Toshiba MJ 1017/18 Service Handbook

File No.
31100204 R02032112400-TTEC Ver01 2002-09
General Precautions for Installation/Servicing/Maintenance for the Finisher MJ-1017/1018, Hole punch unit MJ-6003, Inserter MJ-7001 The installation and service should be done by a qualified service technician. 1. When installing the Finisher MJ-1017/1018, Hole punch unit MJ-6003, Inserter MJ7001 to the Plain Paper Copier, be sure to follow the instructions described in the Unpacking/Set-Up Procedure for the MJ-1017/1018/MJ-6003/MJ-7001 booklet which comes with each unit of the MJ-1017/1018/MJ-6003/MJ-7001. 2. The MJ-1017/1018, MJ-6003, MJ-7001 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 MJ-1017/1018/MJ-7001 and copier on different levels or inclined floors. 5. When servicing or maintaining the MJ-1017/1018/MJ-6003/MJ-7001, 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. Use suitable measuring instruments and tools. 10. 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. 11. 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. 12. For the recovery and disposal of used MJ-1017/1018/MJ-6003/MJ-7001s, consumable parts, packing materials, used batteries, and RAM-ICs including litium batteries, it is recommended that the relevant local regulations/rules. 13. After completing installation, servicing and maintenance of the MJ-1017/1018/MJ-6003/ MJ-7001, return the MJ-1017/1018/MJ-6003/MJ-7001 to its original state, and check operation.
14. 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. Also, when installing the inserter MJ7001, hold it as the figure [B] below shows in order for your hands not to be caught.
[A]
[B]
Copyright 2002 TOSHIBA TEC Corporation
INTRODUCTION
This Service Manual contains basic data and figures for the Finisher (MJ-1017)/Saddle Finisher (MJ-1018) 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 Chapter 7 Chapter 8 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. Puncher (option) Unit Basic Operation discusses the principles of operation used for the puncher units mechanical and electrical systems. It also explains the timing at which these systems are operated. Inserter (option) Unit Basic Operation discusses the principles of operation used for the inserter 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-1017)/Saddle Finisher (MJ-1018)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 ......................... 1-10 III. Using the Machine ..................... 1-14 A. Removing Paper Jams from the Finisher Unit ........................... 1-14 B. Supplying the Finisher Unit with Staples ................................... 1-15 C. Removing Staple Jams from the Finisher Unit ........................... 1-17 D. Removing Paper Jams from the Saddle Stitcher Unit (Saddle Finisher) .................... 1-18 E. Supplying the Saddle Stitcher Unit with Staples (Saddle Finisher) .................... 1-20 F. Removing Staple Jams from the Saddle Stitcher Unit (Saddle Finisher) .................... 1-21 G. Removing Paper Jams from the Puncher Unit (option) ............. 1-23 H. Removing Punched Scrap from the Puncher Unit (option) ....... 1-25 IV. MAINTENANCE BY THE USER ........................................ 1-26 A. Maintenance by the User ....... 1-26
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 ............. 2-10 A. Outline .................................... 2-10 B. Type of Delivery Paths ............ 2-15 C. Feeding and Delivering .......... 2-18 D. Job Offset ............................... 2-21 Staple Operation .................... 2-24 Stapler Unit ............................ 2-32 Tray Operation ........................ 2-38 Detecting the Height of Stack on the Tray .................... 2-40 I. Shutter Operation ................... 2-42 J. Buffer Path Operation ............. 2-46 K. Detecting Jams ...................... 2-51 III. POWER SUPPLY SYSTEM ....... 2-56 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 PUNCHER UNIT (OPTION) BASIC OPERATION

I. BASIC OPERATION .................... 4-1 A. Outline ...................................... 4-1 B. Inputs to and Outputs from Punch Driver PCB .................... 4-2 II. PUNCH OPERATION .................. 4-5 A. Outline ...................................... 4-5 B. PUNCH OPERATION ............... 4-7 C. Horizontal Registration Operation ............................... 4-11 III. POWER SUPPLY SYSTEM ....... 4-14
CHAPTER 5 INSERTER UNIT (OPTION) BASIC OPERATION

I. BASIC OPERATION .................... 5-1 A. Outline ...................................... 5-1 B. Symbols and Layout of Electric Parts/Diagram of Signal Blocks ............................ 5-2 C. Drive System ............................ 5-6 D. Operation ................................. 5-8 E. JAM/ERROR DETECTION AND LED DISPLAY ........................ 5-32 F. CIRCUIT................................. 5-36
iv
CHAPTER 6 MECHANICAL CONSTRUCTION

I. FINISHER UNIT .......................... 6-1 A. Externals and Controls ............. 6-1 B. FEEDING SYSTEM ................. 6-9 C. PCBs ...................................... 6-13 II. SADDLE STITCHER UNIT ........ 6-14 A. Externals and Controls ........... 6-14 B. SADDLE UNIT ....................... 6-17 C. PCBs ...................................... 6-27 D. Accessory .............................. 6-28 III. PUNCHER UNIT (OPTION) ...... 6-29 A. Externals and Controls ........... 6-29 B. Puncher Driver System .......... 6-30 C. PCBs ...................................... 6-41 IV. INSERTER UNIT (OPTION) ...... 6-43 A. Exterior Parts ......................... 6-43 B. Feeding Section ..................... 6-44 C. Drive Section .......................... 6-46 D. Upper Inserter Unit ................. 6-49 E. Tray Unit ................................. 6-50 F. Notes for Installing ................. 6-52
CHAPTER 7 MAINTENANCE AND INSPECTION

I. PERIODICALLY REPLACED PARTS ......................................... 7-1 A. Finisher Unit ............................. 7-1 B. Saddle Stitcher Unit ................. 7-1 C. Puncher Unit (option) ............... 7-1 D. Inserter (option) ........................ 7-1 II. CONSUMABLES AND DURABLES ................................. 7-2 A. Finisher Unit ............................. 7-2 B. Saddle Stitcher Unit ................. 7-2 C. Puncher Unit (option) ............... 7-2 D. Inserter (option) ........................ 7-2 III. PERIODICAL SERVICING .......... 7-2 IV. FIRMWARE UPDATING (only for inserter section) ............. 7-3
CHAPTER 8 TROUBLESHOOTING
I. ADJUSTMENTS .......................... 8-1 A. Electrical System (finisher unit) ............................ 8-1 B. Electrical System (saddle stitcher unit) ................. 8-5 C. Electrical System (puncher unit (option)) .............. 8-7 D. Electric Unit/(Inserter Section (Optional)) ................................ 8-9 E. Inserter Section ...................... 8-10 II. ARRANGEMENT OF ELECTRICAL PARTS ................ 8-12 Finisher Unit ........................... 8-12 Saddle Stitcher Unit ............... 8-19 Puncher Unit (option) ............. 8-25 Light-Emitting Diodes (LED) and Check Pins by PCB ......... 8-29 III. TROUBLESHOOTING ............... 8-31 A. Finisher Unit ........................... 8-31 B. Saddle Stitcher Unit ............... 8-41 C. Puncher Unit (option) ............. 8-48 D. Inserter Section (Option) ........ 8-49 A. B. C. D.
APPENDIX
A. FINISHER UNIT GENERAL TIMING CHART .......................... A-1 B. SADDLE STITCHER UNIT GENERAL TIMING CHART ........ A-2 C. PUNCHER UNIT (option) GENERAL TIMING CHART ........ A-3 D. INSERTER UNIT (option) GENERAL TIMING CHART ........ A-4 E. SIGNAL AND ABBREVIATIONS ..................... A-14 F . FINISHER UNIT CIRCUIT DIAGRAM ................................. A-15 G. SADDLE STITCHER UNIT CIRCUIT DIAGRAM ................. A-26 H. PUNCHER UNIT (option) CIRCUIT DIAGRAM ................. A-34 I. INSERTER UNIT (option) CIRCUIT DIAGRAM ................. A-41 J. SOLVENTS AND OILS ............. A-45
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I. FEATURES .................................. 1-1 II. SPECIFICATIONS ....................... 1-2 A. Specifications ............................. 1-2 B. Cross Section .......................... 1-10 III. Using the Machine ..................... 1-14 A. Removing Paper Jams from the Finisher Unit ............................. 1-14 B. Supplying the Finisher Unit with Staples ..................................... 1-15 C. Removing Staple Jams from the Finisher Unit ............................. 1-17 D. Removing Paper Jams from the Saddle Stitcher Unit (Saddle Finisher) ..................... 1-18
E. Supplying the Saddle Stitcher Unit with Staples (Saddle Finisher) ..................... 1-20 F. Removing Staple Jams from the Saddle Stitcher Unit (Saddle Finisher) ..................... 1-21 G. Removing Paper Jams from the Puncher Unit (option) ............... 1-23 H. Removing Punched Scrap from the Puncher Unit (option) ......... 1-25 IV. MAINTENANCE BY THE USER ........................................ 1-26 A. Maintenance by the User ......... 1-26
I.
1.
FEATURES
Accommodates large quantities of sheets q 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 q The finisher is capable of handling papers between 60 and 256 gm/m2. Offers a job offset function q The finisher has a job offset function for sorting non-stapled stacks of copies. Offers four types of auto stapling q 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 q 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 (Saddle Finisher MJ-1018) q The finisher can staple along the center of paper and fold it in two (up to 15 sheets). Offers a punch function (option) q 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) q 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.
1-1
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 60 to 256 g/m2 Trays 1 and 2 Non-sort: Sort: Staple sort: Non sort Non staple sort trays 1 and 2 trays 1 and 2 trays 1 and 2 Small-size
(Note 1)
Stacking method Stacking orientation Stacking size Paper weight Bins Modes
Stacking capacity
250 mm (2000 sheets) (Note 2) 140 mm (1000 sheets) 110 mm/50 sets (750 sheets) (Note 2) 74 mm/50 sets (500 sheets)
Large-size
(Note 1)
Staple sort
Small-size
(Note 1)
Large-size
(Note 1)
Size mixing Stacking mixing
Size mixing: 74 mm or less (500 sheets) (Note 1) Staple mixing: 74 mm or less (500 sheets) (Note 1) Face-down
Notes: 1. Approximate when computed with reference to 80 g/m2 paper. 2. Alignment may not be correct if 750 or more small-size sheets are stacked. 3. The accuracy of the stack height is 7 mm/0.28 in.
Table 1-201
1-2
Item Stapling Stapling position Stapling capacity

(Note1)
Description By rotating cam See Figure 1-201. Small-size 50 sheets (60 ~ 80 g/m2) Large-size 30 sheets (60 ~ 80 g/m2) 30 sheets (90 g/m2) 30 sheets (105 g/m2) 15 sheets (90 g/m2) 15 sheets (105 g/m2)
Staple supply Staples Staple detection Manual stapling Stapling size
Special staple cartridge (5000 staples) Special (STAPLE-700: 3 cartridges of 5000 staples in a package) 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 A4-R, LT-R, LG, FOLIO
A3, B4, A4, B5, A4-R, LD, LG, LT-R, FOLIO, COMPUTER
Paper detection Control panel Display Dimensions (W D H)
Provided Not provided Not provided 740 630 1023 mm/29.25 24.88 40.38 in 813 630 1023 mm/32.13 24.88 40.38 in (with Puncher Unit attached) 922 630 1023 mm/36.38 24.88 40.38 in (with Inserter Unit attached) 995 630 1023 mm/39.25 24.88 41.38 in (with Puncher Unit and Inserter Unit attached) Finisher (MJ-1017): 42 kg/92.59 lb Saddle finisher (MJ-1018): 62 kg/136.68 lb Puncher unit (option): 5.4 kg/11.68 lb Inserter unit (option): 20 kg/44.09 lb From host machine (24 VDC, 5 VDC) 170 W or less
Weight
Power supply Maximum power consumption
Note1: Equivalent of 80 g/m2 paper. Including two sheets of thick stock or cover (200 ~ 256 g/m2) Table 1-202 Reference: The term small-size stands for A4, A5-R, B5, LT, ST-R, while the term large-size stands for A3, B4, A4-R, B5-R, LT-R, LD, LG, FOLIO, COMPUTER.
1-3
Stapling Positions (finisher unit)
1-point stapling (rear)
1-point stapling (diagonal; front)
1-point stapling (diagonal; rear)
30 4.44mm/ -0.170.16in Specified paper width -64mm/ -0.240.16in
30
54mm/ 0.20.16in
2-point stapling A3 and A4 B4 and B5 LD and LT
54mm/ 0.20.16in
54mm/ 0.20.16in
4.44mm/ 0.170.16in
834mm/ 3.260.16in 2034mm/ 7.980.16in
634mm/ 2.470.16in 1834mm/ 7.190.16in
54mm/ 0.20.16in
744mm/ 2.90.16in 1944mm/ 7.630.16in
A4-R and FOLIO
LT-R and LG
54mm/ 0.20.16in
54mm/ 0.20.16in
62.54mm/ 2.460.16in 138.54mm/ 5.450.16in
62.54mm/ 2.460.16in 144.54mm/ 5.690.16in
Figure 1-201
1-4
44mm/ 0.160.16in
Specified paper width -64mm/ -0.240.16in
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) 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
Stapling method Folding position Paper size Capacity Paper weight Stacking capacity Stapling
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
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
3.
Puncher Unit (Option)

Item Description Sequential punching 2 holes (puncher unit MJ-6003E): 2 or 3 holes (puncher unit MJ-6003N): A3, A4, A4-R, B4, B5, B5-R 2 holes/LG, LT-R 3 holes/LD, LT 4 holes (puncher unit MJ-6003F/ 6003S): A3, A4, A4-R (MJ-6003S) 60 to 256 g/m2 (Note 1) 2 holes (puncher unit MJ-6003E): 2 or 3 holes (puncher unit MJ-6003N): 6.5mm 2 holes/8.0mm 2 holes/0.31in 3 holes/8.0mm 3 holes/0.31in 4 holes (puncher unit MJ-6003F/ 6003S): 6.5mm 5,000 sheets or more (64g/m2 equivalent) 2 or 3 holes (puncher unit MJ-6003N): 3,000 sheets or more (75 g/m2 equivalent) 4 holes (puncher unit MJ-6003F/6003S): 5,000 sheets or more (80 g/m2 equivalent) 2 holes (puncher unit MJ-6003E): From finisher unit (24 VDC, 5 VDC) 120 W or less
Punching method Paper size
Paper weight Punched hole diameter
Punched scrap capacity
Power supply Power consumption
Note1: Transparencies, reproducibles, label paper, postcards and hole-punched paper cannot be handled.
Hole position (Puncher Unit)
[1] 2 holes (Puncher Unit MJ-6003E)
801 mm/ 3.150.04 in 123 mm/ 0.470.12 in
Figure 1-203-1
1-7
[2] 2 or 3 holes (Puncher Unit MJ-6003N)
701 mm/ 2.760.04 in 123 mm/ 0.470.12 in
1081 mm/ 1081 mm/ 4.250.04 in 4.250.04 in 123 mm/ 0.470.12 in
[3] 4 holes (Puncher Unit MJ-6003F)
801 mm/ 801 mm/ 801 mm/ 3.150.04 in 3.150.04 in 3.150.04 in
123 mm/ 0.470.12 in
[4] 4 holes (Puncher Unit MJ-6003S)
211 mm/ 701 mm/ 211 mm/ 0.830.04 in 2.760.04 in 0.830.04 in
123 mm/ 0.470.12 in

Figure 1-203-2
Specifications are subject to change without notice.
1-8
4.
Inserter section
Item Details A3, A4, A4-R, B4, B5, FOLIO, LD, LG, LT, LT-R 60g/m2 ~ 256g/m2 (16 lb. ~ 140 lb. Index) OHP film, color paper (coated paper), hole-punched paper (*NOTE) 100 at maximum for papers less than 80g/m2, number of papers up to 12mm of laden height for papers more than 80g/m2 * less than 60% of the above quantities for special papers 533 612 1072mm (21 24.13 42.38 in) (W D H) Approx. 20kg
Paper size Paper weight Special papers Laded number of papers Inserter size Inserter weight
* NOTE: Refer to 1-7, 8 for the hole position
Table 1-204
1-9
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 Feed belt Tray lift motor Saddle stitcher unit (saddle finisher MJ-1018)
Figure 1-204
1-10
2.
[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 1-205
1-11
3.
Puncher Unit (option)
[1]
[2] [3] [4] [5] [6] [7] [8] [9]
[1] [2] [3] [4] [5]
Punch motor Cam Hole puncher (Punch blade) Die Photosensor PCB
[6] [7] [8] [9]
LED PCB Horizontal registration motor Scrap full detector PCB unit Punched scrap container
Figure 1-206
1-12
4.
Inserter section (optional)
[1]
[2]
[3] [4] [5]
[6] [10] [7] [9] [8]
[1] [2] [3] [4] [5]
Tray Pickup roller Feed roller Transport roller 1 Transport roller 2
[6] [7] [8] [9] [10] Figure 1-207
Transport roller 3 Transport roller 4 Transport roller 5 Transport roller 6 Reverse roller
1-13
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) Holding 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
1-14
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) Shift down the blue lever.
Figure 1-307 8) Operate as instructed on the display. Figure 1-309 3) When the staple cartridge has slightly slid out, hold and pull it out.
Figure 1-310
1-15
4) Hold the empty staple case on its sides, and slide it out.
6) Pull the length of tape (used to hold the staples in place) straight out.
Figure 1-311 5) Set a new staple case.
Figure 1-313 7) Push in the stapler unit until the blue lever returns to its original position.
Figure 1-312 Figure 1-314 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. 8) Check to make sure that the stapler has been locked in place, and close the front cover.
Figure 1-315
1-16
C.
Removing Staple Jams from the Finisher Unit
4) When the staple cartridge has slightly slid out, hold and pull it out.
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 1-319 5) Shift down the tab on the staple cartridge.
Figure 1-316 2) Open the front cover.
Figure 1-320 6) Remove all staples that have slid out of the staple case.
Figure 1-317 3) Shift down the blue lever.
Figure 1-321
Figure 1-318
1-17
7) Return the tab on the staple cartridge to its original position. 8) Return the staple cartridge to its original position, and close the front cover.
D.
Removing Paper Jams from the Saddle Stitcher Unit (Saddle Finisher)
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 1-322 Reference When the cover has been closed, the stapler unit will automatically execute idle punching several times to advance the staples.
Figure 1-323 2) Open the front lower cover.
Figure 1-324
1-18
3) Turn the knob on the left side.
6) Open the inlet cover, and remove the jam.
Figure 1-325 4) Turn the knob on the right side while pushing it in.
Figure 1-328 7) Close the front lower cover.
Figure 1-329 Figure 1-326 8) 5) Remove the jam. 9) Operate as instructed on the display. Connect the finisher unit.
Figure 1-327
1-19
E.
Supplying the Saddle Stitcher Unit with Staples (Saddle Finisher)
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 1-332 4) Hold the empty cartridge on its sides, and remove it.
Figure 1-330 2) Slide out the stitcher unit.
Figure 1-333 5) Set a new cartridge.
Figure 1-331
Figure 1-334 Reference You must always replace both cartridges at the same time.
1-20
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 (Saddle Finisher)
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 1-335 7) Push in the stitcher unit, and close the front cover.
Figure 1-337 2) Slide out the stitcher unit.
Figure 1-336
Figure 1-338 3) Pull the stapler of the stitcher unit to the front once, and then shift it up.
Figure 1-339 1-21
4) Hold the cartridge on its sides, and remove it.
7) Return the cartridge to its original position.
Figure 1-343 Figure 1-340 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 1-341 Figure 1-344 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 1-342 Figure 1-345 Reference Whenever you have removed a staple jam, be sure to execute staple edging.
1-22
G.
Removing Paper Jams from the Puncher Unit (option)
4) Holding the finisher unit as shown, move it to detach it from the most machine.
If the display indicates a paper jam on the puncher unit, perform the following to remove the jam: 1) Open the front cover of the puncher unit. Figure 1-349 5) Remove any jam visible from the outside.
Figure 1-346 2) Align the triangle mark on the knob within . the range marked by Figure 1-350 6) Open the upper cover, and check the inside of the finisher.
Figure 1-347 3) Close the front cover of the puncher unit.
Figure 1-351 7) Lift the buffer roller cover, and remove the jam.
Figure 1-348
Figure 1-352 1-23
8) Return the buffer roller and the buffer roller cover to their original position, and close the upper cover.
Figure 1-353 9) Connect the finisher to the host machine.
Figure 1-354 10) Operate as instructed on the display.
1-24
H.
Removing Punched Scrap from the Puncher Unit (option)
4) Return the punched scrap container to its original position.
If the display indicates a punched scrap full state on the puncher unit, perform the following to remove the punched scrap: 1) Open the front cover of the puncher unit. Figure 1-358
Figure 1-355 2) Slide out the punched scrap container.
Figure 1-356 3) Discard the punched scrap.
Figure 1-357
1-25
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: The finisher unit and the saddle stitcher unit use different cartridge types. Be sure that the appropriate type is used for each. Table 1-401
1-26

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 ............. 2-10 A. Outline ..................................... 2-10 B. Type of Delivery Paths ............. 2-15 C. Feeding and Delivering ............ 2-18 D. Job Offset ................................ 2-21
Staple Operation ...................... 2-24 Stapler Unit .............................. 2-32 Tray Operation.......................... 2-38 Detecting the Height of Stack on the Tray...................... 2-40 I. Shutter Operation .................... 2-42 J. Buffer Path Operation .............. 2-46 K. Detecting Jams ........................ 2-51 III. POWER SUPPLY SYSTEM ....... 2-56
E. F. G. H.
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 Finisher, 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 (Saddle Finisher) 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
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. In the case of the Saddle Finisher, 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: q IC1 (CPU) Controls sequence of operations. q IC2 (EP-ROM) Backs up adjustment values. q IC3 Contains sequence programs. q IC6/IC7 (RAM) Backs up initial setting data. q IC4 (communications IC) Communicates with the host machine and the saddle stitcher unit. q IC9 (regulator IC) Generates PWM. Figure 2-102 shows the flow of signals between the finisher and the options controller.
2-2
Saddle stitcher controller PCB (Saddle Finisher)
Finisher controller PCB communication

IC1 CPU
Motor
Solenoid
IC2
Switch
Punch driver PCB (Puncher unit (option))
EEP-ROM
IC4 IC
Sensor
IC3
Host machine (DC controller PCB CPU)
EP-ROM
IC6/IC7 RAM
IC9
Regulator IC
Connecting with inserter

Saddle stitcher controller PCB (Saddle Finisher) Finisher controller PCB communication
IC1 CPU
Motor
Solenoid
IC2
Switch
Punch driver PCB (Puncher unit (option))
EEP-ROM
IC4 IC
Sensor
IC3
Host machine (DC controller PCB CPU)
Inserter driver PCB (Inserter unit (option))
EP-ROM
IC6/IC7 RAM
IC9
Regulator IC
Figure 2-102
2-3
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 J134-1 -2 -3 J122-3 -1 -2
-7 -9 -8 -3 -2 -1 -1 -3 -2
-3 -1 -2 -5 -6 -7 -11 -9 -10
J17-7 -9 -8 J11-3 -2 -1 J9A-1 -3 -2
J202
+5V PENT
When the sensor detects paper, 1.
Delivery sensor
PI4
J208
+5V PDEL
J207A
Stapling tray sensor
+5V STPTY
Alignment plate home position sensor
PI6
J207A
J121-3 -1 -2
J205
Shutter open sensor
PI5
J118-3 -1 -2
-1 -3 -2
-3 -1 -2
J12B-4 -6 -5
+5V STOPN
When the shutter opens, 1.
-4 -6 -5
-8 -6 -7
J9A-4 -6 -5
+5V JOGHP
When the alignment plate is at the home position, 1.
Tray 1 home position sensor
PI8
J130-3 -1 -2
J210
Stapler shift home position sensor
PI7
J129-3 -1 -2
-1 -3 -2
-3 -1 -2
J12A-4 -6 -5
+5V STPHP
When the stapler is at the home position, 1.
J14A-1 -3 -2
+5V TRYHP 1
When the tray 1 is at the home position, 1.
Figure 2-103
2-4
2.

PI10 J120-1 -2 -3 J2011-3 -1 -2 J8011-3 -1 -2 J110-3 -1 -2 J117-3 -1 -2 J1130-3 -1 -2 J105-3 -1 -2 J127-3 -1 -2 J6011-3 -4 -1 -6 -2 -5
J6010
J207A
Delivery motor clock sensor

PI11
-9 -8 -7 -1 -3 -2 -1 -3 -2 -3 -1 -2 -3 -1 -2
-3 -4 -5 -1 -3 -2 -7 -9 -8
J9A-9 +5V -8 DELCLK -7
While the delivery motor is rotating, alternately between 0 and 1.
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 J12A-1 +5V -3 JOINT -2
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
J12B-1 +5V -3 DROPN -2
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 J11-8 +5V -10 SWGOPN -9
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.

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.

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.
-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
3.

PI20
J207B

J9B-5 +5V -4 SWGCLK -3
Swing motor clock sensor
J125-1 -2 -3
-5 -4 -3
-7 -8 -9
When the swing motor is rotating, alternately between 0 and 1.
PI25
J135-3 -1 -2
J14B-10 +5V -12 TRYHP2 -11
When the tray 2 is home position, 1.
PS1
Height sensor
J114-3 -2 -4 -1 -2 -3 -1 -4
-3 -4 -2 -1
-2 -1 -3 -4
-3 J6-2 +5V -4 -1 Height -2 -3 PWR -1 -4
Measures the distance between the sensor and the top of the stack on the tray.
J212
Door switch
N. O. MS1 C. +24V J112-1 -2 J112-1 -1
J112
J213
-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
J5-6 +24V SHIFT -7
-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 -5 -4 +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 J7-7 -6 -5 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 -10 TRYLMT +24VSHIFT
When the tray 1 gets close to the tray 2: "0"
Figure 2-105 2-6
4.
Inputs to and 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 switch
*
When a cartridge is present, 0.
Staple switch
*
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 J51-3 -4 -1 -2 -8 -9 -11 -12 -6 -7 -5 JS1
Communication line
Host machine
Figure 2-106 2-7
5.
Outputs from the Finisher Controller PCB

+24V -1 -2 -1 -2 J12A-7
Flapper solenoid
J107 J701
SL1
When "0", the solenoid turns on.

-1 -8 FLPSL* +24V
-2
-1
-2
Buffer inlet solenoid

-1 -3 J12B-9
J108
SL2

-2 -10 ENTSL* +24V
-2
Buffer outlet solenoid

-1 -2 J24-7
J109
SL3

-1 -8 EXITSL* +24V
-2
Paddle solenoid
-1 -2 -1 -11 J9B-1
J207B
J128
SL5

-10 -2 PDLSL* +24V
-2
-1
-2
Escape solenoid
-1 -3 -10 -2 J9A-10
J207A
J123
SL6

-1 -11 ESCPSL* +24V
-2
-2
-11
Belt escape solenoid

-1 -2 -1 -2 J12B-7
J501
J500
SL7

-1 -8 BESCPSL* +24V
-2
-1
-2
First feed motor
M1
J10-6 -1 -2 -4 -3 -5
J10-6 -1 -2 -4 -3 -5
J10-1 -2 -3 B* -4 A* -5 B -6 A
According to rotation direction/speed, changes between + and - in sequence.
Delivery motor According to rotation direction/speed, changes between + and -. Alignment motor
Figure 2-107 2-8
6.
Outputs from the Finisher Controller PCB

Finisher controller PCB Stapler shift motor
According to rotation direction/speed, changes between + and - in sequence. Staple motor According to rotation direction/speed, changes between + and -.
Tray 1 lift motor

J115-1 -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
Figure 2-108
2-9
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 three modes of delivery (four for the Saddle Finisher).
Normal delivery
Method of delivery
Simple stacking Job offset Staple Front diagonal Rear 1-point Rear diagonal 2-point
Saddle stitch delivery (Saddle Finisher only)
Figure 2-201
Normal delivery tray
Normal delivery tray
To saddle stitcher unit (Saddle Finisher)
Figure 2-202
2-10
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
2-11
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
2-12
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
2-13
2.
Saddle Stitch Delivery (Saddle 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. For discussions of stacks in the saddle stitcher, see Chapter 3.
To saddle stitcher
Figure 2-209
2-14
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 stock)
Table 2-202
Buffer roller
Feed roller 2 Delivery roller
Figure 2-211
2-15
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 stock)
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
2-16
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 Cauiton:

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.
2-17
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 (Saddle 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. 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): q Inlet sensor (PI1) q Delivery sensor (PI3) q Stapling tray sensor (PI4) q 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. q No.1 tray paper sensor (PI11) q 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.
2-18
Tray 2 lift motor drive signal Shift motor clock signal 1 SFTCLK 21 Shift motor clock signal 2 SFTCLK 22 Escape solenoid drive signal ESCPSL Alignment motor drive signal Delivery motor drive signal Delivery motor clock signal DELCLK Swing motor drive signal Swing motor clock signal SWGCLK Shift motor clock detection signal 1 SFTCLK11 Shift motor clock detection signal 2 SFTCLK12
PI10 PI20 M2 M7
M3
PI23 PI19 PI9 M5

SL6 SL5
PI24 M8
M10

Tray 1 lift motor drive signal Paddle solenoid drive signal PDLSL
Figure 2-216
M4 SL3 SL2 SL1 SL7 M6 M1 M9
Second feed motor drive signal
First feed motor drive signal
Inlet feed motor drive signal
Buffer outlet solenoid drive signal EXITSL Buffer inlet solenoid drive signal EXTSL Flapper solenoid drive signal FLPSL Belt escape solenoid drive signal BESCPSL Stapler motor drive signal Stapler shift motor drive signal
2-19
2-20
No. 2 tray paper detection signal SNDTRAY No. 1 tray paper detection signal FSTTRAY
PI12 PI4 PI3
PI11
Stapling tray paper detection signal STPTY Buffer path paper detection signal BUFPASS Delivery detection signal PDEL
Figure 2-217
PI14 PI17 PI1
Buffer path inlet paper detection signal BUFENTR Inlet paper detection signal PENT
D.
1.
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. The alignment plate is checked by the alignment plate home position sensor (PI6) to find out whether it is at the home position. The finisher controller PCB drives the alignment motor (M3) 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) in advance, and keeps the alignment plate in wait at a point 10 mm behind the trailing edge of a sheet. Whenever one sheet is moved to the stapling tray, each sheet is aligned, and when the fifth or last sheet in a sort job/group is fed to the stapling tray, the escape solenoid (SL6) moves the guide plate away and under the stapling tray. From then on, the alignment motor shifts the sheets to the front by 30 mm. When the copy has been shifted, the finisher controller PCB rotates the alignment motor counterclockwise to move the alignment plate to a point 10 mm behind 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.
2-21
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) Delivery motor (M2) Staple tray sensor (PI4) Alignment motor (M3) Alignment plate home position sensor (PI6) Swing motor (M7) Swing guide open sensor (PI18) Swing guide closed detecting switch 1 (MS2) Escape solenoid (SL6) : Motor CW rotation : Motor CCW rotation
Figure 2-219 2-22
2.
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 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 2-23
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
2-24
Paper width/2 Front diagonal stapling 2-point stapling
Rear 1-point stapling Rear diagonal stapling
Figure 2-224
2-25
2.
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. 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 motor (M3) 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
First sheet
Feed roller 2
Knurled belts Tray 1/2 Delivery roller
Stapling tray Stapler
Figure 2-225
2-26
Swing guide Swing guide open sensor (PI18) Swing guide closed detecting switch 1,2 (MS2/MS6) Delivery roller
Swing motor clock sensor (PI20)
Delivery motor clock sensor (PI10)
Swing motor (M7) Delivery motor (M2)
Figure 2-226
2-27
3.
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. The finisher controller PCB turns on the paddle solenoid (SL5) as soon as the trailing edge of the second and subsequent sheets have moved past the feed roller 2, causing the drive of the second feed motor (M8) to rotate the paddle. The sheets are pushed by the paddle and moved to the stapling tray. Almost simultaneously with the trailing edge of the sheet falling into the stapling tray, the belt escape solenoid turns off to return the knurled belts that were in the escape position to its original position, and feed the sheet onto the stapling tray. When the sheet has been output onto the stapling tray, the finisher controller PCB rotates the alignment motor (M3) to put the sheets in order.
Swing guide Second and subsequent sheets Paddles
Feed roller 2 Knurled belts

SL7
Tray 1/2
Delivery roller Stapling tray Stapler
Figure 2-227
2-28
Knurled belts
Escape direction
Belt escape solenoid (SL7)
Figure 2-228
Paddles
Paddles Paddle solenoid (SL5) Second and subsequent sheets
First sheet
Stapler
M8
Second feed motor
Stopper
Figure 2-229
2-29
4.
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). 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
2-30
Swing guide
Delivery roller
Swing motor (M7)
Delivery motor (M2)
Figure 2-231
2-31
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 presence/absence of the staple cartridge is detected by the staple switch (MS8). The presence/absence of staples inside the staple cartridge is detected by the staple detecting switch (MS9). 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.
2-32
Staple edge detection signal
Staple motor drive signal

M6
Figure 2-233
Stapling home position detection signal Cartridge detection signal Staple detection signal
Figure 2-232
2-33
Start signal Host machine delivery signal Stacking 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) Alignment motor (M3) Alignment guide home position sensor (PI6) Swing guide open sensor (PI18) Swing guide closed detecting switch 1 (MS2) Paddle solenoid (SL5) Belt escape solenoid (SL7) Staple motor (M6) Staple home position sensor (PI22) Stapler shift motor (M4)
First sheet
Second sheet
: Motor CW rotation
: Motor CCW rotation
Figure 2-234
2-34
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
2-35
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 2-36
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
2-37
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.
2-38
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
2-39
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.
Non-staple sort Stacking mode Height Small-size Large-size Mixed sizes Small-size Staple sort Large-size Mixed sizes 22 mm high (500 sheets/ 50 sets)
250 mm high 140 mm high 74 mm high (2000 sheets) (1000 sheets) (500 sheets)
110 mm high 74 mm high (750 sheets/ (500 sheets/ 50 sets) 50 sets)
Notes: 1. The capacity for the non-staple sort mode is approximate and computed based on 80 g/m2 paper. 2. Alignment for stacks containing 750 sheets or more is not guaranteed. 3. Stacking height precision is 7 mm.
Table 2-204 Caution: 1. The term small-size stands for A4, LT, and B5. 2. The term large-size stands for A3, A4-R, B4, LG, LD, LT-R, FOLIO and COMUTER.
2-40
Height sensor (PS1) Paper
Figure 2-240
2-41
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
2-42
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
2-43
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 2-44
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
2-45
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
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.

ON SL3
Buffer path inlet paper sensor (PI17)
Figure 2-248
2-46
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
2-47
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.
Third sheet Buffer path paper sensor (PI14)
Figure 2-252
2-48
7) When the third sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer roller starts to operate once again.
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.)

OFF
SL3
Third sheet Inlet sensor (PI1)
Figure 2-254
2-49
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
K. Detecting Jams
The following sensors are used to detect the presence/absence of paper and to make sure that sheets are moved properly: q Inlet sensor (PI1) q Delivery sensor (PI3) q Stapling tray sensor (PI4) q 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
2-51
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)
Jam
Figure 2-259
2-52
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)
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)
Jam
Figure 2-261
2-53
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)
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)
Jam
Figure 2-263
2-54
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.
2-55
III. POWER SUPPLY SYSTEM

1. 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. 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. The power to the saddle stitcher controller PCB, however, will not be cut off. Figure 2-301 is a block diagram showing the power supply system.
Saddle stitcher controller PCB (Saddle Finisher)
Door switch (MS1) Motor
Motor J1-1 Circuit breaker (CB1) Solenoid
Host machine
Finisher controller PCB Sensors
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 motor (M3), and stapler shift motor (M4) are equipped with a fuse, which is designed to blow when an overcurrent occurs.
2-56

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 by symbol in drawings indicates transmission of mechanical drive, and signals marked 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
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
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: q Q1 Controls the sequence of operations. q Q2 Contains the sequence program. q Q3 Controls the sequence of operations. q Q4 Handles IPC communications. Electrical circuitry block diagram
Sensors

Q1 CPU
Motors Solenoids
Switches
Q2 ROM Q3 RAM
Communications IC
Q4
Host machine
Figure 3-102
3-2
C.
1.
Inputs to and Outputs from the Saddle Stitcher Controller PCB

Inputs to the 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
2.

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
3.

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
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

-1 -4 FLPSL2* +24V -2 J15-5
-2
Feed plate contact solenoid

-1
J116
SL4S

-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

+24V
Paper positioning plate motor
J114-5 -4 -3 -2 -1
M4S

+24V
Alignment motor
J113-5 -4 -3 -2 -1
M5S
Figure 3-106 3-6
5.
Outputs from the 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
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

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
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
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: q 15 sheets (maximum of 14 sheets of 80 g/m2 + 1 sheet of 256 g/m2)
Direction of delivery
Paper positioning plate
Figure 3-202
3-9
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
Figure 3-203
3-10
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
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
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
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
Feed motor drive signal
Guide motor drive signal
M3S M1S
Stitcher motor drive signal
(front/rear)
Alignment motor drive signal
M5S M6S/ M7S
Saddle stitcher controller PCB (2/2)
Figure 3-301
M4S M2S M8S PI4S PI1S SL4S
FLDCLK LUNGECLK
Paper pushing plate motor drive signal
Paper folding motor drive signal
Paper positioning plate motor
drive signal No.1 paper deflecting solenoid drive signal
SL1S SL2S
FLPSL1 No.2 paper deflecting solenoid drive signal FLPSL2
PCB (1/2)
Feed plate contact solenoid drive signal RLNIPSL
Saddle stitcher controller
Paper folding motor clock signal
Paper pushing plate motor clock signal
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

Vertical path paper detection signal VPJM
Figure 3-302
PI15S PI14S
Paper pushing plate top position detection signal LUNGETOP
PI19S
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
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
2.
A3/LD Paper Path (3 sheets)
No.1 paper sensor Passage of paper PI18S No.1 paper deflecting SL1S solenoid No.2 paper sensor PI19S No.2 paper deflecting solenoid OFF
Non-passage of paper
SL2S
OFF
Non-passage of paper
No.3 paper sensor PI20S Top edge
PI18S
PI19S
PI20S
PI18S
PI19S
PI20S Entry of First sheet
Entry of Second sheet
Entry of Third sheet
Figure 3-303
3-18
3.
B4 Paper Path (3 sheets)
No.1 paper sensor PI18S

SL1S
Passage of paper
ON
Passage of paper
SL2S No.3 paper sensor Non-passage of paper
OFF
PI20S
PI18S PI19S Top edge PI20S
PI18S PI19S
Figure 3-304
3-19
4.
A4-R/LT-R Paper Path (3 sheets)

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
Figure 3-305
3-20
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
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
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
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
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
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
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

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
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
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
Cam
Mount
Figure 3-404
3-30
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
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
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
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
[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
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
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.)
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
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
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
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
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
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
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
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

1. This chapter discusses the purpose and role of each of the puncher units functions, and the principles of operation used for the puncher unit mechanical and electrical systems. It also explains the timing at which these systems are operated. The by symbol in drawings indicates transmission of mechanical drive, and signals marked together with the signal name indicates the flow of electrical signals.
2. In descriptions of digital circuits on the puncher unit, 1 indicates a high signal voltage level, while 0 indicates a low signal voltage level. Voltage values differ according to circuit. 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 .................... 4-1 A. Outline ....................................... 4-1 B. Inputs to and Outputs from Punch Driver PCB ...................... 4-2 II. PUNCH OPERATION .................. 4-5
A. Outline ....................................... 4-5 B. PUNCH OPERATION ................ 4-7 C. Horizontal Registration Operation ................................. 4-11 III. POWER SUPPLY SYSTEM ....... 4-14
I.
A.
BASIC OPERATION
Outline
The puncher unit (option) is attached on the feed path between the host machine and the finisher. The puncher unit does not have a paper feed mechanism. Paper from the host machine is fed by feed drive from the finisher via the puncher unit. When the trailing edge of the paper from the host machine reaches the puncher unit, the paper stops temporarily, and the punch shaft is rotated to punch the trailing edge of the paper. This operation is controlled by the finisher controller PCB, and each of the parts on the finisher is driven by the punch driver PCB.
Punch drive system

Finisher unit control system
Punch driver PCB
Horizontal registration drive system
Figure 4-101
4-1
B.
1.
Inputs to and Outputs from Punch Driver PCB

Inputs to Punch Driver PCB (1/3)
Punch driver PCB
PI1P
Horizontal registration home position sensor

PI2P
J102-3 -2 -1
J1A-1 +5V -2 -3 SREGHP
When the punch slide unit is at the home position, 1.
Punch motor clock sensor
J105-1 -2 -3
J1B-6 +5V -5 -4 PUNCHCLK
When the punch motor is rotating, alternatly between 1 and 0.
PI3P
Punch home position sensor
J104-2 -3 -1
J1B-2 +5V -3 -1 PUNCHHP*
When the hole puncher is at the home position, 0.
+24V J5-1 -2
UDROPN
Always 1.
Front door switch
N.O. MS2P
J5-3 -4
FDROPN
When the front door is closed, 1.
Photosensor PCB
+5V PTR1 PTR2 PTR3 PTR4 PTR5 J11-2 -3 -4 -5 -6 -7 J115-2 -3 -4 -5 -6 -7 J7-12 -11 -10 -9 -8 -7 +5V SREG1* SREG2* SREG3* SREG4* PAEND*
When a paper is detected, 0.
-1
-1
-13
Figure 4-102
4-2
2.
Outputs from Punch Driver PCB (2/3)

Punch driver PCB LED PCB
LED5 LED4 LED3 LED2 LED1 J10-6 -5 -4 -3 -2 -6 -5 -4 -3 -2 J116-6 -5 -4 -3 -2 J7-1 -2 -3 -4 -5 LEDON5 LEDON4 LEDON3 LEDON2 LEDON1
When 1, LED is ON.
-1
-1
-1
-6
Scrap full detector PCB

LED6 PTR6 J112-3 -4 J1B-8 7
+5V LEDON*
When light is blocked, 0.

-2 -1 9 DFULL 10
Punch motor
J113-1 M1P -2 -2 -2 J114-1 J2-1
According to direction of motor rotation, changes between + and -.
Horizontal registration motor

-1 -2 M2P -3 -4 J101-4 -3 -2 -1 J1A-7 -8 -9 -10 B* A* B A
The pulse signal is switched according to motor rotation.
Figure 4-103
4-3
3.
Outputs from Punch Driver PCB (3/3)

Punch driver PCB

J21A-14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 J3A-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14
J21B-13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1
J3B-2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 +24V
J23-4 -3 -2 -1
J4-4 -3 -2 -1
+5V
Figure 4-104 4-4
II.
A.
PUNCH OPERATION
Outline
The puncher unit is located on the feed path between the host machine and the finisher, and successively punches holes when the paper stops temporarily. When the trailing edge of the paper reaches the puncher unit, the inlet roller of the finisher unit temporarily stops the paper and holes are punched on the trailing edge of the paper. The puncher unit consists of a die and hole puncher (punch blade). The hole puncher is driven by the punch motor (M1P). The hole puncher is attached to the eccentric cam of the punch shaft, and rotary action of the punch shaft is converted to reciprocal motion to perform punching. Punch motor (M1P) is a DC motor. The home position of the punch shaft is detected by punch home position sensor (PI3P). To stop the DC punch motor accurately at its home position, the punch motor clock sensor (PI2P) counts a predetermined number of clock pulses to stop the punch motor. A single punch operation is performed by rotating the punch shaft 180 from its home position. Five light sensors (photosensor PCB) are located at the upper side of the inlet paper feed path of the puncher unit and a set of five LEDs (LED PCB) are located at the lower side. These sensors and LEDs function as five sensors. The frontmost sensor (LED5, PTR5) are the trailing edge sensor and are used for detecting the trailing edge of the paper. The remaining sensors (LED1 to LED4, PTR1 to PTR4) are horizontal registration sensors, and are used for detecting the inner position of the paper for determining the hole punching position. The punch motor, puncher unit and above sensors comprise the punch slide unit. This unit moves backwards and forwards according to the size of the paper. Backward and forward movement is driven by the horizontal registration motor (M2P). The home position of the punch slide unit is detected by the horizontal registration home position sensor (PI1P). The horizontal registration motor (M2P) is a 2-phase stepping motor. The punch motor and horizontal registration motor is driven by the punch driver PCB according to control signals from the finisher controller PCB. Punch scraps caused by punching are stored in the punched scrap container. Scrap full detection is performed by a reflective sensor (LED6 and PTR6 on the scrap full detector PCB unit).
4-5
4-6
Trailing edge detection signal PAEND Horizontal registration detection signal (LED1 to 4, PTR1 to 4) SREG1 to 4
5 5
Punch driver PCB (1/2)
Punch driver PCB (2/2)

4 4 3 3 2 2 PTR1 LED1
Figure 4-201
Scrap full detection signal (LED6,PTR6) DFULL
Punch motor (M1P) drive signal Punch motor clock (PI2P) detection signal PUNCHCLK
Horizontal registration home position (PI1P) detection signal SREGHP
Horizontal registration motor (M2P) drive signal
Punch home position (PI3P) detection signal PUNCHHP
B.
PUNCH OPERATION
The hole puncher is driven by the punch motor (M1P). The hole puncher home position is detected by the punch home position sensor (PI3P). In all, there are four types of puncher units depending on the destination: 2-hole type (Puncher unit MJ-6003E), 2-/3-hole Dual Use (Puncher unit MJ-6003N), and two 4-hole types (Puncher unit MJ-6003F and Puncher unit MJ-6003S). With the 2-hole and 4-hole types, the hole puncher is moved reciprocally and punching is performed by the punch shaft rotating 180 from its home position. With the 2-/3-hole dual use type, too, the hole puncher is moved reciprocally and punching is performed by the punch shaft rotating 180 from its home position. However, half of the peripheral area of the punch shaft can be used as a 2-hole type while the other half can be as a 3-hole type. Whether the punch shaft is used as a 2-hole punch or a 3-hole punch depends on the instructions from the host machine. 1. 2-/4-hole Type At the home position, the punch home position sensor is ON. Punching of the first sheet ends when the punch shaft has rotated in the forward direction 180, and the state of the punch home position sensor has changed from OFF to ON. Punching of the second sheet ends when the punch shaft has rotated in the reverse direction 180, and the state of the punch home position sensor has changed from OFF to ON. The following illustrates punching when two sheets are punched. 1) A hole is punched in the trailing edge of the first sheet.
Sensor flag Punch home position sensor

(PI3P)
Punch shaft
Eccentric cam Die Die
Hole puncher Sheet Punched scrap [punch shaft rotated 90 in the forward direction / hole punched] [punch shaft rotated 180 in the forward direction / punch operation completed]
[punch shaft stopped/ home position]
Figure 4-202
4-7
2) A hole is punched in the trailing edge of the second sheet.
[punch shaft rotated 90 in the reverse direction/ hole punched]
[punch shaft rotated 180 in the reverse direction/ punch operation completed]
Figure 4-203
4-8
2.
2-/3-hole Dual Use Type At the home position, the punch home position sensor is ON. To punch two holes, punching of the first sheet ends when the punch shaft half peripheral area has rotated in the forward direction 180, and the state of the punch home position sensor has changed from OFF to ON. At this time, the 3-hole puncher is moved reciprocally in the escape direction (hole puncher rise direction) on the remaining half peripheral area on the punch shaft. Punching of the second sheet ends when the punch shaft half peripheral area has rotated in the reverse direction 180, and the state of the punch home position sensor has changed from OFF to ON. Also at this time, the 3-hole puncher is moved reciprocally in the escape direction (hole puncher rise direction) on the remaining half peripheral area on the punch shaft. To punch three holes, the 2-hole puncher is moved reciprocally in the escape direction (hole puncher rise direction). The following illustrates punching when two sheets are punched with two holes. 1) A hole is punched in the trailing edge of the first sheet.
Sensor flag Punch home position sensor (PI3P) Punch shaft
Eccentric cam Die Die
Hole puncher Sheet Punched scrap [punch shaft is rotated 90 in the forward direction/ hole punched] [punch shaft is rotated 180 in the forward direction/ punch operation completed]
Figure 4-204 When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction (hole puncher rise direction) as shown below.
[punch shaft is rotated 90 in the forward direction/ hole puncher rises to topmost position]
[punch shaft is rotated 180 in the forward direction/ hole puncher returns to original position]
Figure 4-205 4-9
2) A hole is punched in the trailing edge of the second sheet.
[punch shaft is rotated 90 in the reverse direction/ hole punched]
[punch shaft is rotated 180 in the reverse direction/ punch operation completed]
Figure 4-206 When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction (hole puncher rise direction) as shown below.
[punch shaft is rotated 90 in the reverse direction/ hole puncher rises to topmost position]
[punch shaft is rotated 180 in the reverse direction/ hole puncher returns to original position]
Figure 4-207
4-10
C.
Horizontal Registration Operation
Horizontal registration drive of the punch slide unit is performed by the horizontal registration motor (M2P). The home position of the punch slide unit is detected by the horizontal registration home position sensor (PI1P). The punch slide unit detects the trailing edge of the paper by the trailing edge sensor (LED5, PTR5) and horizontal registration sensors (LED1 to 4, SREG1 to 4) and is moved to the trailing edge position matched to the paper size. The following shows horizontal registration operation. 1) When the leading edge of the paper from the host machine is detected by the trailing edge sensor (LED5, PTR5) on the puncher unit, the horizontal registration motor (M2P) starts to move the punch slide unit towards the front.
Punch slide unit Horizontal registration motor (M2P)
Trailing edge detection sensor (LED5,PTR5)
Sheet delivery direction
Sheet
Figure 4-208
4-11
2) After the horizontal registration sensors (LED1 to 4, PTR1 to 4) detect the edge of the paper at its inner side in keeping with the paper size signals arriving from the host machine, the horizontal registration motor (M2P) drives the punch slide unit to a predetermined position further towards the front, and stops the unit at this position.
Horizontal registration sensor 1(LED1,PTR1) : detects the edge of A3, A4, LT, and LD papers Horizontal registration sensor 2 (LED2,PTR2) detects the edge of B4, B5, LT-R, and LG papers Horizontal registration sensor 3 (LED3,PTR3) : detects the edge of A4-R paper Horizontal registration sensor 4 (LED4,PTR4) : detects the edge of B5-R paper
Figure 4-209 3) When the trailing edge sensor (LED5, PTR5) detects the trailing edge of the paper, drive of the inlet feed motor (M9) and first feed motor (M1) on the finisher is stopped to stop paper feed. Next, the punch motor (M1P) is driven to punch holes in the paper.
Punch
Figure 4-210
4-12
4) When punching ends, drive of the inlet feed motor (M9) and first feed motor (M1) on the finisher is started, the horizontal registration motor (M2P) is operated in the reverse direction, and the punch slide unit is returned to its home position where it comes to a stop. 5) Even if paper to be punched continues to arrive, the punch slide unit returns to its home position for each arriving sheet, and steps 1 to 4 are repeated.
Trailing edge detection sensor (LED5, PTR5) Horizontal registration sensor (LED1 to 4, PTR1 to 4) Punch home position sensor (PI3P) Horizontal registration home position sensor (PI1P) Horizontal registration motor (M2P) Punch motor (M1P) Inlet feed motor (M9) First feed motor (M1) : Motor CW : Motor CCW
Figure 4-211
4-13
III. POWER SUPPLY SYSTEM

1. Outline 24V power and 5V power are supplied from the finisher controller PCB when the power switch on the host machine is turned ON. 24V power is used for driving motors, while 5V power is used for driving sensors and the ICs on the punch driver PCB. 24V power to the motors is not supplied when either of the two door switches on the puncher unit is open.
Front door switch (MS2P)
J23-4 J4-4 24V
24V
Motor system
Punch driver PCB 5V Sensors
J23-2 5V
J4-2 5V Logic
Figure 4-301 2. Protection Function The 24V power supplies for the punch motor (M1P) and horizontal registration motor (M2P) are equipped with a fuse designed to blow when an overcurrent flows.
4-14

1. This chapter discusses the purpose and role of each of the puncher units functions, and the principles of operation used for the puncher unit mechanical and electrical systems. It also explains the timing at which these systems are operated. The by symbol in drawings indicates transmission of mechanical drive, and signals marked together with the signal name indicates the flow of electrical signals.
2. In descriptions of digital circuits on the puncher unit, 1 or H indicates a high signal voltage level, while 0 or L indicates a low signal voltage level. Voltage values differ according to circuit. 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 .................... 5-1 A. Outline ....................................... 5-1 B. Symbols and Layout of Electric Parts/Diagram of Signal Blocks ............................. 5-2
C. Drive System ............................. 5-6 D. Operation ................................... 5-8 E. JAM/ERROR DETECTION AND LED DISPLAY .......................... 5-32 F. CIRCUIT .................................. 5-36
I.
A.
BASIC OPERATION
Outline
The inserter is a device to insert paper such as a cover sheet, thick paper and special paper without passing through the fuser unit in the copier. It can operate itself, so the paper fed at the inserter can be stapled at the finisher and punched at the hole punch unit.
Empty sensor Feed section Tray section Pickup roller Feed roller Transport roller 1 Separation sensor Transport roller 2 Paper length sensor Paper width detection volume Shutter Reverse roller Reverse path sensor Reverse section Vertical transport section Transport roller 4 Transport roller 5 Transport roller 3
Transport sensor Transport roller 6
Horizontal transport section
Stand
Figure 5-101
5-1
B.
1.
Symbols and Layout of Electric Parts/Diagram of Signal Blocks

Electric parts layout
TRYOPS SLENGS EMPS WIDTH
COV1S PKUPCL PUTSOL
TLENGS FAN FMOT
RVRS
RSOL TMOT COV2S TRANS
JOINSW JOINS
TMOT FMOT FAN RSOL PUTSOL JOINS COVIS EMPS SLENGS RVRS TRYOPS TLENGS COV2S TRANS JOINSW WIDTH
Transport motor Feed motor Fan motor Reverse solenoid Pickup trigger solenoid Joint sensor Transport cover 1 open/close sensor Empty sensor Separation sensor Reverse path sensor Tray open/close sensor Paper length sensor Transport cover 2 open/close sensor Transport sensor Joint switch Paper width detection volume
Figure 5-102
Table 5-101 5-2
2. Symbols 1) Motors
Symbol TMOT FMOT Name Transport motor Feed motor Functions Driving of the transport roller 3, 4, 5, 6 and transport roller 1, 2 Lifting and lowering of the pickup roller Opening of the shutte FAN Fan motor Cooling of the feed motor Fan motor Remarks Pulse motor
Driving of the pickup roller, feed roller, reverse roller Pulse motor
Table 5-102 2) Solenoid/Clutch

Symbol RSOL Name Reverse solenoid solenoid PKUPCL Pickup clutch Functions Switching of the flapper Controlling of the pickup roller lifting and lowering Controlling of the shutter opening Controlling of the rotation of the feed roller and pickup roller Electromagnetic clutch Remarks DC solenoid DC solenoid
PUTSOL Pickup trigger
Table 5-103 3) Switch/Sensor

Symbol JOINS COVIS EMPS SLGS EVRS Name Joint sensor Transport cover 1 open/close sensor Empty sensor Separation end sensor Reverse path sensor sensor TLENGS Paper length sensor COV2S TRANS WIDTH Transport cover 2 open/close sensor Transport sensor Paper width detection volume Paper detection on the horizontal transport section Connection detection to the copier Paper width detection on the tray Semiconductor sensor Micro switch Rotary volume JOINSW Joint switch Paper length detection on the tray Horizontal transport section cover open/close detection Semiconductor sensor Semiconductor sensor TRYOPS Tray open/close Paper detection on the feeding tray Paper length detection on the vertical transport section Paper detection at the reverse section Tray guide open/close detection Semiconductor sensor Semiconductor sensor Semiconductor sensor Semiconductor sensor Functions Joint open/close detection Vertical transport section cover open/close detection Remarks Semiconductor sensor Semiconductor sensor
Table 5-104
5-3
3.
Signal block layout
Copier
RXD1 SGND TXD1 SHOT_1 SHOT_2
Inserter
Communication circuit
Finisher
RXD2 SGND TXD2 SHOT_1 SHOT_2
JOINS COV1S EMPS SLENGS COV2S TRYOPS TLENGS RVRS TRANS WIDTH FAN EEPROM
Flash memory
Sensor input circuit
CPU
RSOL
PUTSOL PUPCL
Inserter operationl panel
Switch input circuit
Driver
FMOT
LED light ON circuit
TMOT
Power loss detection circuit

Irruptive current control circuit
DC +24V DC +24V DC +5V DC +5V DC +5V DC +24V
Figure 5-103
5-4
4.
Interface signals
The following signals are used in communicating data between copier and inserter, and finiser and inserter. Between copier and inserter RxD1: Signal sending data to copier from inserter TxD1: Signal sending data to inserter from copier Between finisher and inserter RxD2: Signal sending data to finisher from inserter TxD2: Signal sending data to inserter from finisher Since these data communications are done through a serial communication, a tester and such can not be used to check the signal sending/receiving.
RxD1
RxD2
TxD1
TxD1
Copier
Inserter
Finisher
Figure 5-104
5-5
C.
Drive System
1. When the feed motor rotates forward (clockwise rotation seen at the front side), the transport roller 1, 2 and reverse roller rotate. When the pickup solenoid is turned ON, the pickup roller and shutter are brought down and the feeding operation is started (transporting a paper to the reverse section when reversing).
One-way clutch Transport roller 1 Feed motor Transport roller 2 Pickup unit
Shutter
Front Reverse roller Pickup solenoid
Figure 5-105 2. When the feed motor rotates in reverse (counterclockwise rotation seen at the front side), the reverse roller rotates and transports a paper to the perpendicular transport section from the reverse section.
One-way clutch Transport roller 1 Feed motor Transport roller 2 Pickup unit
Shutter Front Reverse roller Pickup solenoid
Figure 5-106
5-6
3. Whe the transport motor rotates (clockwise rotation seen at the front side), the transport roller 3, 4, 5, 6 rotate.
Transport motor
Transport roller 3
Transport roller 4 One-way clutch

Transport roller 5
Front Transport roller 6
Figure 5-107
5-7
D.
1.
Operation
Feeding/Transporting operation (Simplicial operation, A4/LT)
1) The empty sensor is turned ON when papers are set on the tray.
Figure 5-108 2) The feed motor starts to rotate forward at a low speed, and the transport roller 1, 2 and reverse roller then start to rotate. The pickup clutch and pickup trigger solenoid turn ON, and the pickup roller and feed roller start to rotate. At this time, the shutter is brought down and the pre-feeding begins at the same time the pickup roller goes down. (The pickup trigger solenoid is being absorbed for a specified time and then released, and the rotation of the feed motor makes the pickup roller and shutter return to their uprising position.) The separation sensor detects the leading edge of the pre-fed paper and then turns ON. 3) When the separation sensor has detected the leading edge of the pre-fed paper and turned ON, the transport motor starts to rotate forward at a low speed and the transport roller 3, 4, 5, 6 rotate to prepare the feeding operation. When the leading edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn ON, the pickup clutch turns OFF. (Both the pickup and feed rollers stop rotating.)
Figure 5-109
Figure 5-110 5-8
When the paper has been transported even more distance, the feed motor stops rotating. (The transport roller 1,2 and reverse roller stop rotating.) The leading edge of the paper reaches the pre- feeding position (over 10mm short of the transprot roller 3). 4) When the feed motor starts to rotate forward at a low speed, the transport roller 1, 2 and reverse roller start to rotate and feed, too. The transport sensor detects the leading edge of the paper and turns ON.
Figure 5-111 5) The paper is transfered to the finisher, and the transport sensor detects the trailing edge of the paper and turns OFF. After the transport sensor has turned OFF, the paper is transported a specified distance by the transport roller 6. At this time, the transport motor accelerates to a high speed and prepares the next feeding operation.
Figure 5-112 6) The pickup clutch and pickup trigger solenoid turn ON and the pickup and feed rollers start to rotate. The pickup clutch and pickup trigger solenoid turn ON and the pickup roller and feed roller start to rotate. At this time, the shutter is brought down and the pre-feeding begins at the same time the pickup roller is lowered. (The pickup trigger solenoid is being absorbed for a specified time and then released, and the rotation of the feed motor makes the pickup roller and shutter return to the uprise position.) Separation sensor detects the leading edge of the pre-fed paper and turns ON.
Figure 5-113 5-9
7) When the leading edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn ON, the pickup clutch turns ON. (Both the pickup and feed rollers stop rotating.) After the paper has been transported even more distance, the feed motor stops rotating. (The tranport roller 1, 2 and reverse roller stop rotating, too.) The leading edge of the paper reaches the pre-feeding position (over 10mm short of the transport roller 3). Figure 5-114 8) The feed motor starts to rotate forward at a high speed, and the transport roller 1, 2 and reverse roller start to rotate to begin the next feeding operation. The empty sensor detects the trailing edge of the paper and turns OFF. When the trailing edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn OFF, the feed motor stops rotating. (The transport roller 1, 3 and reverse roller stop rotating, too.) The transport sensor detects the leading edge of the paper and turns ON. Figure 5-115 9) The paper is transported to the finisher and the trailing edge of the paper makes the transport sensor turn OFF. When the trailing edge of the paper has been transported a specified distance by the transport roller 6, the transport motor stops rotating. (The transport roller 3, 4, 5, 6 stop rotating, too.)
Figure 5-116
5-10
2.
Feeding/Transporting operation (Normal operation, A4/LT)
1) The empty sensor turns ON when papers are set on the tray.
Figure 5-117 2) The feed motor starts to rotate forward at a low speed, and the transport roller 1, 2 and reverse roller start to rotate. Then the pickup clutch and pickup trigger solenoid turn ON, and the pickup roller and feed roller start to rotate. At this time, the shutter is brought down to prepare the prefeeding at the same time the pickup roller is lowered. (The pickup trigger solenoid is being absorbed for a specified time and then released, and the rotation of the feed motor makes the pickup roller and shutter return to the uprise position.) Separation sensor detects the leading edge of the pre-fed paper and then turns ON. 3) When the separation sensor has detected the leading edge of the pre-fed paper and turned ON, the transport motor starts to rotate forward at a high speed and the transport roller 3, 4, 5, 6 rotate to prepare feeding. When the leading edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn ON, the pickup clutch turns OFF. (Both the pickup and feed rollers stop rotating.) When the paper has been transported even more distance, the feed motor stops rotating. (The transport roller 1,2 and reverse roller stop rotating.) The leading edge of the paper reaches the pre- feeding position (over 10mm short of the transprot roller 3).
Figure 5-118
Figure 5-119
5-11
4) When the feed motor starts to rotate forward at a high speed, the transport roller 1, 2 and reverse roller start to rotate to prefeeding. When the trailing edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn OFF, the feed motor decelerates to a low speed to prepare the next pre-feeding. The transport sensor detects the leading edge of the paper and turns ON.
Figure 5-120 5) After the feed motor has finished decelerating, the pickup clutch and pickup trigger solenoid turn ON, and both the pickup and feed rollers start to rotate. At this time, the shutter is brought down to prepare the prefeeding at the same time the pickup roller is lowered. (The pickup trigger solenoid is being absorbed for a specified time and then released, and the rotation of the feed motor makes the pickup roller and shutter return to the uprise position.) The paper is transported to the finisher, and the transport sensor detects the trailing edge of the paper and turns OFF. The separation sensor detects the leading edge of the next pre-feeding paper and turns ON. 6) When the leading edge of the paper has been transported a specified distance by the transport roller 2 after turning ON the separation sensor, the pickup clutch turns ON. (Both the pickup and feed rollers stop rotating.) After the paper has been transported even more distance, the feed motor stops rotating. (The transport roller 1, 2 and reverse roller stop rotating, too.) The leading edge of the paper reaches the pre-feeding position (over 10mm short of the transport roller 3). Figure 5-122
Figure 5-121
5-12
7) The feed motor starts to rotate forward at a high speed, and the transport roller 1, 2 and reverse roller start to rotate to begin the next feeding. The empty sensor detects the trailing edge of the paper and turns OFF. When the trailing edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn OFF, the feed motor stops rotating. (The transport roller 1, 2 and reverse roller stop rotating, too.) The transport sensor detects the leading edge of the paper and it turns ON. Figure 5-123 8) The paper is transported to the finisher and the trailing edge of the paper makes the transport sensor turn OFF. When the trailing edge of the paper has been transported a specified distance by the transport roller 6, the transport motor stops rotating. (The transport roller 3, 4, 5, 6 stop rotating, too.)
Figure 5-124
5-13
3.
Reverse feeding/Transporting operation (Normal operation, A4/LT)
1) The empty sensor turns ON when papers are set on the tray.
Figure 5-125 2) The feed motor starts to rotate forward at a low speed, and the transport roller 1, 2 and reverse roller start to rotate, too. Then the pickup clutch and pickup trigger solenoid turn ON, and both the pickup and feed rollers start to rotate and the reverse solenoid turns ON to switch the transport path toward the reverse section. At this time, the shutter is brought down to prepare the pre-feeding operation at the same time the pickup roller is lowered. (The pickup trigger solenoid is being absorbed for a specified time and then released, and the rotation of the feed motor makes the pickup roller and shutter return to their uprising position.) Separation sensor detects the leading edge of the pre-fed paper and then turns ON. 3) When the leading edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn ON, the pickup clutch turns OFF. (Both the pickup and feed rollers stop rotating.) The reverse path sensor detects the leading edge of the paper and turns ON. The paper is transported even more, and the separation sensor detects the trailing edge of the paper and turns OFF.
Figure 5-126
Figure 5-127
5-14
4) When the trailing edge of the paper has been transported a specified distance after making the separation sensor turn OFF, the feed motor stops rotating. (The transport roller 1, 2 and reverse roller stop rotating, too.) Shortly before the feed motor stops rotating, the reverse path sensor detects the trailing edge of the paper and turns OFF. The reverse solenoid turns OFF and the transport path is switched. The paper reaches the temporal stop position at the reverse section (the position where the leading few score milimeters paper is nipped with the reverse roller). 5) After the reverse path sensor has turned OFF, the feed motor starts to rotate in reverse at a low speed, and the reverse roller starts to rotate to begin the transporting operarion to the reverse pre-feeding position. When the reverse path sensor has detected the leading edge of the reversed paper, the transport motor starts to rotate forward. (The transport roller 3, 4, 5, 6 start to rotate to prepare feeding of the reversed and pre-fed paper.) When the feed motor drives for a specified distance, it stops rotating. (The reverse roller stops rotating, too.) The leading edge of the reversed paper has reached the pre-feeding position (over 10mm short of the transport roller 3). 6) When the feed motor starts to rotate in reverse, the reverse roller starts to rotate to begin the feeding operation. After the trailing edge of the paper has made the reverse path sensor turn OFF, the feed motor stops rotating to prepare the next reverse pre-feeding operation. (The reverse roller stops rotating, too.) The transport sensor detects the leading edge of the reversed paper and turns ON.
Figure 5-128
Figure 5-129
Figure 5-130
5-15
7) The feed motor starts to rotate forward, and the transport roller 1, 2 and reverse roller start to rotate, too. Then the pickup clutch and pickup trigger solenoid turn ON, and the pickup roller and feed roller start to rotate and the reverse solenoid turns ON to switch the transport path toward the reverse section. At this time, the shutter is brought down to prepare the pre-feeding at the same time the pickup roller is lowered. (The pickup trigger solenoid is being absorbed for a specified time and then released, and the rotation of the feed motor makes the pickup roller and shutter return to their uprising position.) Separation sensor detects the leading edge of the pre-fed paper and turns ON. At the same time, the paper which has been transported first is transported to the finisher, and the transport sensor detects the trailing edge of the paper and then turns OFF. 8) When the leading edge of the paper has been transported a specified distance by the transport roller 2 after making the separation sensor turn ON, the pickup clutch turns ON. (Both the pickup and feed rollers stop rotating.) The reverse path sensor detects the leading edge of the paper and turns ON. The empty sensor detects the trailing edge of the paper and turns OFF. The separation sensor detects the trailing edge of the paper and turns OFF.
Figure 5-131
Figure 5-132
5-16
9) When the trailing edge of the paper has been transported a specified distance after making the separation sensor turn OFF, the feed motor stops rotating. (The transport roller 1, 2 and reverse roller stop rotating, too.) Shortly before the feed motor stops rotating, the reverse path sensor detects the trailing edge of the paper and then turns OFF. The reverse solenoid turns OFF and the transport path is switched. The paper reaches the temporal stop position at the reverse section (the position where the leading few score milimeters paper is nipped with the reverse roller). 10) After the reverse path sensor has turned OFF, the feed motor starts to rotate in reverse at a low speed, and the reverse roller starts to rotate to begin the transporting operationg to the reverse pre-feeding position. When the leading edge of the reversed paper makes the reverse path sensor turn ON, the feed motor stops rotating after driving a specified distance. (The reverse roller stops rotating, too.) The leading edge of the reversed paper reaches the pre-feeding position (over 10mm short of the transport roller 3).
Figure 5-133
Figure 5-134 11) When the feed motor starts to rotate in reverse at a high speed, the reverse roller starts to rotate to begin the feeding operation. Aftr the trailing edge of the paper has made the reverse path sensor turn ON, the feed motor stops rotating to prepare the next prefeeding operation. (The reverse roller stops rotating, too.) The transport sensor detects the leading edge of the paper and turns ON.
Figure 5-135
5-17
12) The reversed paper is transported to the finisher, and the trailing edge of the paper makes the transport sensor turn OFF. The transport motor stops rotating when the trailing edge of the paper has passed a specified distance from the transport roller 6. (Transport roller 3, 4, 5, 6 stop rotating, too.)
Figure 5-136
5-18
4.
Paper size detection
Each size of the paper feeding and widthwise directions is detected, and their combination decides a paper size. 1) Paper widthwise direction size detection The paper widthwise direction size is detected in real time by a value of the paper width detection volume inside the tray. 2) Paper feeding direction size detection When carrying out a pre-feeding operation, the number of motor pulses during the period after the separation sensor has detected the leading edge of the paper until it detects the trailing edge of the paper is counted. Then the paper feeding direction size is decided depending on this number of pulses.
Feeding direction ~ 196mm ~ 165mm ~ 196mm ~ 237mm ~ 269mm ~ 289mm ~ 314mm ~ 343mm ~ 392mm ~ 445mm 446mm ~ * : Not determined B5-R ~ 236mm 8.5 8.5 LT-R A4-R FOLIO LG Widthwise direction ~ 268mm B5 B4 ~ 288mm LT LD ~ 317mm A4 A3 318mm ~
Table 5-105
5-19
5.
Flow chart
Power ON
Power ON
Is jig board installed?
NO
YES
Program updating
Data reading from EEPROM
Program updated IPC board initializing
Communication started
Figure 5-137
5-20
Are all covers closed?
NO
YES
Is jam occured?
YES
NO
Initializing
YES
Is there any cover opened?
NO
Is jam detected during initializing?
YES
Is job finished?
NO
NO
YES
YES
NO
Is jam occured?
YES
NO
NO
YES
NO
Is job started?
YES
Operation processing started
Figure 5-138
5-21
Paper no removal detection processing

Initializing started
Does any sensor on transport path detect paper?
YES
NO
Has a specified time passed after a loop process of paper no removal detection started?
Feed motor rotated in reverse
YES
Do separation sensor and transpor sensor detect paper?
NO
Has a specified time passed after a loop process of paper no removal detection started? Does reverse path sensor detect paper?
NO
Loop process of paper no removal detection
YES
Initializing finished
Loop process of paper no removal detection
Feed motor rotated forward
Jam
Transport motor rotated forward
Figure 5-139 5-22
Job standby
Copier paper path operation Inserter simple body operation
Is finisher operational signal set?

YES
NO
Is only inserter operation start switch ON?

YES
NO
Simple body request signal cleared
Fan motor ON
Simple body request signal set
Is only inserter operation response signal cleared?

NO
YES
Operational processing program started
Is only inserter operation response signal set?

YES
NO
Job finished
Is finisher operational signal cleared?

YES
NO
Fan motor ON
Fan motor OFF
Operational processing program started
Job finished
Is there any paper on the tray?

NO
YES
Fan motor OFF
Figure 5-140
5-23
Pre-feeding control 1
Inserting paper pre-feeding started
1
Pickup trigger Is pre-feeding allowed?

YES NO
solenoid ON
Is feed motor driving at low speed?

NO
YES
Pickup clutch ON
NO
Is feed motor stopped?

YES
Is reverse feeding operating?

YES NO
NO
Is separation sensor ON?

YES
NO

YES
Reverse solenoid ON
Paper length detection started
Reverse solenoid ON
Is transport motor driving?

NO
YES
Feed motor rotating forward
Transport motor rotating forward
NO
Is feed motor driving at normal speed?

YES 1
Figure 5-141
5-24
Pre-feeding control 2
C 1
Has paper leading edge passed specified distance from transport roller 2?
NO
Feed motor stopped
YES
Pickup clutch OFF
Reverse solenoid OFF

YES
NO
Feed motor rotating in reverse
Is reverse path sensor ON?

YES
NO
Is reverse path sensor ON?

YES
NO
Is separation sensor OFF?

YES
NO
Has paper reached pre-feeding position?
NO
YES
Feed motor stopped
Has paper reached reverse section temporal stop position?
NO
Pre-feeding finished
YES 1
Figure 5-142
5-25
Pre-feeding position standby control

Pre-feeding position standby control started
Is only inserter operating?
YES
NO
NO
Is there any paper before transported paper?
YES NO
1st paper?
YES 2
Pre-feeding waiting time<0?

YES
NO
Has previous paper transpoting operation finished?
NO
YES
YES
Is transport motor driving?

NO
Pre-feeding operation started
Transport motor driving
Pre-feeding position standby control finished
Is transport motor driving normally?

YES
NO
Figure 5-143
5-26
Paper transporting control 1

Paper transporting control 1 started
Straight feeding?
NO
YES
Feed motor rotating forward
Feed motor rotating in reverse
NO
Has paper leading edge reached transport roller 3?
YES
Paper transporting control 1 finished
Figure 5-144
5-27

Straight feeding?
YES
NO
Is separation sensor OFF?

YES
NO
Is reverse path sensor OFF?

YES
NO
Feed motor stopped
Has paper trailing edge passed specified distance from transport roller 2?
NO
YES
Is there next pre-feeding sign?

YES
NO
Feed motor changed to low speed
Feed motor stopped
Figure 5-145
5-28

Has paper reached transport roller 4?
NO
YES
Is transport sensor ON?
NO
YES
Has paper reached transport roller 6?
NO
YES
Figure 5-146
5-29

1
Has paper passed transport roller 3?

YES
NO
Has job been finished?

NO
YES
Has paper passed transport roller 4?

YES
NO
Is only inserter operating?

YES
NO
Transport motor stopped
YES
Has transporting speed been received?

NO
Is transport sensor OFF?

YES
NO
Transport motor driving
Transport motor stopped
Has paper trailing edge passed specified distance from transport roller 6?
NO
YES
Figure 5-147
5-30
Copier paper discharging through transport control

Copier paper discharging through transport control started
Discharging signal receiving counter>0?
NO
YES
NO
YES
Is transport sensor ON?
NO
YES
Has specified distance been passed since transport sensor ON?
NO
YES
NO
YES
Has specified distance been passed from transport roller 5?
NO
YES
Copier paper discharging through transport control finished
Figure 5-148
5-31
E.
JAM/ERROR DETECTION AND LED DISPLAY
1. Jams 1-1) Feeding disabled jam An inserter feeding disabled jam occurs when the inserter operation demand signal is sent from the copier while the inserter is in a feeding disabled condition (ex., no paper on the tray, cover opened, jam occuring,initializing being operated). 1-2) Size difference jam An inserter size difference jam occurs when the paper size information sent to the inserter from the copier and the size detected at the inserter are different. 1-3) Jam at power on A jam at power on occurs when either of the separation sensor, reverse path sensor and transport sensor detects a paper in turning ON the power while the inserter joint sensor, transport cover 1 open/close sensor and tray open/close sensor are detected to be closed. 1-4) Door open jam A door open jam occurs when either of the joint sensor, transport cover open/close sensor and tray open/close sensor is opened during the inserter operation. 1-5) Transport delay jam in feeding A feeding delay jam occurs when the leading edge of the paper does not turn ON the separation sensor even after the number of the feed motor pulses corresponding to 5 times as long as the distance, which is taken to transport a paper from where it is when the pickup clutch is turned ON at the separation to where the leading edge of the paper turns ON the separation sensor, is counted. 1-6) Transport stop jam in feeding a. When reversal feeding is not operated: An inserter transport stop jam in feeding occurs when the trailing edge of the paper does not pass the separation sensor during the pre-feeding even after the number of the feed motor pulses corresponding to the distance, which is taken to transport a maximum-sized paper from where it is when the feed motor starts to rotate forward to where the trailing edge of the paper passes the separation sensor, plus 30mm is counted. b. When reversal feeding is operated: An inserter transport stop jam in feeding occurs when the trailing edge of the paper does not pass the separation sensor during the reversal feeding even after the number of the feed motor pulses corresponding to the distance, which is taken to transport a maximumsized paper from where the leading edge of the paper turns ON the separation sensor to where the trailing edge of the paper turns OFF the separation sensor, plus 30mm is counted. 1-7) Transport delay jam at reverse path 1 An inserter transport delay jam at reverse path 1 occurs when the reverse path sensor does not detect the leading edge of the paper during the reversal feeding even after the number of the feed motor pulses corresponding to the distance, which is taken to transport a paper from where the leading edge of the paper turns ON the separation sensor to where the trailing edge of the paper turns OFF the separation sensor, plus 30mm is counted.
5-32
1-8) Transport stop jam at reverse path 1 An inserter transport stop jam at reverse path 1 occurs when the separation sensor still detects the paper during the reversal feeding even after the number of the feed motor pulses corresponding to the distance, which is taken to transport a paper from where the trailing edge of the paper passes the separation sensor to the reverse section temporal stop position, plus 17mm is counted. 1-9) Transport delay jam at reverse path 2 An inserter transport delay jam at reverse path 2 occurs when the reverse path sensor is not turned ON during the reversal feeding even after the number of the feed motor pulses corresponding to the distance, which is taken to transport a paper from where the paper is when the feed motor starts to rotate in reverse at the reverse section temporal stop position to where the leading edge of the paper turns ON the reverse path sensor, plus 60mm is counted. 1-10) Transport stop jam at reverse path 2 An inserter transport stop jam at reverse path 2 occurs when the transport path sensor remains ON during the reversal feeding even after the number of the feed motor pulses corresponding to the distance, which is taken to transport a paper from where the paper is when the feed motor starts to rotate forward at the pre-feeding position to where the trailing edge of the paper turns OFF the reverse path sensor, plus 30mm is counted. 1-11) Transport delay jam 1 A transport delay jam 1 occurs when the transport sensor is not turned ON even after the number of the transport motor pulses corresponding to the distance, which is taken to transport a paper before passing the transport roller 4 to where the leading edge of the paper turns ON the transport sensor plus 100mm is counted. 1-12) Transport stop jam 1 A transport stop jam 1 occurs when the transport sensor is not turned OFF even after the number of the transport motor pulses corresponding to the distance, which is taken to transport a paper before passing the transport roller 4 to where the trailing edge of the paper turns OFF the transport sensor, plus 30mm is counted. 1-13) Transport delay jam 2 A transport delay jam 2 occurs, during the time after the inserter receives a paper exit signal from the copier until the leading edge of the paper turns ON the inserter transport sensor, when the transport sensor is notturned ON and the inserter has received the next paper exit signal after the number of the transport motor pulses corresponding to twice as long as the distance from the copier exit roller to the inserter transport sensor is counted. 1-14) Transport stop jam 2 A transport stop jam 2 occurs when the transport sensor is not turned ON in transporting paper from the copier even after the number of the transport motor pulses corresponding to the distance, which is taken to transport a maximum-sized paper from where the leading edge of the paper turns ON the transport sensor to where the trailing edge of the paper turns OFF the transport sensor, plus 60mm is counted.
5-33
2. Errors 2-1) Communication error a. A communication error occurs when the initialization is not finished in a regulation time even if the operation is repeated up to 3 times. b. A communication error occurs when the IPC is not in the operable condition within the regulation time after the IPC initialization is finished. 2-2) EEPROM error a. An EEPROM error occurs when either of the EEPROM clearing, reading and writing operations is not finished within the regulation time. b. An EEPROM error occurs when the writing data does not correspond to the readout data during the EEPROM writing operation. 2-3) Fam motor error A fan motor error occurs when the fan motor is detected to be locked for more than the regulation time while it is being drived.
5-34
3.
LED display The type of jam and error is confirmed by the mode LED of the inserter control panel, and the start LED illuminates red when a jam or an error occurs.
LED1 Feeding disabled jam Size difference jam Power ON jam Door open jam Transport delay jam in feeding Transport stop jam in feeding Transport delay jam at reverse path 1 Transport stop jam at reverse path 1 Transport delay jam at reverse path 2 Transport stop jam at reverse path 2 Transport delay jam 1 Transport stop jam 1 Transport delay jam 2 Transport stop jam 2 Communication error EEPROM error Fan motor error : Blinking : Light ON : Light OFF LED2 LED3 LED4
Table 5-106
Mode LED Punch LED

LED1 LED2 LED3 LED4
Start LED
Punch key
Mode key
Start key
Figure 5-149
5-35
F.
1.
CIRCUIT
Irruptive current control circuit This is a circuit for controlling to keep the irruptive current running into the current regenerative capacitors, which are comprised in the motor drive circuit, below a certain amount. It is composed of the PTC thermistor (PTH1) controlling the current and FET (Q20) applying the current on a steady basis. The base current is not supplied to Q18 after the joint switch has been turned ON until the ZD2 cathode voltage reaches the zener voltage by R61 and C63, and during Q20 being OFF, the current flows into the PHT1 and the current regenerative capacitors are then charged. After the current regenerative capacitors are fully charged up, and when the ZD2 cathode voltage exceeds the zener voltage by R62 and C63, the base current is supplied to Q18, which is then turned ON, and Q20 is turned ON. By this, the current, which has been running into the PHT1 heartofore, runs into Q20 and the current limit is released. R63 is a resistance to discharge the charges stored in the current regenerative capacitors as soon as the joint switch is turned OFF. Also, the circuit composed of the PHT2 and D8 is for discharging the charges stored in C63 as soon as the joint switch is turned OFF and controlling the incoming corrent even for the momentary cover open/close.
Figure 5-150
5-36
2.
Drive circuit for transport motor This circuit controls the activation, stopping, excitation mode and motor current of the transport motor. The motor rotating direction and speed are controlled by putting the drive pattern signal into IC4-5,6,16,17 pins. Also, the motor current is dicided by inputting the voltage of the D/A converter from the CPU into the H_MOT_REF, dividing the voltage at R 125 and R127, switching the control signal at the circuit composed of the H_REF_1, H_REF_2 and H_REF3 and inputting the signal into IC4-3,14 pins. The motor current can be changed by altering the voltage of the D/A converter.
Figure 5-151
5-37
3.
Drive circuit for feed motor This circuit controls the activation, stopping, rotating direction, excitation mode and motor current of the feed motor. The motor rotating direction and speed is controlled by inputting the drive pattern signal into IC9-13,14,15,16 pins. Also, the motor current is dicided by inputting the voltage of the D/A converter from the CPU to the K_MOT_REF, dividing the voltage at R126 and R107 and inputting the voltage to IC9-9 pin. The motor current can be changed by altering the voltage of the D/A converter.
Figure 5-152
5-38
4.
Drive circuit for reverse solenoid, pickup trigger solenoid and pickup clutch This circuit controls ON/OFF of the reverse solenoid, pickup trigger solenoid and pickup clutch. When the HF_SOL is in the H level, Q19 is turned ON and the reverse solenoid is closed, and when the PT_SOL is in the H level, Q1 is turned ON and the pickup solenoid is closed, and when the B_CL is in the H level, Q2 is turned ON and the pickup clutch is turned ON. The solenoid drive signal is a PWM signal and the duty value becomes 100% when the flapper starts to be opened/closed, but after finishing closing, the duty value is decreased down to 50% to lower the temperature rising of the solenoid.
Figure 5-153
5-39
5.
Drive circuit for fan motor This circuit controls the rotation and stopping of the fan motor. When the output level of the CPU is H, Q11 and Q16 are turned ON and the fan motor activates. At this time, a lock detention signal is output from the fan motor and sent to the CPU. The level of the lock detection signal is L during a normal operation and becomes H during an abnormal operation.
Figure 5-154
5-40
6.
Reset circuit This circuit generates a CPU reset signal when the power is turned ON and the power voltage is lowered. It has a watchdog timer for diagnasis of the CPU system operation. The level of IC7-8pin (*RES) is normally H after the power is turned ON. However, when the power is turned OFF or the voltage of the +5V power sopply is decreased to 4.2V or lower for some reason, the level of IC7-8 pin becomes L and the CPU is reset. A clock with a fixed cycle is input into IC7-8 pin (CK) from the CPU to clear the watchdog timer of IC7. If the clock is not input from the CPU due to a system error and such, the level of IC7-8 pin becomes L to reset the CPU and the system operation is stopped.
Figure 5-155
5-41
7.
EEPROM circuit This circuit is an EEPROM to store data and its peripheral circuit. IC5 is a memory to store the adjustment value for the tray volume resistance, and data are sent/received between the CPU and IC5 through the serial interface. Data once saved in IC5 is not deleted when the power is turned OFF. IC5-1 pin (CS) : A chip selection terminal, which level is H when data are being sent/received IC5-2 pin (SK) : A serial clock terminal to which the serial data are sent in synchronization with the clock input. IC5-3 pin (DI) : An input terminal for serial data IC5-4 pin (DO) : An output terminal for serial data
Figure 5-156
5-42
8.
Control circuit for control panel This circuit is composed of the key input circuit for the control panel and LED display circuit. The circuit for CN15-4,5,6 pins is the key input circuit for the control panel, and the input signal for each key is L level when being ON and H level when being OFF. The circuit for CN15-7~14 pins is the LED display circuit, and each LED signal lights off when being H level and lights on when being L level.
Figure 5-157
5-43
9.
Circuit for control panel This circuit is for the control panel board. By receiving signals from the control panel control circuit, the LED2~7 are lighted off/on and also the inputs into the PWS1~3 are detected.
Punch LED Mode LED 1 Mode LED 2 Mode LED 3 Mode LED 4 Punch key Mode key Start key Start LED 1 Start LED 2
Figure 5-158
5-44
10. Inupt/Output signals 1) TXD signal This circuit is an output circuit for communication with the copier and finisher, and the output is H for 5V and L for 0V. The logic for the connector and that for the CPU port are the same.
Copier
Finisher
Figure 5-159 2) RXD signal This circuit is an input circuit for communication with the copier and finisher, and the input is H for 5V and L for 0V. The logic for the connector and that for the CPU port are the same.
Copier
Finisher
Figure 5-160
5-45
3) Input circuits for sensors This is an input detection circuit consisted of each sensor, the volume resistance and power detection circuits.
Joint sensor
Transport cover 1 open/close sensor
Empty sensor
Separation sensor
Reverse path sensor
Transport sensor
Tray open/close sensor
Paper length sensor
Paper width detection volume
Transport cover 2 open/close sensor
Power detection circuit
Figure 5-161 5-46
The following is the logic for the input signals of the circuit for sensors.
Name Joint sensor Transport cover 1 open/close sensor Empty sensor Separation sensor Reverse path sensor Tray open/close sensor Paper length sensor Transport cover 2 open/close sensor Transport sensor Connector level 5V Not connected to the copier Cover closed No paper Paper existing Paper existing Tray closed Paper existing Cover opened Paper existing Connector level 0V Connected to the copier Cover opened Paper existing No paper No paper Tray opened No paper Cover closed No paper
Table 5-107
Name Paper width detection volume Connector level more than 4V Guide width maximum Connector level within 2.5V Guide width minimum
Table 5-108
5-47

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 .......................... 6-1 A. Externals and Controls .............. 6-1 B. FEEDING SYSTEM ................... 6-9 C. PCBs........................................ 6-13 II. SADDLE STITCHER UNIT ........ 6-14 A. Externals and Controls ............ 6-14 B. SADDLE UNIT ......................... 6-17 C. PCBs........................................ 6-27 D. Accessory ................................ 6-28 III. PUNCHER UNIT (OPTION) ...... 6-29
A. Externals and Controls ............ 6-29 B. Puncher Driver System ............ 6-30 C. PCBs ........................................ 6-41 IV. INSERTER UNIT (OPTION) ...... 6-43 A. Exterior Parts ........................... 6-43 B. Feeding Section ....................... 6-44 C. Drive Section ........................... 6-46 D. Upper Inserter Unit .................. 6-49 E. Tray Unit ................................... 6-50 F . Notes for Installing ................... 6-52
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 6-101
[12]
[10]
[13]
[11]
Figure 6-102
6-1
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 6-103
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 6-104
6-2
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 6-105
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 6-106
6-3
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 6-107 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 6-108 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 6-109
6-4
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 6-110 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 6-111 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 6-112
6-5
5) Disconnect the connector [1], and remove the two screws [2].
[2]
[1]
Figure 6-113 6) Pull out the motor slightly, and remove the parallel pin [1] and the motor.
[1]
Figure 6-114
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 6-115
6-6
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 6-116 4) Free the harness [9] from the harness stop [8]. 5) Disconnect the two connectors [10], and remove the grate-shaped lower guide [7].
[10] [8]
[9]
[7]
Figure 6-117
6-7
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 6-118 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 6-119
6-8
B.
FEEDING SYSTEM
[1]
[4]
1. 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 connectors [2]. 5) Remove the screw [3], and remove the stapler stay holder [4].
[3] [2]
Figure 6-120 6) Remove the three screws [5], and slide out the swing unit [6] towards you.
[5] [6]
[5]
[5]
Figure 6-121 7) Remove the claws of the two knurled belt holders (front [7a], rear [7b]) and remove the swing unit.
[7a]
Figure 6-122a 6-9
[7b]
Figure 6-122b 2. Removing the Feed Drive Unit 1) Remove the finisher controller PCB (see IC-1). 2) Remove the ground lead [1] and the three screws [2], and pull down PCB base [3] towards you.
[2] [3]
[2]
[1]
Figure 6-123 3) Remove the harness leads [5] from the two edge saddles [4], and remove the PCB base.
[5] [4] [4]
Figure 6-124 6-10
4) Remove the three screws [6], and remove the feed drive unit [7].
[7]
[6]
[6] [6]
Figure 6-125 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. 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.
[8]
Figure 6-126 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]
[3]
[2]
Figure 6-127
6-11
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 6-128 4. Removing the Stapler 1) Open the front cover, and move the stapler assembly to the front. 2) Remove the screw [1], and slide out the stapler assembly [2].
[2]
[1]
Figure 6-129 3) Disconnect the connector [4] of the stapler assembly [3].
[4]
[3]
Figure 6-130 6-12
4) Remove the two screws [6] from the stapler cover [5], and remove the stapler.
[6]
[5]
Figure 6-131
C.
1.
PCBs
[2]
Removing the Finisher Controller PCB 1) Remove the rear cover. 2) Disconnect the 17 connectors [1]. 3) Remove the four screws [2], and remove the finisher controller PCB [3].
[3]
[2] [2]
[1]
Figure 6-132
6-13
II.
A.
1.
SADDLE STITCHER UNIT

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 6-201 2. Removing the Rear Lower Cover 1) Remove the four screws [1], and remove the rear lower cover [2].
[1] [1]
[2]
Figure 6-202
6-14
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 6-203 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 6-204 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 6-205 6-15
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 6-206 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 6-207 6. Removing the PCB Cover 1) Remove the four screws [1], and remove the PCB cover [2].
[1]
[2]
[1]
Figure 6-208 6-16
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 6-209
7) Remove harness stop [3] and harness lead [4]. 8) Remove the upper delivery guide (see IIA-5). 9) Remove the PCB cover (see II-A-6). 10) Disconnect two connectors [1] and remove the two screws [2].
[4]
[3]
Figure 6-210
6-17
11) Remove the screw [5].
[5]
Figure 6-211
[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 6-212 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 6-213 6-18
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 (see IIA-5). Remove the PCB cover (see II-A-6). Disconnect the two connectors [1].
[1]
Figure 6-214
6) Disconnect two connectors [2], remove the three screws [3], and remove the paper pushing motor mount [4].
[4]
[2]
[3]
[2]
Figure 6-215
6-19
7) Remove the tension springs (front [5], rear [6]).
[5]
Figure 6-216
[6]
Figure 6-217
6-20
8) Remove the two C-rings [7], and remove the sensor flag [8] and two bearings [9] at the rear.
[9] [7]
[8]
Figure 6-218 9) Remove the two C-rings [10], and remove the two gears [11] at the front.
[11] [10]
Figure 6-219
6-21
10) Remove the two bearings [12].
[12]
Figure 6-220
[ 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 6-221 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 6-222 6-22
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 6-223 3) Pull out the stitcher mount unit [4] to the front.
[4]
Figure 6-224
5. 1) 2) 3) 4)
Adjusting the Stitcher Position Remove the front lower door (see II-A-1). Remove the front inside cover (see II-A-3). Open the front door assembly. 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 6-225
6-23
6) Remove the stitcher positioning tool [3] from the back of the cover.
[3]
Figure 6-226 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 6-227 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 6-228
6-24
9) Insert the tool [10] into the staple slot of the stitcher [9].
[9] [10]
Figure 6-229 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 6-230
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 stops [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 6-231
6-25
7.
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 deflecting plate shaft [2] toward the rear. (The procedure is the same for the No.2 paper deflecting plate.)
[1]
[2]
Figure 6-232 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 6-233
6-26
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 6-234
6-27
D.
1.
Accessory
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 suddle delivery tray (see II-A4). 2) Install the support tray [2] to the saddle delivery tray [1] with 2 screws.
[2]
[3] [1]
Figure 6-235 3) Install the saddle delivery tray.
Figure 6-236
6-28
III. PUNCHER UNIT (OPTION)

[1]
A.
[2]
[4]
[3]
[1] Upper cover (3) [2] Upper cover 2 [3] Front door [4] Right guide assembly (5) Figures in parentheses ( ) indicate the number of mounting screws.
Figure 6-301
[2]
1.
Removing the Right Guide Assembly 1) Remove the five screws [1], and remove the right guide assembly [2].
[1] [1]
Figure 6-302
6-29
2. Removing the Upper Cover 1) Open the front door [1], remove the three screws [2], and slacken the inner side of the right cover [3] to remove the upper cover [4] from the hook [5].
[4]
[4] [2] [1]
[5]
[2] [3]
Figure 6-303
B.
Puncher Driver System
[1]
[3] [2]
1. Removing the Punch Motor 1) Remove the upper cover (see III-A-2). 2) Disconnect the connector [1]. 3) Remove the two screws [2], and remove the punch motor [3].
Figure 6-304
6-30
2.
Removing the Horizontal Registration Motor 1) Remove the right guide assembly (see IIIA-1). 2) Disconnect the connector [1]. 3) Remove the two screws [2], and slide the horizontal registration motor [3] in the direction of the arrow.
[2]
[1]
[3]
Figure 6-305 3. Removing the Punch Unit Caution:

When removing the punch unit, the punch unit section sometimes opens. If necessary, perform work with the punch unit section in an open state.
1) Remove the right guide assembly (see IIIA-1). 2) Remove the upper cover (see III-A-2). 3) Remove the E-ring [1], washer [2] and puncher spring [3].
[3]
[2]
[1]
Figure 6-306
6-31
4) Turn the gear [4] in the direction of the arrow, and move the punch unit section [5] to the front side.
[5]
[4]
Figure 6-307
5) Remove the three screws [5], and remove the sensor mount (upper) [7]. Then, remove the connector on the photosensor PCB.
[6]
[8]
[6] [7] [6]
Figure 6-308
6-32
6) Disconnect the connector [9] and remove the screw [10], and remove the horizontal registration sensor [11].
[11]
[10]
[9]
Figure 6-309
7) Turn the gear [12] in the direction of the arrow, and move the punch unit section [13] to the inner side.
[13]
[12]
Figure 6-310
6-33
8) Remove the tie wrap with lock [14] while holding its claw between your fingers. (The tie wrap must be removed without being cut.) 9) Disconnect the three connectors [15] and remove the screw [16], and remove the harness guide [17].
[15]
[15]
[14] [16]
[17]
Figure 6-311 10) Lift up the front side of the punch unit section [18] first, then move in the direction of the arrow to remove the punch unit section [18].
[18]
Figure 6-312 11) Disconnect the connector [19] on the LED PCB.
[19]
Figure 6-313 6-34
12) Remove the slide shaft support [20], the sensor mount (lower) [21] and the puncher knob [22] from the punch unit section. Caution:
The slide shaft support [20] is not attached to punch unit sections that are currently set as consumable parts. When replacing the punch unit section, be sure to attach the slide shaft support that was in use beforehand. If you forget to attach the slide shaft support, the machine may malfunction.
[22]
[20]
[21]
Figure 6-314
6-35
4.
Removing the Punch Unit Harness Caution:

When removing the punch unit, the punch unit section sometimes opens. If necessary, perform work with the punch unit section in an open state.
[1]
1) Remove the punch unit from the finisher assembly. 2) Remove the right guide assembly (see IIIA-1). 3) Remove the upper cover (see III-A-2). 4) Disconnect the four connectors [2] on the punch driver PCB [1].
[2]
[2]
Figure 6-315
5) Remove the two tie wraps with lock [14] while holding its claw between your fingers. (The tie wraps must be removed without being cut.) 6) Disconnect the three connectors [4]. 7) Free the harness [6] from the three harness stops [5].
[4]
[4] [5] [3]
[5]
[3]
[6] [5]
Figure 6-316
6-36
8) Turn the gear [7] in the direction of the arrow, and move the punch unit section [8] to the front side.
[8]
[7]
Figure 6-317
9) Remove the three screws [9] and sensor mount (upper) [10]. Disconnect the connector [11] on the photosensor PCB and the connector [12] on the LED PCB.
[9]
[11]
[9] [10] [12] [9]
Figure 6-318
6-37
10) Draw out the punched scrap container [13].
[13]
Figure 6-319
11) Remove the two tie wraps with lock [14] while holding its claw between your fingers. (The tie wraps must be removed without being cut.)
[14]
Figure 6-320
12) Disconnect the three connectors [15], and free the harness [16] from the harness stop [17].
[15]
[17] [16]
Figure 6-321
6-38
13) Free the harness [19] from the four harness stops [18].
[18]
[18]
[19] [18]
Figure 6-322
14) Disconnect the connector [20] of the horizontal registration and the connector [21] of the horizontal registration home position sensor, and remove the pun.
[20]
[21]
Figure 6-323
6-39
5.
Installing the Punch Unit Harness Caution:

If the punch unit harnesses shift away from their installation positions, this may cause defective operation. The punch unit harnesses must be firmly installed at the positions described below.
[1]
[2]
1) Fasten the punch unit harnesses at the positions where the two tie wraps [1] of the punch unit harnesses are outside the two respective harness fasteners [2].
[2]
[1]
Figure 6-324
PI2P PI3P M1P Photosensor PCB LED PCB
[1]
PI1P M2P
[1]
Scrap full detector PCB MS1P
MS2P
Punch driver PCB
Figure 6-325
6-40
C.
PCBs
1. Removing the LED PCB 1) Remove the punch unit assembly (see IIIB-3). 2) Remove the screw [1] and the LED PCB [2].
[2] [1]
Figure 6-326
2. Removing the Photosensor PCB 1) Remove the upper cover (see III-A-2). 2) Remove the two screws [1], and remove the sensor plate [2]. 3) Disconnect the connector [2], and remove the photosensor PCB [4].
[4]
[3]
[2] [1]
Figure 6-327
6-41
3.
Removing the Scrap Full Detector PCB Unit 1) Remove the right guide assembly (see IIIA-1). 2) Remove the screw [1], disconnect the connector [2], and remove the scrap full detector PCB unit [3].
[3]
[2]
[1]
Figure 6-328 4. Removing the Punch Driver PCB 1) Remove the puncher unit from the finisher. 2) Remove the four screws [1], disconnect four connectors [2], and remove the punch driver PCB [3].
[3]
[1]
[2] [1]
[2]
[1]
Figure 6-329
6-42
IV. INSERTER UNIT (OPTION)

A. Exterior Parts
1. Removal of upper cover 1) Remove 1 screw [1], and take off the upper cover [2].
[2]
[1]
Figure 6-401 2. Removal of front cover 1) Remove 3 screws [1], and push the hook [2] to move the front cover [3] forward.
[3]
[1] [2]
Figure 6-402 2) Disconnect 1 connector [4], and take off the front cover.
[4]
Figure 6-403
6-43
3. Removal of rear cover 1) Remove 1 screw [1], cut off the bundled wire band [2], and take off the sub cover [3].
[3]
[2]
[1]
Figure 6-404 2) Disconnect the connector [4] of the finisher. 3) Remove 4 screws [5], and take off the rear cover [6].
[6]
[5]
[5]
[4]
Figure 6-405
B.
Feeding Section
1. Removal of empty sensor 1) Remove the upper cover. 2) Remove 1 screw [1], disconnect 1 connector [2], and take off the empty sensor [3] with the bracket.
[2]
[1] [3]
Figure 6-406
6-44
2.
Removal of pickup/feed/ separation rollers 1) Remove the empty sensor. 2) Remove 1 screw [1], and take off the feed guide [2].
[2]
[1]
Figure 6-407 3) Lift the feed tray [3], remove 1 screw [4], and take off the maintenance cover [5].
[5]
[3] [4]
Figure 6-408
[8]
4) Catch the latch [6] of each roller and move it sideways. Then take off the pickup roller [7], feed roller [8] and separation roller [9].
[9]
[7] [6]
Figure 6-409
6-45
3.
Reverse solenoid/Pickup trigger solenoid 1) Remove the front cover. 2) Remove 1 screw [1], and take off the reverse solenoid [2].
[1]
[2]
Figure 6-410
3) Remove 2 screws [3], and take off the pickup solenoid [4] with the bracket.
[3]
[4] [3]
Figure 6-411
C.
1.
Drive Section
[3] [4] [1]
Feed motor/Transport motor/ Board 1) Remove the rear cover. 2) Release 1 harness clamp [1], disconnect 1 connector [2], remove 2 screws [3], and take off the fan motor [4].
[2]
Figure 6-412
6-46
3) Release 1 harness clamp [4], disconnect 1 connector [5], remove 3 screws [6], and take off the feed motor [7] with the bracket.
[6] [7] [6]
[4]
[5]
Figure 6-413 4) Disconnect 14 connectors [8], remove 4 screws [9], and take off the main board [10].
[8] [8] [9]
[9]
[8]
[8] [8] [10]
Figure 6-414 5) Release 5 harness clamps [11], remove 7 screws [12], and take off the board bracket [13].
[13]
[11]
[12] [12]
Figure 6-415
6-47
6) Remove 4 screws [14], and take off the transport motor [15] with the bracket.
[14]
[15]
[14]
Figure 6-416 2. Sensors 1) Remove the front cover, and take off the feed motor, main board and transport motor. 2) Remove 3 connectors [1] and release the harness clamp [2]. Then remove 2 screws [3], and take off the joint sensor [4] and joint switch [5] with the bracket [6].
[1] [3] [5] [3]
[6] [4] [1]
[2]
Figure 6-417 3) Open the transport cover 1 [7], disconnect 1 connector for each sensor, and take off the transport cover 1 open/close sensor 1 [8] and separation sensor [9].
[7] [9] [8]
Figure 6-418
6-48
4) Lift the tray, disconnect 1 connector [10], and take off the tray open/close sensor [11].
[10]
[11]
Figure 6-419
D.
1.
Upper Inserter Unit

[2]
Reverse sensor/Transport sensor/ Transport cover 2 open/close detection sensor 1) Remove 2 screws [1], and take off the upper inserter unit [2].
[1]
Figure 6-420 2) Remove 2 screws [3], and take off the stay [4].
[4]
[3]
Figure 6-421
6-49
3) Disconnect 1 connector [5], remove 1 screw [6], and take off the reverse sensor [7] with the bracket.
[5]
[7]
[6]
Figure 6-422 4) Disconnect 1 connector [8] for each sensor, and take off the transport sensor [9] and transport cover 2 open/close sensor [10].
[10] [8] [9]
Figure 6-423
E.
Tray Unit
[2] [1] [1]
1. Paper width detection volume 1) Lift the tray, remove 2 screws [1], and take off the tray lower guide [2].
Figure 6-424
6-50
2) Remove 3 screws [3], and take off the tray lower cover [4].
[4] [3]
[3]
Figure 6-425
3) Remove 1 connector [5], and take off the empty sensor [6].
[6] [5]
Figure 6-426 4) Remove 2 screws [7], and take off the paper width detection volume [8].
[8]
[7]
Figure 6-427
6-51
Note: Put together both marks at the rack and pinion as the right figure shows when installing the paper width detection volume.
Figure 6-428 2. Tray guide adjustment When the tray guide is not placed at the proper position, do the following operations to adjust it. 1) Remove the tray lower guide. 2) Loosen 2 screws [1], and tuck the latch of the tray guide and adjust the guide looking at the marks [3].
[3] [1]
[1]
[2]
Figure 6-429
F.
1.
Notes for Installing

[A] [C] 4
Notes for installing the pickup drive gear 1) When installing the gear [A], put into the concave portion of the gear [A]. 2) When installing the gear [B], to put the gear [A] into the concave portion of the gear [B] and gear [C] into the portion of it. Also, put the leaf spring [D] on the portion of the gear [B].
1 2 [D]
3 [B] 5
Figure 6-430
6-52
2. Notes for installing the tray gear 1) When Installing the tray gear, install the tray to the gear and bring it down, and then put together the mark [A], [B] and [C], [D].
[A] [B]
[C] [D]
Figure 6-431 2) Install the bracket [1] and make sure to put the spring [2] on it.
[2] [1]
Figure 6-432
6-53
3.
Attachment of Mylars
Note: Clearn the surface of the portions where the mylar are attached to.
2 1 3
Separation before sheet Separation before rubber Guide mylar Separation before mylar Entrance mylar
Figure 6-433
6-54
Separation before sheet
Inside concave position (Do not stick out.)
Separation before mylar Separation before rubber
Tolerance:
0.5 0.5
Separation before sheet
Separation before rubber
Separation before mylar
Tolerance:
+0.5 0
Figure 6-434
Inside concave position
6-55
Put together edges of the double-faced tape and bracket. Entrance mylar
Tolerance:
351
Entrance mylar
Figure 6-435Figure 6-435
6-56
Guide mylar
Tolerance:
1.50.5
Tolerance:
1.50.5
Figure 6-436
6-57
I.
PERIODICALLY REPLACED PARTS ......................................... 7-1 A. Finisher Unit ............................... 7-1 B. Saddle Stitcher Unit ................... 7-1 C. Puncher Unit (option) ................. 7-1 D. Inserter (option) ......................... 7-1 II. CONSUMABLES AND DURABLES ................................. 7-2
A. Finisher Unit ............................... 7-2 B. Saddle Stitcher Unit ................... 7-2 C. Puncher Unit (option) ................. 7-2 D. Inserter (option) ......................... 7-2 III. PERIODICAL SERVICING .......... 7-2 IV. FIRMWARE UPDATING (only for inserter section) ............. 7-3
I.
A.
PERIODICALLY REPLACED PARTS

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

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

The puncher unit does not have parts that must be replaced on a periodical basis.
D.
Inserter (option)
The inserter unit does not have parts that must be replaced on a periodical basis.
7-1
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 Feed 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

No. Name Stitcher Qty 2 Estimated Life 200,000 operations Remarks 2,000 operations/cartridge
C.
1 2

No. Name Punch unit Punch unit harness Qty 1 1 Estimated Life 1,000,000 operations 1,000,000 operations Remarks
D.
1 2 3
Inserter (option)
No. Name Pickup roller Feed roller Separation roller Qty 1 1 1 Estimated Life 150,000 copies 150,000 copies 150,000 copies Remarks
III. PERIODICAL SERVICING

Item Feed belt Paddle Transmission sensor (Puncher Unit) (option) Host machine minimum servicing interval Pickup roller Feed roller Separation roller (Inserter Unit) (option) Use dry cloth Cleaning Interval Work Remarks Use moist cloth
Use moist cloth
7-2
IV. FIRMWARE UPDATING (only for inserter section)

The firmware updating can be automatically done by connecting the downloading jig to its own connector and turning ON the power. The K-PWA-DLM-320 is used as a jig board. 1) Connect the inserter to the copier after the inserter rear cover is removed. * At this time, do not connect the finisher interface cable to the inserter. 2) Connect the jig board to the connector on the inserter main board. 3) Turn the power ON with pressing the [3] and [9] keys of the copier. (The data starts to be updated and the LED of the jig board turns ON.) 4) About 15 sec. later, the updating is finished and the LED of the jig board blinks to show the result. 5) Turn the power OFF and take off the jig board. * When failing to update, try again after turning OFF the power.
LED display (light ON period/light OFF period) 500msec/500msec 100msec/900msec 900msec/100msec Light-out 1500msec/500msec Success in updating Wrong checksum with the updating EPROM Failure in erasing the flash memory Failure in writing into the flash memory Success in writing into the flash memory but wrong checksum with the flash memory Result
Table 7-401
LED
[K-PWA-DLM-320]
Figure 7-401
Figure 7-402
7-3
I.
ADJUSTMENTS .......................... 8-1 A. Electrical System (finisher unit) .............................. 8-1 B. Electrical System (saddle stitcher unit) .................. 8-5 C. Electrical System (puncher unit (option)) ............... 8-7 D. Electric Unit/(Inserter Section (Optional)) .................................. 8-9 E. Inserter Section ....................... 8-10 II. ARRANGEMENT OF ELECTRICAL PARTS ................ 8-12
Finisher Unit ............................. 8-12 Saddle Stitcher Unit ................. 8-19 Puncher Unit (option) ............... 8-25 Light-Emitting Diodes (LED) and Check Pins by PCB ........... 8-29 III. TROUBLESHOOTING ............... 8-31 A. Finisher Unit ............................. 8-31 B. Saddle Stitcher Unit ................. 8-41 C. Puncher Unit (option) ............... 8-48 D. Inserter Section (Option) ......... 8-49
A. B. C. D.
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 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 8-102
1 2 3 4 5 6 7 8
Figure 8-101 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 alignment plate to move to A4/LT positions. 4) Place 10 sheets of A4/LT paper between the alignment plate and the guide plate, butting them against the stoppers. 5) Press SW1 or SW2 on the finisher controller PCB, and butt the alignment plate against the sheets. Pressing SW1 will shift the alignment plate to the front in 0.35 mm increments. Pressing SW2 will shift the alignment plate to the rear in 0.35 mm increments.
8-1
Alignment plate Shift by SW2 A4/LT paper Shift by SW1
Stopper
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 feed belt to rotate. 4) Within 5 secs after pressing the switch, place one sheet of A4/LT paper between the alignment plate and the guide 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.
Stopper
Alignment Stapler plate
Guide plate
Figure 8-103 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. 3. Adjusting the Staple Position (stapler movement range) Adjust as follows if you have replaced the finisher controller PCB. Performing the steps will affect all paper sizes and all stapling positions. 1) Remove the rear cover from the finisher unit. 2) Set SW3 on the finisher controller PCB as indicated.
ON
Stopper
Stopper
Guide plate
Figure 8-105
2 3 4 5 6 7 8
Figure 8-104
8-2
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.
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.
2912mm (A4)/ 2732mm (LT)
Staple Paper
Paper delivery direction
Second sheet Third sheet
Shift by SW2
Shift by SW1 Feeding direction
Winding amount
First sheet
Figure 8-106 7) Press SW1 and SW2 simultaneously. This will open the swing guide, and cause the feed belt to rotate. Placement of one sheet of A4/LT 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.
Figure 8-107 1) Set SW3 on the finisher controller PCB as indicated.

ON
Figure 8-108 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. 8-3
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.
10) Turn the host machine OFF, and then set SW3 on the finisher controller PCB as indicated.
ON
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
Figure 8-111 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.
Third sheet Second sheet First sheet
Figure 8-109 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
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 8-112
1 2 3 4 5 6 7 8
Figure 8-110 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)
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.
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 8-101 8-4
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 8-114 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 8-113 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 8-115 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.
8-5
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 8-102 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 8-102 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 8-102 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 8-116 8-6
C.
1.
Electrical System (puncher unit (option))
Sensor output adjustment Perform this adjustment when the punch driver PCB, transmission sensor (photosensor PCB/LED PCB) or reflection sensor (scrap full detection PCB unit) has been replaced. 1) Remove the rear cover of the finisher unit. 2) Set bits 1 through 6 of DIPSW3 on the finisher controller PCB as indicated.
4) Press SW1 on the finisher controller PCB. Press SW2 when setting a 2-/3-hole model (MJ-6003N). Pressing this switch registers the number of punch holes to the punch driver PCB.
Number of Punch Holes 2-hole (MJ-6003E) 2-/3-hole (MJ-6003N) 4-hole (MJ-6003F) DIPSW3 bit settings bit 7 OFF OFF ON ON bit 8 OFF OFF OFF ON Push switch SW1 SW2 SW1 SW1
4-hole (MJ-6003S)
Figure 8-117 3) Press SW1 on the finisher controller PCB. Pressing this switch automatically adjusts sensor output. 4) Set all bits on DIPSW3 to OFF. 2. Registering the number of punch holes This operation registers which puncher unit is attached to the IC on the punch driver PCB so that the puncher unit can be identified by the finisher. For this reason, this operation must be performed when the punch driver PCB has been replaced. 1) Remove the rear cover of the finisher unit. 2) Set bits 1 through 6 of DIPSW3 on the finisher controller PCB as indicated.
Table 8-103 5) Set all bits on DIPSW3 to OFF. 3. Checking the sensitivity level of the transmission sensor How dirty the transmission sensor (photosensor PCB/LED PCB) can be checked by the number of times that LED1 on the finisher controller PCB lights. For this reason, how dirty the transmission sensor is serves as a guide for when to perform cleaning during periodic maintenance. 1) Remove the rear cover of the finisher unit. 2) Set bits 1 through 6 of DIPSW3 on the finisher controller PCB as indicated.
5
5 6 7 8
Figure 8-119
Figure 8-118 3) Set bits 7 and 8 on DIPSW3 on the finisher controller PCB to match the number of punch holes of the attached puncher unit according to Table 8-103.
8-7
3) Press SW1 on the finisher controller PCB. Pressing this switch lights LED1 on the finisher controller PCB as indicated in Table 8-104 so that you can check the sensitivity level of the transmission sensor.
Sensitivity Level Sensor not dirty Sensor slightly dirty Sensor dirty Number of LED Lightings Lit 1X Lit 2X Lit 3X
Table 8-104 4) Set all bits of DIPSW3 to OFF.
8-8
D.
Electric Unit/(Inserter Section (Optional))
1.
Each adjustment condition and such at the inserter can be checked through the LEDs on the inserter control panel.
Mode LED
LED1 LED2 LED3 LED4
Punch LED
Start LED
Punch key
Mode key Start key
Figure 8-120
Tray guide width adjustment When replacing boards and volumes and disassembling or installing the tray unit, make sure to follow these adjustments. 1) Turn ON the power with pressing the control panel mode key and start key. (The start LED blinks in green.) 2) Press the mode key and set up only the mode LED3 to light ON, and press the start key. (The start LED lights ON in green.) * With pressing the mode key for more than 1 sec., all the mode LEDs light OFF and become able to be reset. 3) Press the start key. (The mode LED2, 3 blink.) 4) Move the tray guide to the position where its width becomes the narrowest, and press the start key. 5) The mode LED display switches. (The mode LED1, 4 blink.) 6) Move the tray guide to the position where its width becomes the broadest. 7) The mode LED1~4 light OFF and the writing operation of the tray width adjustment data into the EEPROM is finished. * When the writing into the EEPROM has been finished, make sure to check the result with the following table.
Writing result Success Failure (minimum position) Failure (maximum position) Failure (both maximum ) and minimum positions) : Blinking : Light ON : Light OFF Mode LED display LED1 LED2 LED3 LED4
Table 8-105
8-9
E.
1.
Inserter Section
Input check 1 This is a mode at which the checking of each motor, solenoid and clutch operation is carried out. 1) Turn ON the power with pressing the control panel mode key and start key. (The start LED blinks in green.) 2) Press the mode key and set up the LED1 to blink and LED2~4 to light OFF, and press the start key. (The start LED lights ON in green.) * With pressing the mode key for more than 1 sec., all the mode LEDs light OFF and become able to be reset. 3) Press the mode key and check the operations refering to the right table. The operational mode is switched at every time the mode key is pressed. * Num (at the right table): the number of times which the key is pressed * At the operational mode 7~36, the motor rotation speed is switched whenever the start key is pressed. The motor rotation speed can be checked by refering to the mode LED blinking speed. Mode LED blinking at 1000msec. cycle: Mode LED blinking at 700msec. cycle: Mode LED blinking at 500msec. cycle: Mode LED blinking at 250msec. cycle: Mode LED blinking at 100msec. cycle:
*Num. 1 2 3 4 5 6 7
Low speed Medium speed High speed 1 High speed 2 High speed 3
Operation LED1 LED2 LED3 LED4 Pickup trigger solenoid ON Pickup trigger solenoid OFF Pickup clutch ON Pickup clutch OFF Reverse solenoid ON Reverse solenoid OFF Feed motor rotated forward (low speed) 8 Feed motor stopped 9 Feed motor rotated forward (medium speed) 10 Feed motor stopped 11 Feed motor rotated forward (high speed 1) 12 Feed motor stopped 13 Feed motor rotated forward (high speed 2) 14 Feed motor stopped 15 Feed motor rotated forward (high speed 3) 16 Feed motor stopped 17 Feed motor rotated in reverse (low speed) 18 Feed motor stopped 19 Feed motor rotated in reverse (medium speed) 20 Feed motor stopped 21 Feed motor rotated in reverse (high speed 1) 22 Feed motor stopped 23 Feed motor rotated in reverse (high speed 2) 24 Feed motor stopped 25 Feed motor rotated in reverse (high speed 3) 26 Feed motor stopped 27 Transport motor rotated forward (low speed) 28 Transport motor stopped 29 Transport motor rotated forward (medium speed) 30 Transport motor stopped 31 Transport motor rotated forward (high speed 1) 32 Transport motor stopped 33 Transport motor rotated forward (high speed 2) 34 Transport motor stopped 35 Transport motor rotated forward (high speed 3) 36 Transport motor stopped 37 Fan motor ON 38 Fan motor OFF : Blinking : Light ON : Light OFF
Table 8-106 8-10
2.
Check of sensor operations 1 This is a mode 1 to check each sensor operation separately. 1) Turn ON the power with pressing the control panel mode key and start key. (The start LED blinks in green.) 2) Press the mode key and set up the mode LED2 to blink and mode LED1, 3, 4 to light OFF, and press the start key. (The start LED lights ON in green.) * With pressing the mode key for more than 1 sec., all the mode LEDs light OFF and become able to be reset. 3) Check the ON/OFF status of each sensor through the mode LED display. * The display is switched whenever the start key is pressed. LED display When the start switch is OFF:
Mode LED LED1 LED2 LED3 LED4 Display Light OFF Light ON Light OFF Light ON Light OFF Light ON Light OFF Light ON Sensor status Separation sensor OFF Separation sensor ON Reverse path sensor OFF Reverse path sensor ON Transport sensor OFF Transport sensor ON DC 24V supplied DC 24V cut off
3.
Check of sensor operations 2 This is a mode 2 to check each sensor operation separately. 1) Turn ON the power with pressing the control panel mode key and start key. (The start LED blinks in green.) 2) Press the mode key and set up the mode LED1, 2 to blink and mode LED3, 4 to light OFF, and press the start key. (The start LED lights ON in green.) * With pressing the mode key for more than 1 sec., all the mode LED light OFF and become able to be reset. 3) Check the ON/OFF status of each sensor through the mode LED display. * The display is switched whenever the start key is pressed. LED display When the start switch is OFF:
Mode LED LED1 LED2 LED3 Display Light OFF Light ON Light OFF Light ON Light OFF Light ON LED4 Light OFF Light ON Sensor status Joint sensor OFF Joint sensor ON Tray open/close sensor OFF Tray open/close sensor ON Transport cover 1 open/close sensor OFF Transport cover 1 open/close sensor ON Transport cover 2 open/close sensor OFF Transport cover 2 open/close sensor ON
Table 8-107 When the start switch is ON:

Mode LED LED1 LED2 Display Light OFF Light ON Light OFF Light ON Sensor status Empty sensor OFF Empty sensor ON Paper length sensor OFF Paper length sensor ON
Table 8-109 When the start switch is ON:

Mode LED LED1 LED2 LED3 LED4 Display Light OFF Light ON Light OFF Light ON Light OFF Light ON Light OFF Light ON Sensor status Dip-switch 1 OFF Dip-switch 1 ON Dip-switch 2 OFF Dip-switch 2 ON Dip-switch 3 OFF Dip-switch 3 ON Dip-switch 4 OFF Dip-switch 4 ON
Table 8-108
Table 8-110
8-11
II.
A.
ARRANGEMENT OF ELECTRICAL PARTS

Finisher Unit
8-12
1.
Sensors
PI9 PI19
PI23 PI24
PI18 PI17 PS1 PI10 PI14 PI3 PI16 PI11 PI12 PI5 PI21 PI22 PI6 PI4 PI20 PI8 PI1 PI15
PI7
PI25
Figure 8-201
8-13
Name Photointerrupter
Notation PI1 PI3 PI4 PI5 PI6 PI7 PI8 PI10 PI11 PI12 PI14 PI15 PI16 PI17 PI18 PI9 PI19 PI20 PI21 PI22 PI23 PI24 PI25
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 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 the height of the stack on the tray
Height sensor
PS1
Table 8-201
8-14
2.
Microswitches
MS9
MS2 MS6 MS1 MS3
MS4 MS7 MS8
Figure 8-202
Name Microswitches Notation MS1 MS2 MS3 MS4 MS6 MS7 MS8 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 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) Detects the tray coming close
Table 8-202 8-15
3.
Motors
M5
M10
M7
M8 M1 M9
M2 M3
M4
M6
Figure 8-203
Name Motor Notation M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 Function 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
8-16
Table 8-203
4.
Solenoids
SL5 SL3
SL2 SL1
SL7
SL6
Figure 8-204
Name Solenoid Notation SL1 SL2 SL3 SL5 SL6 SL7 Flapper solenoid Buffer inlet solenoid Buffer outlet solenoid Paddle solenoid Escape solenoid Belt escape solenoid Function
Table 8-204 8-17
5.
PCBs
[4]
[4]
[1] [3]
[4] [2]
Figure 8-205
Reference [1] [2] [3] [4] Finisher controller PCB Relay PCB 4 Relay PCB 3 Sensor PCB Name
Table 8-205
8-18
B.
1.

Photointerrupters
PI18S PI19S PI20S
PI16S PI9S
PI21S PI2S PI11S PI6S PI5S PI3S PI17S
PI14S PI15S
PI12S PI13S
PI8S PI7S
PI4S PI1S
Figure 8-206
8-19
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 8-206
8-20
2.
Microswitches
MS1S MS4,5S MS6,7S MS2S
MS3S
Figure 8-207
Name Microswitches Notation MS1S MS2S MS3S MS4S MS5S MS6S MS7S Function Detects the state (open) of the inlet door Detects the state (open) of the front door Detects the state (open) of the delivery door Detects the presence of staples (rear) Detects stitching home position (rear) Detects the presence of staples (front) Detects stitching home position (front)
Table 8-207 8-21
3.
Motors
M6S M7S M4S M3S M1S M2S M5S
M8S
Figure 8-208
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 8-208 8-22
4.
Solenoids
SL1S
SL2S
SL4S
Figure 8-209
Name Solenoid Notation SL1S SL2S SL4S Function No. 1 paper deflecting plate solenoid No. 2 paper deflecting plate solenoid Feed plate contact solenoid
Table 8-209
8-23
5.
PCBs
[2]
[1]
Figure 8-210
Reference [1] [2] Saddle stitcher controller PCB Paper sensor PCB Name
Table 8-210
8-24
C.
1.

Photointerrupters
Pl2P Pl3P
PI1P
Figure 8-211
Name Photointerrupter Notation PI1P PI2P PI3P Function Horizontal registration home position detection Punch motor clock detection Punch home position detection
Table 8-211
8-25
2.
Microswitches
MS2P
Figure 8-212
Name Microswitch Notation MS2P Front door open detection Function
Table 8-212
8-26
3.
Motors
M1P
M2P
Figure 8-213
Name Motor Notation M1P M2P Punch motor Horizontal registration motor Function
Table 8-213
8-27
4.
PCBs
[1]
[3] [2] [4]
Figure 8-214
Reference [1] [2] [3] [4] Punch driver PCB Photosensor PCB LED PCB Scrap full detector PCB Name
Table 8-214
8-28
D.
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 10 B J12 1
A B J14
1 12
1 J3
8 1 J2
7 J6
11 1
A B J9
1 11
1 J11
10 1 J16 7 1 J24 8 1 J17
1 A 10
SW1 SW2
1 A 14 4
14 SW3 B J21 1 LED2 J23 J7 LED1 J10
11 1 6 1
1 J8 1 15 11 J5 J1 J19 1 2 1 2
Figure 8-215
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 8-215
8-29
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 8-216
Switch DIPSW1 (bits 1-2) DIPSW1 (bits 6-8) SW2 Function Starts correction of discrepancy between stitching position and folding position. Stores corrected settings for stapling position and folding position. Starts correction of discrepancy between stitching position and folding position.
Table 8-216
8-30
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.
8-31
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
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 or J213 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.
8-32
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 J11-4 and J11-5 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
8-33
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 sensor (PI6) Wiring
No
Correct the wiring.
Alignment plate
Yes
Remove the mechanical obstacle. End. Replace the finisher controller PCB.
Alignment motor (M3) 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.
8-34
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.
8-35
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 range switch (MS3) Step 1 2 Swing guide closed detection switch 2 (MS6) 3 Checks Check the safety range switch. Is the switch normal? Is the safety range 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.
8-36
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 J11-6 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.
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 lift mechanism (PI25) Finisher controller PCB Step 1 Checks 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 Action Correct the mechanism. Replace the finisher controller PCB.
No
Wiring Tray 2 lift motor (M10)
No Yes
Correct the wiring. Replace the tray 2 lift motor.
8-37
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.
8-38
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
8-39
21. Faulty second feed motor (related to MS3)

Cause Safety range switch (MS3) Step 1 2 Shutter closed detection switch (MS4) 3 Checks Check the safety range switch. Is the switch normal? Is the safety range 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.
8-40
B.
1.

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
Replace the paper folding motor. Is the problem corrected?
Yes No
8-41
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
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
Replace the alignment motor. Is the problem corrected?
Yes No
8-42
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.
Replace the paper pushing plate motor. Is the problem corrected?
Yes No
8-43
7.

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
Yes No
8.

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
Yes No
8-44
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
Ground
No
8-45
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
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.
8-46
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.
8-47
C.
1.

Faulty punch motor
Cause Step 1 2 Checks Check the punch motor clock sensor. Is the sensor normal? Check the punch home position sensor. Is the sensor normal? Is the wiring between the punch home position sensor and the finisher controller PCB normal? Is there any trouble with the punch mechanism? Yes/No No No Action Replace the sensor. Replace the sensor.
Punch motor clock sensor (PI2P) Punch home position sensor (PI3P) Wiring
No
Correct the wiring.
Punch mechanism Punch motor (M1P) Punch driver PCB
Yes No
Correct the punch mechanism. Replace the punch motor. Replace the finisher controller PCB. End.
Replace the punch driver PCB. Is the problem corrected?
No Yes
2.
Faulty horizontal registration motor

Cause Step 1 Checks Check the horizontal registration home position sensor. Is the sensor normal? Is the wiring between the horizontal registration home position sensor and the finisher controller PCB normal? Is there any problem with the horizontal registration mechanism? Yes/No No Action Replace the sensor.
Horizontal registration home position sensor (PI1P) Wiring
No
Correct the wiring.
Horizontal registration mechanism Horizontal registration motor (M2P) Punch driver PCB
Yes
Correct the horizontal registration mechanism. Replace the horizontal registration motor. Replace the finisher controller PCB. End.
No 4 Replace the punch driver PCB. Is the problem corrected? No Yes
8-48
D.
1.
Inserter Section (Option)

Inserter operation failure
Cause Step 1 2 Checks Is the interface cable connected properly? Is DC+24V supplied to the FUSE1? Is DC+5V supplied to the TP1? Is DC+24V supplied to the TP57? Does the empty sensor (TP49) become 0V when there is a paper? Yes/No No No Action Connect the cable properly. Check the FUSE1 and replace it. Check the copier. Check the TP1 and the copier. Check the inserter joint switch. Check the empty sensor. Check the inserter main board and replace it.
Interface cable FUSE1
TP1 TP57 Empty sensor (TP49) Inserter main board
3 4 5
No No No Yes
2.
Motor operation failure

Cause Step 1 Checks Is the load of the motor shaft normal? Is the power voltage supplied to the motor connectors? Is the excitation pattern signal supplied to the motor connectors? Yes/No No Action Adjust the structure and remove extraneous materials. Check the connectors and PC board, and replace them. Check the PC board and replace it. Check the motor and replace it.
Motor load
Power voltage
No
Signal Motor
No Yes
3.
Communication failure
Cause Step 1 Checks Is the interface cable normal? Yes/No No Yes Action Replace the interface cable. Check the PC board and replace it.
Interface cable PC board
8-49
4.
Size detection failure

Cause Step 1 Checks Does the paper length sensor (TP48) become +5V when there are papers? Does the separation sensor (TP50) become +5V when there are papers? Does the output (TP47) of the paper width detection volume become more than +4V with the guide broadened and less than +2.5V with the guide narrowed? Are the separation roller and paper not slipping? Yes/No No Action Check the paper length sensor and replace it. Check the separation sensor and replace it. Check the paper width detection volume and replace it.
Paper length sensor
Separation sensor
No
Paper width detection
No
Separation roller
No Yes
Check the PC board and replace it. Clean up the separation roller and replace it, and adjust the pressure and so on.
5.
Fan operation failure

Cause Step 1 2 Checks Is the fan load normal? Is the power voltage supplied to the motor connector? Is the connector connected properly? Is the power supplied to the CN8_1pin? Yes/No No No Action Remove the extraneous materials. Check the connector and connect it properly. Check the PC board and replace it. Check the fan motor and replace it.
Fan load Connector
Power supply Fan motor
No Yes
8-50
APPENDIX
A. FINISHER UNIT GENERAL TIMING CHART .......................... A-1 B. SADDLE STITCHER UNIT GENERAL TIMING CHART ........ A-2 C. PUNCHER UNIT (option) GENERAL TIMING CHART ........ A-3 D. INSERTER UNIT (option) GENERAL TIMING CHART ........ A-4 E. SIGNAL AND ABBREVIATIONS ..................... A-14
F .
FINISHER UNIT CIRCUIT DIAGRAM ................................. A-15 G. SADDLE STITCHER UNIT CIRCUIT DIAGRAM ................. A-26 H. PUNCHER UNIT (option) CIRCUIT DIAGRAM ................. A-34 I. INSERTER UNIT (option) CIRCUIT DIAGRAM ................. A-41 J. SOLVENTS AND OILS ............. A-45
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 (PI2) 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 Alignment motor (M3) 9 Alignment position home position sensor (PI6) 10 Swing motor (M7) 11 Swing guide open sensor (PI18) 12 Swing guide closed detecting switch (MS2)
13 Paddle solenoid (SL5) 14 Belt escape solenoid (SL7) 15 Staple motor (M6) 16 Staple home position sensor (PI22)
17 Stapler shift motor (M4) 18 Height sensor (PS1) 19 Tray 1 lift motor (M5)
: Motor CW rotation
A-1
B.
SADDLE STITCHER UNIT GENERAL TIMING CHART

Copy Start Key ON Operation Initialize Delivery signal 1st sheet delivery 2nd sheet delivery 3rd sheet delivery Stitching
Stack feeding
A4R, 3 Sheets, Stitching, 1 Set
Folding,/delivery
1 Inlet feed motor (M9) 2 Finisher unit flapper solenoid (SL1)
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
A-2
C.
A4, 2 Sheets, Punching, Job offset (front)
PUNCHER UNIT (option) GENERAL TIMING CHART
Operation start signal Host machine delivery signal Operation 1 2 3 4 5 6 7 8 9 Trailing edge detection sensor (LED5, PTR5) Horizontal registration sensor (LED 1 to 4, PTR 1 to 4) Punch home position sensor (PI3P) Horizontal registration home position sensor (PI1P) Horizontal registration motor (M2P) Punch motor (M1P) Inlet sensor (PI1) Delivery sensor (PI3) Inlet feed motor (M9)
10 First feed motor (M1) 11 Second feed motor (M8) 12 Delivery motor (M2) 13 Staple tray sensor (PI4) 14 Alignment motor (M3) 15 Alignment plate home position sensor (PI6)
16 Swing motor (M7) 17 Swing guide open sensor (PI18) Swing guide closed detecting 18 switch (MS2) 19 Paddle solenoid (SL5) 20 Belt escape solenoid (SL7) 21 Height sensor (PS1) 22 Tray 1 lift motor (M5) 23 Escape solenoid (SL6)
: Motor CW rotation
A-3
D.
INSERTER UNIT (option) GENERAL TIMING CHART
Connect with e-STUDIO810, A4, 2 sheets, Normal operation (Pre-feeding standby position that for next paper)
1363msec
Empty direction for inserted paper
Empty sensor
ON OFF
96ms
Separation end sensor
ON OFF
498ms 217ms
498ms 217ms
Transport sentor Reverse path sensor
ON OFF
376ms 277ms
376ms 277ms
ON OFF
50ms
50ms 146ms 50ms 200ms 35ms 35ms 146ms
Pickup clutch Pickup trigger solenoid Reverse solenoid
ON OFF
50ms 200ms
ON OFF
ON OFF
1070msec
Separation to pre-feeding standby position
1040msec
Separation to pre-feeding standby position for next paper
36ms 100ms 342ms
Inserting operation
36ms 100ms 342ms
Inserting operation for next paper
Feed motor
High speed Low speed Start/stop High speed Low speed Start/stop
30ms
30ms
70ms 100ms 93ms 184ms
30ms 100ms
Reached finisher roller (without the puncher unit).
100ms 93ms 184ms
100ms
Transport motor
When the 1st job paper is inserted paper
100ms
Reached finisher roller (with the puncher unit).
100ms
When the last job paper is inserted paper
A-4
Connect with e-STUDIO810, A4, 2 sheets, Reversal operation (1/3) (Reversal pre-feeding standby position that for next paper)
Empty sensor
ON OFF
ON OFF
498ms 392ms
ON OFF
ON OFF
450ms 458ms 50ms 63ms
ON
OFF
50ms 200ms
146ms
ON OFF
ON OFF
2864msec
521ms 500ms
210ms 100ms
Reverse rotation
Feed motor
Forward rotation
30ms
30ms
30ms
30ms
Transport motor
100ms
A-5
3313msec
Empty sensor
ON OFF
295ms
ON OFF
498ms 392ms
ON OFF
384ms 277ms 450ms 249ms 458ms 63ms
ON OFF
ON OFF
50ms 50ms 200ms 35ms 146ms
ON OFF
ON OFF
2864msec 706msec
Inserting operation Separation to pre-feeding standby position for next paper
100ms 100ms
521ms 500ms
Forward rotation
210ms 100ms
Reverse rotation
Feed motor
Reverse rotation
100ms
30ms 93ms 184ms

Reached finisher roller (without the puncher unit). Reached finisher roller (with the puncher unit).
30ms
30ms
30ms
Transport motor
A-6
Empty sensor
ON OFF
ON OFF
ON OFF
384ms 277ms
ON OFF
249ms
ON
OFF
ON OFF
35ms
ON OFF
706msec
100ms 100ms
Feed motor
100ms
100ms 93ms 184ms 100ms
When the last job paper is inserted paper Reached finisher roller (without the puncher unit). Reached finisher roller (with the puncher unit).
Transport motor
A-7
Connect with e-STUDIO810, A3, 2 sheets, Normal operation (1/2) (Pre-feeding standby position that for next paper)
1626msec
Empty sensor
ON OFF
ON
498ms 480ms
498ms
OFF
ON
376ms 540ms
OFF
ON OFF
50ms
ON
50ms 146ms 50ms 200ms 35ms 146ms
OFF
50ms 200ms
ON OFF
ON OFF
1070msec
Separation to pre-feeding standby position Inserting operation
1040msec
36ms 100ms 342ms
100ms 342ms
Feed motor
30ms
30ms
70ms 100ms 93ms

Reached finisher roller (without the puncher unit).
30ms
Transport motor
100ms
184ms
Reached finisher roller (with the puncher unit).
A-8
Connect with e-STUDIO810, A3, 2 sheets, Normal operation (2/2) (Pre-feeding standby position that for next paper)
Empty sensor
ON OFF
96ms
ON OFF
480ms
ON OFF
376ms 540ms
ON OFF
ON
OFF
ON OFF
35ms
ON OFF
36ms
Feed motor
High speed Low speed Start/stop

100ms
100ms 93ms 184ms

100ms
Reached finisher roller (without the puncher unit). Reached finisher roller (with the
Transport motor
100ms puncher unit).
A-9
Empty sensor
ON OFF
ON
498ms 1200ms
OFF
ON
OFF
ON OFF
450ms 458ms
ON
OFF
50ms 50ms 200ms
146ms
ON OFF
ON OFF
3672msec
521ms 500ms
Feed motor
30ms
30ms
Transport motor
100ms
A-10
Empty sensor
ON OFF
Refer to the next page
ON OFF
ON OFF
376ms 540ms 35ms
ON OFF
63ms
512ms
ON
OFF
50ms 50ms 200ms
ON OFF
ON OFF
Separation
961msec
Inserting operation
210ms 100ms
100ms 100ms
Reverse rotation Forward rotation
Feed motor
Reverse rotation
30ms 30ms
100ms 93ms 184ms
Transport motor
A-11
4384msec
Empty sensor
ON OFF
295ms
ON OFF
498ms 1200ms
ON
OFF
ON OFF
450ms
458ms
ON
50ms 50ms
146ms
OFF
ON OFF
200ms
ON OFF
3672msec
521ms 500ms
Feed motor

30ms
Forward rotation
30ms
Transport motor
A-12
Empty sensor
ON OFF
ON OFF
ON OFF
376ms 540ms
ON OFF
63ms
512ms
ON
OFF
ON OFF
35ms
ON OFF
Separation
961msec
210ms 100ms
100ms 100ms
Reverse rotation
Feed motor
Reverse rotation
30ms 30ms
100ms
100ms
Transport motor
93ms 184ms 100ms
A-13
E.
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 BESCPSL BUFENTR BUFPASS CRTSET DELCLK DROPN DRSW ENTSL ESCPSL EXITSL FLPSL FSTTRAY HOOKEMP HOOKTOP JOGHP JOINT PDEL PDLSL PENT SFTCLK1 SFTCLK2 SHUTCLD SNDTRAY STOPN STPCON STPDRHP STPHP STPTY SWGCLK SWGGCLD SWGOPN TRAYSAF TRYHP1, TRYHP2 TRYLMT 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 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
BELT ESCAPE SOLENOID DRIVE Signal BUFFER PATH INLET PAPER DETECT Signal BUFFER PATH PAPER DETECT Signal CARTRIDGE DETECT Signal DELIVERY MOTOR CLOCK DETECT Signal DOOR OPEN DETECT Signal DOOR SWITCH Signal BUFFER INLET SOLENOID DRIVE Signal ESCAPE 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 ALIGNMENT PLATE HP DETECT Signal JOINT DETECT Signal DELIVERY DETECT Signal PADDLE SOLENOID DRIVE Signal INLET PAPER DETECT Signal SHIFT MOTOR CLOCK DETECT Signal 1 SHIFT MOTOR CLOCK DETECT Signal 2 SHUTTER CLOSED DETECT SWITCH Signal TRAY 2 PAPER DETECT Signal SHUTTER OPEN DETECT Signal STAPLER CONNECT DETECT Signal STAPLER DRIVE HP DETECT Signal STAPLER HP DETECT Signal STAPLE TRAY PAPER DETECT Signal SWING GUIDE CLOCK DETECT Signal SWING GUIDE CLOSED DETECT SWITCH Signal SWING GUIDE OPEN DETECT Signal TRAY SAFETY SWITCH Signal TRAY HOME POSITION DETECT Signal TRAY UPPER LIMIT DETECTING SWITCH 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
Puncher unit (option) DFULL DUST FULL DETECT Signal FDROPN FRONT DOOR OPEN DETECT SWITCH Signal LEDON LED ON Signal LEDON1 LED1 ON Signal LEDON2 LED2 ON Signal LEDON3 LED3 ON Signal LEDON4 LED4 ON Signal LEDON5 LED5 ON Signal PAEND PAPER END DETECT Signal PUNCHHP PUNCH HOME POSITION DETECT Signal PUNCHCLK PUNCH MOTOR CLOCK DETECT Signal SREG1 SIDE REGISTRATION DETECT Signal 1 SREG2 SIDE REGISTRATION DETECT Signal 2 SREG3 SIDE REGISTRATION DETECT Signal 3 SREG4 SIDE REGISTRATION DETECT Signal 4 SREGHP SIDE REGISTRATION HOME POSITION DETECT Signal UDROPN UPPER DOOR OPEN DETECT SWITCH Signal
A-14
F. FINISHER UNIT CIRCUIT DIAGRAM

12 11 10
J206 J206-3 J206-2 J206-1 MS4-C MS4-NO MS4-NC 3 2 1
4
J14A-6 J14A-5 J14A-4 1 2 3
Joint sensor
3
J201 1 2 3 J601 1 2 3 4 5 6 J115 1 2 3 4 J201 3 2 1 J601 6 5 4 3 2 1 J115 1 2 3 4 J2010 1 2 3 J6010 1 2 3 4 5 6 J2010 3 2 1 J6010 6 5 4 3 2 1
2
1 2 3 J6011 1 2 3 4 5 6 1 2 3 1 2 3
1
1
1 2 3
Tray 1 paper sensor Tray 1 Tray 1 lift motor lift motor clock clock sensor2 sensor1
J2011
PI11 PI9
Shutter closed detection switch
J140 C NO NC 1 2 3
Shutter unit
J206 J7-5 3 J7-6 2 J7-7 1 J9A J9A 1 2 3 4 5 6 7 8 9 10 11 +5V G STPTY +5V G JOGHP G DELCLK +5V +24V ESCPSL J12A +5V 1 G 2 JOINT 3 +5V 4 G 5 STPHP 6 +24V 7 FLPSL 8 NC 9 NC 10 J12B +24V PDLSL G SWGCLK +5V +24V B A B A +5V 1 G 2 DROPN 3 +5V 4 G 5 STOPN 6 +24V 7 BESCPSL 8 +24V 9 ENTSL 10 J5 G PDEL +5V EJECTM EJECTM SWINGM SWINGM +5V G SWGOPN +24V +24MOVE +24VMOVE +24VSHIFT OPEN3 OPEN1 +24VSHIFT +24VMOVE +24VSTPL +24VSHIFT TRAYSW 1 2 3 4 5 6 7 8 9 10 11 J7 1 2 3 4 SHUTCLD 5 6 7 SHFTM2 SHFTM2 SHFTM1 SHFTM1 J6 HEIGHT +5V PWR G 1 2 3 4 J17 J12A 1 2 3 4 5 6 7 8 9 10 J12B 1 2 3 4 5 6 7 8 9 10 J5 1 2 3 4 5 6 7 8 9 10 11 J7 1 2 3 4 5 6 7 J6 1 2 3 4 J17 1 2 3 4 5 6 7 8 9 10 11 J202-9 J202-8 J202-7 J202-6 J202-5 J202-4 J202-3 J202-2 J202-1 J213-4 J213-3 J213-2 J213-1 J116-1 J116-2 J115-1 J115-2 J206-3 J206-2 J206-1 J112-1 J112-2 J131-3 J131-1 J131-2 J209-1 J209-2 J209-3 J209-4 J115-3 J115-4 J113-3 J113-2 J113-1 J205-3 J205-2 J205-1 J500-2 J500-1 J108-3 J108-2 J117-3 J117-2 J117-1 J210-3 J210-2 J210-1 J701-2 J701-1
J12A-3 J12A-2 J12A-1
J117 1 2 3
MS4
PI15
Shutter closed sensor
J118 1 2 3 1 2 3 J205-3 J205-2 J205-1
J7-3 J7-4 J5-10 J5-11
FG5 J119
Delivery motor
J14B-12 J14B-11 J14B-10
J120 1 2 3 1 2 3 J207A-9 J207A-8 J207A-7
Safety range switch
PI10
FG4
J5-3 J5-5 J5-4
Alignment guide home position sensor
J121 1 2 3 1 2 3
FG8
Inlet sensor
Stapling tray sensor
Escape solenoid
J123 1 2 3 J207A-10 3 J207A-11 2 1 J128-2 J128-1 J125-3 J125-2 J125-1 J124-5 J124-4 J124-3 J124-2 J124-1
SL
J207B 1 2 3 4 5 6 7 8 9 10 11
J207B 11 10 9 8 7 6 5 4 3 2 1 J9B-1 J9B-2 J9B-3 J9B-4 J9B-5 J9B-6 J9B-7 J9B-8 J9B-9 J9B-10 J9B-11
J5-2 J5-1 J213 J6-4 J6-3 J6-2 J6-1 J12B-7 J12B-8 J24-1 J24-2 J24-3 J24-4 J24-5 J24-6 J24-7 J24-8 1 2 3 4 4 3 2 1 J500 2 1 1 2
J124 1 2 3 4 5 1 2 3 4 5 J128
SL
J112 2 2 1 1 J212 1 2 3 4 4 3 2 1 J501 2 1 J105 3 2 1 J110 3 2 1 J109 2 1

PI7 Stapler shift home position sensor
J112 2 2 1 1 J114 1 2 3 4 1 2
Buffer path inlet sensor
NC NO C
J207B-10 J207B-9 J207B-8 J207B-7 J207B-6
Alignment motor
2 1 J501 2 1
1 2
J207B-2 J207B-1
M7 Swing motor
1 2
J208-7 J208-6 J134-3 J134-2 J134-1 J119-2 J119-1 J501-2 J501-1
J208 1 2 3 4 5 6 7 J204 J127-3 J127-2 J127-1 1 2 3
J208 7 6 5 4 3 2 1 J204 3 2 1 J11-8 J11-9 J11-10 J11-1 J11-2 J11-3 J11-4 J11-5 J11-6 J11-7
J135-1 J135-2 J135-3 J801-1 J801-2 J801-3 J801-4 J801-5 J801-6 J801-7 J801-8 J801-9 J16
M8 Second feed motor
J14B 12 11 10 9 8 7 6 5 4 3 2 1 J16 1 2 3 4 5 6 7 1 2 J3 1 2 3 4 5 6 7 8 J2
J14B 12 TRYHP2 11 G 10 +5V 9 SNDTRAY 8 G 7 +5V 6 SFTCLK21 5 G 4 +5V 3 SFTCLK22 2 G 1 +5V J16 1 2 3 4 5 6 7 +24V +24V B A B A
+24V +24V B A B A +5V G PENT NC NC
Swing guide Swing guide Swing guide Swing guide closed detection closed detection closed sensor clock sensor switch1 switch2
1 2 3
J127 1 2 3
1 2
J204-3 J204-2 J204-1
PI18
J19 J19 J500-1 J500-2 J400-6 J400-5 J400-4 J400-3 J400-2 J400-1 1 +24V 2 G J3 1 2 3 4 5 6 7 8 J2 1 2 3 4 5 6 7 J1 1 +24V 2 G G G G +5V G G +5V G G G CONCT
J210 J12A-6 J12A-5 J12A-4 1 2 3
J210 3 2 1
MS2
J209 J209 J209-1 MS2-C MS2-NO MS6-C MS6-NO 1 2 3 4 1 2 3 4 1 2
NO C
J209-4 J209-3
J5-6 J5-7 J5-8 J5-9 J401
Relay PCB3
NO
J209-2
J129 1 2 3
1 2 3
1 2 3
J125 1 2 3
J207B-5 J207B-4 J207B-3
1 2 3 4 5 6
1 2 3 4 5 6
+5V G BUFENTR +5V G BUFPASS +24V EXITSL
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
J105-3 J105-2 J105-1 J110-3 J110-2 J110-1 J109-2 J109-1
PI20
SL3
PI14
J24 J24
3 2 1
Buffer path paper sensor
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4
SL
SL5 Paddle solenoid
SL7
Height sensor
M3
PS1
Door switch
J601-1 J601-2 J601-3 J601-4 J601-5 J601-6 J201-1 J201-2 J201-3 J130-1 J130-2 J130-3
Inlet feed motor
Swing guide
M9
1 2 3
J122 1 2 3
J207A-3 J207A-2 J207A-1
J14A 12 11 10 9 8 7 6 5 4 3 2 1
J14A 12 SFTCLK11 11 G 10 +5V 9 SFTCLK12 8 G 7 +5V 6 FSTTRAY 5 G 4 +5V 3 TRYHP1 2 G 1 +5V
SL6
MS1
PI16
J12B-3 J12B-2 J12B-1
3 2 1
1 2 3
1 2 3
Door open sensor
J17-9 J17-8 J17-7 J17-6 J17-5 J17-4 J17-3 J17-2 J17-1
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
PI1
1 2 3 4 5 6
1 2 3 4 5 6
SL1
PI4
J12A-7 J12A-8
2 1
1 2 J113 1 2 3
2 1 J113
1 2
Flapper solenoid
J502
J701
SL2
J12B-9 J12B-10
3 2 1
1 2 3
J207A-6 J207A-5 J207A-4
FG9 J108
SL
PI6
J202
J106 1 1 2 2 3 3
J107
Tray 2 lift motor
M10
1 2 3
J134 1 2 3
Delivery sensor
J208-3 J208-2 J208-1
PI3
J207A J122-3 J122-2 J122-1 J121-3 J121-2 J121-1 J120-3 J120-2 J120-1 J123-3 J123-2 1 2 3 4 5 6 7 8 9 10 11
J207A 11 10 9 8 7 6 5 4 3 2 1 J9A-1 J9A-2 J9A-3 J9A-4 J9A-5 J9A-6 J9A-7 J9A-8 J9A-9 J9A-10 J9A-11 J208-7 J208-6 J208-5 J208-4 J208-3 J208-2 J208-1 J204-3 J204-2 J204-1
J11 J11 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
1 2 3
1
J7-1 J7-2
J116 J116 1 1 2 2 3 3
J1160 J1160 1 1 2 2
Tray 2 lift motor clock sensor2
3 C 2 NO 1 NC
MS3
PI124
PI23
J131
J14B-9 J14B-8 J14B-7 J14B-6 J14B-5 J14B-4 J14B-3 J14B-2 J14B-1
J801 1 2 3 4 5 6 7 8 9
J801 9 8 7 6 5 4 3 2 1
1 2 3 J8021 1 2 3 4 5 6
1 2 3 1 2 3
Delivery motor clock sensor
J8020 1 2 3 4 5 6
Tray 2 Tray 2 lift motor paper sensor clock sensor1
1 2
1 2
M2
J208-5 J208-4
J9B J9B J207B-11 J207B-10 J207B-9 J207B-8 J207B-7 J207B-6 J207B-5 J207B-4 J207B-3 J207B-2 J207B-1 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
J135 1 2 3
1 2 3
FG6
J1151 J1151 1 1 2 2 3 3 FG7 J8010 1 2 3 J8010 3 2 1 J8020 6 5 4 3 2 1
PI25
J8011
PI12
Tray coming close detection switch
J138 1 2 2 3 3
TRAY_SW
MS9
Tray 1 lift motor
3 2 1
J14A-3 J14A-2 J14A-1
1 2 3
PI8
J118-3 J118-2 J118-1
J205 1 2 3
J205 J12B-4 J12B-5 J12B-6
J207A-11 J207A-10 J207A-9 J207A-8 J207A-7 J207A-6 J207A-5 J207A-4 J207A-3 J207A-2 J207A-1
1 2 3 4 5 6 7 8 9 10 11
J130 1 2 3
PI5
J1150 J1150 1 1 2 2
M5
PI19
J14A-12 J14A-11 J14A-10 J14A-9 J14A-8 J14A-7
3 2 1
PI17 SL
J301 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
J302 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 J305 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 J304 1 2 3 4 5 1 2 3 4 5 J307 1 2 3 4 5 6 7 8 9 10 11 12 13 J306 5 4 3 2 1 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13
MS6
J8 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J8 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J400 1 2 3 4 5 6 7 8
J1-1 J1-2
JS1-FG1
JS1
M1 First feed motor
1 2 3 4 5 6 7 8 9 10 11 12
Staple unit
Host machine
Relay PCB4
J12-6 J12-7
6 5 4 3 2 1 J10
J10 1 2 3 4 5 6 1 2 3 4 5 6
Staple shift motor
J2-4 J2-5 J2-2 J2-3 FG1
JS1-3 JS1-4 JS1-1 JS1-2 JS1-8 JS1-9 JS1-11 JS1-12
1 2 3 4 5 6 7 J1 1 2
M4
G +5V HOOKEMP CRTSET STPDRHP STPCON HOOKTOP +24V B A B A J10 6 5 4 3 2 1

A B A B +24V +24V
Saddle unit
Staple motor
M6
A-15
1.
Finisher Controller PCB (A501)

+5V
ADDRESS0
ADDRESS1
ADDRESS2
ADDRESS3 ADDRESS4
ADDRESS5
ADDRESS6
ADDRESS7
2 1
DATA10
DATA11
DATA12
DATA13
DATA14
STPLMM1
STPLMM0
FEED2M3
FEED2M2
FEED2M1
FEED2M0
PREGS5
PREGS4
PREGS3
PREGS2
PREGS1
PREGS0
64
63
DQ2
DATA9
DQ3
EJECT_S0 BUF_PS0 ENTRANS_S0 STPLHP0
DUST0
+5V
118 P14/PO12/TIOCA1 117 P15/PO13/TIOCB1/TCLKC P16/PO14/TIOCA2 116 P17/PO15/TIOCB2/TCLKD 115 Vss16 114 AVss 113 P47/AN7/DA1 112 P45/AN6/DA0 111 P45/AN5 110 P44/AN4 109 P43/AN3 108 P42/AN2 107 P41/AN1 106 P40/AN0 105 104 103
DATA8 ADDRESS24 ADDRESS23
128
PG1/_CS3 127 PG0/_CAS/_OE 126 MD2 125 MD1 124
MD0 123 122
121
120
119
+5V
1 2
1
P12/PO10/TIOCC0/TCLKA
P13/PO11/TIOCD0/TCLKB
P10/PO8/TIOCA0/_DACK0
P11/PO9/TIOCB0/_DACK1
PG0/_CD
UREF
AVCC
C2
ADDRESS20 ENTM3 ENTM2 SERIAL4 SERIAL5 ENTM1 ENTM0 SERIAL2 SERIAL3 SERIAL0 SERIAL1
1 DQ1 2 DQ0 3 W 4 R 5 S
C1
PG3/_CS4 PG4/_CS5
P53/_ADTRG
102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65
P52/SCK2
6 BM 7 INTR 8 9 RXD3 TXD3
3 4
Vss1
Vss15 Vss14 P51/RxD2 P50/TxD2 PF0/_BREQ PF1/_BACK PF2/_WAIT/_BREQO PF3/_LWR PF4/_HWR PF5/_RD PF6/_AS Vcc5 PF7/fa1 Vss13 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/_DREG0/_CS4
ADDRESS0 ADDRESS1 ADDRESS2 ADDRESS3 ADDRESS4 ADDRESS5 ADDRESS6 ADDRESS7 ADDRESS8 ADDRESS9 ADDRESS10 ADDRESS11 ADDRESS12 ADDRESS13 ADDRESS14 ADDRESS15 ADDRESS16 ADDRESS17 ADDRESS18 ADDRESS19
Vss2 5 Vcc1 6 PC0/A0 7 PC1/A1 8 PC2/A2 9 PC3/A3 10 Vss3 11 PC4/A4 12 PC5/A5 13 PC6/A6 14 PC7/A7 15 PB0/A8
EEPROM3 EEPROM2 EEPROM1 ADDRESS25 ADDRESS24 ADDRESS23
+5V
R354
R356 SHIFTM2_0 SHIFTM2_1
21 INT 22 P10 23 XIN 24 XOUT
CNVSS
RST
27 P06 28 P05 29 P04
30 P03 31 P02
19
20
EEPROM0 EXTAL0 [A503]
32 P01
25 Vss 26 P07
10 RXD2 11 TXD2 12 RXD1 13 TXD1 14 CTS3 15 CTS2 16 CTS1 17 CLK 18 P12
62 DQ4 61 DQ5 60 DQ6 59 DQ7 58 Vcc 57 A0 56 A1 55 A2 54 A3 53 A4 52 A5 51 A6
BUF_EP0
24VS0
ENTM [3:0]
JOGM1 JOGM0
STPLMM [1:0] FEED2M [3:0]
JOGM [1:0] PREGS [5:0]
DATA15
A7 50 PA0 49 PA1 48 PA2 47 PA3 46 PA4 45 PA5 44
IC4
PA6 43 PA7 42 PB0 41 PB1 40 PB2 39 PB3 38 PB4 37 PB5 36 PB6 35 PB7 34 P00 33
[A509] PWMG_WRB PWMG_CSB STPL_CONO
C4
[A509] [A509] [A509] R356 [A508] [A502]
CARTRIDGEO STPL_READYO HOOKO TRAYS [2:0] SERIAL [5:0] RESET0
TRAYS2
TRAYS1
TRAYS0
16 PB1/A9 17 PB2/A10 18 PB3/A11 19 Vss4 20 PB4/A12 21 PB5/A13 22 PB6/A14 23 PB7/A15 24 PA0/A16 25 PA1/A17 26 PA2/A18 27 PA3/A19 28 Vss5 29 PA4/A20/_IRQ4 30 PA5/A21/_IRQ5 31 PA6/A22/_IRQ6 32 PA7/A23/_IRQ7 33 P67/_CS7/_IRQ3 34 P66/_CS6/_IRQ2 35 Vss6 36 Vss7
P65/_IRQ1 P64/_IRQ0
X2
2 2 1 1
+5V
C5
C6
IC1
1 2
IC36
4 9
IC30
8
C7
[A502] [A505] [A506] [A507]
SHIFTM_PWM0 EJECTM_PWM0 SWINGM_PWM0 PUNCHM_PWM0 PREGM1 PREGM0 PWMG_SCLK PWMG_SIN FEEDM1 FEEDM0 PUNCH_CLK0 ADDRESS19 ADDRESS18 ADDRESS17 ADDRESS20 ADDRESS21 ADDRESS22
1
+5V IC8
1 4 VOUT GND 2 M-RST VCC 3
C8
R1
SHIFTCK0 SHIFTCK1 SWINGM_CK0 EJECTM_CK0 FEEDM_STEP0
3 C 2 B 1 A
R2
Y6 Y5 Y4 Y3 Y2 Y1 Y0
9 10 11 12 13 14
R3
Y7
IC2 +5V
1 2 3 4 1 2 3 4
CS SK DI DO
VCC
8 6 5
P34/SCK0
P35/SCK1
FEED2M_STEP0
39 Vcc2 40 PE0/D0 41 PE1/D1 42 PE2/D2 43 PE3/D3 44 Vss8 45 PE4/D4 46 PE5/D5 47 PE6/D6 48 PE7/D7 49 PD0/D8 50 PD1/D9 51 PD2/D10 52 PD3/D11 53 Vss9 54 PD4/D12 55 PD5/D13 56 PD6/D14 57 PD7/D15 58 Vcc3 59 P30/TxD0 60 P31/TxD1 61 P32/RxD0 62 P33/RxD1 63
ENTM0
37 38
STPL_TRAY0 [A508]
EEPROM1
EEPROM3
EEPROM2
+5V
HEIGHT1 LAMP0 HEIGHT0 R353 PWMG_OGB 6 4 EEPROM [3:0] 5
+5V
RA2
RA4
64
G1 G2A G2B
+5V
RA1
RA3
DATA10
DATA11
DATA12
DATA13
DATA14
DATA15
DATA0 DATA1
DATA2
DATA3
DATA4 DATA5
DATA6
DATA7
DATA8
DATA9
DATA [15:0] [A502]
C3
+5V
1
ADDRESS [25:0] [A502]
A-16
EEPROM0
Vss10
7 NC 6 TEST 5 GND
15
C10
C9
IC16
1.
ADDRESS [25:0] +5V
+5V
2
IC3
ADDRESS19 DATA7 DATA6 DATA5 DATA4 DATA3 DATA2 DATA1 DATA0
C11
IC6
ADDRESS15 ADDRESS13 ADDRESS8 ADDRESS7 ADDRESS6 ADDRESS5 ADDRESS4 ADDRESS3 ADDRESS2 ADDRESS1 DATA0 DATA1 DATA2
+5V VCC WE A13 A8 A9 A11 OE A10 CS I/O7 I/O6 I/O5 I/O4 I/O3
28 27 ADDRESS25 26 ADDRESS14 25 ADDRESS9 24 ADDRESS10 23 ADDRESS12 22 ADDRESS23 21 ADDRESS11 20 ADDRESS21 19 DATA7 18 DATA6 17 DATA5 16 DATA4 15 DATA3
ADDRESS15
IC7
1 ADDRESS13 2
ADDRESS8 ADDRESS7 ADDRESS6 ADDRESS5 ADDRESS4 ADDRESS3 ADDRESS2
+5V VCC WE A13 A8 A9 A11 OE A10 CS I/O7 I/O6 I/O5 I/O4 I/O3
28 27 ADDRESS24 26 ADDRESS14 25 ADDRESS9 24 ADDRESS10 23 ADDRESS12 22 ADDRESS23 21 ADDRESS11 20 ADDRESS21 19 DATA15 18 DATA14 17 DATA13 16 DATA12 15 DATA11
C12
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
38 ADDRESS17 37 ADDRESS16 36 ADDRESS15 35 ADDRESS14 34 ADDRESS13 33 ADDRESS12 32 ADDRESS11 31 ADDRESS10 30 29 ADDRESS9 28 ADDRESS8 27 ADDRESS7 26 ADDRESS6 25 ADDRESS5 24 ADDRESS4 23 ADDRESS3 22 ADDRESS2 21 ADDRESS1
3 4 5 6 7 8 9 10 11 12 13 14
3 4 5 6 7 8 9 11 12 13 14
C13
1 2 3
PWMG_CSB [IC4 PB7] RESETO [A501] PWMG_WRB [IC4 PB6] PWMG_SIN [CPU P27] PWMG_SCLK [CPU P26] PWMG_OCB [CPU P31]
1 2 3 4 5 6 7
ADDRESS1 10 DATA8 DATA9 DATA10
CSB RB WRB SIN SCLK OCB GND
VCC PWM1 PWM2 PWM3 PWM4 XOUT XIN
14 13 12 11 10 9 8
40 39 ADDRESS18
1 2
DATA15 DATA14 DATA13 DATA12 DATA11 DATA10 DATA9 DATA8
A14 A12 A7 A6 A5 A4 A3 A2 A1 A0 I/O0 I/O1 I/O2 VSS
A14 A12 A7 A6 A5 A4 A3 A2 A1 A0 I/O0 I/O1 I/O2 VSS
C171
IC30
11 10 SHIFTM2_PWMO [A504]
IC38
2
PWMO [A503]
SERIAL [5:0] [A501] +5U +5U PPC OUT 1 2 3 4 Q1 5

1 2
D1
R7
J2 J2 J2 J2
19 ADDRESS23 20
SERIAL0
R5
100P.50V
2
R6
DATA [15:0]
OPEN6 SHIFTCK2_1 SHIFTCK2_0 TRAY_HP2
IC21 +5V RESET

ADDRESS22
SOLOUT [7:0]
SOLOUT6 SOLOUT5 SOLOUT4 SOLOUT3 SOLOUT2 SOLOUT1 DATA15 DATA14 DATA13 DATA12 SOLOUT0 SOLOUT7 DATA11 DATA10 DATA9 DATA8
SERIAL1
C16
R8 R9
+5V +5U
ISS270A
100
+5U
J2 SADDLE OUT 1 J3 2 J3 J3 J3 J3 J3 J3 J3
6 5
RA17
99
98 97
96 95
94 93
92
91 90 89
88
87
86 85 84
83
82
81
80
79
78
77
DBS P87/D15 P86/D14 P85/D13 P84/D12 P83/D11 P82/D10 P81/D9 P80/D8 GND8 GND7 D7 D6 D5 D4 D3 D2 D1 D0 P77 P76 P75
RESETB
P74 76
CSB
R12
D2
ADDRESS23
1 RDB ADDRESS24 2 WRB ADDRESS0 3 A0/HWRB

ADDRESS1 ADDRESS2 ADDRESS3
75 P73 P72 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
2
SERIAL2
3 4
C17
PUNCH_U1
+5V
8 9 11 12 13
SERIAL3 3
PUNCH_U [4:0]
PUNCH_U0 PUNCH_U2
6 7
IC21
R15
PUNCH_U3 10
+5V
R352 R351 R357
IC5
UPD65625GC-052-7EA
JOGM_I0 STPLMM_I0 HEIGHT_ON0 SHIFTM_0 SHIFTM_1 EEPSK0 EEPCS0 EEPDO0 C14

1
PUNCH_U4 14
15 16 17 PUSH_SW1 18
29 DIP_SW4 30 DIP_SW5 31 DIP_SW6 32 DIP_SW7 33
49 50 P45
P17
26 P20 27 P21 DIP_SW2 28 P22
34 35 36 37 38 39
40 41 42
43
44
45 46
47
48
P23 P24 P25 P26 P27 P30 P31 P32 P33 GND3 GND4 VDD2 P34 P35 P36 P37 P40 P41 P42 P43 P44
PUSH_SW [1:0] EEPDI0 STPLMM_HP0 JOG_HP0 TRAY_HP0 SHUTER_S0 SWING_S0
PUSH_SW0
19 20 21 22 23 24 25
A1 A2 A3 P00 P01 P02 P03 GND1 GND2 VDD1 P04 P05 P06 P07 P10 P11 P12 P13 P14 P15 P16
P71 P70 P67 P66 P65 P64 P63 P62 P61 P60 VDD3 GND6 GND5 P57 P56 P55 P54 P53 P52 P51 P50 P47
R10
R11 +5U
5 6 +5U R16 7 8
R13 R14
Q2
1
+5V
2
SS_CONNECTO
C15
1
+5U
SERIAL4
OPTION OUT
FEEDM_I0 LAMP_1 FEED2M_I0 ENTM_I0 ENTM_I1 PREG_I0 STEPMOFF0 STPLM_W0 STPLM_W1

EJECTM_W0 EJECTM_W1 PUNCHM0 PUNCHM1 SWINGM_W0 SWINGM_W1 OPEN [4:0]
R17
+5V R350 IC21

SERIAL5 5 6
52 P46 51
DIP_SW0
DIP_SW1
DIP_SW3
+5V
OPEN4
DIP_SW [7:0] JOINT0 UPPERC_S0 SS_CONNECT0
OPEN3 OPEN2 OPEN1 OPEN0
A-17
1.
J2 J2
6 7 +24R
+5V
C20
R23
C23
C26
R26
R24
IC9
1 N.IN1 N.IN2 16
X1
R30
D4
C25
IC10
1
XIN VDD
C23 R28
2 ININ1 ININ2 15 3 FB ROUT 14 4 TCON OCON 13 5 CT 6 RT Vcc 12 C2 11 E2 10 9 E1
8 7
Q4
1 2 2
ICP11
1
L1
R33
1 2
JNT1
2
R37
C28
C27
R25
R27
R29
JP100
1
R349
R35
J19 J19
1 2
ETH1
1
IC17 EXTAL0 [A501] R34

4 2 1
+24V
CB1
J1
1
[A502]
PWM0 [A505] [A506]
C19
ETH2
1 2 3 E 2
J1
ICP12
1
R36
C21
R31
CP1
C174
C22
D5
7 GND 8 C1
+5V
1
R32
R39
+5U +5V
2 XOUT
MODOUT/RS0 3 REF-OFF 6 REFOUT/RS0 4 5 LF Vss
R38
3
+24U
+24VSHIFT [A504]
DOOR_SW 1 J5
+24VMOVE
+5V +5V
R42
ZD1
J5
2
1 2 3
Q5
2
R40
J5 J5 J5
C29
AREA_SW
+5V
OPEN2 P33 P35 OPEN4
ZD2
5
1 2 3
Q6
2
R44
OPEN3 P34 OPEN3
SWING_GUIDE_SW1 6 J5
J5 J5 J5
7
R43
C30
+5V
+24VSTPL
ZD4
9
1 2 3
Q7
2
R46
SWING_GUIDE_SW2
OPEN0 P37 OPEN0 +5V

11 12
R48
R45
C32
C31
+ SHATTER_OPEN_SW J7 J7 J7
7
IC22
13
5 6
IC22
4 2 3
C36
IC22
1
SHIFT_BREAK [A504]
R47
ZD3
5
1 2 3
Q8
2
OPEN1 P36 OPEN1
JP105
IC22 8
9 10
C33
OPEN [4:0] [A503]
A-18
1.
+5V +24VSHIFT
[A503]
IC16
VCC GND 8
16
C41 IC17
1
C42
5
2
IC18
VCC GND 7
14
C43
2
IC19
VCC GND 7
14
C44
2
IC20
VCC GND 8
16
C45
2
IC21
VCC GND 7
14
C46
2
IC22
VCC GND 7
14
C47
2
IC23
VCC GND 7
14
C48
2
TRAY_SW J5
J5
10 11
C37 +5V
R50
2 1
C38
2 1
+5V C49 IC25

14
1
R55
IC24
2 3 1
R56
IC24
VCC GND 7
C50
14
2
IC26
VCC GND 7
14
C51
2
IC27
VCC GND 7
14
C52
2
IC28
VCC GND 7
14
C53
2
IC29
VCC GND 7
14
C54
2
IC30
VCC GND 7
14
C55
2 1
SHIFTM_PWM0
[CPU P20]
R57
Q13 3
Q14 SHIFT MTR1 4 J7 3 J7 +5V C56 IC32

14
1
Q11
1
SHIFT_BREAK
[A503]
2 2
[65625 P64]
R53
Q16
VCC GND 7
VCC GND 7
VCC GND 7
VCC GND 3
SHIFTM_0
IC23 Q15 3
IC31
C57
14
IC33
14
C58
IC36
5
C59
+5U +5U SHIFTM_1

R54
[65625 P63]
4 5
VCC GND 7
R68
SHIFT CLK2
A7 A8
J14 J14 J14
IC23
5 6 1
IC24
4 3
R58
Q12
SHIFTCK1
[CPU PA6]
IC25
6 5
R65
2
R67
A9
C61 +5V
R348
1
C62
1
+5U R72
SHIFT CLK1
A10 A11
+5U
R71
J14 J14 J14
OPEN6
[65625 P83]
Q65
2
ZD7
2
2
3
1
SHIFTCK0
[CPU PA5]
IC25
8 9
R69
2
A12
2
C172 +24VSHIFT
[A503]
C63 +5U C40

2 1
C64
1
+5U R76
SHIFT CLK2_2
B1 B2
J14 J14 J14
C39 +5V
R51
2 1
SHIFTCK2_1
[65625 P82]
IC25
10 11
R73
2
R75
B3
R61
IC24
2 3 10
R62
C65
1
C66
1
+5U R80
SHIFT CLK2_1
B4 B5
SHIFT2_PWM0
[A502]
R63
+5U Q19 3
3
Q20 SHIFT MTR2 2 J7 1 J7 IC25

12 13
SHIFT_BREAK
[A503]
2 2
SHIFTCK2_0
[65625 P81]
R77
2
R79
Q17
J14 J14 J14
B6
SHIFTM2_0
[IPC CLK]
9 10
IC23
8
R59
Q22
SHIFTM2_1
R60
[IPC P12]
12 13
IC23
11 11 12 1
IC24
13 3
R64
Q18
Q21 3
C67
C68
A-19
VCC GND 3
1.

JOGM [1:0] +5U EJECT SENS STEPMR0 [A509] +5V JOGM0
[CPU P17]
2 1 3 2
+5V
+5V
+24V
1
R83
EJECTM_S0
[CPU PG1]
IC31
8 9 6
IC31
5
J11 J11
JOGM_I0
[IC5 P67]
+5U
3
Q35 R106
3 5 7 9
R81
2
R82 C69
1
R105
C77
REFA INA RSA RSB TDB REFB OUTB
TDA GNDA OUTA VS OUTB GNDB INB
2 4 6 8 10 12 14
OUTA
C80
J11
R109
IC11
R110
ICP5 JOG MOTOR

B6 B7 B8 B9 B10 B11
J9 J9 J9 J9 J9 J9
C70
1
R102
R103
CP2 +24V
1
R108
R107
C78
11 13 15
R104
ICP3 +5V
2
C79
C71
2 1
C72
2 1
+24V ICP6 JOGM1

1 2
1
R87
R88
3
R86
EJECTM_PWM0
[CPU P21
+5V
2 1
IC26
Q23
R89
Q25 3
Q26 EJECT_MT 4 J11 5 J11
[CPU P16]
PADDLE_SL B1 J9
+5V
R84
D6 SOLOUT4
[IC5 P75]
[IC5 P44 CW]
+5V
Q27 3
R112
EJECTM_W1
IC26
3
R113
Q36
2 3 1
Q28
+5V
R85
SOLOUT5
R111
4
8 9
R114 IC33
8
B2 J9 ESCAPE_SL A10 J9
EJECTM_W0
[IC5 P45 CCW]
10 11 12
IC18
Q 5 Q 6
IC26
13
Q24
3
2 1
R90 PWM0 [A503]
2 3
PR D K CLR
[IC5 P77]
Q37
1
SOLOUT6
10
R115
IC26
[IC5 P76]
D7
A11 J9
FLAP SL A7 J12 D8
2
+24V
1
IC28
3
SOLOUT3
[IC5 P74]
ICP4 +5V
2
Q38
1
C73
2 1
C74
2 1
R116
A8 J12 BUFFER INT SL B9 J12
D9
RESET0 [A501]
R93
[IC5 P73]
Q39
1
SWINGM_PWM0
[CPU P22]
IC27
2 3 1
Q29
3
2 1
R96
Q31 3
Q32 SWING_MT 6 J11 7 J11

9
R94
R95
SOLOUT2
IC28
R117
B10 J12 BUFFER OUT SL 7 J24
R91
[IC5 P40 CW]
R92
+5V
SWINGM_W1
IC27 Q33 3
3
SOLOUT0
[IC5 P71]
10
R118
+5V
D10 IC28
8
J24
Q40
IC28
11
Q34
RB_ SL B7 J12 D11

B8
SWINGM_W0
[IC5 P41 CCW]
[IC5 P70]
11 12
IC27
13
Q30
3
2 1
R97
+5V SOLOUT1
[IC5 P72]
Q41
IC27
10
SOLOUT7
13
12
R119
J12 J24 J12 J12
NC NC NC
9 A9 A10
R120
+5U +5U R101
SWING OPEN SENS

8 9
J11 J11 J11
IC21 SWING_S0
[IC5 P17]
10
11
R98 C75
R100
SOLOUT [7:0] [A502]
10
C76
A-20
1.
+5U +5U
1
+5U R158
ENTRANCE_SENS
7 8
+5U
R123 R157
J17 J17 J17 J17 J17
D12
[CPU P33]
HEIGHT0 C81
1
R121
D13
CP3
IC25 ENTRANS_S0
1 4 3
R122
+5U
R155 C98 C99
J6
[CPU PG3]
NC NC
10 11
J6 +5U
R161
C82
+2
IC20 Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11

9 7 6 5 3 2 4 13 14 15 1 12
4 5
R126
+5U R162
JOINT_SENS
A1 A2
J12 J12 J12
IC29
6
J6 JOINT0 R159
2
IC29 PWM0
[A503]
1 2
10
Q42
C83
1 4
R160
2
A3
CP
[IC5 P30]
J6
HEIGHT_ON0
[IC5 P65]
11
MR
R124
R125
IC29
9 10 8
+5U
R169
C100
C101
+5U R170
STPL MOVE H .P
A4 A5
CP4 HEIGHT1
[CPU P35] 8
IC21
9 12 13
J12 J12 J12
IC29
11
IC25 STPLMM_HP0
[IC5 P13]
C84
1
R167
2 2
A6
+5V
IC18
12 11
10
+5U
R173
Q 9 Q
8
C104
C105
+5U R174
UPPER_COVER_SENS
B1 B2
PR D K CLR
FEEDM_STEP0
[CPU P66]
J12 J12 J12
UPPERC_S0
[IC5 P31]
R171
2
R172
2
B3
RESET0
[A501]
13
+5V
R135
+24V
2
FEEDM0
[CPU P62]
+5V
R134
IC12
1 OUTA 3 REFA 2 4 6 8 10 12
+5U ICP7 J10 J10 J10 J10 J10 J10 SHUTER_S0

[IC5 P16]
C106
C107
+5U R178
SHUTTER_OPEN_SENS
B4 B5
STEPMR0
[A509]
J12 J12 J12
+5V Q43
1
R130
2
C88
2 3 4 5 6
FEEDM_I0
[IC5 P25]
TDA GNDA OUTA Vs OUTB
R175
2
R176
2
R177
R127
R128
CP5
R133
R132
C86
9 RSB 11 TDB
R129 C87 FEEDM1

[CPU P63]
13 REFB GNDB 14 INB 15
OUTB
FEED MOTOR 1
R131
C85
1
5 INA 7 RSA
B6
C108
C109
A-21
1.

FEED2M_STEP0
[A501]
[CPU P64]
+5V
10
IC19
Q Q
9
PR
12 11
D CK CLR
RESETO
[A501]
13
+24V +5V
2
[A501]
R143
IC13
2
[CPU P13]
FEED2M0 +5V Q44 FEED2M_I0

[IC5 P55]
2 3 1
FEED MOTOR2
1 2 3 4 5 6 7
4
PR 2 3 D K
FEED2M [3:0]
[A509]
R144
ICP8
STEPMR0
+5V
IC19
Q Q 5 6
J16 J16 J16 J16 J16 J16 J16
R139
2
R140
C89
R141 R142
C90
C91
[CPU P12] [CPU P10] [CPU P11]
FEED2M1 FEED2M3 FEED2M2 RA5 +5V

2 1
RA5
3 4
CP6
R138
1 OUTA 3 REFA TDA 5 INA GNDA 7 RSA OUTA VS 9 RSB OUTB 11 TDB 13 REFB GNDB INB 15 OUTB
2 4 6 8 10 12 14
1
C92
CLR
R136
R137
+24V ENTM0 +5V
ENTM[3:0]
[A501] [CPU P50]
[A509]
FEED2M0
R154
ICP9
STEPMR0
[A501]
[CPU P65]
+5V
C97
R153
+5V ENTM_I0
[IC5 P53]
1 3 1 3 2
IC14
2
1 2 3 4 5 6
J17 J17 J17 J17 J17 J17
[A502]
Q45
2
2
ENTM_I1
[IC5 P52]
R146
[A502]
Q46
R150
R145
R147
C93
2
CP7
R148
R152
R151
C94
5 INA GNDA 6 7 RSA OUTA 8 VS 9 RSB 10 11 TDB OUTB 12 13 REFB GNDB 14 INB 15 OUTB
1 2
C95
R149
1 OUTA 3 REFA
TDA
C96
[CPU P51] [CPU P53] [CPU P52]
ENTM1 ENTM3 ENTM2 +5V RA51 RA5

3 2
ENTRANCE FEED MOTOR
A-22
1.
+5U TRAYS [2:0] (A502) +5U R182
R181

STPLTRAY EMP SENS R216
R215
FIRST TRAY SENS A4 J14 A5 A6 J14 J14 IC30

12 13
+5U
+5U
[ICP P05]
TRAYS0
R179
2
R180
2
A1 A2 A3
J9 J9 J9
C110
1
+5U
R185
C111
1
+5U R186
SECOND TRAY SENS B7 J14 B8 B9 J14 J14
STPL_TRAY0 [CPU P60]
R213
2 2
C123
1
C124
[ICP P06]
TRAYS1 +5V
R187
R183
2
R184
2
+5U
R219
+5U R220
C112
1
+5U
R190
C113
1
+5U R191
JO H.P SENS A4 J9 A5 A6 J9 J9
TRAY H.P SENS A1 J14 A2 A3 J14 J14 JOG_HP0 [IC5 P14]

12
IC21
13
R217
2 2
[ICP P07] TRAY_HP0 [IC5 P15]
TRAYS2
R188
2
R189
2
C125
1
C126
1
C114
1
+5U
C115
1
+5U R195
TRAY H.P SENS2 B10 J14 B11 J14 B12 J14 R221
2
+5U EJECT_CLK A7 J9 A8 +5U

2
R194
TRAY_HP2 [IC5 P80]
R192
2
R193 C116
1
CP8
1
+5U
R202
C117
1
+5U R203
BUF_ENT_SENS 1 J24 2 3 J24 J24
EJECTM_CK0 [CPU P67]
R222 C127
1
R223
J9 J9
C128
1
A9
BUF_PS0 [CPU PG0]
IC30
2 1
R200
2
+5U SWINGM_CLK B3 J9 B4 +5U

2 2
C118
1
+5U
R206
+5U R207
5 6
J24 J24
BUF_EP0 [CPU PG2]
IC30
2 1
R204
2
SWINGM_CK0 [CPU PA7]
R224 C129
1
R225 C130
1
R226
BUF_P_SENS 4 J24
J9 J9
C119
1
+5V
1
B5
+24U
R209
D14
R191
C120
R211 R212
+5V
R210
24VS0 [CPU P41] PUSH_SW [1:0] [A502] [IC5 P11] [IC5 P10] DIP_SW [7:0] [A502] RA7 [IC5 [IC5 [IC5 [IC5 [IC5 [IC5 [IC5 [IC5 P27] P26] P25] P24] P23] P22] P21] P20] DIP_SW7 DIP_SW6 DIP_SW5 DIP_SW4 DIP_SW3 DIP_SW2 DIP_SW1 DIP_SW0 PUSH_SW0 PUSH_SW1
R208
LED2 LAMP1 [IC5 P56] IC30 LAMP0 [CPU P34]

5 6 1 2 1 2
+5V R227
SW1 SW2
LED1 R228
+5V
2 4 6 8 2 4 6 8
LED1
RA6 SW3
8 7 6 5 4 3 2 1 9 10 11 12 13 14 15 16
A-23
1.
+5U
STPL_READY0 [IC4 P02]
R229 C131
R230
R231
J8
READY1
+5U
STPL_CON0 [IC4 P00]
R232 C132
R233
R234
J8
CONNECT1
+5U
IC31 STPLHP0 [IC4 PG4]

2 1
R235
2
R237
J8
STAPLE H.P1
C133
+5U
CARTRIDGE0 [IC4 P01]
R238 C134
1
R239
R240
J8
NO CARTRIDGE1
+5U
HOOK0 [IC4 P03] +5V

1
IC31
4 3
R241 C135
R243
10
J8 J8 J8
HOOK SENSE1
+24VSTPL C151
2 1
+5U
C152
2 1
11 12
+5V
R269
Q49
2
R274
Q50
2
R275
1 1
R268
R270
2
2 3
IC32
1 3
R276
Q53 3
Q54
13 14
J8 STPL MTR1 J8
C146
1 2
IC33
2 2
3 3 3
STPLM_W1
[IC5 P46] [CW]
+24U
Q55
Q56
15
R283
+5V
D15
C149 D17
1 2
J8
IC34
8 1 4
IC34
7
R278
6 5
+ -
3 2
R279 IC33
11 8 9
R282
R271
12 13
IC32
10
D16
R284 C150 2
R277 +5V
1 11 12 2
R285
C148
R281
R280
STPLM_W0
[IC5 P47] [CCW]
IC33
4
IC32
13
R272 C147
5 6
IC32
4 3
+5V
1
Q52
+5V
+24VMOVE
1
R266
R267
STPLMM [1:0] [A501]
R273 STPLMM0 [CPU P15]

1
Q51
2
IC15
1 OUTA 3 REFA TDA 5 INA GNDA 7 RSA OUTA VS 9 RSB 11 TDB OUTB 13 REFB GNDB INB 15 OUTB 2
ICP10
C144
Q47
2
R262
2
+5V
3
5 4 3
J8 J8 J8 J8 J8
STPLMM_I0
[IC5 P66]
4 6 8 10 12 14
R259
Q48
3
CP9
R260
+5V
R263
C141
STEPMOFF0
[IC5 P50]
R265
R264
C142
C143
2
C145
STEPMR0 [A505] [A506] [A507]
STPLMM1 [CPU P14]
A-24
R261
STPL MOVE MOTOR
1.
+5U
R306
PREGS[5 : 0] [A501]
[CPU P42]
PUNCH_U[4 : 0]
+5U A4
B1
PREGS0
R304
2
R305 C160
+5U
R309
[IC5 P01]
PUNCH_U1
IC31
10 11
R332
R334
J21
P_HP
B7
J21
J21 +5U
C161
[CPU P43]
PREGS1
R307
R308
B4
B2
C166
+5U
R312
[IC5 P02]
PUNCH_U2
IC31
12 13
R335
R337
C162
R315
+5U
C167
[CPU P44]
PREGS2
R310
R311
REG_HP
B8
A4R
B3
J21
J21
+5U
[CPU P45]
PREGS3
R313
2
R314 C163
B5R +5U
B4
J21
[IC5 P03]
PUNCH_U3
R338
R339
R340
PUNCH_F_COVER
B9
J21
[CPU P46]
PREGS4
R316
2
R317 C164
R318
R_EDGE
B5
J21 NC +5U J21 PUNCH_CLK0 [CPU P61]

B10
C168
J21
+5U
R344 C170
2
R345
R346
[CPU P47]
PREGS5
R319
EDGE_LED
B6
PUNCH_CLK B11
J21
RA10 PUNCHM1 PUNCHM_PWM0 PUNCHM0 PREGM0

[IC5 P42] [CPU P23] [IC5 P43] [CPU P25]
1 3 5
1 3 5 7 2 4 6 8
R320
RA8
A1
+5U
J21 A2 J21 A3 J21 A4 J21

[IC5 P00] [IC5 P04]
A5
6 5
RA12 PUNCH_U0 PUNCH_U4

1 3 7
RA11
1 3 5 7 2 4 6 8
PREG_I0 PREGM1 STEPMOFF0 EEPDO0
[IC5 P51] [CPU P24] [IC5 P50] [IC5 P60]
RA9
1 3 5 7 2 4 6 8
PUNCH_U_UMU PUNCH_U_COVER NC NC NC
B12 J21 A13 J21 B14 J21 A13 J21 A14 J21
J21 A6 J21 A7 J21 A8 J21
R321
R322
+5U
1
+5V EEPCS0
[IC5 P61]
J23 J23 J23 J23
R323 R324 R325 +5U
A9
J21
A10
2 3 4
EEPSK0
[IC5 P62]
J21
A11
+24VMOVE
EEPDI0
[IC5 P12]
J21
R327
DUST0
[IC5 P80]
R329
R330
R331
R328
R326
A12
C165
1
J21
A-25
G.
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
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
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-26
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
VCC
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
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
A23
A22
A21
A20
P77
P76
P75
P74
P73
P72
P71
PB4
PB3
PB2
PB1
PB0
AVSS
VSS6
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-27
1.

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-28
1.
24S<502> 1 2
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-29
1.

+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-30
1.

+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-31
1.

+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-32
1.
ICP10 C160
2 1 +24U
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-33
H.
PUNCHER UNIT (option) CIRCUIT DIAGRAM

12 11 10 9 8 7 6 5 4 3 2 1
PI1P Punch home position sensor
J102 1 2 3 1 2 3 J1A-3 J1A-2 J1A-1 J1A J102-3 J102-2 J102-1 1 2 3 4 5 6 7 8 9 10 11 J1A 1 2 3 4 5 6 7 8 9 10 11 +5V SREGHP G J5 +24V 1 UDROPN 2 3 FDROPN 4 J5 1 2 3 4
PI2P Punch motor clock sensor
1 2 3
1 2 3
J1B-6 J1B-5 J1B-4
J101-4 J101-3 J101-2 J101-1
B A B A
1 NO 2 C 3 NC
J1B J104-3 J104-2 J104-1 J105-3 J105-2 J105-1 J112-4 J112-3 J112-2 J112-1 1 2 3 4 5 6 7 8 9 10 11 PI3P Punch home position sensor
J1B 1 2 3 4 5 6 7 8 9 10 11 G +5V PUNCHHP G PUNCHCLK +5V +5V LEDON DFULL G G +5V G +24V
J104 1 2 3 1 2 3 J1B-1 J1B-2 J1B-3
MS2P Front door switch
J105
J106
D
J4 1 2 3 4 J4 1 2 3 4 J23 1 G 2 +5V 3 G 4 +24V
M2P Horizontal registration motor
J101 4 3 2 1
J101 1 2 3 4 J1A-10 J1A-9 J1A-8 J1A-7
Punch driver PCB

J3A J7 J10-6 J10-5 J10-4 J10-3 J10-2 J10-1 J11-7 J11-6 J11-5 J11-4 J11-3 J11-2 J11-1 1 2 3 4 5 6 7 8 9 10 11 12 13 J7 1 2 3 4 5 6 7 8 9 10 11 12 13 LEDON5 LEDON4 LEDON3 LEDON2 LEDON1 G PAEND SREG4 SREG3 SREG2 SREG1 +5V G 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J3A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J21A 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J11
J11 1 2 3 4 5 6 7 -1 -2 -3 -4 -5 -6 -7
J115 -1 -2 -3 -4 -5 -6 -7 J7-13 J7-12 J7-11 J7-10 J7-9 J7-8 J7-7
Photosensor PCB
1 2 3 4 5 6 7
C
Finisher unit
J10 1 2 3 4 5 6
J10 1 2 3 4 5 6 -1 -2 -3 -4 -5 -6
J116 -1 -2 -3 -4 -5 -6 J7-6 J7-5 J7-4 J7-3 J7-2 J7-1
LED PCB
J3B 1 2 3 4 5 6 7 8 9 10 11 12 13 14
J3B 1 2 3 4 5 6 7 8 9 10 11 12 13 14
J21B 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Scrap full detection PCB
J112 1 2 3 4
J112 1 2 3 4 J1B-10 J1B-9 J1B-8 J1B-7
M1P Punch motor
J113 1 2 1 2 M
J114 1 2
J114 1 2
J2 1 2
J2 1 2
A-34
1.
+24U +5V ICP2 TO DCON J3
A14
Punch Driver PCB (A502)
R14
R2 R7 +5V R15 Q5
2 3 1 3 2 1
R1
1
R4
3
R3
Q1 3
Q2
2 1
J2 PUNCH MOTOR J2
Q7
2 2
J3
Q7 +5V
8 9 10
A13
R8
5 6
Q3
4 3
Q4
R16
Q7 R9 Q6
11 12 13 3 2 1
R5 R6
J3
A12
Q7
+24U ICP1 +5V
+
C3 C1 C2
Q8
1 MB T Vmm GND GND Vcc I1 Ph E MA Vmm GND GND VR C I0 16 15 1 2
Q22
MB T Vmm GND GND Vcc I1 Ph E MA Vmm GND GND VR C I0 16 15
C19
R22
C5
4 5 6
13 12
4 5
13 12 11 10 9
R23
11 10 9
R21
R25
7 8
7 8
R10
R11
R12
R13
C18
C4
R19
14
14
R20
+5V
A7 A8 A8 A10 A11 A9 N.C.
J3 J3 J3 J3
J1 J1 A9 J1 A10 J1 A11 J1
PUNCH REG MOTOR
Q12 J3 J3 J3 J3
A6 A5 A7 A4
+5V
8 7 6 5
R58
R59 R60 R61
1 2 3 4
CS SK DI DO
VCC NC TEST GND
C11
R35
R36
R37
R38
A-35
1.
Punch Driver PCB (A503)

TO DCON J4 J4
4
+24V +5V + +24V Q7 +5V

14 VCC 7 GND
+5V
C6
C10 J5 PUNCH UPPER COVER J5 J5
1 2 3
R43 ZD1 Q14 +5V R41 +24U C14 R44

B2
J4 J4 TO DCON
+
1
J3
C7
+5V
13 12
J7 J7 J7 J7 J7 J7 J7 PHOTO_SENS_PCB PUNCH FRONT COVER J5

4
ZD2 C15 R42
Q15
B6
J3 J3 J3 J3 J3
B10
11 10 9 8 7
J3
+ C16
J7 +5V R34 REG HP SENS A1 J1

A2
+5V
R52 R46
5
+24V C9
+5V
Q17
J7
+5V
R53 R47
4
J1 J1
D1
J3
B9
R30 C17
Q11
5 6 4 8 7
Q18
J7 LED_PCB
J3
B7
A3
+5V
R54 Q19 R48
3
+5V DUSTBOX SENS R33

A4 A5
J1 J1
J7
+5V
R55 Q20 R49
2
J7
J3
B5
J1 PUNCH HP SENS
B1
A6
+5V
R56 Q21
B10
R50
1
J1 J1 J1
J7 J1 J1 DUST_SENS_PCB
J3
B8
B2
+5V
B3
J3
A3
B9
+5V +24V Q11

8 1 3 4 2
R57 Q16
R45
B8
PUNCH CLK SENS

B4 B4 B5
+5V
B7
J1 J1 J3 +5V
B6
J1 J1 J1
+5V R39 J3 J3 J3
B1 A2 B3
R40
J3
A1
N.C
A-36
APPENDIX
2.
1 J10 LED1 2 J10
LED PCB
LED2
3 J10
LED3
4 J10
LED4
5 J10
LED5
6 J10
A-37
3.
Photosensor PCB
C7 R13 +5V +5V +5V 6 5 Q2 +5V PTR1 6 J11 1
C1 R1
JP2 R4
R16
Q1 2 3
PTR4 1
2 3
- 8 + 4
7 C14
JP3
JP4
2 3
8 1 3 J11
+ 4
D4
D1
C9 R17 +5V +5V Q3 2 3 +5V PTR2 1 4 7 J11 1 2 3 6
C3 R5 +5V Q1
R20
R8
PTR5 1
2 3
- 8 + 4
7 C13
JP1
J11
JP6 D5 D2
C5 +5V Q3 6 5 8 7 C15 PTR3 1 2 3 +5V +5V R9 +5V 2 J11 8 1 4 5 J11 1 J11
JP5 R12
+ 4
Q2 2 3
D3
A-39
4.
Scrap full detector PCB
+5U
4 3
J671 J671
C673 R674 1 R673 2
C672 +5U 8 1 1 3 2 LED6 1 1 PTR6 3 1 2 1 D671 1 J671 Q671 2 2 R671 4 2 R672 2 J671
+5U
+5U
6 Q671 5
8 7 4 2 C671 1
A-40
I.
12 11 10 9 8 7 6 5
INSERTER UNIT (option) CIRCUIT DIAGRAM

1.
4 3 2
Harness diagram
1
Joint switch
Host machine interface Transport sensor
Control panel
Finisher interface
Transport motor
Joint sensor
Connector of jig board

Transport cover 1 open/close sensor Feed motor Empty sensor
Separation sensor Reverse solenoid Reverse path sensor Pickup trigger solenoid
Tray open/close sensor
Pickup clutch
Paper length sensor
Fan motor
Paper width detection volume
PCB-VR Transport cover 2 open/close sensor
A-41
2.
Control PC Bood Circuit
12
11
10
Joint switch
Transport motor
Power from host machine
Power for finisher
E
Host machine interface Feed motor
Finisher interface
Joint sensor Transport cover 1 open/close sensor
D
Reverse solenoid Pickup trigger solenoid Pickup clutch
Empty sensor Separation sensor Reverse path sensor
Transport sensor Tray open/close sensor
Fan motor
Paper length sensor Connector of jig board Paper width detection volume Transport cover 2 open/close sensor Control panel
Punch LED Mode LED1 Mode LED2 Mode LED3 Mode LED4 Punch key Mode key
not mounted parts
Start key Start LED1 Start LED2
A-43
3.
Circuit Diagram
12
11
10
F
Joint switch Transport motor
Host machine interface
Finisher interface
Feed motor
D
Joint sensor Transport cover 1 open/close sensor
Reverse solenoid Pickup trigger solenoid Pickup clutch
Empty sensor Separation sensor Reverse path sensor Transport sensor Tray open/close sensor
Fan motor
Paper length sensor Connector of jig board Paper width detection volume Transport cover 2 open/close sensor
B
Control panel
Punch LED Mode LED1 Mode LED2 Mode LED3 Mode LED4 Punch key Mode key Start key Start LED1 Start LED2
not mounted parts
A-44
APPENDIX
J.
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-45
1-1, KANDA NISHIKI-CHO, CHIYODA-KU, TOKYO, 101-8442, JAPAN

Toshiba MJ 1017/18 Service Handbook

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Toshiba MJ 1017/18 Service Handbook

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File No.

31100204 R02032112400-TTEC Ver01 2002-09

Copyright 2002 TOSHIBA TEC Corporation

CHAPTER 2 FINISHER UNIT BASIC OPERATION

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION

CHAPTER 5 INSERTER UNIT (OPTION) BASIC OPERATION

CHAPTER 6 MECHANICAL CONSTRUCTION

CHAPTER 7 MAINTENANCE AND INSPECTION

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

Size mixing Stacking mixing

CHAPTER 1 GENERAL DESCRIPTION

Item Stapling Stapling position Stapling capacity

Staple supply Staples Staple detection Manual stapling Stapling size

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

Paper detection Control panel Display Dimensions (W D H)

Power supply Maximum power consumption

CHAPTER 1 GENERAL DESCRIPTION

Stapling Positions (finisher unit)

1-point stapling (rear)

1-point stapling (diagonal; front)

1-point stapling (diagonal; rear)

30 4.44mm/ -0.170.16in Specified paper width -64mm/ -0.240.16in

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

834mm/ 3.260.16in 2034mm/ 7.980.16in

634mm/ 2.470.16in 1834mm/ 7.190.16in

744mm/ 2.90.16in 1944mm/ 7.630.16in

A4-R and FOLIO

62.54mm/ 2.460.16in 138.54mm/ 5.450.16in

62.54mm/ 2.460.16in 144.54mm/ 5.690.16in

Specified paper width -64mm/ -0.240.16in

CHAPTER 1 GENERAL DESCRIPTION

Saddle Stitcher Unit

Folding method Folding mode Folding position Position adjustment

Power supply Power consumption

From finisher unit DC24V, DC5V 160 W or less

CHAPTER 1 GENERAL DESCRIPTION

Staple and Folding Position (saddle stitcher unit)

Edge Edge of of staple staple

632mm/ 2.70.08in 1832mm/ 7.420.08in

39.52mm/ 1.770.08in 159.52mm/ 6.50.08in

Stack front edge

742mm/ 3.140.08in 1942mm/ 7.860.08in

42mm/ 1.890.08in 1622mm/ 6.610.08in

CHAPTER 1 GENERAL DESCRIPTION

Puncher Unit (Option)

Punching method Paper size

Paper weight Punched hole diameter

Punched scrap capacity

Power supply Power consumption

Hole position (Puncher Unit)

[1] 2 holes (Puncher Unit MJ-6003E)

801 mm/ 3.150.04 in 123 mm/ 0.470.12 in

CHAPTER 1 GENERAL DESCRIPTION

[2] 2 or 3 holes (Puncher Unit MJ-6003N)

701 mm/ 2.760.04 in 123 mm/ 0.470.12 in

1081 mm/ 1081 mm/ 4.250.04 in 4.250.04 in 123 mm/ 0.470.12 in

[3] 4 holes (Puncher Unit MJ-6003F)

801 mm/ 801 mm/ 801 mm/ 3.150.04 in 3.150.04 in 3.150.04 in

123 mm/ 0.470.12 in

[4] 4 holes (Puncher Unit MJ-6003S)

211 mm/ 701 mm/ 211 mm/ 0.830.04 in 2.760.04 in 0.830.04 in