift motor J8A-14 According to rotation direction/speed, changes between + and - in sequence. Staple motor J8A-1,2,3 According to rotation direction/speed, changes between + and -. Tray-1 lift motor J25-12 UPTRY-M-ON...

  • Page 39: Feed/Drive System

    CHAPTER 2 FINISHER UNIT BASIC OPERATION FEED/DRIVE SYSTEM Outline The finisher is designed to operate according to the commands from its host machine to deliver arriving copies to trays in the appropriate mode: simple stacking, job offset, stapling. See Figure 2-201 for a diagram of the three modes of delivery (four for the Saddle Stitch Finisher).
  • Page 40 CHAPTER 2 FINISHER UNIT BASIC OPERATION Normal Delivery Simple Stacking The finisher delivers copies directly to the tray. Tray Tray Copies Copies Feed roller 1 Delivery roller Feed roller 2 Figure 2-203 2-11...
  • Page 41 CHAPTER 2 FINISHER UNIT BASIC OPERATION Job Offset The finisher forwards all copies of each sort job to the stapling tray. The first sort job on the stapling tray is delivered with a shift to the front of about 30 mm, and the second sort job is deliv- ered without being shifted.
  • Page 42 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapling The finisher stacks copies arriving from its host machine on the stapling tray. Then, it staples and delivers the copies to the appropriate tray. Tray Copies Staple Swing guide Stopper Stapling tray Delivery roller Feed roller 1 Figure 2-207 Paper width/2...
  • Page 43 CHAPTER 2 FINISHER UNIT BASIC OPERATION Saddle Stitch Delivery (Saddle Stitch Finisher) A copy arriving in the finisher from the host machine is routed to the saddle stitcher by the paper deflecting plate. The saddle stitcher executes stitching and saddling operations on the copy and then delivers it to the saddle stitcher tray.

  • Page 44: Type Of Delivery Paths

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Type of Delivery Paths The finisher has three different paper paths for delivery, each selected to suit paper size and delivery mode. Straight Path When stacking copies shown in Table 2-201, the copies pass under the buffer roller. Copy size Length or width 182 mm or less Typical copy examples...
  • Page 45 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Paper Path 2 This is the paper path when copy sizes shown in Table 2-203 are stacked. A maximum of three copies (three originals or more in the staple mode) are wrapped round the buffer roller, during which job offset and stapling are performed on the stapling tray.
  • Page 46 CHAPTER 2 FINISHER UNIT BASIC OPERATION 3) The second copy is laid over the first copy and, at the same time, the third copy arrives from the host machine. First copy Second copy Third copy Figure 2-214 4) The first, second and third copies are simultaneously pulled into the stapling tray. Second copy Third copy First copy...

  • Page 47: Feeding And Delivering

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Feeding and Delivering Outline The finisher moves copies arriving from the host machine to the delivery tray, stapling tray, or the saddle stitcher unit (Saddle Stitch Finisher) according to the mode of delivery. On the stapling tray, the copies are subjected to job offset or stapling as instructed by the host machine.
  • Page 48 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB PI20 PI10 Figure 2-216 2-19...
  • Page 49 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB PI17 PI14 PI11 PI12 Figure 2-217 2-20...

  • Page 50: Job Offset

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Job Offset Outline In the job offset mode, sort jobs and entire copy groups are shifted to the front for delivery to the tray, and other copies are delivered to the tray without a shift. The copies are shifted by the alignment plate.
  • Page 51 CHAPTER 2 FINISHER UNIT BASIC OPERATION Alignment plate Guide plate Alignment plate home position sensor (PI6) Alignment motor (M3) Paper Escape solenoid (SL6) 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)
  • Page 52 CHAPTER 2 FINISHER UNIT BASIC OPERATION Flow of Job Offset Operations 1) The swing guide moves up and, at the same time, the feed belts move the sheet to the stapling tray. Swing guide Offset sheet Feed roller 2 Knurled belts Tray-1/-2 Delivery roller...

  • Page 53: Staple Operation

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Staple Operation Outline The stapler unit staples a stack of as many sheets as specified. The stapling position differs according to the selected staple mode and paper size. The stapler unit is checked by the stapler shift home position sensor (PI7) to find out whether it is at the home position.
  • Page 54 CHAPTER 2 FINISHER UNIT BASIC OPERATION Paper width/2 2-point stapling Front diagonal stapling Rear 1-point stapling Rear diagonal stapling Figure 2-224 2-25...
  • Page 55 CHAPTER 2 FINISHER UNIT BASIC OPERATION First Sheet 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.
  • Page 56 CHAPTER 2 FINISHER UNIT BASIC OPERATION Swing guide Swing guide open sensor (PI18) Swing guide closed Delivery roller detecting switch 1,2 (MS2/MS6) Swing motor clock sensor (PI20) Delivery motor clock sensor (PI10) Swing motor (M7) Delivery motor (M2) Figure 2-226 2-27...
  • Page 57 CHAPTER 2 FINISHER UNIT BASIC OPERATION Second and Subsequent Sheets The finisher controller PCB turns on the belt escape solenoid (SL7) before the trailing edge of the second and subsequent sheets have moved past the feed roller 2 to make the knurled belt escape. This operation is performed to reduce the time it takes for the trailing edge of the paper to fall on the stapling tray, and to improve the product duty.
  • Page 58 CHAPTER 2 FINISHER UNIT BASIC OPERATION Knurled belts Escape direction Belt escape solenoid (SL7) Figure 2-228 Paddles Paddles Paddle solenoid (SL5) Second and subsequent sheets First sheet Stapler Second feed motor Stopper Figure 2-229 2-29...
  • Page 59 CHAPTER 2 FINISHER UNIT BASIC OPERATION Last Sheet When the last sheet has been put in order, the finisher controller PCB turns on the alignment motor (M3) to move the alignment plate to the alignment position (to butt the plate against the stack).
  • Page 60 CHAPTER 2 FINISHER UNIT BASIC OPERATION Swing guide Delivery roller Swing motor (M7) Delivery motor (M2) Figure 2-231 2-31...

  • Page 61: Stapler Unit

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapler Unit Stapling is executed by the staple motor (M6). A single rotation of the cam by the motor results in one stapling operation. The cam is checked by the staple home position sensor (PI22) to find out whether it is at the home position.
  • Page 62 CHAPTER 2 FINISHER UNIT BASIC OPERATION Figure 2-232 Finisher controller PCB Figure 2-233 2-33...
  • Page 63 CHAPTER 2 FINISHER UNIT BASIC OPERATION tart signal Host machine delivery signal tacking tapling Delivery First sheet econd sheet Inlet sensor (PI1) Delivery sensor (PI3) Inlet feed motor (M9) First feed motor (M1) econd feed motor (M8) Delivery motor (M2) tapling tray sensor (PI4) Alignment motor (M3) Alignment guide home...
  • Page 64 CHAPTER 2 FINISHER UNIT BASIC OPERATION Shifting the Stapler Unit The stapler unit is moved by the stapler shift motor (M4). Its home position is detected by the stapler shift home position sensor (PI7). When the start signal arrives from the host machine, the stapler moves to the center of its movement range.
  • Page 65 CHAPTER 2 FINISHER UNIT BASIC OPERATION Rear 1-Point Stapling The stapler is kept in wait at the center position. The stapler is moved to and from the stapling position for each stapling operation. Stopper Stapling position Wait position Stapling tray delivery direction Stapler Stopper...
  • Page 66 CHAPTER 2 FINISHER UNIT BASIC OPERATION 2-Point Stapling The stapler is kept in wait at the center of the paper. Stapling occurs at two points, first at the rear and then at the front. Stopper Stapling position Wait position Stapler Stapling tray delivery direction Stapling position...

  • Page 67: Tray Operation

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray Operation The finisher has two delivery trays. The upper tray is called tray-1 and lower tray is called tray-2. The tray-1 and tray-2 move up and down independently. Tray-1 is moved up and down by the tray-1 lift motor (M5), and tray-2 by the tray-2 lift motor (M10).
  • Page 68 CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray-1 lift motor Tray coming close detection switch Rack Tray-2 lift motor Figure 2-239 2-39...

  • Page 69: Detecting The Height Of Stack On The Tray

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Detecting the Height of Stack on the Tray Outline The number of sheets delivered to the tray and the number of sets (number of stapling opera- tions) are stored in memory by the finisher controller PCB. The height of the stack is checked by the height sensor (PS1).
  • Page 70 CHAPTER 2 FINISHER UNIT BASIC OPERATION Height sensor (PS1) Paper Figure 2-240 2-41...

  • Page 71: Shutter Operation

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Shutter Operation When the tray-1 passes the delivery slot, the finisher controller PCB closes the shutter mounted on the delivery slot before moving the tray, preventing the existing stack on the tray by the delivery slot and intrusion of the hands.
  • Page 72 CHAPTER 2 FINISHER UNIT BASIC OPERATION The tray-1,-2 lift motor rotates, and the new tray moves to the stacking lower limit. The dis- tance of movement is detected by1 the tray-1 lift motor clock sensor 1/2 (PI9/19) or tray-2 lift motor clock sensor 1/2 (PI22/PI24).
  • Page 73 CHAPTER 2 FINISHER UNIT BASIC OPERATION 4) The tray lift motor rotates, and the tray moves to suit the height of the stack. The appropriate height in relation to the existing stack is checked by the height sensor (PS1). Height sensor (PS1) Tray-2 lift motor Figure 2-244 Claw...
  • Page 74 CHAPTER 2 FINISHER UNIT BASIC OPERATION Sequence Operations (shutter drive) Move from Tray-1 to Tray-2 Tray moved Shutter Shutter closed opened Second feed motor (M8) Tray-1 lift motor (M5) Tray-2 lift motor (M10) Shutter closed detecting switch (MS4) Shutter open sensor (PI5) Correct height detected Height sensor (PS1)

  • Page 75: Buffer Path Operation

    CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path Operation Outline This machine is provided with a buffer paper path for continuously receiving paper from the host machine during stapling and job offset operation on the stapling tray. A maximum of three copies (three originals or more in the staple mode) are wrapped around the buffer roller.
  • Page 76 CHAPTER 2 FINISHER UNIT BASIC OPERATION 3) When the leading edge of the sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the second sheet. First sheet Second sheet Buffer path paper sensor (PI14) Figure 2-249 4) When the second sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer...
  • Page 77 CHAPTER 2 FINISHER UNIT BASIC OPERATION 5) The buffer roller continues to rotate, and the second sheet overlaps the first sheet. Second sheet First sheet Figure 2-251 6) When the trailing edge of the second sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the third sheet.
  • Page 78 CHAPTER 2 FINISHER UNIT BASIC OPERATION 7) When the third sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer roller starts to operate once again. Second sheet First sheet Third sheet Inlet sensor (PI1) Figure 2-253 8) When the leading edge of the third sheet reaches the inlet sensor (PI1), the buffer outlet sole- noid (SL3) turns off so that the path is directed in the direction of delivery.
  • Page 79 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 2-50...

  • Page 80: Detecting Jams

    CHAPTER 2 FINISHER UNIT BASIC OPERATION K. Detecting Jams The following sensors are used to detect the presence/absence of paper and to make sure that sheets are moved properly: Inlet sensor (PI1) ● Delivery sensor (PI3) ● Stapling tray sensor (PI4) ●...
  • Page 81 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inlet Sensor Delay Jam The inlet sensor does not detect paper when feeding an equivalent of 400 mm from when the host machine delivery signal has been issued. Host machine delivery signal Host machine delivery signal Equivalent of 400 mm Equivalent of 400 mm Jam check...
  • Page 82 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path Paper Sensor Stationary Jam The sheet does not move past the buffer inlet sensor when an equivalent of twice the feeding length of the sheet has been fed after the sensor turned on. Equivalent of size x 2 Equivalent of size x 2 Jam check...
  • Page 83 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path The delivery sensor does not detect paper when an equivalent of 772 mm has been fed after the inlet sensor turned on. Equivalent of 772 mm Equivalent of 772 mm Jam check Jam check Normal Inlet sensor (PI1)
  • Page 84 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapling Tray Sensor Stationary Jam The sheet does not move past the stapling tray sensor 1 sec after the delivery motor (M2) turned 1 sec 1 sec Jam check Jam check Normal Stapling tray Stapling tray sensor (PI4) sensor (PI4)

  • Page 85: Power Supply System

    CHAPTER 2 FINISHER UNIT BASIC OPERATION III. POWER SUPPLY SYSTEM Outline The finisher controller PCB is supplied with 24 VDC power (and 5 VDC power) when the host machine is turned on. 24 VDC one is used to drive the motor solenoids, while 5 VDC is used for sensors and ICs on PCBs.

  • Page 86: Basic Operation

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 1. This chapter discusses the purpose and role of each of the stitcher’s functions, and the prin- ciples of operation used for the stitcher mechanical and electrical systems. It also explains the timing at which these systems are operated. symbol in drawings indicates transmission of mechanical drive, and signals marked together with the signal name indicates the flow of electrical signals.

  • Page 87: Outline

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION BASIC OPERATION Outline The unit “stitches” (2 points) a stack of sheets delivered by the finisher unit and folds it in two for delivery. All these operations are controlled by the saddle stitcher controller PCB in response to commands from the host machine via the finisher unit.

  • Page 88: Electrical Circuitry

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Electrical Circuitry The sequence of operations used for the saddle stitcher is controlled by the saddle stitcher controller PCB. The saddle stitcher controller PCB has a microprocessor. This microprocessor is used to control the sequence of operations and to handle serial communications with the finisher controller PCB, driving solenoids and motors in response to the various commands from the fin- isher controller PCB.

  • Page 89: Inputs To And Outputs From The Saddle Stitcher Controller Pcb

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to and Outputs from the Saddle Stitcher Controller PCB Inputs to the Saddle Stitcher Controller PCB Saddle stitcher controller PCB PI1S J107-1 J11-15 Paper pushing When the paper pushing plate LUNGECLK plate motor motor is rotating, alternately clock sensor between “1”...
  • Page 90 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to the Saddle Stitcher Controller PCB Saddle stitcher controller PCB PI8S J105-3 J6-1 +5V Paper positioning When paper is present at the PPOSPAR plate paper sensor paper positioning plate, “1”. PI9S J124-3 J10-6 +5V When the inlet cover is Inlet cover sensor...
  • Page 91 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to the Saddle Stitcher Controller PCB Saddle stitcher controller PCB Paper sensor PCB PI18S No.1 paper sensor When paper is present at J123-5 J10-1 the No.1 paper sensor, “1”. PI19S 1STPA When paper is present at 2NDPA No.2 paper sensor the No.2 paper sensor, “1”.
  • Page 92 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Outputs from the Saddle Stitcher Controller PCB Saddle stitcher controller PCB +24V No.1 paper deflecting plate solenoid J15-1 When “0”, the solenoid turns ON. SL1S FLPSL1* +24V No.2 paper deflecting plate solenoid J15-3 When “0”, the solenoid turns ON.
  • Page 93 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Outputs from the Saddle Stitcher Controller PCB Saddle stitcher controller PCB Stitcher unit (front) J315-4 J8-4 The states (+ and -) change according to the rotation of the motor. Stitcher motor (front) Stitcher unit (rear) J316-4 J8-11 The states (+ and -) change...

  • Page 94: Feeding/Drive System

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION FEEDING/DRIVE SYSTEM Outline The stitcher unit aligns the sheets coming from the finisher unit and stitches the resulting stack for delivery to the delivery tray according to the commands coming from the finisher controller PCB.
  • Page 95 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Receiving Sheets The stitcher unit receives sheets from the finisher unit and outputs them inside the vertical path in vertical orientation. The vertical path, while sheets are being output, is configured by two paper deflecting plates. The position of the sheets being output is set by the paper positioning plate so that the center of the stack matches the stapling/folding position.
  • Page 96 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Aligning the Sheets The alignment plates operate to put the sheets in order each time a sheet of paper is output to the vertical path assembly. The alignment plates are mounted at the edge of the vertical path assem- bly.
  • Page 97 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Stitching When all sheets have been output, the two stitchers stitch the stack. The stitchers are positioned so that they face the center of a stack. The two stitchers are not operated simultaneously so as to prevent the paper from wrinkling between two staples and to limit the load on the power supply.
  • Page 98 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Feeding the Stack The unit folds the stitched stack of sheets, and then feeds it to the point of delivery. This point is where the center of the stack, i.e., stapling position, matches the height of the paper pushing plate and the paper folding roller nip.
  • Page 99 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Folding/Delivering the Stack The paper pushing plate pushes against the center of the stack to move it in the direction of the paper folding rollers. In response, the paper folding rollers pick the stack along its center and fold it in two.

  • Page 100: Paper Output Mechanism

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION III. PAPER OUTPUT MECHANISM Outline The paper output mechanism serves to keep a stack of sheets coming from the finisher in place for the next steps (stapling, folding). The paper inlet is equipped with the No.1 flapper and the No.2 flapper, which operate to con- figure the paper path to suit the size of paper.
  • Page 101 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION addle stitcher controller PCB (1/2) M6 / addle stitcher controller PCB (2/2) Figure 3-301 3-15...
  • Page 102 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Saddle stitcher controller PCB (1/2) PI18S PI19S PI20S PI21S PI15S PI14S Saddle stitcher controller PCB (2/2) Figure 3-302 3-16...

  • Page 103: Controlling The Inlet Flappers

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Controlling the Inlet Flappers Outline The two flappers mounted at the paper inlet are operated to configure the feed path according to the size of paper. The flappers are used to enable the following: 1.
  • Page 104 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION A3/LD Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18 No.1 paper deflecting solenoid Non-passage of paper No.2 paper sensor PI19 No.2 paper deflecting solenoid Non-passage of paper No.3 paper sensor PI20 Top edge PI18...
  • Page 105 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION B4/LG Paper Path (3 sheets) Passage of paper No.1 paper sensor PI18S SL1S No.2 paper sensor Passage of paper PI19S SL2S No.3 paper sensor Non-passage of paper PI20S PI18S PI19S Top edge PI20S PI18S PI19S PI20S...
  • Page 106 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION A4-R/LT-R Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18S SL1S No.2 paper sensor Passage of paper PI19S SL2S No.3 paper sensor Passage of paper PI20S PI18S PI19S PI20S Top edge PI18S PI19S PI20S...

  • Page 107: Controlling The Movement Of Sheets

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Controlling the Movement of Sheets When the leading edge of a sheet has moved past the inlet flapper, the intermediate feed roller and the crescent roller start to move the sheet forward. The intermediate feed roller is normally not in contact with the path bed. When the leading edge of a sheet reaches the intermediate feed roller contact section, the feed plate contact solenoid (SL4S) causes the roller to come into contact with the path bed so as to move the sheet.
  • Page 108 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 2) The solenoid turn OFF when the paper butts against the paper positioning plate. The feed motor continues to rotate. SL4S Figure 3-307 3) The solenoid turns ON when the next sheet arrives, and the feed plate comes into contact. SL4S Figure 3-308 3-22...

  • Page 109: Aligning The Sheets

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Aligning the Sheets The alignment motor (M5S) drives the alignment plates each time a sheet is output, putting both left and right edges of the sheet in order. The alignment plate motor is a 4-phase stepping motor.
  • Page 110 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 3) The alignment plates escape to points 10 mm from the edge of the stack. Figure 3-311 4) When the following stack arrives, steps 1 through 3 above are repeated. 5) The alignment plates butt against the stack once again, during which stitching takes place. Figure 3-312 6) The alignment plates escape to points 10 mm from the edges of the stack, after which folding and delivery take place.
  • Page 111 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION In case of 2 sheets: Entry of Entry of 1st sheet of follow- 1st sheet 2nd sheet ing stack entry [2] [3] [4] Alignment plate home position sensor (PI5S) Alignment motor (M5S) Paper positioning plate motor (M4S) : Alignment : Escape...

  • Page 112: Controlling The Phase Of The Crescent Roller

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Controlling the Phase of the Crescent Roller Outline If alignment was executed with the crescent roller in contact with the stack of sheets, the result- ing friction against the roller causes the stack to move inappropriately (Figure 3-317). To prevent this problem, the phase of the roller is identified and used to determine the timing of alignment.
  • Page 113 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Alignment plates Crescent roller phase sensor(PI12S) Sensor flag Crescent roller If the crescent roller was in contact with the stack, alignment opera- tion could be obstruct- Figure 3-318 Alignment operation is started when the flag has covered the sensor and the crescent roller is away from the stack.

  • Page 114: Stitching System

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION IV. STITCHING SYSTEM Outline The stitching system “stitches” the center of an output stack with staples. To enable stitching at two locations on a stack, two stitcher units (front, rear) are used. Each stitcher unit is equipped with a stitcher motor (M7S, M6S) for drive, a stitcher home position sensor (MS7S, MS5S) for detection of position and a staple sensor (MS6S, MS4S) for detection of the presence/absence of staples.
  • Page 115 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Stitcher Unit Operation The stitcher base unit consists of two stitchers and stitcher bases. The stitchers are fixed in position, and are not designed to slide or swing. Stitching is executed by driving the rotary cam by the stitcher motor (M7S, M6S). The front and rear stitcher units are operated with a time delay so as to prevent wrinkling of paper and to limit the load applied to the power supply.
  • Page 116 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Mount Figure 3-404 3-30...

  • Page 117: Folding/Delivery System

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION FOLDING/DELIVERY SYSTEM Outline The paper folding mechanism consists of a guide plate, paper folding rollers, paper pushing plate, and paper positioning plate. The guide plate is used to cover the folding rollers while sheets are output so as to prevent sheets from coming into contact with the folding rollers during output.
  • Page 118 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Controlling the Movement of Stacks When a stack has been stitched (2 points), the paper positioning plate lowers so that the stack will move to where the paper folding rollers come into contact with the stack and where the paper pushing plate is located.
  • Page 119 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Folding a Stack A stack is folded by the action of the paper folding rollers and the paper pushing plate. The paper pushing plate pushes against the center of a stack toward the roller contact section. The paper pushing plate starts at its home position and waits at the leading edge position until the stack has been drawn to the paper folding roller and is gripped for a length of 10 mm.
  • Page 120 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Paper pushing plate home Paper pushing plate top position sensor position sensor (PI14S) (PI15S) Sensor flag Paper folding home position sensor (PI21S) Paper pushing plate Paper pushing plate motor Paper folding motor Figure 3-503 [Paper folding start position] Stack of sheets Paper pushing plate...
  • Page 121 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION [Paper folding roller stop position] Delivery outlet Paper feed inlet Sensor flag Paper folding home position sensor (PI21S) Paper folding/feeding is performed. Paper feeding is performed. Figure 3-505 Paper folding motor (M2S) Paper pushing plate motor (M8S) Paper pushing plate home...
  • Page 122 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Double Folding a Stack To fold a stack consisting of 10 or more A4-R or LT-R sheets, folding is executed twice for the same sheet. The paper folding rollers rotate in reverse for an equivalent of 20 mm after gripping the stack for a length of 20 mm, enabling the paper folding rollers to apply an increased degree of pressure along the crease on the stack.
  • Page 123 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 3) The paper folding rollers rotate in reverse, pushing back the stack for a length of about 20 mm (reverse feeding). Paper folding motor Figure 3-509 4) The paper folding rollers rotate again, feeding out the stack. The paper pushing plate returns to its home position.

  • Page 124: Checking For A Jam

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION VI. CHECKING FOR A JAM Checking for a Jam The saddle stitcher unit identifies any of the following conditions as a jam, and sends the jam signal to the host machine. In response, the host machine may stop copying operation and indicate the presence of a jam on its control panel.
  • Page 125 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inlet Delay Jam The No.1 paper sensor (PI18S) on the paper sensor PCB does not turn ON for a specific period of time after the inlet sensor (PI1) of the finisher turned ON. Inlet sensor (PI1) Inlet sensor (PI1) No.1 paper...
  • Page 126 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION B4/LG Stack No.1 paper sensor Normal No.1 paper sensor (PI18S) (PI18S) No.2 paper sensor No.2 paper sensor Normal (PI19S) (PI19S) Feed motor Feed motor Load stops T: feeding of (paper length x 1.5) mm T: feeding of (paper length x 1.5) mm Note: The diagram shows two sensors checking for jams.
  • Page 127 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Delivery Delay Jam By delivery sensor The delivery sensor (PI11S) does not turn ON within a specific period of time after the paper pushing plate top position sensor has turned ON. Paper pushing plate top Paper pushing plate top Normal position sensor...
  • Page 128 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION By delivery sensor The delivery sensor (PI11S) does not turn OFF within a specific period of time (feeding) after it has turned ON. Normal Delivery sensor Delivery sensor Paper folding motor Paper folding motor Load stops Paper length Paper length...

  • Page 129: Power Supply

    CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION VII. POWER SUPPLY Outline When the host machine power switch is turned ON, 24V and 5V power lines are supplied by the finisher controller PCB. The 24V power is used to drive solenoids. The 24V power from the finisher controller PCB to solenoids does not pass through any protective mechanisms (microswitches, or the like).
  • Page 130 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: Before performing disassembly and assembly, be sure to unplug the power plug for safety’s sake.

  • Page 131: Finisher Unit

    CHAPTER 4 MECHANICAL CONSTRUCTION FINISHER UNIT Externals and Controls [1] Upper door [2] End cap [3] Front door [4] Front lower door [5] Tray-1 [6] Tray-2 [7] Grate-shaped upper guide (6) [8] Grate-shaped lower guide (6) [9] Saddle Stitcher delivery tray [10] Sub-support upper cover (2) [11] Sub-support lower cover (2) [12] Rear cover (3)
  • Page 132 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Front Door Assembly 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the bush- ing [3] (center). 3) Remove the screw [4], and remove the bush- ing (top) [5]. Then, remove the front door assembly.
  • Page 133 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Upper Door Assembly 1) Open the upper door assembly [1]. 2) Remove the two claws [2], and remove the upper door assembly. Figure 4-105 Removing the Front Cover 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the front cover [3].
  • Page 134 CHAPTER 4 MECHANICAL CONSTRUCTION How to Lower the Tray -1/-2 Unit 1) Insert a screwdriver or similar object into the hole [2] while supporting the tray as- sembly [1]. 2) Release the tray lift motor one-way gear, and lower the tray -1/-2 unit. Figure 4-107 Removing the Tray-1 Unit 1) Open the upper cover, and then remove the...
  • Page 135 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Tray-2 Unit 1) Remove the tray-1 unit. 2) Disconnect the harness band [1] of the tray- 2 from the bracket [2]. 3) Disconnect 1 connector [3] and remove 1 screw [4]. 4) Lift the tray-2 unit to remove. Figure 4-110 Removing the Tray-1 and -2 Lift Motor...
  • Page 136 CHAPTER 4 MECHANICAL CONSTRUCTION 6) Disconnect the connector [1] and remove 4 screws [2] to take off the tray-1 and -2 lift motor [3]. Figure 4-113 Removing the Grate-Shaped Upper Guide 1) Remove the slide guide [1] and end caps [2].
  • Page 137 CHAPTER 4 MECHANICAL CONSTRUCTION 10. Removing the Grate-Shaped Lower Guide 1) Remove the tray assembly. 2) Remove the five screws [1] (M4), and re- move the front sub-support [2]. 3) Remove the three screws [3] (M4). 4) Remove the three screws [4] (M3), and open the grate-shaped lower guide [5] to the front.
  • Page 138 CHAPTER 4 MECHANICAL CONSTRUCTION 11. Installing the Rear Sub-Support 1) Install the front sub-support [1]. Loosely fasten the rear sub-support [2]. 2) Install tray-2. Fasten the rear sub-support so that the tray drive gear [3] is placed at the center of the rack gear [4] of the rear sub-support when tray-2 is at the upper limit position and the lower limit position.

  • Page 139: Feeding System

    CHAPTER 4 MECHANICAL CONSTRUCTION FEEDING SYSTEM Removing the Swing Unit 1) Remove the tray assembly (see I-A-5). 2) Remove the grate-shaped upper guide (see I-A-6). 3) Remove the grate-shaped lower guide (see I-A-7). 4) Remove the harness from the two harness stops [1], and disconnect the four connec- tors [2].
  • Page 140 CHAPTER 4 MECHANICAL CONSTRUCTION [7b] Figure 4-121b Removing the Feed Drive Unit 1) Remove the finisher controller PCB (see I- C-1). 2) Remove the ground lead [1] and the three screws [2], and pull down PCB base [3] to- wards you. Figure 4-122 3) Remove the harness leads [5] from the two edge saddles [4], and remove the PCB base.
  • Page 141 CHAPTER 4 MECHANICAL CONSTRUCTION 4) Remove the three screws [6], and remove the feed drive unit [7]. Figure 4-124 Caution: Before re-attaching the removed feed drive unit back on the finisher unit, loosen the move gear stop screw [8] to relieve the tension, and then fasten the screw after attaching the feed drive unit.
  • Page 142 CHAPTER 4 MECHANICAL CONSTRUCTION 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]. Figure 4-127 Removing the Stapler 1) Open the front cover, and move the stapler assembly to the front.

  • Page 143: Pcbs

    CHAPTER 4 MECHANICAL CONSTRUCTION 4) Remove the two screws [6] from the sta- pler cover [5], and remove the stapler. Figure 4-130 PCBs Removing the Finisher Controller 1) Remove the rear cover. 2) Disconnect the 17 connectors [1]. 3) Remove the four screws [2], and remove the finisher controller PCB [3].

  • Page 144: Saddle Stitcher Unit

    CHAPTER 4 MECHANICAL CONSTRUCTION SADDLE STITCHER UNIT Externals and Controls Removing the Front Lower Door Assembly 1) Open the front lower door assembly [1]. 2) Remove the screw [2] and remove the bush- ing [3], and then remove the front lower door assembly.
  • Page 145 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Front Inside Cover 1) Open the front lower door assembly [1]. 2) Remove the screw [2], and remove the fold- ing roller knob [3]. 3) Remove the five screws [4], and remove the front inside cover [5]. Figure 4-203 Removing the Saddle Stitcher Delivery Tray Assembly...
  • Page 146 CHAPTER 4 MECHANICAL CONSTRUCTION 3) Remove the harness leads from the harness stop [5] and edge saddle [6]. 4) Disconnect the two connectors [7], and re- move the saddle stitcher delivery tray as- sembly [8]. Figure 4-206 Removing Upper Delivery Guide Assembly 1) Remove the grate-shaped lower guide (see I-A-10).

  • Page 147: Saddle Stitcher Unit

    CHAPTER 4 MECHANICAL CONSTRUCTION SADDLE STITCHER UNIT Removing the Saddle Stitcher Unit 1) Remove the grate-shaped lower guide (see I-A-7). 2) Remove the right guide assembly (see I-A- 3) Remove the front lower door assembly (see II-A-1). 4) Remove the rear lower cover (see II-A-2). 5) Remove the front inside cover (see II-A-3).
  • Page 148 CHAPTER 4 MECHANICAL CONSTRUCTION 11) Remove the screw [5]. Figure 4-211 12) Remove the two screws [6], and remove the saddle stitcher unit [7] by moving it in the pick-up direction. Figure 4-212 Caution: When removing the saddle stitcher unit from the finisher unit body, prevent the timing belt [8] from catching on the communications cable bracket [9].
  • Page 149 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Paper Folding Roller 1) Remove the front lower door assembly (see II-A-1). 2) Remove the front inside cover (see II-A-3). 3) Remove the upper delivery guide (see II- A-5). 4) Remove the PCB cover (see II-A-6). 5) Disconnect the two connectors [1].
  • Page 150 CHAPTER 4 MECHANICAL CONSTRUCTION 7) Remove the tension springs (front [5], rear [6]). Figure 4-216 Figure 4-217 4-20...
  • Page 151 CHAPTER 4 MECHANICAL CONSTRUCTION 8) Remove the two C-rings [7], and remove the sensor flag [8] and two bearings [9] at the rear. Figure 4-218 9) Remove the two C-rings [10], and remove the two gears [11] at the front. [11] [10] Figure 4-219...
  • Page 152 CHAPTER 4 MECHANICAL CONSTRUCTION 10) Remove the two bearings [12]. [12] Figure 4-220 [16] 11) Open the saddle stitcher delivery tray as- sembly [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 direc- tion.
  • Page 153 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Stitcher Mount Unit 1) Remove the front inside cover (see II-A-3). 2) Remove the E-ring [1], and remove the roll [2] and the shaft [3]. Figure 4-223 3) Pull out the stitcher mount unit [4] to the front.
  • Page 154 CHAPTER 4 MECHANICAL CONSTRUCTION 6) Remove the stitcher positioning tool [3] from the back of the cover. Figure 4-226 7) If you must adjust the front stitcher, remove the center guide plate [5] and front guide plate [4] (one screw each). If you must ad- just the rear stitcher, remove the center guide plate [5] and the rear guide plate [6] (one screw each).
  • Page 155 CHAPTER 4 MECHANICAL CONSTRUCTION 9) Insert the tool [10] into the staple slot of the stitcher [9]. [10] Figure 4-229 10) Shift down the stitcher, and turn the stitcher gear so that the boss on the tool [11] and the recess of the mount match. Then, tighten the screws [12] on the mount to fix the two in place.
  • Page 156 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the No.1 and No.2 Paper Deflecting Plates 1) Remove the rear cover (see I-A-2). 2) Remove the lower rear cover (see II-A-2). 3) Remove the claw [1] of the No.1 deflecting plate bushing, and pull out the No.1 deflect- ing plate shaft [2] toward the rear.

  • Page 157: Pcbs

    CHAPTER 4 MECHANICAL CONSTRUCTION PCBs [ 2 ] [ 2 ] [ 2 ] [ 3 ] [ 1 ] [ 1 ] Removing the Saddle Stitcher Controller PCB 1) Remove the PCB cover (see II-A-6). 2) Remove the four screws [1] and 14 connec- tors [2], and remove the saddle stitcher con- troller PCB [3].

  • Page 158: Accessory

    CHAPTER 4 MECHANICAL CONSTRUCTION Accessory Support tray Install the support tray (accessory) to the suddle delivery tray when the paper stacking on the saddle stitcher delivery tray is signifi- cantly 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.

  • Page 159: I. Periodically Replaced Parts

    CHAPTER 5 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED A. Finisher Unit ....... 5-2 PARTS ......... 5-1 B. Saddle Stitcher Unit ....5-2 A. Finisher Unit ....... 5-1 III. PERIODICAL SERVICING ..5-2 B. Saddle Stitcher Unit ....5-1 IV. FIRMWARE UPDATING ....5-3 CONSUMABLES AND A.

  • Page 160: Chapter 5 Maintenance And Inspection

    CHAPTER 5 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED PARTS Finisher Unit The finisher unit does not have parts that must be replaced on a periodical basis. Saddle Stitcher Unit The saddle stitcher unit does not have parts that must be replaced on a periodical basis.

  • Page 161: Durables

    CHAPTER 5 MAINTENANCE AND INSPECTION CONSUMABLES AND DURABLES Some of the parts of the machine may need to be replaced one or more times because of wear or tear during the machine’s warranty period. Replace them as necessary. Finisher Unit Name Q’ty Estimated Life...

  • Page 162: Firmware Updating

    CHAPTER 5 MAINTENANCE AND INSPECTION IV. FIRMWARE UPDATING Finisher Unit (1) Install the ROM to the download jig. Make sure the direction and the type of ROM are correct. [Download jig: K-PWA-DLM-320] Identification for the ROM Connector installation direction (2) Turn OFF the power of the equipment. (3) Connect the finisher to the equipment after the finisher rear cover is removed.
  • Page 163 CHAPTER 5 MAINTENANCE AND INSPECTION (5) Turn ON the power while pressing [0] and [8] simultaneously. The update starts automatically and LED on the download jig lights. (6) After the update is completed properly, the LED on the download jig blinks slowly. The LED starts blinking in approx.

  • Page 164: Saddle Stitcher Unit

    CHAPTER 5 MAINTENANCE AND INSPECTION Saddle Stitcher Unit (1) Install the ROM to the download jig. Make sure the direction and the type of ROM are correct. [Download jig: K-PWA-DLM-320] Identification for the ROM Connector installation direction (2) Turn OFF the power of the equipment. (3) Remove the PCB cover on the saddle stitcher.
  • Page 165 CHAPTER 5 MAINTENANCE AND INSPECTION (5) Turn ON the power while pressing [0] and [8] simultaneously. Updating starts automatically and the LED on the download jig lights. (6) After the update is completed properly, the LED on the download jig blinks slowly. The LED starts blinking in approx.
  • Page 166 CHAPTER 6 TROUBLESHOOTING ADJUSTMENTS ......6-1 A. Finisher Unit ....... 6-7 A. Electrical System B. Saddle Stitcher Unit ....6-14 (finisher unit) ......6-1 C. Light-Emitting Diodes (LED) B. Electrical System and Check Pins by PCB ... 6-20 (saddle stitcher unit) ....6-5 III.

  • Page 167: Adjustments

    CHAPTER 6 TROUBLESHOOTING ADJUSTMENTS Adjusting the Alignment Position If you have replaced the finisher control- ler PCB or if an alignment fault occurs, adjust Note as follows. Performing the steps will affect Before performing each adjustment, make all paper sizes. sure that all covers (incl.
  • Page 168 CHAPTER 6 TROUBLESHOOTING 4) Turn the host machine ON while [0] but- Alignment plate ton and [8] button are pressed simultane- Shift by SW2 ously. 5) If you are using A4 paper, press SW1 on Shift by SW1 A4/LT paper the finisher controller PCB.
  • Page 169 CHAPTER 6 TROUBLESHOOTING 7) If the stapling position is correct, set all Adjusting the Buffer Roller Wind- bits on SW3 to OFF to end the adjust- ing Amount ments. If you need to change the stapling Perform this adjustment in the following position, on the other hand, go to the next instances: step.
  • Page 170 CHAPTER 6 TROUBLESHOOTING 7) Measure the winding amount (shift) of 12) Turn the host machine OFF, and then set the stack of sheets, and compare this SW3 on the finisher controller PCB as amount with the standard amounts. indicated. • This amount should be measured at the center of the paper leading edge.

  • Page 171: Electrical System (Saddle Stitcher Unit)

    CHAPTER 6 TROUBLESHOOTING Electrical System (saddle Mark stitcher unit) Adjusting the Folding Position The folding position is adjusted by changing the settings of bits 6 through 8 of DIPSW1 on the saddle stitcher control- ler PCB to match the stitching position (i.e., adjusting the distance over which the paper positioning plate is moved to the folding po- sition from the stitching position.)
  • Page 172 CHAPTER 6 TROUBLESHOOTING 10) Measure the distance (L) between the 11) Change the settings of bits 6 through 8 on stitching position and the folding posi- DIPSW1 referring to Table 8-102 below. tion. Then, perform “positive width ad- • If the width adjustment is “0”, justment”...

  • Page 173: Arrangement Of Electrical Parts

    CHAPTER 6 TROUBLESHOOTING ARRANGEMENT OF ELECTRICAL PARTS Finisher Unit...
  • Page 174 CHAPTER 6 TROUBLESHOOTING Sensors PI18 PI17 PI10 PI20 PI14 PI16 PI15 PI11 PI12 PI21 PI22 PI25 Figure 6-20...
  • Page 175 CHAPTER 6 TROUBLESHOOTING Name Notation Function Photointerrupter Detects paper in the inlet area Detects paper in the delivery area Detects paper on the stapling tray Detects the state (open) of the shutter Detects alignment plate at home position Detects the stapler at home position Detects the tray at home position PI10 Detects delivery motor clock pulses...
  • Page 176 CHAPTER 6 TROUBLESHOOTING Microswitches Figure 6-202 Name Notation Function Microswitches Detects the state (open) of the front door and the upper door Detects the state (closed) of the swing guide 1 Detects the safety range Detects the state (closed) of the shutter Detects the state (closed) of the swing guide 2 Detects the cartridge (inside stapler) Detects the presence/absence of staples (inside stapler)
  • Page 177 CHAPTER 6 TROUBLESHOOTING Motors Figure 6-203 Name Notation Function Motor First Feed motor Delivery motor Alignment motor Stapler shift motor Tray-1 lift motor Staple motor Swing motor Second feed motor Inlet feed motor Tray-2 lift motor Table 6-203 6-...
  • Page 178 CHAPTER 6 TROUBLESHOOTING Solenoids Figure 6-204 Name Notation Function Solenoid Flapper solenoid Buffer inlet solenoid Buffer outlet solenoid Paddle solenoid Escape solenoid Belt escape solenoid Table 6-204 6-2...
  • Page 179 CHAPTER 6 TROUBLESHOOTING PCBs Figure 6-205 Reference Name Finisher controller PCB Relay PCB 4 Relay PCB 3 Table 6-205 6-3...

  • Page 180: Saddle Stitcher Unit

    CHAPTER 6 TROUBLESHOOTING Saddle Stitcher Unit Photointerrupters PI18S PI19S PI20S PI16S PI9S PI21S PI14S PI2S PI15S PI11S PI17S PI12S PI6S PI13S PI5S PI8S PI3S PI7S PI4S PI1S Figure 6-206 6-4...
  • Page 181 CHAPTER 6 TROUBLESHOOTING Name Notation Function Photointerrupter PI1S Detects clock pulses from the paper pushing plate motor PI2S Detects the state (open) of the front door PI3S Detects the state (open) of the delivery cover PI4S Detects clock pulses from the paper folding motor PI5S Detects the alignment plates at home position PI6S...
  • Page 182 CHAPTER 6 TROUBLESHOOTING Microswitches MS1S MS4,5S MS6,7S MS2S MS3S Figure 6-207 Name Notation Function Microswitches MS1S Detects the state (open) of the inlet door MS2S Detects the state (open) of the front door MS3S Detects the state (open) of the delivery door MS4S Detects the presence of staples (rear) MS5S...
  • Page 183 CHAPTER 6 TROUBLESHOOTING Motors Figure 6-208 Name Notation Function Motor Feed motor Paper folding motor Guide motor Paper positioning plate motor Alignment motor Stitcher motor (rear) Stitcher motor (front) Paper pushing plate motor Table 6-208 6-7...
  • Page 184 CHAPTER 6 TROUBLESHOOTING Solenoids SL1S SL2S SL4S Figure 6-209 Name Notation Function Solenoid SL1S No. 1 paper deflecting plate solenoid SL2S No. 2 paper deflecting plate solenoid SL4S Feed plate contact solenoid Table 6-209 6-8...
  • Page 185 CHAPTER 6 TROUBLESHOOTING PCBs Figure 6-20 Reference Name Saddle stitcher controller PCB Paper sensor PCB Table 6-20 6-9...

  • Page 186: Light-Emitting Diodes (Led) And Check Pins By Pcb

    CHAPTER 6 TROUBLESHOOTING Light-Emitting Diodes (LED) and Check Pins by PCB This section discusses the LED s and check pins used in the machine that are needed in the field. Caution: The VRs and check pins not discussed in this section are for factory use only. Making adjustments and checks using these will require special tools and instruments and adjustments must be to high accuracy.
  • Page 187 CHAPTER 6 TROUBLESHOOTING Saddle Stitcher Controller PCB Figure 6-26 Switch Function DIPSW1 (bits 1-2) Starts correction of discrepancy between stitching position and folding position. DIPSW1 (bits 6-8) Stores corrected settings for stapling position and folding position. Starts correction of discrepancy between stitching position and folding position. Table 6-26 6-2...

  • Page 188: Troubleshooting

    CHAPTER 6 TROUBLESHOOTING III. TROUBLESHOOTING Finisher Unit Fault in communication with host machine Cause Step Checks Yes/No Action Finisher controller PCB, Turn the host machine OFF End. Host machine DC then ON. Is the problem controller PCB corrected? Wiring Is the wiring between the Correct it.
  • Page 189 CHAPTER 6 TROUBLESHOOTING Faulty height sensor (communication) Cause Step Checks Yes/No Action Finisher controller PCB Turn the host machine OFF End. then ON. Is the problem corrected? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the sensors normal? Power supply Measure the voltage between...
  • Page 190 CHAPTER 6 TROUBLESHOOTING Faulty height sensor (adjustment) Cause Step Checks Yes/No Action Adjustment Try making adjustments using End. the DIP switch once again. Is the problem corrected? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and sensors normal? Power supply Measure the voltage between...
  • Page 191 CHAPTER 6 TROUBLESHOOTING Faulty alignment motor Cause Step Checks Yes/No Action Alignment plate home Check the alignment plate Replace the sensor. position sensor (PI6) home position sensor. Is it normal? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the alignment plate motor normal? Alignment plate...
  • Page 192 CHAPTER 6 TROUBLESHOOTING 10. Faulty stapler shift motor Cause Step Checks Yes/No Action Stapler shift home Check the stapler shift home Replace the sensor. position sensor (PI7) position sensor. Is the sensor normal? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the stapler shift motor normal?
  • Page 193 CHAPTER 6 TROUBLESHOOTING 12. Faulty swing motor (related to PI18) Cause Step Checks Yes/No Action Swinging mechanism Turn the delivery motor in Correct the swinging reverse by hand. Does the mechanism. swing guide move up and down? Swing guide open sensor Is the swing guide open Replace the sensor.
  • Page 194 CHAPTER 6 TROUBLESHOOTING 14. Faulty swing motor (related to PI20) Cause Step Checks Yes/No Action Swing motor clock Check the swing motor clock Replace the sensor. sensor (PI20) sensor. Is the sensor normal? Finisher controller PCB Does the voltage of the swing Replace the finisher motor between J11-6 and -7 controller PCB.
  • Page 195 CHAPTER 6 TROUBLESHOOTING 17. Faulty tray-1 motor (related to M5) Cause Step Checks Yes/No Action Does the tray-1 move up/ Go to step 2. down? Go to step 4. Is the motor supplied Go to step 3. withpower by the finisher controller PCB as soon as the Finisher controller PCB Replace the finisher...
  • Page 196 CHAPTER 6 TROUBLESHOOTING 20. Faulty second feed motor (related to PI5) Cause Step Checks Yes/No Action Second feed motor (M8) Does the second feed motor in Replace the second reverse at a specific timing? feed motor or the finisher controller PCB.
  • Page 197 CHAPTER 6 TROUBLESHOOTING 22. Faulty second feed motor (related to MS3) Cause Step Checks Yes/No Action Safety range switch Check the safety range Replace the switch. (MS3) switch. Is the switch normal? Is the safety range detection Correct mechanical switch passed correctly? operation.

  • Page 198: Saddle Stitcher Unit

    CHAPTER 6 TROUBLESHOOTING Saddle Stitcher Unit Faulty paper positioning plate Cause Step Checks Yes/No Action Paper positioning plate Check the paper positioning Replace the sensor. home position sensor plate home position sensor. Is (PI7S) the sensor normal? Saddle stitcher controller Do the paper positioning Replace the saddle plates operate at a specific...
  • Page 199 CHAPTER 6 TROUBLESHOOTING Faulty guide motor Cause Step Checks Yes/No Action Guide home position Check the guide home Replace the sensor. sensor (PI13S) position sensor. Is the sensor normal? Saddle stitcher controller Does the guide motor operate Replace the saddle at a specific timing? stitcher controller PCB.
  • Page 200 CHAPTER 6 TROUBLESHOOTING Faulty stitcher Cause Step Checks Yes/No Action Stitcher (installation) Are the front and rear Install them correctly. stitchers and bases installed correctly? Stitching home position Is the stitching home position Replace the front or switch (MS7S/MS5S) switch of the front and the rear stitcher.
  • Page 201 CHAPTER 6 TROUBLESHOOTING Faulty paper pushing plate motor (related to PI15S) Cause Step Checks Yes/No Action Paper pushing top Check the paper pushing plate Replace the sensor. position sensor (PI15S) top position sensor. Is the sensor normal? Saddle stitcher controller Does the paper pushing plate Replace the saddle motor operate at a specific...
  • Page 202 CHAPTER 6 TROUBLESHOOTING Disconnected sensor connector (related to PI13S) Cause Step Checks Yes/No Action Guide home position Are the connectors of the Connect the sensor (PI13S; guide home position sensor connectors. disconnected) and the saddle stitcher controller PCB connected correctly? Wiring Is the wiring between the Correct the wiring.
  • Page 203 CHAPTER 6 TROUBLESHOOTING 11. Disconnected sensor connector (PI15S) Cause Step Checks Yes/No Action Paper pushing plate Are the connectors of the Connect the home position top paper pushing plate top connectors. position sensor (PI15S; position sensor and the saddle disconnected) stitcher controller PCB connected correctly? Wiring...
  • Page 204 CHAPTER 6 TROUBLESHOOTING 13. Faulty microswitch (related to MS2S) Cause Step Checks Yes/No Action Switch actuator Check the switch actuator of Correct the the front door. Do the switch mechanism. and the sensor operate correctly? Front door switch Check the front door switch. Replace the switch.

  • Page 205: C. Signal And Abbreviations

    APPENDIX A. FINISHER UNIT GENERAL D. FINISHER UNIT CIRCUIT TIMING CHART ......A-1 DIAGRAM ......... A-14 B. SADDLE STITCHER UNIT E. SADDLE STITCHER UNIT GENERAL TIMING CHART ..A-2 CIRCUIT DIAGRAM ....A-18 C. SIGNAL AND ABBREVIATIONS ....... A-3...

  • Page 206: Finisher Unit General Timing Chart

    A. FINISHER UNIT GENERAL TIMING CHART A4, 2 Sheets, 1-Point Stapling (rear), 1 Set Operation start signal Host machine delivery signal Operation Inlet sensor (PI1) Delivery sensor (PI2) Inlet feed motor (M9) First feed motor (M1) Second feed motor (M8) Delivery motor (M2) Staple tray sensor (PI4) Alignment motor (M3)

  • Page 207: Saddle Stitcher Unit General Timing Chart

    B. SADDLE STITCHER UNIT GENERAL TIMING CHART A4R, 3 Sheets, Stitching, 1 Set Copy Start Key ON Delivery signal Stack Operation Initialize 1st sheet delivery 2nd sheet delivery 3rd sheet delivery Stitching Folding,/delivery feeding Inlet feed motor (M9) Finisher unit flapper solenoid (SL1) Feed motor (M1S) No.

  • Page 208: Signal And Abbreviations

    C. SIGNAL AND ABBREVIATIONS The following presents the abbreviations of signals used in this manual and in drawings, and the mean- ings of each signal. Reference: Signals enclosed by brackets [ ] are electrical signals. However, the state “1” or “0” of these analog signals cannot be indicated.

  • Page 209: Diagram

    D. FINISHER UNIT CIRCUIT DIAGRAM SWING_GUIDE_UNIT SWING_UNIT FEED_UNIT PI10 PI20 Swing guide Swing guide PI18 Stapling tray sensor Alignment plate Alignment motor Delivery motor Swing motor Swing motor clock sensor Delivery sensor closed detecting closed detecting Safety zone switch Door swich Delivery motor home position sensor Swing guide open sensor...
  • Page 210 SHUTTER_UNIT FEED_UNIT BUF_P_UNIT ENT_FEED_UNIT Stapler shift home PI16 position sensor Height sensor Belt escape solenoid Buffer inlet solenoid Door open sensor PI15 Inlet feed motor PI14 PI17 Shutter closed Inlet sensor Flapper solenoid detecting swich Joint sensor Buffor path Buffer path inlet Buffer outlet Shutter open sensor solenoid...
  • Page 211 UPTRY_UNIT PI25 LOWTRY_UNIT Tray-2 home Tray-1 home position sensor position sensor PI12 PI11 J135 Tray-1 lift motor J130 Tray-1 paper sensor Tray-2 paper 03XR-6Y-P 03XR-6Y-P sensor Tray-2 lift motor Staple switch J201 J115 J8010 8-292112-3 PHNR-9-H 8-292112-3 J116 J138 PHNR-9-H 1-172075-1 CABLE_UPTRY J222L...
  • Page 212 Finisher Controller PCB (A501) 22K,0.063W IC2S 22K,0.063W 22K,0.063W TEST 22K,0.063W BR93L46-W DICF-8CS-E P53/_ADTRG PG3/_CS1 DL_LED P52/SCK2 PG4/_CS0 [A503] VSS1 VSS15 IC10 15P,50V VSS2 VSS14 RA11 ENTM1 100,0.063W [A507] VCC1 P51/RXD2 ENTM0 ADDRESS0 [A507] PC0/A0 P50/TXD2 XOUT REFOUT/RS0 ADDRESS1 15P,50V PC1/A1 PF0/_BREQ REF_OFF MODOUT/RS1...
  • Page 213 Finisher Controller PCB (A502) ADDRESS[19:0] [A501] [A503] ADDRESS15 ADDRESS15 ADDRESS13 ADDRESS13 ADDRESS8 ADDRESS14 ADDRESS8 ADDRESS14 1U,16V ADDRESS7 ADDRESS9 ADDRESS7 ADDRESS9 ADDRESS6 ADDRESS10 ADDRESS6 ADDRESS10 ADDRESS5 ADDRESS12 ADDRESS5 ADDRESS12 ADDRESS4 ADDRESS4 ADDRESS3 ADDRESS11 ADDRESS3 ADDRESS11 ADDRESS2 RAM_CS ADDRESS2 RAM_CS ADDRESS1 DATA7 ADDRESS1 DATA15 I/O7...
  • Page 214 Finisher Controller PCB (A503) DATA[15:0] ADDRESS[18:0] ADDRESS17 ADDRESS16 ADDRESS15 /BYTE ADDRESS14 VSS2 ADDRESS13 DATA7 DQ15 ADDRESS12 DATA15 ADDRESS11 DATA6 DQ14 ADDRESS10 DATA14 ADDRESS9 DATA5 DQ13 IC42 DATA13 DATA4 DQ12 [A501] RESET0 DATA12 [A501] EXP_CS RESET0 [A501] /RESET [A501] DATA3 DQ11 DATA11 SOLOUT2 [A505]...
  • Page 215 Finisher Controller PCB (A504) CP10 R404 TICPIN-1/NOTMNT JNT1 +24V 4.7K,0.1W R405 TBC6011-211-0941 R401 1K,0.1W IC41 C174 24K,0.1W PWM0 ETH1 [A505] 100U,35V C202 LM393D ETH2 560U,35V 0.1U,50V R402 R403 24K,0.1W 47K,0.1W C201 4700P,50V 4.7K,0.1W 4.7K,0.1W/NOTMNT +24VMOVE DTC114EUAF OPEN2 HZS18-2-E (MS1) (UPTRY-M-CLK) [IC5-42 P35] DTC114EUAF [A503]...
  • Page 216 Finisher Controller PCB (A505) (PI3) +24V Delivery sensor 4.7K,0.1W JOGM0 [IC1-115 P17] J10P [A501] IC31 IC31 EJECT_S0 STEPMR0 ICP5 J10P IC11 10K,0.1W 10K,0.1W [A509] HC14 HC14 20N1000-U [IC1-127 PG1] SMA7029MRP [A501] 1000P,50V (M3) DTA114EUAF 1000P,50V Alignment motor J10P +24V R105 JOGM_I0 OUTA 2.4K,0.1W...
  • Page 217 Finisher Controller PCB (A506) TICPIN-1/NOTMNT R123 R121 1SS270A-E 10K,0.1W (PI15) R122 1K,0.1W HIGHT0 Joint sensor 1K,0.1W [IC1-62 P33] R162 [A501] 1SS270A-E R161 WJ20P 1000P,50V 220,0.25W 22K,0.1W WJ20P IC20 R159 R160 JOINT0 R126 10U,50V WJ20P 10K,0.1W 10K,0.1W 4.7K,0.1W [IC5-34 P30] [A503] C101 C100 IC29...
  • Page 218 Finisher Controller PCB (A507) +24V ENTM0 [A501] [IC1-37 P65] ENTM0 [A501] [IC1-97 P50] STEPMR0 [A509] ICP9 20N2000-U (M9) DTA114EUAF IC14 SMA7029MRP Inlet feed motor ENTM_I0 [A503] R149 [IC5-56 P53] J11P OUTA 2.4K,0.1W 1000P,50V ENTM_I1 J11P [A503] REFA GNDA R150 [IC5-55 P52] J11P DTA114EUAF 1,1W...
  • Page 219 Finisher Controller PCB (A508) (PI11) Tray-1 paper sensor R182 R181 J12P 220,0.25W 22K,0.1W J12P R179 R180 TRAYS0 [A502] J12P 10K,0.1W 10K,0.1W [IC4-29 P04] C111 C110 1000P,50V (PI25) 1000P,50V Tray-2 home position sensor R195 R194 220,0.25W 22K,0.1W R192 R193 [A503] TRAY_HP2 10K,0.1W 10K,0.1W [IC5-90 P80]...
  • Page 220 Finisher Controller PCB (A509) R231 10K,0.1W (PI21) R229 R230 IC25 IC26 IC27 IC28 IC29 IC30 [A502] STPL_READY0 Staple edging J15P 10K,0.1W 10K,0.1W sensor [IC4-31 P02] C225 C131 R234 1000P,50V 1000P,50V HC14 HC02 HC02 HC08 HC14 HC32 1K,0.1W 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V...
  • Page 221 Finisher Controller PCB (A510) +24VSTPL C151 C152 0.01U,50V 0.01U,50V R274 R275 R269 DTA114EUAF 3.3K,0.1W 1K,0.1W 1K,0.1W DTC114EUAF R276 IC32 R270 2SJ529(L)-E 2.4K,0.25W 2SJ529(L)-E 10K,0.1W (M6) HC02 J15P Staple motor C146 0.01U,50V J15P IC33 2SK2925(L)-E 2SK2925(L)-E J15P STPLM_W1 +24V [IC5-51 P46] [CW] HC08 [A503]...
  • Page 222 Finisher Controller PCB (A511) R306 22K,0.1W R304 R305 PREGS0 [A501] WJ28P [IC1-107 P42] 10K,0.1W 10K,0.1W C160 1000P,50V R309 22K,0.1W RA10 R320 R307 R308 PREGS1 22K,0.063W [A501] 22K,0.1W WJ28P [IC101-108 P43] 10K,0.1W 10K,0.1W PUNCHM1 [IC5-47 P42] [A503] C161 WJ28P 1000P,50V PUNCHM_PWM0 [IC1-76 P23] [A501] WJ28P...

  • Page 223: Saddle Stitcher Unit Circuit Diagram

    SADDLE STITCHER UNIT CIRCUIT DIAGRAM J107 J11-15 J11-14 J125 J325 J225 J425 J525 J11-13 J9-3 J9-2 J124 J9-1 J10-8 J10-7 J104 J10-6 J11-12 J11-11 J11-10 J130 J126 J18-3 J9-6 J18-2 J9-5 J18-1 J9-4 J103 J303 J203 J11-9 J11 J16 J11-8 J107-1 J11-7 J304...
  • Page 224 Saddle Stitcher Unit PCB (A501) 1U,16V 0.1U,50V VCC1 AVCC ALIGNMENT_M0 [A508] ALIGNMENT_M1 [A508] FOLD_PWM [A505] PUSH_CCW [A505] GUIDE_M0 100,0.1W [A508] [A502] GUIDE_M1 100,0.1W [A508] [A502] RESET [A502] GUIDE_M2 15P,50V [A508] ALIGNMENT_M2 VCC3 [A508] VSS1 XTAL 15P,50V 2ND_P_SENS EXTAL [A506] 4.7K,0.1W 3RD_P_SENS VSS5 [A506]...
  • Page 225 Saddle Stitcher Unit PCB (A502) [A501] ABUS[19:0] [A503] 1U,16V ABUS12 [A501] ABUS7 ABUS6 ABUS8 DBUS7 ABUS5 ABUS9 DBUS6 ABUS4 ABUS11 DBUS5 1U,16V ABUS3 DBUS4 [A501] ABUS2 ABUS10 DBUS3 ABUS1 RAM_CS DBUS2 [A501] ABUS0 DBUS7 I/O8 DBUS0 DBUS6 I/O1 I/O7 DBUS1 DBUS1 DBUS5 I/O2...
  • Page 226 Saddle Stitcher Unit PCB (A503) DBUS[7:0] ABUS[19:0] ABUS17 ABUS0 J34P ABUS16 ABUS1 J34P ABUS15 ABUS2 /BYTE J34P ABUS14 ABUS3 VSS2 J34P ABUS13 ABUS4 DQ15 J34P ABUS12 DBUS7 ABUS5 J34P ABUS11 ABUS6 DQ14 J34P ABUS10 DBUS6 ABUS7 J34P ABUS9 ABUS8 DQ13 DBUS0 J34P DBUS5...

  • Page 227: Saddle Stitcher Unit

    Saddle Stitcher Unit PCB (A504) (PI5S) +24V Alignment plate home position sensor R145 TBC6011-211-0941 J15P 470,0.1W R146 J15P 10K,0.1W HC14 R148 R147 ETH2 470U,35V ALIGNMENT_HP J15P [IC2-38] 10K,0.1W 10K,0.1W [A502] 1000P,50V (PI4S) J10P Paper folding motor clock sensor 24STPL R154 [A505] J15P 4.7K,0.1W...
  • Page 228 Saddle Stitcher Unit PCB (A505) +24U ICP5 ICP-N70F 1K,0.1W 1K,0.1W 0.01U,50V 0.01U,50V DTC114EUAF (M2S) FOLDDIR0 2.4K,0.25W Paper folding motor 2SJ529(L)-E [IC1-31] 2SJ529(L)-E [A501] J10P J10P IC10 10K,0.1W HC02 2SK2925(L)-E R245 R233 FOLD_PWM 100,0.1W [IC1-4] 4.7K,0.1W [A501] IC10 2SK2925(L)-E HC02 R246 100,0.1W 2.4K,0.25W FOLDDIR1...
  • Page 229 Saddle Stitcher Unit PCB (A506) (PI18S) No.1 paper sensor R174 IC22 10K,0.1W HC14 R176 R175 1ST_P_SENS [IC1-13] 10K,0.1W 10K,0.1W [A501] 1000P,50V (PI21S) R179 Paper folding home IC22 (PI19S) 10K,0.1W position sensor R110 HC14 No.2 paper sensor R181 R180 2ND_P_SENS 470,0.1W 10K,0.1W [IC1-11] 10K,0.1W...
  • Page 230 Saddle Stitcher Unit PCB (A507) ICP8 ICP-N70F 24STPL [A504] 0.01U,50V 0.01U,50V (M6S) 1K,0.1W 1K,0.1W Stitcher motor (rear) IC24 (MS5S) 2.4K,0.25W 4.7K,0.1W IC24 Stitcher home J14P DTC114EUAF HC14 position sensor (rear) STPLM0 2SJ529(L)-E STPLHPS0 [IC1-27] 2SJ529(L)-E HC14 J14P [IC1-25] 10K,0.1W 10K,0.1W [A501] J14P IC13...
  • Page 231 Saddle Stitcher Unit PCB (A508) +24U R144 IC14 47K,0.1W (M5S) SMA7022MURP ALIGNMENT_M0 Alignment motor J10P [IC1-2] Q102 C101 [A501] OUTA R149 DTA114EUAF 2200P,50V J10P REFA 2.4K,0.1W GNDA FEED_POWER_UP ALIGNMENT_M2 R157 OUTA [IC1-9] J10P R162 [A501] 1,1W R216 R173 1,1W 10K,0.1W OUTB 270,0.1W J10P...
  • Page 232 Saddle Stitcher Unit PCB (A509) R227 4.7K,0.1W IC19 LM393D R230 47K,0.1W 4700P,50V ICP7 +24V 20N2000-U SOLTMR [IC2-48] (SL1S) IC20 [A502] HC74 No.1 paper deflecting plate solenoid AK04V0SN IC21 2SK3065F HC08 R231 (SL2S) 100,0.1W No.2 paper deflecting plate solenoid AK04V0SN IC21 2SK3065F R123 HC08...
  • Page 233 Saddle Stitcher Unit PCB (A510) (PI11S) Delivery sensor R129 IC10 IC13 IC20 HC14 HC02 HC02 HC74 J15P 470,0.1W R130 10K,0.1W IC22 J15P HC14 R132 R131 DELIV_SENS J15P [IC1-68] 10K,0.1W 10K,0.1W 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V [A501] 1000P,50V (PI12S) Crescent roller phase sensor IC21 IC22...
  • Page 234 APPENDIX SOLVENTS AND OILS Name Description Composition Remarks Cleaner Cleaning: Hydrocarbon · Do not bring near fire. e.g.,glass, (fluorine family) · Procure locally. plastic, Alcohol · Isopropyl alcohol may be rubber parts, Surface activating substituted. external agent covers Water Lubricant Drive, friction Silicone oil parts, lead cam...
  • Page 235 2-17-2, HIGASHIGOTANDA, SHINAGAWA-KU, TOKYO, 141-8664, JAPAN...

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