Oki Data C 9600, C 9800, ES 3640 finisher, 2H, 2/3H, 4HF, 4HS puncher Service manual

Oki Data CONFIDENTIAL

PRINTING SOLUTIONS

C9600/C9800/ ES3640

Finisher Maintenance

Manual

051108A


INTRODUCTION

Meaning of Symbols

The symbols below are used in this manual.

Symbol Meaning

Denotes general caution, warning or danger.

Denotes caution against electrical shock.

Denotes caution against fire.

Denotes prohibition in the case where disassembling the machine may result in electrical shock or other damage.

Denotes prohibition in the case where the machine must be unplugged before starting a task.

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Overview of Manual

This service manual provides basic information necessary for servicing the finisher to maintain its quality and functions.

Each chapter of the manual contains information below.

Chapter 1. Overview: Features and specification

Chapter 2. Operation: Operating principles and timing of the mechanical system and electric system classified by function.

Electric circuit configuration and its summary

Chapter 3. Parts replacement: Mechanical configuration and procedures for disassembly, assembly and adjustment

Chapter 4. Maintenance & inspection: Periodical replacement parts list, expendable parts durability guide list, and periodical servicing list

Chapter 5. Troubleshooting:

Appendix:

Standards, adjustment and troubleshooting, etc.

Overall timing chart, signal name/abbreviation list, overall circuit diagram, etc.

This service manual doesn’t contain the installation procedure. The installation guide is enclosed in the package of each machine.

This service manual provides explanations on the basis of rules below.

1.Each chapter summarizes the purpose and role of each function, its relation to electric and mechanical systems, and operation timing of each component and part.

In the schematic diagrams, the symbol ( symbol is accompanied by an arrow ( the electricity.

) represents transmission of mechanical drive. If this

) and a signal name, the symbol represents the flow of

As used in this manual, “turn on power” means supply power to the machine by turning on the power switch, closing the front door, or closing the paper delivery door.

2.In the explanation of the digital circuits of this machine, “1” represents the high voltage level of the signal and “0” represents the low voltage level. The voltage values differ from circuit to circuit.

This machine uses a CPU. The explanation of the CPU operation, however, is omitted in the service manual, since it is practically impossible to check the CPU internal operation. Also, the manual provides only the summary of the PCB circuits using block diagrams, because the printed circuit boards are not supposed to be repaired at a customer’s place. The circuits explained in this manual include those from the sensors to the inputs on the circuit boards for control and drive, those from the outputs on these circuit boards to loads, and block diagram of each function.

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Table of contents

1.

Overview ...........................................................................................................9

1.1

Features .......................................................................................................................... 9

1.2

Specification ................................................................................................................. 10

1.2.1

Specification .................................................................................................... 10

1.2.1.1

Finisher/Saddle-Stitcher Unit .......................................................... 10

1.2.1.2

Puncher (Optional) .......................................................................... 13

1.3

Names of Parts ............................................................................................................ 15

1.3.1

Sectional View ................................................................................................. 15

1.3.1.1

Finisher Unit .................................................................................... 15

1.3.1.2

Saddle-Stitcher Unit ........................................................................ 15

1.3.1.3

Puncher Unit (Optional) ................................................................... 16

1.4

User Maintenance ........................................................................................................ 17

2.

Operation ........................................................................................................18

2.1

Basic Operation ............................................................................................................ 18

2.1.1

Specification .................................................................................................... 18

2.1.2

Electric Circuit Overview ................................................................................. 19

2.1.3

Finisher Controller Circuit Board Input/Output ................................................ 20

2.1.3.1

Finisher Controller Circuit Board Input ............................................ 20

2.1.3.2

Finisher Controller Circuit Board Output ......................................... 22

2.1.3.3

Finisher Controller Circuit Board Input/Output ................................ 24

2.1.4

Punch Controller Circuit Board Input/Output (Optional) .................................. 25

2.1.4.1

Punch Controller Circuit Board Input/Output ................................... 25

2.1.4.2

Punch Controller Circuit Board Output ............................................ 26

2.2

Feeding/Driving Systems ............................................................................................. 27

2.2.1

Overview ......................................................................................................... 27

2.2.1.1

Standard Output .............................................................................. 28

2.2.2

Feeding and Output ......................................................................................... 32

2.2.2.1

Overview ......................................................................................... 32

2.2.3

Job Offsetting .................................................................................................. 35

2.2.3.1

Overview ......................................................................................... 35

2.2.3.2

Paper Stacking for Jog Tray ............................................................ 36

2.2.3.3

Offsetting ......................................................................................... 36

2.2.3.4

Multi-Sheet Output .......................................................................... 37

2.3

Stapling ......................................................................................................................... 38

2.3.1

Overview ......................................................................................................... 38

2.3.2

Stapling ........................................................................................................... 39

2.3.3

Paper Output after Stapling ............................................................................. 40

2.3.4

Stapler Unit ...................................................................................................... 41

2.3.4.1

Stapler Unit Movement Control ....................................................... 43

2.4

Tray Operation ............................................................................................................. 46

2.4.1

Overview ......................................................................................................... 46

2.5

Saddle-Stitcher Unit ..................................................................................................... 47

2.5.1

Basic Operation ............................................................................................... 47

2.5.1.1

Overview ......................................................................................... 47

2.5.2

Feeding/Driving Systems ................................................................................ 47

2.5.2.1

Overview ......................................................................................... 47

2.5.3

Paper Infeeding System .................................................................................. 50

2.5.3.1

Overview ......................................................................................... 50

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2.5.4

Multi-Sheet Feeding System ........................................................................... 51

2.5.4.1

Overview ......................................................................................... 51

2.5.5

Folding/Output System .................................................................................... 52

2.5.5.1

Overview ......................................................................................... 52

2.5.5.2

Paper Folding .................................................................................. 52

[Paper Folding Start Position] .......................................................................... 53

2.6

Puncher Unit (Optional) ............................................................................................... 55

2.6.1

Basic Operation ............................................................................................... 55

2.6.1.1

Overview ......................................................................................... 55

2.6.2

Punching ......................................................................................................... 56

2.6.2.1

Overview ......................................................................................... 56

2.6.2.2

Punching ......................................................................................... 58

2.6.2.3

Side Registration ............................................................................. 61

2.7

Jam Detection .............................................................................................................. 63

2.7.1

Overview ......................................................................................................... 63

2.7.1.1

Paper Delay Jam at Inlet Sensor (1011) ......................................... 64

2.7.1.2

Paper Stopped Jam at Inlet Sensor (1021) ..................................... 64

2.7.1.3

Paper Delay Jam at Fold Position Sensor (1012) ........................... 64

2.7.1.4

Paper Stopped Jam at Fold Position Sensor (1022) ....................... 65

2.7.1.5

Residual Jam (1007) ....................................................................... 65

2.7.1.6

Door Open Jam (1008) ................................................................... 65

2.7.1.7

Staple Jam (1006) ........................................................................... 65

2.7.1.8

Non-ejection Jam ............................................................................ 65

2.8

Power Supply System ................................................................................................. 66

2.8.1

Finisher/Saddle-Stitcher Unit ........................................................................... 66

2.8.1.1

Overview ......................................................................................... 66

2.8.1.2

Protective Function ......................................................................... 66

2.8.2

Puncher Unit (Optional) ................................................................................... 67

2.8.2.1

Overview ......................................................................................... 67

2.8.2.2

Protective Function ......................................................................... 67

3.

Parts Replacement ........................................................................................68

3.1

Finisher/Saddle-Stitcher Unit ....................................................................................... 68

3.1.1

Exterior Controlling Parts ................................................................................ 68

3.1.1.1

Removing Output Tray .................................................................... 69

3.1.1.2

Removing Front Cover .................................................................... 69

3.1.1.3

Removing Rear Cover ..................................................................... 70

3.1.1.4

Removing Top Cover ....................................................................... 70

3.1.1.5

Removing Jog Tray Top Cover ........................................................ 71

3.1.1.6

Removing Top Right Cover Unit ...................................................... 71

3.1.1.7

Removing Side Guide ..................................................................... 72

3.1.2

Feeding Parts .................................................................................................. 73

3.1.2.1

Removing Stapler Unit .................................................................... 73

3.1.2.2

Synchronizing Stapler Motions ........................................................ 74

3.1.2.3

Synchronizing Gears of Saddle-Stitcher Unit .................................. 77

3.1.2.4

Removing Saddle-Stitcher Unit ....................................................... 78

3.1.2.5

Removing Jog Tray Unit .................................................................. 79

3.1.2.6

Removing Paddle Unit .................................................................... 80

3.1.2.7

Removing Staple/Fold Drive Unit .................................................... 81

3.1.2.8

Removing Feed Motor Unit ............................................................. 83

3.1.2.9

Removing Feed Roller .................................................................... 84

3.1.2.10

Removing Multi-Sheet Delivery Roller (Top) ................................... 85

3.1.2.11

Removing Paddle ............................................................................ 86

3.1.2.12

Removing Multi-Sheet Delivery Roller (Bottom)/Delivery Belt ........ 87

3.1.3

Circuit Boards .................................................................................................. 89

3.1.3.1

Removing Finisher Controller Circuit Board .................................... 89

3.1.3.2

Removing Slide Home Position Circuit Board ................................. 90

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3.2

Puncher Unit (Optional) ............................................................................................... 91

3.2.1

Puncher Driving Parts ..................................................................................... 91

3.2.1.1

Removing Punch Motor ................................................................... 91

3.2.1.2

Removing Side Registration Motor ................................................. 91

3.2.1.3

Removing Puncher Unit .................................................................. 92

3.2.2

Circuit Boards .................................................................................................. 94

3.2.2.1

Removing Punch Controller Circuit Board ...................................... 94

3.2.2.2

Removing Photo Sensor Circuit Board ........................................... 94

3.2.2.3

Removing LED Circuit Board .......................................................... 95

3.2.2.4

Removing Dust Full Photo Sensor Circuit Board ............................ 96

3.2.2.5

Removing Dust Full LED Circuit Board ........................................... 96

4.

Maintenance and Inspection .......................................................................97

4.1

Periodical Replacement Parts ..................................................................................... 97

4.1.1


4.1.2

Puncher Unit (Optional) ................................................................................... 97

4.2

Expendable Parts Durability Guide ............................................................................. 97

4.2.1


4.3

Periodical Maintenance ................................................................................................ 97

5.

Troubleshooting ............................................................................................98

5.1

Standards and Adjustment .......................................................................................... 98

5.1.1

Electrical System, Finisher/Saddle-Stitcher Unit ............................................. 98

5.1.1.1

Adjusting Fold Position .................................................................... 98

5.1.1.2

Adjusting Saddle-Stitch Double Stapling Position ........................... 99

5.1.2

Electrical System, Puncher Unit (Optional) ................................................... 100

5.1.2.1

Adjusting Punch Hole Position (Feeding Direction) ...................... 100

5.1.2.3

Registering Number of Punch Holes ............................................. 100

5.1.2.4

Procedure after Replacement of EEP-ROM (IC1002) .................. 101

5.2

Electrical Parts Layout ............................................................................................... 102

5.2.1

Finisher/Saddle-Stitcher Unit ......................................................................... 102

5.2.1.1

Sensors, Microswitches and Clutch .............................................. 102

5.2.1.2

Motors and Circuit Board .............................................................. 104

5.2.2

Puncher Unit (Optional) ................................................................................. 105

5.2.2.1

Sensors ......................................................................................... 105

5.2.2.2

Motors ........................................................................................... 106

5.2.2.3

Circuit Boards ................................................................................ 106

5.3

LED/Check Pin List by PCB ..................................................................................... 107

5.3.1

Finisher Controller circuit Board .................................................................... 107

5.3.2

Punch Controller Circuit Board ...................................................................... 108

5.4

Troubleshooting .......................................................................................................... 109

5.4.1

Troubleshooting Procedure (Finisher/Saddle-Stitcher Unit) .......................... 109

5.4.1.1

186 - Failure in communications with printer ................................. 109

5.4.1.2

096-09 - Failure of finisher unit backup memory ........................... 109

5.4.1.3

096-01 - Feed motor failure ........................................................... 109

5.4.1.4

096-05 - Delivery motor failure ....................................................... 110

5.4.1.5

096-03 - Rear jog plate motor failure ............................................. 110

5.4.1.6

096-03 - Front jog plate motor failure ............................................. 111

5.4.1.7

096-04 - Staple/fold motor failure ................................................... 111

5.4.1.8


5.4.1.9


5.4.1.10


5.4.1.11

096-06 - Slide motor failure ............................................................ 113

5.4.1.12

096-02 - Shift motor failure............................................................. 114

5.4.1.13


5.4.1.14


5.4.1.15

096-07 - Paddle motor failure ......................................................... 115

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5.4.2

Troubleshooting Procedure (Optional Puncher Unit) ...................................... 116

5.4.2.1

096-0C - Failure in communications with puncher ......................... 116

5.4.2.2

096-0E - Failure of puncher unit backup memory .......................... 116

5.4.2.3

096-0D - Puncher unit power supply failure ................................... 116

5.4.2.4

096-0A - Punch motor failure ......................................................... 117

5.4.2.5

096-0F, 096-10 - Punch sensor (side registration) failure .............. 117

5.4.2.6

096-11 - Punch sensor (dust full) failure ........................................ 118

5.4.2.7

096-0B - Side registration motor failure ......................................... 118

5.5

Self-Diagnosis ............................................................................................................. 119

5.5.1

Overview ........................................................................................................ 119

5.5.2

Error ............................................................................................................... 119

5.5.2.1

Finisher/Saddle-Stitcher Unit ......................................................... 119

5.2.2.2

Puncher Unit (Option) ................................................................... 121

5.5.3

Alarm ............................................................................................................. 122

5.5.3.1

Finisher/Saddle-Stitcher Unit ........................................................ 122

5.5.3.2

Puncher Unit (Optional) ................................................................. 122

Appendix A Overall Timing Chart ...................................................................123

Appendix B Signal Name/Abbreviation List ...................................................126

Appendix C Jam Code/Stack Paper Code List .............................................128

Appendix D Solvents/Oils List .........................................................................129

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1.

OVERVIEW

1.1

Features

1) Use of Through-Type Stapler

As a through-type stapler is used, saddle-stitch stapling is available without changing the stapler.

2) Three Auto Staple Functions

There are three stapling positions (front single, rear single, and center double).

3) Saddle-Stitch Function

The finisher saddle-stitches or V-folds up to 7 sheets of paper.

4) Punch Function (Optional)

Using the puncher unit, holes for a binder can be punched in paper (available for paper weighing 65 to 128 g/m 2 and not available for OHP films).

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1.2

Specification

1.2.1 Specification

1.2.1.1

Finisher/Saddle-Stitcher Unit

Item

Stacking method

Table 1-01 (1/2)

Specification

Stacking in 2 places [1] Descending output tray (1 tray)

Face-down/up stacking [2] Fixed booklet tray

Center Paper feed reference position

Stacking paper size

Paper weight

Operation mode

Stacking capacity

(Note 1)

Stacking of mixed sizes

Paper detection

Operating unit

Display unit

Dimensions

Weight

Power supply

Maximum power consumption

Stapling method

Stapling position

Stapling capacity

Staple loading

Applicable staple

Staple empty detection

Paper size for stapling

A3, A4-LEF, A4, A5, B4, B5-LEF, B5, A6,

279mm ×432mm(11×17), LGL, Exective, LTR-LEF, LTR

Finisher: 65 g/m 2 to 90 g/m 2

Saddle-stitcher: 65 g/m 2 to 80 g/m 2 (65 g/m 2 to 128 g/m 2

(Thick paper: One-sheet is possible only for a cover.))

Non-sort, Sort, Staple, and Booklet

Non-sort staple Large size: 500 sheets

Small size: 1000 sheets (note 2)

Staple-sort Large size: 30 sets or 500 sheets

Booklet

Small size: 30 sets or 1000 sheets

6 to 7 sheets/set: 10 sets

2 to 5 sheets/set: 20 sets

Mixed sizes: 500 sheets (note 3)

Mixed stapling: 30 sets (in the same order)

Output tray: Available

Booklet tray: Available

N/A

N/A

636.5 (W) × 603 (D) × 464 (H) mm

Approximately 27 kg

A voltage of 24 VDC is supplied from the inverter.

Standby: 13 W / During operation: 84 W (staple-sort)

Driving staples using the rotary cam.

See Figure 1-01.

Finisher: Large size: 22 sheets

Small size: 45 sheets

Saddle-stitcher: 7 sheets

Staple cartridge designed for the finisher

Staples designed for the finisher (5000 staples)

Available (nearly empty: 40 staples left)

Front single stapling: A3, A4-LEF, A4, B4, B5-LEF,

279 mm ×432 mm (11×17), LGL, LTR-LEF, LTR

Rear single stapling: A3, A4-LEF, B4, B5-LEF,

Center double stapling: A3, A4-LEF, A4, B4, B5-LEF,

279 mm ×432 mm (11×17), LGL, LTR-LEF, LTR

Saddle-stitch double stapling: A3, A4, B4,

279 mm ×432 mm (11×17), LTR, A4-LEF, B5-LEF,

LGL, LTR-LEF

Remarks

Large size: A3, B4, 279 mm ×

432 mm (11 ×17), LGL

The mounting kit is not included.

80 g/m 2 or equivalent



When the saddle-stitcher is used.

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Item

Manual stapling

Folding method

Folding mode

Folding position

Paper size for saddle-stitching

Model No.

Table 1-01 (2/2)

Specification

Not available.

Folding paper by pressing with a roller

V-folding (with one unstapled sheet)

Paper center

A3, A4, B4, 279mm ×432mm(11×17), LTR

N31240A

Remarks

A margin of at least 5 mm each must be left from the center of paper.

Special paper cannot be used.

Note 1: The stacking capacity above is a rough estimate using paper weight of 80 g/m 2 .

Note 2: When more than 500 sheets are stacked, the stacking registration is not guaranteed.

Note 3: When documents of mixed sizes are stacked, the stackability is not guaranteed.

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Staple Position

Front single stapling

Paper orientation direction

Rear single stapling

X1


Double stapling

X1



X1

Size

A3

A4-LEF

Direction

Front single staple

Rear single staple

X1

Y1

5.0

±2

4.5

±2

5.0

±2

4.5

±2

Y2

X1

Y1

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

Y2

A4

B4

B5-LEF

X1

Y1

Y2

X1

Y1

Y2

X1

Y1

Y2

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

Double stapling

5.0

±2

83 ±4

203 ±4

5.0

±2

83 ±4

203 ±4

5.0

±2

39.5

±4

159.5

±4

5.0

±2

63 ±4

183 ±4

5.0

±2

63 ±4

183 ±4

Size

Exective

Direction

Front single staple

Rear single staple

X1

Y1

5.0

±2

4.5

±2

5.0

±2

4.5

±2

Y2

Ledger

X1

Y1

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

Y2

Legal

Letter-

LEF

Letter

X1

Y1

Y2

X1

Y1

Y2

X1

Y1

Y2

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

5.0

±2

4.5

±2

—

Double stapling

5.0

±2

26.6

±4

146.6

±4

5.0

±2

74.2

±4

194.2

±4

5.0

±2

42.5

±4

162.5

±4

5.0

±2

74.2

±4

194.2

±4

5.0

±2

42.5

±4

162.5

±4

Stapling/Folding position

X1 X2

Paper orientation direction when booklet making

X1

±1.5mm (Staple to folding position)

X2

±2mm (Top of the paper to folding position)

Y1

±4mm

Y2

±4mm

Size

A3

A4

B4

Ledger

Letter

0

0

0

X1

0

0

X2

210

Y1

83

148.5

39.5

Y2

203

159.5

182

215.9

139.7

63

74.2

42.5

183

194.2

162.5

Folding position

Figure 1-01

Stacking Registration

42872701TH Rev.1

Paper output direction

20 mm or less

Figure 1-02

* Measure on the vertical-wall side.

12 /


1.2.1.2

Puncher (Optional)

Item

Punch method

Paper size

Paper weight

Punch hole diameter

Punch dust capacity

Dimensions

Weight

Power supply

Power consumption

Model No.

Table 1-02

Specification

Reciprocating system (punching one by one)

2 holes (puncher unit •2H): A3, A4, A4R, B4, B5, B5R

2 or 3 holes (puncher unit •2/3H): 2 holes for LGL and LTRR

3 holes for 279 mm x 432 mm (11

× 17) and LTR

4 holes (puncher unit •4HF/4HS): A3, A4

65g/m 2 ~ 128g/m 2

Remarks

Not available for envelopes, postcards and OHP films

2 holes (puncher unit •2H): 6.5 mm

2 or 3 holes (puncher unit •2/3H): 2 holes / 8.0 mm

3 holes / 8.0 mm

4 holes (puncher unit •4HF/4HS): 6.5 mm

2 holes (puncher unit •2H): 10,000 sheets

2 or 3 holes (puncher unit •2/3H): 2 holes / 3000 sheets

3 holes / 3000 sheets

4 holes (puncher unit •4HF/4HS): 5000 sheets

90 (W) × 560 (D) × 170 (H) mm

Approximately 2.5 kg

A voltage of 24 VDC is supplied from the finisher unit.

Standby: 2 W or less

During operation: 21 W or less (punching)

N31260A (puncher unit •2H)

N31261A (puncher unit •2/3H)

N31262A (puncher unit •4HF)

N31263A (puncher unit •4HS)

80g/m 2 or equivalent

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Hole Position

[1] 2 Holes (Puncher Unit •2H)

80 ±1mm χ1

12

±3mm

χ1

A3/A4-LEF

Executive

B5-LEF/B4

LGL/LTR

108.5

±3mm

93.35

±3mm

88.5

±3mm

65

±3mm

A4

B5 51

±3mm

Ledger/LTR-LEF 99.5

±3mm

68

±3mm

[2] 2 or 3 Holes (Puncher Unit •2/3H)

χ1

LGL/LTR-LEF/

Ledger

73 ±3mm

70

±1mm χ1

12 ±3mm

108

±1mm 108±1mm χ1

χ1

279mm

× 432mm

(11

× 17)/LTR-LEF 31.5±3mm

A3/A4-LEF 40.5

±3mm

12

±3mm

[3] 4 Holes (Puncher Unit •4HF)

χ1

A3/A4-LEF 28.5

±3mm

80

±1mm

80

±1mm

80 ±1mm

χ

1

12

±3mm

[4] 4 Holes (Puncher Unit •4HS)

21 ±1mm 70 ±1mm

21 ±1mm

χ

1

12

±3mm

χ1

A3/A4-LEF

B5-LEF/B4

A4

LGL/LTR

92.5

±3mm

72.5

±3mm

49 ±3mm

35

±3mm

B5

Executive 36.1

±3mm

Ledger/LTR-LEF 83.5

±3mm

52

±3mm

Figure 1-03

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1.3

Names of Parts

1.3.1 Sectional View

1.3.1.1

Finisher Unit

Jog tray stopper

Jog plate (front/rear)

Paddle

Delivery roller

Feed roller

Puncher unit (optional)

Output tray

Delivery belt

Multi-sheet delivery roller

Stapler

Figure 1-04

Saddle-stitcher unit

1.3.1.2

Saddle-Stitcher Unit

Multi-sheet feed roller

Paper pressure plate

Paper folding roller

Booklet stopper

Booklet tray Booklet delivery roller

Figure 1-05

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1.3.1.3

Puncher Unit (Optional)

Die

Cam

Punch

Punch dust receptacle


Figure 1-06

42872701TH Rev.1

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1.4

User Maintenance

No.

Item

1 Staple cartridge replacement

2 Punch dust disposal (optional)

Table 1-03

Timing

The indicator lamp lights up (operation panel on the printer).

The indicator lamp lights up (operation panel on the printer).

42872701TH Rev.1

17 /


2.

OPERATION

2.1

Basic Operation

2.1.1 Specification

The finisher outputs paper fed from a machine connected to it with non-sort stacking, job off-setting or stapling. The saddle-stitcher built in the finisher V-folds a set of documents sent from the finisher unit. These movements are controlled by the finisher controller circuit board and the commands sent from the connected machine.

The optional puncher unit is installed in the paper feeder of the finisher and it makes holes in paper sent from the connected machine. This movement is controlled by the puncher controller circuit board and the finisher controller circuit board.

Puncher unit driving system

(optional)

Jog driving system

Stapler driving system

Delivery driving system

Feeder driving system

Tray driving system

Saddle-stitcher driving system

Figure 2-01

Note!

Job off-setting is stacking document sets slightly offset from one another in the direction of output to make it easier to sort them out.

42872701TH Rev.1

18 /


2.1.2 Electric Circuit Overview

The finisher’s operational sequence is controlled by the finisher controller circuit board. The finisher controller circuit board uses a 16-bit micro computer (CPU) for sequence control and serial communications with the connected machine.

The finisher controller circuit board drives the motors or other components according to a command transmitted from the connected machine over the serial communications line. The finisher controller circuit board also notifies the connected machine of information on the sensors and switches over the serial communications line.

The ICs mounted on the finisher controller circuit board serve the functions below.

• IC13 (CPU)

Sequence control

• IC12 (EEP-ROM)

Settings backup

• IC6 (EP-ROM)

Sequence program

• IC11 (expansion port)

Input/output-port expansion

• IC1 (Regulator IC)

5V voltage generation

Figure 2-02 shows the flow of signals between the finisher and the optional controller.

Finisher unit

Finisher controller

PCB

IC13

CPU

IC12

EEP-ROM

IC11

Expansion port

IC6

EP-ROM

IC1

Regulator IC

To Inverter

Motor

Clutch

Switch

Sensor

Puncher unit (optional)

Sensor

Punch controller

PCB

Motor

Figure 2-02

42872701TH Rev.1

19 /


2.1.3 Finisher Controller Circuit Board Input/Output

2.1.3.1

Finisher Controller Circuit Board Input

Inlet sensor

Paddle home position sensor

PI1 CN44-3

-1

-2

CN43-1

-3

-2

PI2 CN51-1

-3

-2

Swing guide home position sensor

PI3 CN55-3

-1

-2

CN54-1

-3

-2

Front jog plate home position sensor

Rear jog plate home position sensor

PI4 CN23-3

-1

-2

PI5 CN36-3

-1

-2

Finisher Controller Circuit Board

CN42-3

-1

-2

CN16-10

-12

-11

+5V

ENT_S

Becomes "1" when the sensor detects paper.

CN9-1

-3

-2

+5V

PDL_HP

Becomes "1" when the paddle is in home position.

CN53-3

-1

-2

CN9-7

-9

-8

+5V

BDL_ROL_HP

Becomes "1" when the swing guide is in home position.

CN4

-3

-2

+5V

FJOG_HP

Becomes "1" when the front jog plate is in home position.

CN5-13

-15

-14

+5V

RJOG_HP

Becomes "1" when the rear jog plate is in home position.

Jog tray sensor

PI6 CN30-3

-1

-2

CN29-1

-3

-2

Delivery belt home position sensor

PI7 CN31-3

-1

-2

-4

-6

-5

CN28-9

-7

-8

CN5-1

-3

-2

+5V

ADJ_TRAY_S


-6

-4

-5

-4

-6

-5

+5V

EJCT_BLT_HP

Becomes "1" when the delivery belt is in home position.

Tray paper sensor

PI8 CN32-3

-1

-2

Paper level sensor

PI9 CN35-3

-1

-2

CN34-1

-3

-2

-7

-9

-8

Fold position sensor

PI10 CN39-3

-2

-1

CN38-1

-2

-3

-3

-1

-2

-7

-9

-8

+5V

TRY_EMPS Becomes "1" when the tray contains paper.

CN33-3

-1

-2

CN5-10

-12

-11

+5V

LVL_S Becomes "1" when the sensor detects paper surface.

CN37-9

-8

-7

CN16-1

-2

-3

+5V

BIND_P

BIND_L

Becomes "0" when the sensor detects paper and "1" when

LED lights up.

Figure 2-03 (1/2)

42872701TH Rev.1

20 /


Folding home position sensor

PI11 CN40-3

-1

-2

CN38-4

-6

-5

Multi-sheet feed roller (top) home position sensor

PI12 CN41-3

-1

-2

Booklet tray sensor

PI13 CN47-3

-1

-2

-7

-9

-8

Staple/fold motor clock sensor

Shift upper limit sensor

Shift lower limit sensor

PI14 CN52-1

-2

-3

PI15 CN50-3

-1

-2

PI16 CN49-3

-1

-2

Shift motor clock sensor

Front door sensor

Top cover sensor

Paper full sensor

PI17 CN48-3

-1

-2

PI22 CN25-3

-1

-2

PI23

CN24-3

-1

-2

PI24 CN73-3

-1

-2

Joint switch

MS2

N. O.

CN69-2

-1

Front door switch

MS1

N. O.

CN68-2

-1

Staple safety switch

MS3

N. O.

CN66-2

-1


CN37-6

-4

-5

-3

-1

-2

CN16-4

-6

-5

+5V

BIND_HP Becomes "0" when the unit is in home position for folding.

-7

-9

-8

+5V

BIND_ROL_HP

Becomes "1" when the multi-sheet feed roller (top) is in home position.

CN15-1

-3

-2

+5V

BIND_EMPS


CN9-6

-5

-4

+5V

BIND_CLK

Repeats "1" and "0" while the staple/fold motor is running.

CN15-10

-12

-11

+5V

SIFT_UPLMT

CN15-7

-9

-8

+5V

SIFT_DNLMT

CN15-4

-6

-5

+5V

SIFT_CLK

CN4-7

-9

-8

+5V

FDOOR_S

CN4-4

-6

-5

+5V

TOPCOV_S

CN19-1

-3

-2

+5V

PAPER_F

Becomes "1" when the tray reaches the upper limit.

Becomes "1" when the tray reaches the lower limit.

Repeats "1" and "0" while the shift motor is running.

Becomes "1" when the front door is open.

Becomes "1" when the top cover is open.

Becomes "1" when the tray is full.

CN8-6

-5

+24VP

JOINT SW

Becomes "1" when the finisher is connected to the machine to connect.

CN8-4

-3

FRONT SW

Becomes "1" when the front door is closed.

CN8-2

-1

STPLSAFE SW

Becomes "1" when the swing guide is closed.

Figure 2-03 (2/2)

42872701TH Rev.1

21 /


2.1.3.2

Finisher Controller Circuit Board Output

Booklet clutch

CL1

Feed motor

M1

Paddle motor

M2

Delivery motor

M3

-1

-2

Front jog plate motor

CN63-1

M4

-2

-3

-4

-5

Rear jog plate motor

CN65-1

-2

-3

M5

-4

-5

-6

-5

-4

-3

-2

-1

-6

-5

-4

-3

-2

-1

-3

-2

-1

-6

-5

-4

CN62-5

-4

-3

-2

-1

CN64-5

-4

-3

-2

-1

-2

-1

-1

-2

-3

-4

-5

-6

-1

-2

-3

-4

-5

-6

-4

-5

-6

-1

-2

-3

+24V

CN18-1

-2

B_CLU


Becomes "1" when drive is transmitted.

+24V

CN10-1

-2

-3

-4

-5

-6

FEEDMTR_A

FEEDMTR_*A

FEEDMTR_B

FEEDMTR_*B

+24V

CN10-7

-8

-9

-10

-11

-12

PDLMTR_A

PDLMTR_*A

PDLMTR_B

PDLMTR_*B

+24V

CN13-1

-2

-3

-4

-5

-6

EJCTMTR_A

EJCTMTR_*A

EJCTMTR_B

EJCTMTR_*B

+24V

CN3-1

-2

-3

-4

-5

FJOGMTR_A

FJOGMTR_*A

FJOGMTR_B

FJOGMTR_*B

+24V

CN3-6

-7

-8

-9

-10

RJOGMTR_A

RJOGMTR_*A

RJOGMTR_B

RJOGMTR_*B

Becomes "1" or "0" depending on the direction of motor rotation.





Figure 2-04 (1/2)

42872701TH Rev.1

22 /


Shift motor

M6

-2

-1

-2

-1

-2

-1


-2

-1

CN6-1

SIFTMTR_1

-2 SIFTMTR_0

Becomes "+" or "-" depending on the direction of motor rotation.

Staple/fold motor

M7

-2

-1

-2

-1

CN6-3

-4

BINDMTR_1 Becomes "+" or "-" depending on the

BINDMTR_0 direction of motor rotation.

Figure 2-04 (2/2)

42872701TH Rev.1

23 /


2.1.3.3

Finisher Controller Circuit Board Input/Output

Stapler Unit

Slide home position sensor

PI18

+5V

CN72-5 CN72A-5

Finisher controller Circuit Board

CN72A-5 CN11-3

SLID_HP

Becomes "1" when the stapler is in home position.

Staple home position sensor

PI19

+5V

CN72-4 CN72A-4 CN72A-4 CN11-4

STPL_HP

Becomes "0" when the stapler is in home position for stapling.

Staple empty sensor

PI20

+5V

CN72-3 CN72A-3 CN72A-3 CN11-5

HOOK_S

Becomes "0" when the cartridge contains staples.

Staple top position sensor

PI21

+5V

CN72-2 CN72A-2

Slide motor

M8

+5V

CN72-6

CN72-1

CN72A-6

CN72A-1

CN72-7 CN72A-7

CN72-10 CN72B-5

CN72-11 CN72B-4

CN72-12 CN72B-3

CN72-13 CN72B-2

CN72A-2 CN11-6

SELF_P

Becomes "0" when a staple is at the top of the stapler.

+5V

CN72A-6 CN11-2

CN72A-1 CN11-7

CN72A-7 CN11-1

STPL_CNCT

Becomes "0" when the stapler is connected.

CN72B-5

CN72B-4

CN72B-3

CN72B-2

CN7-3

CN7-5

SLIDMTR_A

CN7-4

SLIDMTR_*A

SLIDMTR_B

CN7-6

SLIDMTR_*B


Inverter

CN17-1

-2

-3

-4

Rxd

Communications line

Txd

SEN - Inverter discharge sensor

CN1-1

-3

+24V

Figure 2-05

42872701TH Rev.1

24 /


2.1.4 Punch Controller Circuit Board Input/Output (Optional)

2.1.4.1

Punch Controller Circuit Board Input/Output

Punch home position sensor

PI1P

J2008-3

-1

-2

Side registration home position sensor

PI2P

J2007-3

-1

-2

Punch motor clock sensor

PI3P

J2009-3

-1

-2

Dust full LED circuit board

LED121

Dust full photo sensor circuit board

PT131

Photo sensor circuit board

+5V

PT1

PT2

PT3

PT4

PT5

Punch Controller Circuit Board

J1006-4

-6

-5

+5V

PUNCH

Becomes "0" when the punch is in home position.

J1006-1

-3

-2

+5V

SLIDE

Becomes "1" when the punch slide unit is in home position.

J1006-7

-9

-8

+5V

CLOCK

J1005-1

+5V

-2

DUSTLED

Repeats "1" and "0" while the punch motor is running.

Becomes "0" when the light is blocked.

J1005-3

DUSTPTR

4

+5V

J1007-12

-11

-10

-9

-8

-7

SREG1*

SREG2*

SREG3*

SREG4*

PAEND*

-13

Becomes "0" when paper is detected.

Figure 2-06

42872701TH Rev.1

25 /


2.1.4.2

Punch Controller Circuit Board Output

LED circuit board

LED5

LED4

LED3

LED2

LED1

J1007-6

+5V

Punch Controller Circuit Board

Punch motor

M1P

J1002-1

-2

-1

-5

-4

-3

-2

LEDON5

LEDON4

LEDON3

LEDON2

LEDON1

When an output is "1", the LED is ON.

Becomes "+" or "-" depending on the direction of motor rotation.

Side registration motor

M2P

J1001-1

A

-2

-3

B

A*

-4

B*

The pulse signal varies depending on motor rotation.

Figure 2-07

42872701TH Rev.1

26 /


2.2

Feeding/Driving Systems

2.2.1 Overview

This finisher delivers documents sent from the printer to the output tray with simple stacking, job offsetting, stapling or V-folding in accordance with commands sent from the printer.

When the optional puncher unit is installed, documents are punched before delivered to the output tray.

Including the punching, there are five paper output methods all together.

Paper output method Standard output

Saddle-stitch output

Punching

Stitching

Simple stacking

Job offsetting

Stapling Front single stapling

Rear single stapling

Center double stapling

Saddle-stitch double stapling

42872701TH Rev.1

27 /


2.2.1.1

Standard Output

1) Simple Stacking

Documents are drawn onto the jog tray and then delivered to the output tray.

42872701TH Rev.1

Figure 2-08

Tray

Paper

28 /


2) Job Offset

Before delivered to the output tray, a sheet is drawn onto the jog tray and moved to the front or rear. When 2 sheets stack on the jog tray, the set of the sheets are output together.

42872701TH Rev.1

Paper output in 4-set job offsetting

3rd set

1st set

Direction of output

Figure 2-09

4th set

2nd set

29 /


3) Stapling

Documents fed from the connected machine are stacked on the jog tray. When one set of documents stack on the tray, the finisher staples them together and sends out the stapled set to the output tray.

Figure 2-10

42872701TH Rev.1

30 /


4) Saddle-Stitch Output

A set of documents stacked on the jog tray are stapled together (double stapling in the center) and then sent to the saddle-stitcher unit. The saddle-stitcher V-folds the stapled set and delivers it to the booklet tray.

42872701TH Rev.1

Figure 2-11

31 /


2.2.2 Feeding and Output

2.2.2.1

Overview

The finisher feeds documents sent from the printer to the output tray, the jog tray or the saddle-stitcher unit depending on output mode. When documents are fed to the jog tray or the saddle-stitcher unit, they are offset, stapled or V-folded in accordance with the command sent from the printer.

Table 2-01 shows the motors relating to paper feeding and jogging. These motors rotate forward or backward by the control of the micro computer (CPU) on the finisher controller circuit board.

Table 2-02 shows the sensors installed in the paper feeding path. These sensors detect the arrival or passing of paper.

If paper fails to arrive at or pass a sensor within the specified time, the finisher controller circuit board determines that a paper jam has occurred. The finisher stops operation and notifies the printer of the jam.

Table 2-01

Code

M1

M2

M3

M4

M5

M7

Description

Feed motor

Paddle motor

Delivery motor



Staple/fold motor

Remarks

Stepping motor

Stepping motor

Stepping motor

Stepping motor

Stepping motor

Brush DC motor

Connector on the finisher controller PCB

CN10

CN10

CN13

CN3

CN3

CN6

42872701TH Rev.1

32 /

Finisher Controller Circuit Board (1/2)


M4 M5 M2

M6

M3

M8

M1

CL

M7

PI14

42872701TH Rev.1

Finisher Controller Circuit Board (2/2)

Figure 2-12 (1/2)

33 /



PI1

PI10

Code Description

Pl1 Inlet sensor

Pl10 Fold position sensor

Figure 2-12 (2/2)

Table 2-02

Remarks

Photo interrupter

Photo reflector

Connector on the finisher controller PCB

CN16

CN16

42872701TH Rev.1

34 /


2.2.3 Job Offsetting

2.2.3.1

Overview

The Job offset function sorts out documents by moving each set of documents to the front or the rear before sending them out to the output tray.

The documents are moved to the front or the rear by the front or rear jog plate. After passing the delivery roller, paper is fed onto the jog tray and sent towards the stopper by the paddle.

The swing guide is in its upper position, while paper is drawn onto the jog tray and jogged. The guide is in its lower position during multi-sheet feeding, multi-sheet delivery, and stapling.

When power is turned on, the finisher controller circuit board drives the front jog plate motor (M4) and the rear jog plate motor (M5) to return the two jog plates to home position.

Sensor Code Connector

Front jog plate home position sensor PI4

Table 2-03

CN4-3

Function Motor Code

Drive the front jog plate. Front jog plate motor M4

Rear jog plate home position sensor PI5 CN5-15 Drive the rear jog plate. Rear jog plate motor M5

Swing guide home position sensor

Paddle home position sensor

PI3

PI2

CN9-9

CN9-3

Drive the swing guide.

Drive the paddle

(feed paper).

Paddle motor

Paddle motor

M2

M2

Rear jog plate

Rear jog plate home position sensor (PI5)

Front jog plate motor (M4)

Rear jog plate motor (M5)

Front jog plate

(Front) Shield plate

Front jog plate home position sensor (PI4)

Figure 2-13

Paper

Shield plate

42872701TH Rev.1

35 /


2.2.3.2

Paper Stacking for Jog Tray

After passing through the ejector roller, the paper is fed to the processing tray. The paddle then presses against* the upper surface of the paper to align the rear edge of the paper with the processing-tray stopper.

* Number of cycles:

Non-staple mode: Twice for the first sheet; once for each subsequent sheet

Staple mode: Once or three times, as selected by a command from the main unit

Paper

Jog plate

Paddle

Multi-sheet delivery roller (top)

Swing guide

Delivery belt

Jog tray stopper

Multi-sheet delivery roller (bottom)

Figure 2-14

2.2.3.3

Offsetting

The front or rear jog plate moves documents to the front or rear. Offsetting is performed every time a document is drawn onto the jog tray.

Rear jog plate

Paper to be offset

Tray

Front jog plate

Figure 2-15 (1/2) Moving to Front

Rear jog plate

Paper to be offset

Tray

Front jog plate

Figure 2-15 (2/2) Moving to Rear

42872701TH Rev.1

36 /


2.2.3.4

Multi-Sheet Output

Every time 2 large-size sheets or 2 small-size sheets have stacked on the jog tray, they are output all together from the tray.

The paddle motor starts running and the swing guide is lowered, which causes the top and bottom multi-sheet delivery rollers to sandwich the stack of documents. The delivery motor rotates forward and the documents sandwiched between the multi-sheet delivery rollers are fed in the output direction.

The delivery belt home position sensor is turned off and, after the delivery motor runs for the specified number of pulses, the swing guide goes up. The delivery motor continues to run and the documents are output by the claw that rotates in synchronization with the rotation of the bottom multi-sheet delivery roller.

Swing guide

Figure 2-16 (1/2)

Job Offset Sequence

Inlet sensor (PI1)

Jog tray sensor (PI6)

Feed motor (M1)

Delivery motor (M3)

Delivery belt home position sensor (PI7)

Paddle motor (M2)

Paddle home position sensor (PI2)

Swing guide home position sensor (PI3)


(MS3)



Rear jog plate motor (M5)


Action start signal

Delivery signal of connected machine

360msec* 360msec*

60msec*

360msec*

30msec 220msec

360msec*

: Forward motor rotation : Backward motor rotation

*: Varies depending on the paper size

Figure 2-16 (2/2)

42872701TH Rev.1

37 /


2.3

Stapling

2.3.1 Overview

The stapling function does stapling of the specified number of documents using the stapler unit. The stapling positions vary depending on the staple mode and paper size.

After power is turned on or when the front door is opened and closed, the finisher controller circuit board drives the slide motor (M8) to return the stapler unit to home position. The stapler unit begins to move towards the front of the stapler frame. The stapler unit stops, when the slide home position sensor (PI18) on the slide circuit board at the bottom of the stapler unit detects the shield plate. The slide motor is driven for the specified number of pulses. The stapler unit begins to move again and stops in the standby position in the rear.

Sensor

Slide home position sensor

Staple home position sensor

Staple empty sensor

Staple top position sensor

Table 2-04

Code Connector

PI18 CN11-3

Function

Detects stapler home position in movement to the front and the rear.

PI19

PI20

CN11-4

CN11-5

Remarks

-

Detects stapling home position. Inside the stapler

Detects if the cartridge contains Inside the stapler staples.

PI21 CN11-6 Detects the staple at the top of the stapler.

Inside the stapler

Function

Driving for stapler movement Slide motor

Motor

Driving for stapling Staple/fold motor

Code Remarks

M8 -

M7 -

Stapler

Paper (Output direction)

Slide motor

(M8)

Shield plate

Slide home position sensor (PI18)

Figure 2-17

42872701TH Rev.1

38 /


2.3.2 Stapling

The finisher controller circuit board, upon completion of stacking onto the jog tray and jogging, runs the paddle motor backward to lower the swing guide. Lowering the swing guide, the top and bottom multi-sheet delivery rollers sandwich the documents set.

The finisher controller circuit board moves the stapler in accordance with the specified stapling position and the stapler staples the documents (the stapler is not moved for rear single stapling and it does stapling in its standby position). When the stapler is moved to the front, the jog tray stopper is knocked down.

Paper

Output tray

Swing guide


Jog tray stopper

Stapler


(bottom)

Figure 2-18 (1/2)

Paddle motor (M2)


Shield plate

42872701TH Rev.1


(MS3)

Swing guide



Figure 2-18 (2/2)

39 /


2.3.3 Paper Output after Stapling

After stapling is completed, the finisher controller circuit board runs the delivery motor forward to feed a set of documents sandwiched between the multi-sheet delivery rollers in the output direction. The delivery belt home position sensor is turned off. After the delivery motor has run for the specified number of pulses, the swing guide goes up. As soon as the swing guide goes up, the slide motor begins to run and the stapler is returned into the standby position in the rear. The delivery motor continues to run and the document set is output by the claw that rotates in synchronization with the rotation of the bottom multi-sheet delivery roller.

Paper

Swing guide

Stapler

Output tray

Delivery belt


(bottom)

Figure 2-19 (1/2)


Paddle motor (M2)

Shield plate

42872701TH Rev.1

Staple safety switch (MS3)

Swing guide


Figure 2-19 (2/2)


40 /


2.3.4 Stapler Unit

The stapling movement is produced by the staple/fold motor (M7). As the motor rotates the cam one revolution, the stapler does stapling. The cam’s home position is detected by the staple home position sensor (PI19).

The staple/fold motor is controlled by the microcomputer (IC13) on the finisher controller circuit board whether it rotates forward or backward.

When the staple home position sensor is off, the finisher controller circuit board runs the staple/fold motor forward until the sensor is turned on to return the staple cam into the initial state.

The staple empty sensor (PI20) detects whether there is a staple cartridge or staples in the cartridge.

The staple top position sensor (PI21) detects whether a staple is pushed to the top of the cartridge.

The finisher controller circuit board doesn’t drive the staple/fold motor (M7) unless the staple safety switch (MS3) is on (the swing guide is closed). This is to ensure safety, for example, in case an operator puts his/her finger in the stapler.

42872701TH Rev.1

41 /


Figure 2-20 (1/2)

M7

42872701TH Rev.1


Figure 2-20 (2/2)

42 /


2.3.4.1

Stapler Unit Movement Control

The stapler unit is moved by the slide motor (M8). Its home position is detected by the slide home position sensor (PI18). The stapler stands by in the rear of the stapler frame in any staple mode and for any paper size. After documents have been stacked on the jog tray, upon receipt of a command for stapling from the printer, the stapler moves into the specified stapling position.

Figures from 2-21 below show the stapler’s standby position and stapling positions according to staple mode.

1) Front Single Stapling

The stapler stands by in the rear. The stapler moves to the stapling position and then comes back to the standby position every time it does stapling.

Standby position

Stapler

Feeding direction

Stopper

Stapling position

Figure 2-21

2) Rear Single Stapling

The stapler stands by in the rear. The stapling position is the same as the standby position.

Standby position

Stapling position

Stapler

Feeding direction

Stopper

Figure 2-22

42872701TH Rev.1

43 /


3) Center Double Stapling

The stapler stands by in the rear. The stapler moves to the stapling position and then comes back to the standby position every time it does stapling. Documents are stapled in the rear first and then in the front.

Feeding direction

Standby position

Stapler

Stapling position

Stopper

Stapling position

Figure 2-23

4) Saddle-Stitch Double Stapling (in booklet mode)

The stapler stands by in the rear. The stapler moves to the stapling position and then comes back to the standby position every time it does stapling. Documents are stapled in the rear first and then in the front.

Feeding direction

Standby position

Stapler

Stapling position

Stopper

Stapling position

Figure 2-24

42872701TH Rev.1

44 /


Stapling Sequence

Two-Sheet Rear Single Stapling

Action start signal

Delivery signal of connected machine

Inlet sensor (PI1)

Jog tray sensor (PI6)

Feed motor (M1)

Delivery motor (M3)


Paddle motor (M2)




(MS3)



Staple/fold motor (M7)

Staple home position sensor (PI19)

360msec* 360msec*

Stapling Multi-sheet delivery

20msec

10msec


*: Varies depending on the paper size

Figure 2-25

42872701TH Rev.1

45 /


2.4

Tray Operation

2.4.1 Overview

The finisher has the output tray in the finisher unit and the booklet tray in the saddle-stitcher unit.

The booklet tray in the saddle-stitcher unit is a fixed tray. All the bound document sets are output to this tray. The booklet tray is equipped with the booklet tray sensor (PI13) for detecting paper on the tray.

The output tray in the finisher unit moves up and down, driven by the shift motor (M6). The finisher unit has the tray paper sensor (PI8) for detecting paper on the output tray.

The home position of the output tray is detected by the paper level sensor (PI9). The home position is where the top surface of paper stack is detected, if documents are stacked on the output tray. It is where the edge of the output tray is detected, if no paper is stacked on the tray. When power is turned on, the finisher controller circuit board drives the shift motor (M6) to return the output tray to home position.

When paper is delivered from the jog tray to the output tray, the shift motor runs for the specified number of clock signals and the output tray is lowered. The clock signals are detected by the shift motor clock sensor (PI17). The output tray returns to home position for next stacking.

The shift upper limit sensor (PI15) detects the upper limit of the output tray. When the shift upper limit sensor (PI15) is turned on, the finisher controller circuit board stops the drive (ascent) of the shift motor (M6).

The shift lower limit sensor (PI16) detects the lower limit of the output tray. When the shift lower limit sensor (PI15) is turned on, the finisher controller circuit board stops the drive (descent) of the shift motor (M6).

The finisher unit also has the paper full sensor (PI24) to detect over-stacking due to large-size or mixedsize paper stacking.

Shift upper limit sensor

(PI15)

Paper full sensor

(PI24)

Shift lower limit sensor

(PI16)

Shift motor clock sensor

(PI17)

Edge

Tray paper sensor (PI8)

Paper level sensor (PI9)

Output tray

Shift motor (M6)

Figure 2-26

42872701TH Rev.1

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2.5


2.5.1 Basic Operation

2.5.1.1

Overview

The finisher, after the finisher unit has saddle-stitched a set of documents (saddle-stitch double stapling), folds the set in two and outputs it to the tray. These movements are controlled by the finisher controller circuit board in accordance with commands sent from the printer.

2.5.2 Feeding/Driving Systems

2.5.2.1

Overview

After saddle-stitching documents sent from the finisher unit in accordance with commands sent from the printer, the finisher folds the document set together and outputs the set to the booklet tray in the saddle-stitcher unit.

This movement is divided into four steps below.

1) Paper infeeding

2) Saddle-stitching

3) Multi-sheet feeding

4) Folding/output

1) Paper infeeding

2) Saddle-stitching

3) Multi-sheet feeding

4) Folding/output

Figure 2-27

42872701TH Rev.1

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1) Paper Infeeding

A set of documents, after jogged on the jog tray, are sandwiched between the multi-sheet delivery rollers and then fed in towards the saddle-stitcher by the rotation of the multi-sheet delivery rollers.


Document set


Figure 2-28

2) Saddle-Stitching

When the document set is further fed and its center (position to be saddle-stitched) reaches the stapler’s staple position, the document set stops and the stapler saddle-stitches it in the center.

Staple

Stapler (top)

42872701TH Rev.1

Stapler (bottom)

Figure 2-29

48 /


3) Multi-Sheet Feeding

The multi-sheet feed roller feds the document set into the multi-sheet folding/delivery position. The multi-sheet folding/delivery position is where the center of the document set

(saddle-stitched position) is aligned with the paper pressure plate and the nip of the paper folding rollers.

Multi-sheet feed roller (top)


Multi-sheet feed roller (bottom) Paper feed roller

Figure 2-30

4) Folding/Output

The paper pressure plate presses the center of the document set towards the paper folding rollers. The paper folding rollers sandwich the document set and V-fold it. The paper folding rollers then the booklet delivery rollers feed the document set to the booklet tray.

42872701TH Rev.1

Booklet delivery roller

Paper folding roller

Figure 2-31

49 /


2.5.3 Paper Infeeding System

2.5.3.1

Overview

The paper infeeding system feeds further a document set sent from the finisher unit and stops it where its center (position to be saddle-stitched) in the stapler’s staple position for saddle-stitching and paper folding in the next process.

Upon completion of paper stacking on the jog tray and jogging, the paddle motor (M2) begins to run backward to lower the swing guide. As the swing guide is lowered, the document set is sandwiched between the top and bottom multi-sheet delivery rollers. The delivery motor (M3) runs backward and the multi-sheet delivery rollers rotate, and the document set will be fed to the saddle-stitcher unit. When the edge of the document set reaches the fold position sensor (PI10), the finisher controller circuit board drives the delivery motor for the specified number of motor pulses and stops the center of the document set (position to be saddle-stitched) in the stapler’s staple position. Before the document set passes the multi-sheet feed rollers, the multi-sheet feed roller (bottom) is rotated by the drive of the feed motor

(M1) to prevent the edges of the documents from bending.


Document set

Fold position sensor


(bottom)

Multi-sheet feed roller (bottom)

Figure 2-32

42872701TH Rev.1

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2.5.4 Multi-Sheet Feeding System

2.5.4.1

Overview

The multi-sheet feeding system feeds a saddle-stitched document set to the folding position.

Upon completion of saddle-stitching, the feed motor (M1) runs backward to lower the multi-sheet feed roller (top). The document set is sandwiched between the multi-sheet feed rollers. The booklet clutch

(CL1) is turned on and the feed motor (M1) runs forward to feed the document set to the folding position.

The feed distance to the folding position is determined by the number of motor pulses for which the feed motor (M1) runs.

Multi-sheet feed roller (top)

Feed distance

Multi-sheet feed roller (bottom)

Figure 2-33

42872701TH Rev.1

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2.5.5 Folding/Output System

2.5.5.1

Overview

The paper folding mechanism consists of the guide plate, paper folding rollers, and paper pressure plate. The guide plate, paper folding rollers, and paper pressure plate are all driven by the staple/ fold motor (M7) via the gears and cam. The motor driving is monitored by the staple/fold motor clock sensor (PI14).

The guide plate covers the paper folding rollers until a document set is fed into the folding position.

The guide plate helps feed the documents to the saddle-stitcher and also prevents them from touching the paper folding rollers.

The folding home position sensor (PI11) is used to detect the positions of the paper folding rollers and paper pressure plate.

After V-folded by the paper folding rollers, the document set is output by the booklet delivery rollers.

The booklet delivery rollers are also driven by the staple/fold motor (M7).

On the booklet tray, the booklet tray sensor (PI13) is provided. This sensor detects document sets on the tray but it doesn’t detect a paper jam.

2.5.5.2

Paper Folding

Paper folding is performed by the paper folding rollers and the paper pressure plate.

As soon as the paper folding rollers begin to rotate, the paper pressure plate begins to move and pushes the document set into the nip of the paper folding rollers. When the paper folding rollers continue to rotate and the document set is sandwiched approximately 10 mm between the paper folding rollers, the paper pressure plate returns to home position. The document set sandwiched between the paper folding rollers is delivered by the paper folding rollers and then by the booklet delivery rollers to the booklet tray.

One semicircular part of each paper folding roller is made hollow except for the center and both ends of the roller. This hollow semicircular parts of the top and bottom paper folding rollers touch each other only in the center and on both ends. This makes the rollers do paper feeding only and prevents crease in the paper. The other semicircular parts of the top and bottom paper folding rollers touch each other fully. Paper folding begins on these surfaces. The rollers feed the document set while folding it.

Sensor flag

Folding home position sensor (PI11)

Cam

Document set


Paper folding roller (top)

Staple/fold motor

M7

Paper folding roller (bottom)

Figure 2-34 (1/4)

42872701TH Rev.1

52 /

42872701TH Rev.1


Paper folding roller (top)

Staple/fold motor

M7

Paper folding roller (bottom)

Document set

[Paper Folding Start Position]

Figure 2-34 (2/4)

Document set



Paper inlet


Paper outlet

Figure 2-34 (3/4)

Fold/feed the documents.

Feed the documents.

53 /


Feed motor (M1)

Delivery motor (M3)

Paddle motor (M2)



Staple safety switch (MS3)

Stapling

Slide motor (M8)

Staple/fold motor (M7)

Staple home position sensor (PI19)

Fold position sensor (PI10)

Multi-sheet feed roller (top) home position sensor (PI12)

Booklet clutch (CL1)


Booklet tray sensor (PI13)

50msec

Folding/delivery

13571msec*


*: Varies depending on the paper orientation speed.

Figure 2-34 (4/4)

42872701TH Rev.1

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2.6


2.6.1 Basic Operation

2.6.1.1

Overview

The optional puncher unit is installed in the paper feeder of the finisher. The puncher unit doesn’t have a paper feeding mechanism. Paper sent from the connected machine passes the puncher unit and then it is fed by the finisher feeding system. When the tail end of the paper reaches the puncher unit, paper stops temporarily. The punch shaft rotates and the puncher punches the paper at its tail.

These movements are controlled by the punch controller circuit board and commands from the finisher controller circuit board.

Punch driving system

Side registration driving system

Punch controller circuit board

Figure 2-35

42872701TH Rev.1

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2.6.2 Punching

2.6.2.1

Overview

The puncher unit is installed in the paper feeder of the finisher and it punches holes in paper when the paper sent from the connected machine stops temporarily. When the tail end of the paper reaches the puncher unit, the inlet roller of the finisher unit stops the paper and the puncher punches the paper at its tail.

The puncher unit consists of the die and the punch (punch blade). The punch is driven by the punch motor (M1P). The punch is fastened to the eccentric cam of the punch shaft. The rotational motion of the punch shaft is converted to the reciprocating motion for punching.

The punch motor (M1P) is a DC motor. The home position of the punch shaft is detected by the punch home position sensor (PI1P). In order to stop the DC punch motor accurately in home position, the punch motor clock sensor (PI3P) counts the number of clock signals. When it reaches the specified number, the punch motor is stopped. As the punch shaft rotates 180 degrees from home position, the puncher makes the punching movement once.

In the inlet paper feeding path of the puncher unit, five light receiving transistors (photo sensor circuit board) are installed at the top and five LED (LED circuit board) are installed at the bottom. These serve as five sensors. The front pair (LED5 and PT5) is the paper end sensor and used for detecting the tail end of paper. The remaining 4 pairs (LED1 to LED4 and PT1 to PT4) are the side registration sensors and used for detecting the rear of paper to determine the punching position.

The punch motor, punch and the sensors above make up the punch slide unit. The unit moves forward and backward according to paper size. This movement is driven by the side registration motor (M2P).

The home position of the punch slide unit is detected by the side registration home position sensor

(PI2P). The side registration motor (M2P) is a stepping motor.

Driving of the punch motor and the side registration motor is controlled by the punch controller circuit board and commands sent from the finisher controller circuit board.

Punch dust is collected in the punch dust receptacle. Whether the receptacle is full is detected by the LED 121 on the dust full LED circuit board and PT131 on the dust full photo sensor circuit board.

42872701TH Rev.1

56 /

Punch Controller Circuit Board (1/2)


5

4

3

2

PT1

4

3

2

LED1

5

PT131

LED121

42872701TH Rev.1

Punch Controller Circuit Board (2/2)

Figure 2-36

57 /


2.6.2.2

Punching

The punch is driven by the punch motor (M1P). The home position of the punch is detected by the punch home position sensor (PI1P).

There are four types of puncher units; J1 for 2 holes, K1 for 2/3 holes, G1 and H1 for 4 holes. With the 2-hole and 4-hole puncher units, the punch is reciprocated once for punching as the punch shaft is rotated 180 degrees from home position. Also with the 2/3-hole puncher unit, the punch is reciprocated once for punching as the punch shaft is rotated 180 degrees from home position. Only a semicircular part of the punch shaft is used for 2-hole punching and the other semicircular part is used for 3-hole punching.

1) 2-Hole and 4-Hole Puncher Units

The puncher unit is in home position, when the punch home position sensor is on.

Punching of the first sheet is completed, when the punch shaft rotates 180 degrees forward and the punch home position sensor is turned on. Punching of the second sheet is completed, when the punch shaft rotates 180 degrees backward and the punch home position sensor is turned on.

The puncher unit works as shown below to punch two sheets of paper.

a) Punching a Hole in the First Sheet at Its Tail

Sensor flag


(PI1P)

Punch shaft

Eccentric cam

Die

Punch

Paper

Die Punch dust

[Punch shaft at a standstill/

Home position]

[Punch shaft 90 degrees forward/A punch hole is made.]

[Punch shaft 180 degrees forward/Punching is completed.]

Figure 2-37 (1/2) b) Punching a Hole in the Second Sheet at Its Tail

42872701TH Rev.1


Home position]

[Punch shaft 90 degrees backward/A punch hole is made.]

[Punch shaft 180 degrees backward/Punching is completed.]

Figure 2-37 (2/2)

58 /


2) 2-Hole/3-Hole Puncher Unit

The puncher unit is in home position, when the punch home position sensor is on. When two punch holes are to be made, punching of the first sheet is completed, when a semicircular part of the punch shaft rotates 180 degrees forward and the punch home position sensor is turned on. On the other semicircular part of the punch shaft, the 3hole punch is reciprocated once in the direction away from the paper (ascending direction).

Punching of the second sheet is completed, when the former semicircular part of the punch shaft rotates 180 degrees backward and the punch home position sensor is turned on.

On the other semicircular part of the punch shaft, again, the 3-hole punch is moved in the direction away from the paper (ascending direction). When three holes are to be made, the 2-hole punch is reciprocated once in the direction away from the paper (ascending direction).

The puncher unit works as shown below to punch two holes in two sheets of paper.

a) Punching a Hole in the First Sheet at Its Tail


(PI1P)

Sensor flag

Punch shaft

Eccentric cam

Die

Punch

Paper

Die Punch dust


Home position]

[Punch shaft 90 degrees forward/A punch hole is made.]

[Punch shaft 180 degrees forward/Punching is completed.]

Figure 2-38 (1/4)

When two holes are made, the 3-hole punch is reciprocated in the direction away from the paper (ascending direction) as shown below.

42872701TH Rev.1


Home position]

[Punch shaft 90 degrees forward/Punch ascends to its highest position.]

[Punch shaft 180 degrees forward/Punch returns.]

Figure 2-38 (2/4)

59 /

b) Punching a Hole in the Second Sheet at Its Tail



Home position]

[Punch shaft 90 degrees backward/A punch hole is made.]

[Punch shaft 180 degrees backward/Punching is completed.]

Figure 2-38 (3/4)

When two holes are made, the 3-hole punch is reciprocated in the direction away from the paper (ascending direction) as shown below.


Home position]

[Punch shaft 90 degrees backward/Punch ascends backward/Punch returns.] to its highest position.]

[Punch shaft 180 degrees

Figure 2-38 (4/4)

42872701TH Rev.1

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2.6.2.3

Side Registration

The side registration of the punch slide unit is driven by the side registration motor (M2P). The home position of the punch slide unit is detected by the side registration home position sensor (PI2P). The punch slide unit detects the edges of paper using the paper end sensor (LED5 and PT5) and the side registration sensors (LED1 to LED4 and SREG1 to SREG4) and moves to an appropriate position at the tail of the paper for the paper size.

The side registration is performed as shown below.

1) Once the leading edge of the paper from the connected device is detected by the rear edge sensor (LED5, PT5) on the puncher unit and the specified time has elapsed, the horizontal resist motor (M2P) starts to move the punch slide unit forward.

Side registration home position sensor (PI2P)

Punch slide unit

Paper end sensor (LED5 & PT5)

Side registration motor (M2P)

Paper output direction

Paper

Figure 2-39

2) The appropriate side registration sensor (LED1 to 4, PT1 to 4) for the paper size signal sent from the connected machine detects the edge of the paper in the rear. The side registration motor (M2P) drives the punch slide unit further towards the front and stops it in the specified position.

Side registration sensor 1 (LED1 & PT1);

Detects the edge of A3, A4, LTR or 279 mm x 432 mm (11x17).


Detects the edge of B4, B5, LTRR or LGL.


Detects the edge of A4R.


Detects the edge of B5R.

Figure 2-40

42872701TH Rev.1

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3) When the paper end sensor (LED5 and PT5) detects the tail end of paper, the feed motor

(M1) of the finisher unit stops running and the paper stops. The punch motor (M1P) begins to run and the paper is punched.

Punch

Figure 2-41

4) After punching has been completed, the feed motor (M1) of the finisher unit begins to run.

At the same time, the side registration motor (M2P) runs backward to return the punch slide unit to home position and stop the unit.

5) If documents come in succession, the punch slide unit returns to home position and repeats the steps 1 to 4 for every document.

Paper end sensor

(LED5 & PT5)

Side registration sensors

(LED1 to 4 & PT1 to 4)

Punch home position sensor (PI1P)



(M2P)

Punch motor (M1P)

Feed motor (M1)


Figure 2-42

42872701TH Rev.1

62 /


2.7

Jam Detection

2.7.1 Overview

Check timings for detection of a jam in the finisher, saddle-stitcher or puncher (optional) unit are stored in the microcomputer (CPU) on the finisher controller circuit board. The finisher controller circuit board sees whether there is paper at sensors at these timings to determine that a paper jam has occurred.

If a jam has occurred, the finisher controller circuit board transmits a code for the jam to the connected machine. The code is viewed in the service mode on the connected machine.

PI1

PI10

PI1: Inlet sensor

PI10: Fold position sensor

Figure 2-43

42872701TH Rev.1

63 /


2.7.1.1

Paper Delay Jam at Inlet Sensor (1011)

About 10 seconds have passed since the delivery signal was sent from the connected machine but the inlet sensor hasn’t detected paper.

Delivery signal from connected machine Delivery signal from connected machine

Jam check

Inlet sensor (PI1)

Feed motor (M1)

Approx. 10 sec.

Normal

Jam check

Inlet sensor (PI1)

Feed motor (M1)

Approx. 10 sec.

Jam

Figure 2-44

2.7.1.2

Paper Stopped Jam at Inlet Sensor (1021)

If the paper does not pass the inlet sensor within approximately 0.85 seconds of the rear edge arriving at the connection position of the finisher and main unit.

Jam check

Inlet sensor (PI1)

Feed motor (M1)

Approx. 0.85 sec.

Normal

Jam check

Inlet sensor (PI1)

Feed motor (M1)

Figure 2-45

Approx. 0.85 sec.

Jam

2.7.1.3

Paper Delay Jam at Fold Position Sensor (1012)

Some 1200 ms have passed since the finisher began to feed paper from the jog tray to the saddlestitcher during saddle-stitch operation but the fold position sensor hasn’t detected paper.

Jam check


Delivery motor (M3)

1200ms

Normal

Jam check


Delivery motor (M3)

Figure 2-46

1200ms

Jam

42872701TH Rev.1

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2.7.1.4

Paper Stopped Jam at Fold Position Sensor (1022)

About 10.5 seconds have passed since the staple/fold motor began to run during saddle-stitch operation but paper hasn’t left the fold position sensor.

Jam check


Staple/fold motor

(M7)

Approx. 10.5 sec.

Normal

Jam check


Staple/fold motor

(M7)

Figure 2-47

Approx. 10.5 sec.

Jam

2.7.1.5

Residual Jam (1007)

If paper is detected inside the finisher when the power is turned on or when initialization has begun

Residual jams include inlet-feed-unit residual jams, processing-unit residual jams, and folding-unit residual jams.

2.7.1.6

Door Open Jam (1008)

The finisher is disconnected from the printer, or the front door or the top cover is opened during operation (paper is being fed).

2.7.1.7

Staple Jam (1006)

Some 600 ms have passed since the stapler was driven but the staple home position sensor (PI19) hasn’t switched off or the stapler hasn’t returned to home position (the position in which the sensor is turned on).

2.7.1.8

Non-ejection Jam

This occurs when the paper-ejection belt does not return to the home position within approximately

3 seconds after the paper-ejection motor has started, or when the home position has not been reached within approximately 1.1 seconds after tray ejection and the consequent operation of the paper-ejection motor.

42872701TH Rev.1

65 /


2.8

Power Supply System

2.8.1 Finisher/Saddle-Stitcher Unit

2.8.1.1

Overview

When power of the inverter is turned on, 24 VDC is supplied to the finisher controller circuit board from the inverter. Voltage of 24 V DC is used to drive the motor clutch and to generate 5 V DC, which in turn is used to drive the ICs on the sensor circuit boards. The 5 V is also used to power the punchcontroller circuit board when the optional puncher unit is installed.

The 24 VDC for driving some of the motors will be shut off, if the joint switch (MS2), the front door switch (MS1) or the staple safety switch (MS3) is turned off.

Figure 2-48 shows a block diagram of the power supply.

Inverter

24VP

Joint switch

(MS2)

Front door switch

(MS1) Staple safety switch

(MS3)

24V

Motor

24V

Motor

24V

Clutch

Finisher controller circuit board

(IC1)

Regulator IC

5V

Sensor system

5V

Logic system


(puncher unit (optional))

Figure 2-48

2.8.1.2

Protective Function

The 24-V drive units, including the feed motor (M1), paddle motor (M2), and paper-ejection motor (M3), incorporate fuses that trip if an overcurrent flows.

42872701TH Rev.1

66 /


2.8.2 Puncher Unit (Optional)

2.8.2.1

Overview

The voltages of 24 V and 5 V are supplied to the puncher unit, when power of the inverter is turned on. The 24 V power supply is used for driving the motors. The 5 V power supply is used for driving the sensors and the ICs on the punch controller circuit board.

The 24 V power supply for the motors won’t be supplied, if the joint switch (MS2) or front door switch

(MS1) of the finisher unit is off.

Figure 2-49 shows a block diagram of the power supply.

24V 24V

Motor system


5V


5V

Sensor system

5V

Logic system

Figure 2-49

2.8.2.2

Protective Function

Fuses are built in for the 24 V power supply for driving the punch motor (M1P) and the side registration motor (M2P). If an excessive current flows, the fuses will be blown.

42872701TH Rev.1

67 /

3.

PARTS REPLACEMENT

3.1


3.1.1 Exterior Controlling Parts

Tray (2)

Top right cover unit (4)

Top door

Rear cover (3)


Jam removal cover

Front door

Front cover (5)

A number in parentheses represents the number of screws.

42872701TH Rev.1

68 /

3.1.1.1

Removing Output Tray

1) Remove the four screws 1 and remove the output tray 2.

2


1

3.1.1.2

Removing Front Cover

1) Open the front door 1.

2) While holding the claws 2, remove the fold jam removal dial 3.

3) Remove the two screws 4.

4) Remove the three screws 5 and remove the front cover 6.

6

1

4

3

2

4

5

5

42872701TH Rev.1

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3.1.1.3

Removing Rear Cover

1) Remove the two screws 1 on the paper feed side and the screw 2 on the delivery side.

Remove the rear cover 3.

3

3

1

2

3.1.1.4

Removing Top Cover

1) Open the top cover 1. Turn the cover band clip 2 clockwise and remove the clip.

2) Remove the cover band 3.

3) Remove the screw 4, the jog tray rear cover 5 and then the top cover 6.

1

6

3

2

5

4

42872701TH Rev.1

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3.1.1.5

Removing Jog Tray Top Cover

1) Remove the front cover. (See 3.1.1.2.)

2) Remove the rear cover. (See 3.1.1.3.)

3) Remove the top cover. (See 3.1.1.4.)

4) Disconnect the connector 1 and remove the screw 2.

5) While lifting the jog tray top cover 3, disconnect the connector 4 and remove the jog tray top cover 3.

3

2

4

1

3.1.1.6

Removing Top Right Cover Unit



3) Remove the two screws in the front 1 and the two screws in the rear 2. Remove the top right cover unit 3.

3

3

1

42872701TH Rev.1

2

71 /


3.1.1.7

Removing Side Guide

1) Remove the output tray. (See 3.1.1.1.)



4) Push the front and rear output tray support plates 1 and 2 away from the rail grooves.

5) Remove the four screws 3.

6) Slightly pull down the side guide 4 to the front. Disengage the paper level detection lever

(rear) 5 and then remove the side guide 4.

Note!

When fastening the side guide, fit the paper level detection lever (rear) 5 into the groove in the paper level detection lever (center) 6. Push each paper level detection lever several times to make sure that the levers are tightly engaged.

3

2

3

1

5

3

3

4

5

5

6

6

42872701TH Rev.1

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3.1.2 Feeding Parts

3.1.2.1

Removing Stapler Unit

1) Open the front door 1.

2) While pressing the stopper lever 2, draw out the stapler unit 3.

Note!

Do not remove the stapler from the shaft of the stapler frame. If the stapler is removed from the shaft, that may upset the alignment of the position in which the staple driver (the lower stapler unit) 4 thrusts out a staple with the position in which the staple clincher (the upper stapler unit) 5 receives the staple.

1

5

3

4

2

42872701TH Rev.1

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3.1.2.2

Synchronizing Stapler Motions

When you have replaced the gear at the front of the stapler or the timing belt, or when you have removed the stapler for some reason, the driving motion of the staple driver (the lower stapler unit) will go out of phase with the clinching motion of the staple clinching (the upper stapler unit). Synchronize these stapler motions in the procedure below.

Gear

3

5

2

Timing belt

Gear

1) Remove the gear cover 2 of the staple driver 1.

2) Remove the E-ring 3 and remove the side cover 5 of the staple clincher 4.

3) Remove the two E-rings 6 and remove the staple jam removal gear 7, the timing belt

8 and then the intermediate gear 1 9. Also, remove the spacer and spring behind the staple jam removal gear.

4) Remove the screw 0 and the spring A and remove the belt tensioner B.

5) Remove the timing belt C.

6) Remove the E-ring D and remove the staple position check gear E.

4

E

D

1

A

6

7

8

0

9

B

42872701TH Rev.1

C

74 /


7) Turn the gear F to align the round hole G in the staple driver with the round hole behind it.

8) Insert a pin with a diameter of about 2 mm H (a 2-mm hex key wrench, for example) into the round holes to fix the gear.

9) Turn the gear I to align the round hole J in the staple clincher cam with the round hole behind it.

10) Insert a pin with a diameter of about 2 mm K (a 2-mm hex key wrench, for example) into the round holes to fix the cam.

F

G

H

I

K

J

42872701TH Rev.1

75 /


11) With the gear and the cam fixed, put the timing belt L on the gear M and the gear N.

12) Fasten the staple position check gear Q with its blue mark O aligned with the round hole

P in the frame.

Note!

Be sure to fasten the staple position check gear in correct position. The position in which the blue mark is aligned with the round hole is the home position for the staple driving motion. If the staple jam removal dial is rotated, the stapler unit will deviate from this home position and the staple cartridge will be stuck in the unit. In that case, this blue mark is used to return the unit into home position.

13) Remove the pins fixing the gear and the cam.

14) Put the spring R, the spacer S, the staple jam removal gear T, the timing belt U and the intermediate gear 1 V back in place and fasten them with the E-rings W.

M

L

N

R

S

T

W

U

V

P

O

Q

42872701TH Rev.1

76 /


3.1.2.3

Synchronizing Gears of Saddle-Stitcher Unit

When you have replaced the gear at the front of the saddle-stitcher unit, the paper folding rollers or when you have removed these parts for some reason, synchronize the gears in the procedure below.

1) Position the paper folding rollers 1 and the saddle cam 2 in the saddle-stitcher unit as shown below.

2) Keeping the paper folding rollers and the saddle cam in position, fasten the gears as shown below.

• Align the triangle mark ( ▲) (either of the two marks) on the saddle cam drive gear 3 with the triangle mark ( ▲) on the intermediate gear 4 (one on the semicircle with shorter teeth).

• Also, align the other triangle mark ( ▲) on the intermediate gear 4 with a rib of the paper folding roller drive gear 5.

2

1

3

4

5

42872701TH Rev.1

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3.1.2.4

Removing Saddle-Stitcher Unit



3) Open the jam removal cover 1 and remove the two screws 2 and the right stay 3.

4) Rotate the fold jam removal dial 4 to move the paper pressure plate 5 inwards.

5) Remove the stop ring 6 and remove the timing belt 7.

6) Disconnect the two connectors 8.

7) Remove the three screws 9 and slightly draw out the stapler unit 0.

8) Draw out the saddle-stitcher unit A.

3

5

2

2

1

4

0

9

8

6

7

A

9

42872701TH Rev.1

78 /


3.1.2.5

Removing Jog Tray Unit

1) Remove the jog tray top cover. (See 3.1.1.5.)

2) Remove the side guide. (See 3.1.1.7.)

3) Remove the two screws 1 and disconnect the five connectors 2.

4) Pull the jog tray stopper base 3 and release the front click 5 and the rear click 6 of the jog tray stopper 4.

5) Disconnect the three connectors 7.

6) Release the two cable clamps 8 and remove the motor bundled cable 9.

7) Remove the stop ring 0 and remove the timing belt A.

8) Disconnect the connector B and remove the bundled cable D from the edge saddle C.

9) Remove the two screws E. Slide the jog tray unit F towards the rear and then lift it up to remove the unit.

1

6

4

5

4

2

2 1 2

3

8

9

A

7

0 C

F

B

D

E

42872701TH Rev.1

79 /

3.1.2.6

Removing Paddle Unit

1) Remove the jog tray unit. (See 3.1.2.5.)

2) Place the jog tray unit 1 as shown below.

Note!

Be careful not to damage the jog plates 2.

3) Remove the timing belt 3 and remove the two screws 4.

4) Separate the paddle unit 6 from the jog tray unit 5.

4


6

1

5

2

3

4

42872701TH Rev.1

80 /


3.1.2.7

Removing Staple/Fold Drive Unit

1) Open the front door 1 and slightly draw out the stapler unit 2.

2) Remove the screw 3 and remove the interface cable bracket 4.

3) Release the six cable clamps 5 and disconnect the connector 6.

4) Release the bundled cable 7 from the cable clamp 5.

5) Release the bundled cable 7 from the edge saddle 8 and disconnect the two connectors

9.

6) Release the cable clamp 0 and disconnect the connector A.

7) Release the bundled cable B from the cable clamp 0.

8) Release the bundled cable B from the edge saddle C and disconnect the two connectors

D.

9

1

8

7

2

D

6

5

7

4

A

3

5 7

B

5

C

0

42872701TH Rev.1

81 /


9) Remove the screw E and release the cable guide click G from the square hole F of the base plate.

10) Disconnect the two connectors H and release the bundled cable J from the edge saddle

I.

11) Remove the three screws K.

12) Remove the screw L and remove the staple/fold drive unit M.

H

E

I

G

F

J H

K

K

L M

K

42872701TH Rev.1

82 /

3.1.2.8

Removing Feed Motor Unit


2) Open the cable clamp 1 and disconnect the two connectors 2.

3) Remove the screw 3 and remove the cable guide 4.

4) Remove the three screws 5 and remove the feed motor unit 6.

3

5

5


4 6

2

1

42872701TH Rev.1

83 /


3.1.2.9

Removing Feed Roller

1) Remove the top cover. (See 3.1.1.4.)

2) Remove the top right cover unit. (See 3.1.1.6.)

3) Remove the feed motor unit. (See 3.1.2.6.)

4) Remove the screw 1.

5) Remove the stop ring 2 and remove the bearing 3.


7) Remove the gear 5. While opening the claw, remove the gear 6.

8) Remove the stop ring 7 and remove the bearing 8.

9) Remove the screw 9 and remove the inlet sensor 0.

10) Remove the paper guide A.

11) Remove the feed rollers B.

4

8

5

9

0

A

7

6

1

3

2

42872701TH Rev.1

B

84 /


3.1.2.10 Removing Multi-Sheet Delivery Roller (Top)

1) Remove the paddle unit. (See 3.1.2.6.)

2) Place the paddle unit 1 as shown below.

3) Turn the gear 2 in the arrow direction to raise the multi-sheet delivery roller (top) 3.

4) Push up the multi-sheet delivery roller (top) 4 and release the multi-sheet delivery roller

(top) 4 from the shaft 5.

5) Swing open the multi-sheet delivery roller (top) 4, push it down and remove it.

6) Remove the multi-sheet delivery roller (top) at the front 6 in the same way.

1

3

4

5

6

4

2

42872701TH Rev.1

85 /


3.1.2.11 Removing Paddle

1) Remove the paddle unit. (See 3.1.2.6.)

2) Place the paddle unit 1 as shown below.

3) Turn the gear 2 in the arrow direction to raise the multi-sheet delivery roller (top) 3.

4) Push up the safety guide 4 and release one side of the safety guide 4 from the shaft

5.

5) Push up the safety guide 4, release the safety guide 4 from the shaft 5 and remove the guide.

6) Move the paddle 6 in the arrow direction and remove it.

7) Remove the remaining paddles in the same way.

1

3

5

4

4

42872701TH Rev.1

5

2

1

86 /


3.1.2.12 Removing Multi-Sheet Delivery Roller (Bottom)/Delivery Belt

1) Remove the paddle unit and separate the jog tray unit from it. (See 3.1.2.6.)

2) Slide the jog plate (front) 2 and the jog plate (rear) 3 of the jog tray unit 1 outwards and remove them.

3) Remove the jog tray stopper 4.

1

4

3

2

4) Remove the screw 5. While releasing the two clicks F, remove the paper guide (front)

7.

5) Remove the screw 8. While releasing the click 9, remove the paper guide (rear) 0.

5

7

8

6

0

9

6) Remove the two stop rings A and move the two bearings B inwards.

7) Remove the four screws C, lift up the multi-sheet delivery roller (bottom) D and remove it.

B C

A

C

D

A

B

42872701TH Rev.1

87 /


8) Remove the multi-sheet delivery roller (bottom) E and the two delivery belts F.

F

E

Note!

When the delivery belts have been put back on, make sure that the tips G of the clicks of the delivery belts are aligned.

G

42872701TH Rev.1

88 /


3.1.3 Circuit Boards

3.1.3.1

Removing Finisher Controller Circuit Board


2) Disconnect the 17 connectors 1 and remove the screw 2.

3) Release the circuit board clip 3 and remove the finisher controller circuit board 4.

3

2

1

1

1 4 1

42872701TH Rev.1

89 /


3.1.3.2

Removing Slide Home Position Circuit Board

1) Open the front door 1. Turn the stapler slide knob 2 in the arrow direction to slide the stapler to its forwardmost position.

2) Remove the stapler unit. (See 3.1.2.1.)

3) Place the stapler unit 3 as shown below.

4) Remove the two screws 4 and remove the guide 5.

5) Turn the stapler slide knob 2 in the arrow direction until the locking screw 7 of the slide home position circuit board 6 is seen through the round hole.

6) Remove the locking screw 7.

7) Disconnect the connector 8.

8) Remove the flexible cable clamp 9.

9) Move the connector lock 0 in the arrow direction to release it. Remove the flexible cable

A and remove the slide home position circuit board B.

1

2

3

4

5

4

2

8 0

A

6

7

B

9

42872701TH Rev.1

90 /

3.2


3.2.1 Puncher Driving Parts

3.2.1.1

Removing Punch Motor


2) Disconnect the connector 2 and remove the punch motor 3.


2

3

1

3.2.1.2

Removing Side Registration Motor

1) Disconnect the connector J1001 1.

2) Release the bundled cable 3 from the cable guide 2.

3) Remove the two screws 4 and remove the side registration motor 5.

4

5

3

2

1

42872701TH Rev.1

91 /

3.2.1.3

Removing Puncher Unit

1) Remove the punch dust receptacle.

2) Remove the screw 1 and remove the jam removal cover 2.



1

2


3

5

4


6) Remove the screw 7 and remove the sensor support plate 8.

7) Remove the screw 9 and washer 0.

8) Disconnect the connector A.

9) Remove the two screws B and remove the base cover C.

6

C

9

0

7

8

A

B

42872701TH Rev.1

92 /


10) Remove the four screws D and remove the transmissive sensor unit units (top)E and

(bottom) F.

11) Remove the puncher unit H from the side registration motor unit G.

G

E

H

D D F D

42872701TH Rev.1

93 /


3.2.2 Circuit Boards

3.2.2.1

Removing Punch Controller Circuit Board


2) Disconnect the five connectors 2 and remove the punch controller circuit board 3.

2 3

2

2

1

3.2.2.2

Removing Photo Sensor Circuit Board

1) Remove the punch motor. (See 3.2.1.1.)


3) Release the bundled cable 3 from the cable guide 2 of the circuit board cover and remove the circuit board cover 4.

4) Disconnect the connector 5 and remove the photo sensor circuit board 6.

1

4

6

3

5

2

42872701TH Rev.1

94 /

3.2.2.3

Removing LED Circuit Board

1) Remove the punch dust receptacle.



4) Remove the screw 4 and washer 5.


6) Remove the screw 7 and remove the base cover 8.


8) Disconnect the connector 0 and remove the LED circuit board A.


1

4

5

8

3

2

6

7

42872701TH Rev.1

9

0

A

95 /


3.2.2.4

Removing Dust Full Photo Sensor Circuit Board

1) Remove the punch controller circuit board. (See 3.2.2.1.)

2) Remove the two screws 1 and remove the circuit board film 2.

3) Disconnect the connector 3 and remove the dust full photo sensor circuit board 4.

2 3

1

3.2.2.5

Removing Dust Full LED Circuit Board


2) Disconnect the connector 2 and remove the LED circuit board 3.

4

2

1

3

42872701TH Rev.1

96 /


4.

MAINTENANCE AND INSPECTION

4.1

Periodical Replacement Parts


These units use no parts requiring periodical replacement.


This unit uses no parts requiring periodical replacement.

4.2

Expendable Parts Durability Guide

The parts listed in the table below can be deteriorated or broken, requiring replacement, at least once during the warranty period of the product. These parts, however, need to be replaced only when problem has occurred.


No.

Parts Name

1 Stapler

Parts No.

43223350 1

Table 4-01

Quantity Durability Remarks

300,000 About 5000 stapling operations with one operations cartridge

4.3

Periodical Maintenance

Item

Table 4-02

Interval

Paper feeder roller

Paper feeder roller

Printer minimum maintenance interval


Feed path/guide Printer minimum maintenance interval

Transmissive sensor

(optional puncher unit)


Detail

Cleaning

Cleaning

Cleaning

Cleaning

Remarks

Wipe with a damp cloth.



Wipe with a dry cloth.

42872701TH Rev.1

97 /


5.

TROUBLESHOOTING

5.1

Standards and Adjustment

(Can be adjusted using a command from the main unit)

5.1.1 Electrical System, Finisher/Saddle-Stitcher Unit

5.1.1.1

Adjusting Fold Position

To adjust the fold position, bring the fold position into the stapling position. Make this adjustment, when the finisher controller circuit board has been replaced or when the fold position has to be changed for some reason.

1) Set the SW1 on the finisher controller circuit board as shown below.

ON

1 2 3 4 5 6 7 8

2) Press the PSW1 or PSW2 on the finisher controller circuit board for the appropriate number of times to adjust the fold position. When the switch is pressed once, the fold position is moved about 0.16 mm.

• Press the PSW1 to move the fold position in the “minus direction.”

• Press the PSW2 to move the fold position in the “plus direction.”

• Press the PSW1 and PSW2 simultaneously to clear the set correction.

Minus direction Plus direction

3) After a correction for the fold position has been set, turn off all the bits of the SW1 on the finisher controller circuit board.

4) Perform the booklet mode of the connected machine to see if the fold position is adjusted properly. If not, make adjustment again.

42872701TH Rev.1

98 /


5.1.1.2

Adjusting Saddle-Stitch Double Stapling Position

To adjust the stapling position, bring the stapling position into the fold position. Make this adjustment, when the finisher controller circuit board has been replaced or when the stapling position has to be changed for some reason.

1) Set the SW1 on the finisher controller circuit board as shown below.

ON

1 2 3 4 5 6 7 8

2) Press the PSW1 or PSW2 on the finisher controller circuit board for the appropriate number of times to adjust the fold position. When the switch is pressed once, the stapling position is moved about 0.14 mm.

• Press the PSW1 to move the stapling position in the “minus direction.”

• Press the PSW2 to move the stapling position in the “plus direction.”

• Press the PSW1 and PSW2 simultaneously to clear the set correction.

Minus direction Plus direction

3) After a correction for the stapling position has been set, turn off all the bits of the SW1 on the finisher controller circuit board.

4) Perform the booklet mode of the connected machine to see if the stapling position is adjusted properly. If not, make adjustment again.

42872701TH Rev.1

99 /


5.1.2 Electrical System, Puncher Unit (Optional)

5.1.2.1

Adjusting Punch Hole Position (Feeding Direction)

This adjustment is available in the service mode only. The correction is set within the range from -

3 to 3 and the hole position is moved in an increment of 1 mm. If the correction setting is increased, the hole position moves towards the leading end of paper. (See the service manual for the connected machine.)

5.1.2.2 Adjusting Sensor Output

Make this adjustment, when the punch controller circuit board, the side registration sensor (photo sensor circuit board/LED circuit board), or the dust full sensor (dust full photo sensor circuit board/dust full

LED circuit board) is replaced.

1) Set the bits 1 to 4 of the DIPSW1001 on the punch controller circuit board as shown below.

ON

1 2 3 4

2) Press the SW1002 or SW1003 on the punch controller circuit board. Pressing these switches, the sensor output is automatically adjusted.

• Adjustment is complete when all the LED1001, LED1002 and LED1003 on the punch controller circuit board light up.

3) Turn off all the bits of the DIPSW1001.

5.1.2.3

Registering Number of Punch Holes

The number of punch holes is registered in the IC on the punch controller circuit board so that the finisher recognizes what type of puncher is installed. The registration is needed, when the punch controller circuit board is replaced.

1) Set the bits 1 to 4 of the DIPSW1001 on the punch controller circuit board as shown below.

2) Press the SW1002 on the punch controller circuit board to choose the number of holes.

• Every time the SW1002 is pressed, the indications below change in order from top to bottom.

Number of Punch Holes

2 holes (Puncher unit •2H)

2/3 holes (Puncher unit •2/3H)

4 holes (Puncher unit •4HF)

4 holes (Puncher unit •4HS)

LED 1001 LED 1002 LED 1003

ON

ON

OFF

OFF

OFF

ON

OFF

OFF

OFF

OFF

OFF

ON

3) Press the SW1003 on the punch controller circuit board twice. Pressing the switch, the number of punch holes is registered in the punch controller circuit board.

• Press the SW1003 once, and the solid light above changes to blinking light. Press the

SW1003 once again, and the blinking light returns to solid light and the registration is complete.

4) Turn off all the bits of the DIPSW1001.

42872701TH Rev.1

100 /


5.1.2.4

Procedure after Replacement of EEP-ROM (IC1002)

1) Turn off power of the connected machine.

ON

1 2 3 4

2) Set the bits 1 to 4 of the DIPSW1001 on the punch controller circuit board.

3) Press the SW1002 and SW1003 on the punch controller circuit board simultaneously.

• This initializes the EEP-ROM. After the initialization has been completed, the LED1001,

LED1002 and LED1003 all light up.

4) Adjust the sensor output and register the number of punch holes.

42872701TH Rev.1

101 /


5.2

Electrical Parts Layout


5.2.1.1

Sensors, Microswitches and Clutch

PI23

PI16

MS3

PI14

PI24

PI4

PI18

MS1

PI19

PI20

PI21

MS2

PI22

PI17

PI8

PI7

PI5

PI13

PI15

PI3

PI2

PI1

PI12

CL1

PI6

PI9

PI10

PI11

Figure 5-01

42872701TH Rev.1

102 /

Description

Photo interrupter

Microswitch

Clutch


Code

PI1

PI2

PI11

PI12

PI13

PI14

PI15

PI16

PI17

PI18

PI19

PI20

PI21

PI22

PI23

PI24

PI7

PI8

PI9

PI10

PI3

PI4

PI5

PI6

Table 5-01

Function

Inlet paper detection

Paddle home position detection

Multi-sheet roller home position detection

Front jog plate home position detection

Rear jog plate home position detection

Jog tray paper detection

Delivery belt home position detection

Tray paper detection

Paper level detection

Fold position detection

Folding home position detection

Folding roller home position detection

Booklet tray paper detection

Staple/fold motor clock detection

Shift upper limit detection

Shift lower limit detection

Shift motor clock detection

Slide home position detection (in the stapler)

Staple drive home position detection (in the stapler)

Staple empty detection (in the stapler)

Staple top position detection (in the stapler)

Front door open detection

Top cover open detection

Paper full detection

MS1

MS2

MS3

Front door open detection

Joint open detection

Staple safety detection

CL1 Booklet clutch

42872701TH Rev.1

103 /

5.2.1.2

Motors and Circuit Board

M2

M1

M8


M4

M5 M3 M7

M6

Figure 5-02

Motor

Description


Table 5-02

Code

M1

M2

M3

M4

M5

M6

M7

M8

Feed motor

Paddle motor

Delivery motor



Shift motor

Staple/fold motor

Slide motor

1 Control of the finisher

Function

42872701TH Rev.1

1

104 /


5.2.2.1

Sensors

PI2P

PI3P

PI1P


Description

Photo interrupter

Figure 5-03

Code

Pl1P

Pl2P

Pl3P

Table 5-03

Function

Punch home position detection

Side registration home position detection

Punch motor clock detection

42872701TH Rev.1

105 /


5.2.2.2

Motors

M1

M2

Motor

Description

Figure 5-04

Table 5-04

Code

M1P

M2P

Punch motor


Function

5.2.2.3

Circuit Boards 1

4

2

5

Figure 5-05

Code

1

2

3

4

5

Table 5-05

Function


Photo sensor circuit board

LED circuit board

Dust full photo sensor circuit board

Dust full LED circuit board

42872701TH Rev.1

3

106 /


5.3

LED/Check Pin List by PCB

This section lists the LEDs and check pins that are necessary for servicing this finisher at a customer’s place.

Note!

Check pins not shown on the list must be used at the factory only, as the adjustments and inspections using these pins need special tools or instruments and very high accuracy is required. Never touch these check pins during servicing at a customer’s place.

5.3.1 Finisher Controller circuit Board

6

CN8

1

4

CN6

1

1 2

CN18 1

CN10

12

1

CN3

10

1

CN13

6

LED3 LED2 LED1

PSW3 PSW2 PSW1

6

CN17

1

SW1

Figure 5-06

1

CN9

9

7

CN11

1

Switch

SW1

PSW1

PSW2

PSW3

Table 5-06

Function

Adjustment of fold position/saddle-stitch double stapling



Factory mode

42872701TH Rev.1

107 /


5.3.2 Punch Controller Circuit Board

13

J1007

1

SW1001

SW1002

SW1003

LED1001

LED1002

LED1003

1

J1003

10 1

J1004

5

Figure 5-07

Switch

SW1001

SW1002

SW1003

Table 5-07

Function

Registration of number of punch holes/adjustment of sensor output



42872701TH Rev.1

108 /


5.4

Troubleshooting

5.4.1 Troubleshooting Procedure (Finisher/Saddle-Stitcher Unit)

5.4.1.1

186 - Failure in communications with printer

Table 5-08

Finisher controller PCB/Inverter DC controller PCB

1) Is the problem solved when the power switch of the printer is turned off and then on?

YES: Completed.

Wiring

2) Is the wiring between the finisher controller circuit board and the inverter DC controller circuit board installed properly?

NO: Correct the wiring.

Finisher controller PCB/Inverter DC controller PCB

3) Is the problem solved when the finisher controller circuit board and inverter DC controller circuit board are replaced?

YES: Completed.

5.4.1.2

096-09 - Failure of finisher unit backup memory

Table 5-09

Finisher controller PCB


YES: Completed.

NO: Replace the finisher controller circuit board.

5.4.1.3

096-01 - Feed motor failure

Table 5-10

Multi-sheet feed roller (top) home position sensor (PI12)

1) Check the multi-sheet feed roller (top) home position sensor. Is the sensor working properly?

NO: Replace the sensor.

Wiring

2) Is the wiring between the finisher controller circuit board and the feed motor installed properly?


Feed roller

3) Rotate the multi-sheet feed roller (top) shaft by hand. Is the multi-sheet feed roller (top) is raised and lowered properly?

NO: Adjust the mechanical mechanism.

Feed motor (M1)/Finisher controller PCB

4) Is the problem solved when the feed motor is replaced?

YES: Completed.


42872701TH Rev.1

109 /


5.4.1.4

096-05 - Delivery motor failure

Table 5-11


1) Check the delivery belt home position sensor. Is the sensor working properly?


Wiring

2) Is the wiring between the finisher controller circuit board and the delivery motor installed properly?



3) Rotate the multi-sheet delivery roller by hand. Does the roller rotate smoothly?

NO: Adjust the mechanical mechanism.

Delivery motor (M3)/Finisher controller PCB

4) Is the problem solved when the delivery motor is replaced?

YES: Completed.


5.4.1.5

096-03 -Rear jog plate motor failure

Table 5-12


1) Check the rear jog plate home position sensor. Is the sensor working properly?


Wiring

2) Is the wiring between the finisher controller circuit board and the rear jog plate motor installed properly?


Rear jog plate

3) Is there a hitch in the jog plate travel path?

YES: Adjust the mechanical mechanism.

Rear jog plate motor (M5)/Finisher controller circuit board

4) Is the problem solved when the rear jot plate motor is replaced?

YES: Completed.


42872701TH Rev.1

110 /


5.4.1.6

096-03 - Front jog plate motor failure

Table 5-13


1) Check the front jog plate home position sensor. Is the sensor working properly?


Wiring

2) Is the wiring between the finisher controller circuit board and the front jog plate motor installed properly?


Front jog plate

3) Is there a hitch in the jog plate travel path?


Front jog plate motor (M4)/Finisher controller circuit board

4) Is the problem solved when the front jot plate motor is replaced?

YES: Completed.


5.4.1.7

096-04 - Staple/fold motor failure

Table 5-14

Wiring

1) Is the wiring between the finisher controller circuit board and the staple/fold motor installed properly?


Stapler unit

2) Rotate the staple jam removal dial. Is there a hitch in the rotation?


Staple/fold motor (M7)/Finisher controller PCB

3) Is the problem solved when the staple/fold motor is replaced?

YES: Completed.


42872701TH Rev.1

111 /


5.4.1.8


Table 5-15

Staple/fold clock sensor (PI14)

1) Check the staple/fold clock sensor. Is the sensor working properly?


Finisher control PCB/Stapler unit

2) Does the staple/fold motor operate at the specified timing?

YES: Replace the finisher controller circuit board.

NO: Check the stapler unit drive mechanism and adjust it if there is problem. If not, go to the step 3.



YES: Completed.


5.4.1.9


Table 5-16


1) Check the folding home position sensor. Is the sensor working properly?


Wiring

2) Is the wiring between the finisher controller circuit board and the staple/fold motor installed properly?


Saddle-stitcher unit

3) Rotate the fold jam removal dial. Is there a hitch in the rotation?




YES: Completed.


42872701TH Rev.1

112 /


5.4.1.10 096-04 - Staple/fold motor failure

Table 5-17

Staple/fold clock sensor (PI14)

1) Check the staple/fold clock sensor. Is the sensor working properly?


Finisher control PCB/Saddle-stitcher unit

2) Does the staple/fold motor operate at the specified timing?


NO: Check the saddle-stitcher unit drive mechanism and adjust it if there is problem. If not, go to the step 3.



YES: Completed.


5.4.1.11 096-06 - Slide motor failure

Table 5-18

Slide home position sensor (PI18)

1) Check the slide home position sensor. Is the sensor working properly?

NO: Replace the sensor circuit board.

Wiring

2) Is the wiring between the finisher controller circuit board and the slide motor installed properly?


Stapler unit

3) Is there a hitch in the stapler travel path?


Slide motor (M8)/ Finisher controller circuit board

4) Is the problem solved when the slide motor is replaced?

YES: Completed.


42872701TH Rev.1

113 /


5.4.1.12 096-02 - Shift motor failure

Table 5-19

Paper level sensor (PI9)

1) Check the paper level sensor. Is the sensor working properly?


Tray elevator mechanism

2) Check the tray elevator mechanism. Is the mechanism working properly?

NO: Adjust the mechanism.


3) Power of 24 VDC is supplied to the shift motor from the finisher controller circuit when the tray is to be driven.


Shift motor (M6)/Wiring

4) Check the wiring between the finisher controller circuit board and the shift motor. Is the wiring installed properly?

YES: Replace the shift motor.



Table 5-20

Tray position

1) Has the tray reached the shift upper limit sensor?

YES: Lower the tray position.

Shift upper limit sensor (PI15)

2) Check the shift upper limit sensor. Is the sensor working properly?


Finisher controller PCB/Wiring

3) Check the wiring between the finisher controller circuit board and the shift upper limit sensor. Is the wiring installed properly?



42872701TH Rev.1

114 /



Table 5-21

—

1) Is the tray raised?

YES: Go to the step 4.

NO: Go to the step 2.


2) Power is supplied to the finisher controller circuit board motor when the tray is to be raised or lowered?

YES: Go to the step 3.


Tray elevator mechanism/Shift motor (M6)

3) Is there problem with the tray elevator mechanism?

YES: Adjust the tray elevator mechanism.

NO: Replace the tray elevator motor.

Shift motor clock sensor (PI17)/ Finisher controller circuit board

4) Check the shift motor clock sensor. Is the sensor working properly?



5.4.1.15 096-07 - Paddle motor failure

Table 5-22


1) Check the paddle home position sensor. Is the sensor working properly?



2) Check the swing guide home position sensor. Is the sensor working properly?


Wiring

3) Is the wiring between the finisher controller circuit board and the paddle motor installed properly?


Paddle/swing guide

4) Rotate the paddle motor forward and backward by hand. Is there a hitch in rotation of the paddle or up/down movement of the swing guide?


Paddle motor (M2)/Finisher controller circuit board

5) Is the problem solved when the paddle motor is replaced?

YES: Completed.


42872701TH Rev.1

115 /


5.4.2 Troubleshooting Procedure (Optional Puncher Unit)

5.4.2.1

096-0C - Failure in communications with puncher

Table 5-23

Finisher controller PCB/Punch controller PCB


YES: Completed.

Wiring

2) Is the wiring between the finisher controller circuit board and the punch controller circuit board installed properly?


Power supply

3) Measure the voltage between CN14-5(+) and CN14-3(-) on the finisher controller circuit board.

Is it 24 VDC?


YES: Replace the punch controller circuit board.

5.4.2.2

096-0E - Failure of puncher unit backup memory

Table 5-24

EEP-ROM (IC1002)

1) Is the problem solved when the EEP-ROM on the punch controller circuit board is initialized?

YES: Completed.

Punch controller PCB


YES: Completed.

NO: Replace the punch controller circuit board.

5.4.2.3

096-0D - Puncher unit power supply failure

Table 5-25

Finisher controller PCB/Connected machine DC controller PCB


YES: Completed.

Wiring

2) Is the wiring between the finisher controller circuit board and the punch controller circuit board installed properly?


Power supply

3) Measure the voltage between CN14-5(+) and CN14-3(-) on the finisher controller circuit board.

Is it 24 VDC?

YES: Replace the punch controller circuit board.


42872701TH Rev.1

116 /


5.4.2.4

096-0A - Punch motor failure

Table 5-26

Punch home position sensor (PI1P)

1) Check the punch home position sensor. Is the sensor working properly?


Punch motor clock sensor (PI3P)

2) Check the punch motor clock sensor. Is the sensor working properly?


Wiring

3) Is the wiring between the finisher controller circuit board and the sensors installed properly?


Punch mechanism/Punch motor (M1P)

4) Is there problem with the punch mechanism?

YES: Adjust the punch mechanism.

NO: Replace the punch motor.

Punch controller PCB/Finisher controller PCB

5) Is the problem solved when the punch controller circuit board is replaced?

YES: Completed.


5.4.2.5

096-0F, 096-10 - Punch sensor (side registration) failure

Table 5-27

Side registration sensor (photo sensor PCB/LED PCB)

1) Check the side registration sensor. Is the sensor working properly?


Wiring

2) Is the wiring between the punch controller circuit board and the side registration sensor installed properly?




YES: Completed.


42872701TH Rev.1

117 /


5.4.2.6

096-11 - Punch sensor (dust full) failure

Table 5-28

Dust full sensor (Dust full photo sensor PCB/Dust full LED PCB)

1) Check the dust full sensor. Is the sensor working properly?


Wiring

2) Is the wiring between the punch controller circuit board and the dust full sensor installed properly?




YES: Completed.


5.4.2.7

096-0B - Side registration motor failure

Table 5-29


1) Check the side registration home position sensor. Is the sensor working properly?


Wiring

2) Is the wiring between the finisher controller circuit board and the side registration home position sensor installed properly?


Side registration mechanism/Side registration motor (M2P)

3) Is there problem with the side registration mechanism?

YES: Adjust the side registration mechanism.

NO: Replace the side registration motor.



YES: Completed.


42872701TH Rev.1

118 /


5.5

Self-Diagnosis

5.5.1 Overview

This finisher has the self-diagnosis function for examining the state of the machine using the CPU on the finisher controller circuit board. The finisher performs the self-diagnosis as necessary. If it detects a problem, the finisher transmits the “code” and the “detail code” of the problem to the printer. The printer displays the code on the operating unit. The detail code is viewed in the service mode of the printer.

5.5.2 Error

5.5.2.1


CU error code

186

096-09

096-01

096-05

096-03

096-04

Interface error

Error

Backup RAM data error

Paper eject motor error

Batch processing motor error

Aligning motor error

Table 5-30 (1/2)

Staple motor (stapling/folding) error

Detection Timing

• Communications is cut off between the printer and the finisher. This error is detected by the printer.

• There is an error in the checksum of the finisher controller circuit board when power is turned on.

• The feed motor has run for 2 seconds but the multisheet feed roller (top) hasn't left the multi-sheet feed roller (top) home position sensor.

• The feed motor has run for 2 seconds but the multisheet feed roller (top) hasn't returned to the multisheet feed roller (top) home position sensor.

• The delivery motor has run for 3 seconds but the delivery belt hasn't left the delivery belt home position sensor.

• If the paper-ejection belt does not return to the paper-ejection-belt home-position sensor within 1.1

seconds after the paper-ejection motor has started

• If alignment-motor errors are detected in the frontalignment and rear-alignment motors.

• If the stapler does not move away from the staple home-position sensor within approximately 0.6

seconds after the staple/folding motors have started.

• If the stapler does not return to the staple homeposition sensor within approximately 0.6 seconds after the staple/folding motors have started.

• The staple/fold motor is running but the staple/fold clock sensor hasn't detected a clock signal more than

0.1 seconds.

• If the folding roller does not move away from the folding home-position sensor within approximately 0.7

seconds after the staple/folding motors have started.

• If the folding roller does not return to the folding home-position sensor within approximately 10 seconds after the staple/folding motors have started the first time, within approximately 4 seconds after they have started the second time, and within approximately 19 seconds after initialization.

• If the clock is interrupted for 0.1 seconds or more while the staple/folding motors are operating.

42872701TH Rev.1

119 /


CU error code

096-06

Error

Stapler unit feed motor error

096-02

096-07

Tray raising/lowering motor error

Paddle motor error

Table 5-30 (2/2)

Detection Timing

• The slide motor has run for 1 second but the stapler unit hasn't left the slide home position sensor.

• The slide motor has run for 6 seconds but the stapler unit hasn't returned to the slide home position sensor

• More than 10 seconds have passed after the shift motor began to run but no change has occurred in the paper level sensor.

• The shift upper limit sensor is turned on while the tray is ascending.

• The shift motor is running but the shift motor clock sensor hasn't detected a clock signal more than 50 msec.

• The paddle motor has run for 2 seconds but the paddle hasn't left the paddle home position sensor.

• The paddle motor has run for 2 seconds but the paddle hasn't returned to the paddle home position sensor.

• The paddle motor has run for 2 seconds but the swing guide hasn't left the swing guide home position sensor.

• The paddle motor has run for 2 seconds but the swing guide hasn't returned to the swing guide home position sensor.

096-08 Folding sensor error

42872701TH Rev.1

120 /


5.2.2.2

Puncher Unit (Option)

CU error code

096-0C

096-0E

096-0D

Error

Punch interface error

Punch backup RAM data error

Table 5-31

Detection Timing

• Communications with the puncher is cut off.

• There is an error in the checksum of the punch controller circuit board when power is turned on.

Punch power failure error

096-0A

096-0F

096-10

096-11

096-0B

Punch motor error

Punch resist sensor error

Punch horizontal resist sensor error

Punch debris sensor error

Punch feed motor error

• Power of 24 VDC is not supplied from the finisher unit but the puncher has received the start signal.

• The punch motor has run for 250 msec. but the puncher hasn't returned to the punch motor home position sensor.

• The punch motor is running but the punch motor clock sensor hasn't detected a clock signal more than

60 msec.

• During automatic sensor output adjustment, the light emitting voltage is set to 4.4 V but the light receiving voltage doesn't exceed 2.5 V.

• During automatic sensor output adjustment, the light emitting voltage is set to 0 V but the light receiving voltage exceeds 2.5 V.

• After automatic sensor output adjustment, the light emitting voltage setting is higher than 4.4 V.







• The side registration motor has run for 1000 msec.

but the puncher hasn't left the side registration home position sensor.

• The side registration motor has run for 1000 msec.

but the puncher hasn't returned to the side registration home position sensor.

42872701TH Rev.1

121 /


5.5.3 Alarm

5.5.3.1


Error

No staple

Alarm Condition

The staple cartridge becomes empty.

Table 5-32

Detection Timing

Always monitored.

When documents exceeding the limit have been output.

Mechanism Operation

The operation can be continued, although that depends on command from the printer.

The operation can be continued.

Reset

Replace the staple cartridge or set it properly.

Remove the documents on the output tray.

Over-stacking on outlet tray

Over-stacking on booklet tray

The number of documents on the output tray exceeds the stackable number of sheets/ sets.

The number of document sets on the booklet tray exceeds 10 sets.

When documents sets exceeding the limit have been output.


Remove the documents on the booklet tray.

5.5.3.2


Error

Punch dust full

Alarm Condition

The punch dust accumulation has reached the limit for the receptacle.

Table 5-33

Detection Timing

During punching

Mechanism Operation


Reset

Remove the punch dust.

42872701TH Rev.1

122 /

APPENDIX A OVERALL TIMING CHART

1.

Finisher Unit

Staple-A4, Two-Sheet Rear Single Stapling


42872701TH Rev.1

123 /

2.


Booklet-LTR, Two Sheets One Set


42872701TH Rev.1

124 /

3.


Punch-A4, Two-Sheet Two Sets, Job Offset


42872701TH Rev.1

125 /


APPENDIX B SIGNAL NAME/ABBREVIATION LIST

The list below shows the signal names and their abbreviations used in this chapter and the circuit diagrams.

Reference: The abbreviations enclosed in brackets are analog electric signals that cannot be expressed by “1” or “0.” All others are digital signals expressed by “1” or “0.”

1.


FJOGMTR

FRONT_SW

HOOK_S

JOINT_SW

LVL_S

PAPER_F

PDL_HP

PDLMTR

RJOG_HP

RJOGMTR

SELF_P

SEN

SIFT_CLK

SIFT_DNLMT

SIFTMTR

SIFT_UPLMT

ADJ_TRAY_S

B_CLU

BDL_ROL_HP

BIND_CLK

BIND_EMPS

BIND_HP

BIND_L

BINDMTR

BIND_P

BIND_ROL_HP

EJCT_BLT_HP

EJCTMTR

ENT_S

FDOOR_S

FEEDMTR

FJOG_HP

SLID_HP

SLIDMTR

STPL_CNCT

STPL_HP

STPLSAFE_SW

TOPCOV_S

TRY_EMPS

JOG TRAY PAPER DETECT Signal

BIND CLUTCH DRIVE Signal

SWING GUIDE HP DETECT Signal

STAPLE/FOLD MOTOR CLOCK DETECT Signal

BIND TRAY PAPER DETECT Signal

FOLDING HP DETECT Signal

FOLD POSITION LED ON Signal

STAPLE/FOLD MOTOR DRIVE Signal

FOLD POSITION PAPER DETECT Signal

BUNDLE FEED ROLLER HP DETECT Signal

EJECT BELT HP DETECT Signal

EJECT MOTOR DRIVE Signal

INLET PAPER DETECT Signal

FRONT DOOR OPEN DETECT Signal

FEED MOTOR DRIVE Signal

FRONT JOG PLATE HP DETECT Signal

FRONT JOG MOTOR DRIVE Signal

FRONT DOOR SWITCH Signal

HOOK EMPTY DETECT Signal

JOINT SWITCH Signal

PAPER SURFACE DETECT Signal

PAPER FULL DETECT Signal

PADDLE HP DETECT Signal

PADDLE MOTOR DRIVE Signal

REAR JOG PLATE HP DETECT Signal

REAR JOG MOTOR DRIVE Signal

HOOK TOP POSITION DETECT Signal

INVERTER DISCHARGE SENSOR

SIFT MOTOR CLOCK DETECT Signal

SIFT DOWN LIMIT DETECT Signal

SIFT MOTOR DRIVE Signal

SIFT UPPER LIMIT DETECT Signal

SLIDE HP DETECT Signal

SLIDE MOTOR DRIVE Signal

STAPLER CONNECT DETECT Signal

STAPLE HP DETECT Signal

STAPLE SAFETY SWITCH Signal

TOP COVER OPEN DETECT Signal

TRAY PAPER DETECT Signal

42872701TH Rev.1

126 /

2.


CLOCK

DUSTLED

DUSTPTR

PAEND

PUNCH

SLIDE

SREG1

SREG2

SREG3

SREG4

LEDON1

LEDON2

LEDON3

LEDON4

LEDON5

PUNCH MOTOR CLOCK DETECT Signal

DUST LED ON Signal

DUST FULL DETECT Signal

PAPER END DETECT Signal

PUNCH HP DETECT Signal

SIDE REGISTRATION HP DETECT Signal

SIDE REGISTRATION DETECT Signal 1




LED1 ON Signal

LED2 ON Signal

LED3 ON Signal

LED4 ON Signal

LED5 ON Signal


42872701TH Rev.1

127 /


APPENDIX C JAM CODE/STACK PAPER CODE LIST

5

6

3

4

7

8

No.

1

2

Jam Code

596

592, 593, 594

595

590

597

591

598

599

Jam code list

Indication

Staple Jam

Residual Paper Jam

Door Open Jam

Paper Delay Jam at Inlet Sensor

Paper Delay Jam at Fold Position Sensor

Paper Stopped Jam at Inlet Sensor

Paper Stopped Jam at Fold Position Sensor

Sets of Paper Jam

No.

1

2

3

4

Operation panel code

643

644

645

646

Stack paper code list

Paper position

Feeding part

Post-processing part

Sets of paper part

Folding part

42872701TH Rev.1

128 /


APPENDIX D SOLVENTS/OILS LIST

No.

1

Name

BUCLEAN C-17

2 Lubricating oil

Application

Cleaning

Ex.) Glass

Plastics

Rubbers

External covers

Driving part

Sliding part

Lead cam

Ingredient

Fluorine hydrocarbon

Alcohols

Surfactant

Water

Silicon oil

Remark

• Keep from flame.

• Substitute

IPA (isopropyl alcohol)

• PERMALVE G2 (Nihon

Koyu Co., Ltd.)

42872701TH Rev.1

129 / 129

Oki Data C 9600, C 9800, ES 3640 finisher, 2H, 2/3H, 4HF, 4HS puncher Service manual

Assistant Bot

051108A

INTRODUCTION

Table of contents

1.

OVERVIEW

2.

OPERATION

Finisher Controller Circuit Board (1/2)

Finisher Controller Circuit Board (2/2)

Finisher Controller Circuit Board

Finisher Controller Circuit Board

Punch Controller Circuit Board (1/2)

Punch Controller Circuit Board (2/2)

3.

PARTS REPLACEMENT

4.

MAINTENANCE AND INSPECTION

5.

TROUBLESHOOTING

APPENDIX A OVERALL TIMING CHART

APPENDIX B SIGNAL NAME/ABBREVIATION LIST

APPENDIX C JAM CODE/STACK PAPER CODE LIST

APPENDIX D SOLVENTS/OILS LIST

Key Features

Frequently Answers and Questions

What is the stacking capacity of the finisher?

What is the paper weight capacity for stapling?

What is the paper size capacity for saddle-stitching?

What is the punch hole diameter for the 2-hole puncher?

What is the punch dust capacity for the 4-hole puncher?

How do I replace the staple cartridge?

How do I dispose of the punch dust?

Related manuals

Table of contents

Oki Data C 9600, C 9800, ES 3640 finisher, 2H, 2/3H, 4HF, 4HS puncher Service manual

Assistant Bot

051108A

INTRODUCTION

Table of contents

1.

OVERVIEW

2.

OPERATION

Finisher Controller Circuit Board (1/2)

Finisher Controller Circuit Board (2/2)

Finisher Controller Circuit Board

Finisher Controller Circuit Board

Punch Controller Circuit Board (1/2)

Punch Controller Circuit Board (2/2)

3.

PARTS REPLACEMENT

4.

MAINTENANCE AND INSPECTION

5.

TROUBLESHOOTING

APPENDIX A OVERALL TIMING CHART

APPENDIX B SIGNAL NAME/ABBREVIATION LIST

APPENDIX C JAM CODE/STACK PAPER CODE LIST

APPENDIX D SOLVENTS/OILS LIST

Key Features

Frequently Answers and Questions

What is the stacking capacity of the finisher?

What is the paper weight capacity for stapling?

What is the paper size capacity for saddle-stitching?

What is the punch hole diameter for the 2-hole puncher?

What is the punch dust capacity for the 4-hole puncher?

How do I replace the staple cartridge?

How do I dispose of the punch dust?

Related manuals

OKI

42872902

Canon

Q3 Finisher-Q3

Canon

V1

Canon

U1

MyBinding

Formax FD 160

Canon

F2 Saddle Finisher-F2

Toshiba

MJ-6005

Canon

Inner A1

Sharp

AR-PN4

Panasonic

Workio DP-4510

Canon

5075

Canon

Q1 R1/S1/T1

Table of contents