Page 1
DF-78
Page 2
CONTENTS
1-1 Specifications
1-1-1 Specifications ....................................................................................................................................... 1-1-1
1-1-2 Part names ........................................................................................................................................... 1-1-2
1-1-3 Machine cross section .......................................................................................................................... 1-1-3
1-1-4 Drive system ........................................................................................................................................ 1-1-4
1-2 Installation
1-2-1 Unpacking ............................................................................................................................................ 1-2-1
1-3 Troubleshooting
1-3-1 Paper misfeed detection ...................................................................................................................... 1-3-1
(1) Paper misfeed indication............................................................................................................... 1-3-1
(2) Paper misfeed detection condition................................................................................................ 1-3-2
(3) Paper misfeeds ............................................................................................................................. 1-3-3
1-3-2 Self-diagnosis....................................................................................................................................... 1-3-4
(1) Self-diagnostic function................................................................................................................. 1-3-4
(2) Self-diagnostic codes.................................................................................................................... 1-3-4
1-3-3 Electrical problems ............................................................................................................................... 1-3-7
(1) The paper conveying motor does not operate. ............................................................................. 1-3-7
(2) The feedshift solenoid does not operate....................................................................................... 1-3-7
(3) The pickup solenoid does not operate. ......................................................................................... 1-3-7
(4) The front side registration motor does not operate. ...................................................................... 1-3-7
(5) The rear side registration motor does not operate........................................................................ 1-3-7
(6) The trailing edge registration motor does not operate. ................................................................. 1-3-7
(7) The cooling fan motor does not operate. ...................................................................................... 1-3-8
1-3-4 Mechanical problems ........................................................................................................................... 1-3-9
(1) Paper jams.................................................................................................................................... 1-3-9
(2) Abnormal noise is heard. .............................................................................................................. 1-3-9
3B5
1-4 Assembly and Disassembly
1-4-1 Precautions for assembly and disassembly ......................................................................................... 1-4-1
(1) Precautions ................................................................................................................................... 1-4-1
(2) Adjusting the positions of the front side registration cursor, rear side registration cursor
and trailing edge registration cursor (reference) ........................................................................... 1-4-2
(3) Cleaning the stapler ...................................................................................................................... 1-4-3
(4) Adjusting the pressure of curl eliminator mechanism ................................................................... 1-4-4
2-1 Mechanical construction
2-1-1 Construction of each section ................................................................................................................ 2-1-1
(1) Paper conveying operation in sort mode ...................................................................................... 2-1-2
2-1-2 Intermediate tray section ...................................................................................................................... 2-1-3
(1) Paper registration on the intermediate tray................................................................................... 2-1-4
2-1-3 Stapler section ..................................................................................................................................... 2-1-5
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1
(1) Paper conveying section............................................................................................................... 2-2-1
(2) Intermediate tray section............................................................................................................... 2-2-2
(3) Stapler section .............................................................................................................................. 2-2-3
2-3 Operation of the PCBs
2-3-1 Main PCB ............................................................................................................................................. 2-3-1
1-1-1
2-4 Appendixes
Timing chart No. 1 ........................................................................................................................................... 2-4-1
Timing chart No. 2 ........................................................................................................................................... 2-4-2
Timing chart No. 3 ........................................................................................................................................... 2-4-3
Periodic maintenance procedure.................................................................................................................... 2-4-4
Wiring diagram ................................................................................................................................................ 2-4-5
Page 3
1-1-1 Specifications
Type ............................................... Built-in
Number of trays..............................1 (intermediate tray)
Stapling limit................................... A4/11" × 81/2" or smaller: 30 sheets
Other sizes than above: 20 sheets
Power source ................................. Electrically connected to the copier
Weight............................................Approximately 11 kg/24.2 lbs
3B5
1-1-1
Page 4
3B5
1-1-2 Part names
Figure 1-1-1
1 Intermediate tray
2 JAM release lever
3 Eject tray
1-1-2
Page 5
1-1-3 Machine cross section
3B5
Figure 1-1-2 Machine cross section
1 Paper conveying section
2 Intermediate tray section
3 Eject section
Paper path
1-1-3
Page 6
3B5
1-1-4 Drive system
Figure 1-1-3
1 Paper conveying motor gear
2 Gear 31/20
3 Gear 28
4 Gear 18
5 Gear 18
6 Gear 25
7 Gear 14
8 Gear 16
9 Central gear
0 Gear 21
! Gear 26
@ Clutch cam
# Stopper gear
$ Gear 32
% Gear 26
1-1-4
Page 7
1-2-1 Unpacking
3B5
Figure 1-2-1 Unpacking
1 Paper conveying unit
2 Intermediate tray unit
3 Eject tray
4 Stapler cover
5 Staple cartridge
6 Large eject cover
7 Cross-head chrome TP-A screws M3 × 05
8 Cross-head bronze binding TP-A screws M3 × 05
9 Front eject cover
0 Rear eject cover
! Paper conveying unit pad
@ Upper intermediate tray pad
# Lower intermediate tray pad
$ Outer case
% Spacer 1
^ Spacer 2
& Spacer 3
* Spacer 4
( Plastic bag
) Plastic bag
⁄ Plastic sheet
¤ Plastic bag
‹ Plastic bag
› Air-padded bag
fi Bar-code labels
1-2-1
Page 8
3B5
1-3-1 Paper misfeed detection
(1) Paper misfeed indication
When paper jams, the machine immediately stops operation and the occurrence of a paper jam is indicated on the copier
operation panel.
To remove the jammed paper, lower the intermediate tray.
To reset the paper misfeed detection, detach and refit the intermediate tray to turn the tray open/close switch off and on.
PCSW
Figure 1-3-1 Paper misfeed detection
1-3-1
Page 9
3B5
(2) Paper misfeed detection condition
• Jam between the finisher and copier (jam code 81)
The paper conveying switch does not turn on within 1550 ms of the signal requesting paper ejection is output from the
copier.
• Intake jam (jam code 82)
During paper intake from the copier, the paper conveying switch (PCSW) does not turn off within 1960 to 3480 ms
(depending on paper size) of paper conveying switch (PCSW) turning on.
PCSW
1960 to 3480 ms
Off
On
Timing chart 1-3-1
• Jam during paper conveying for batch ejection 1 (jam code 83)
When ejection a stack of paper, the paper conveying switch (PCSW) does not turn on within 1590 ms of the paper
conveying motor (PCM) turning on.
PCM
PCSW
1590 ms
Off
On
Off
On
Timing chart 1-3-2
• Jam during paper conveying for batch ejection 2 (jam code 84)
When ejection a stack of paper, the paper con v eying switch (PCSW) does not turn off within 2260 to 3190 ms (depending
on the paper size) of the paper conveying motor (PCM) turning on.
PCSW
2260 to 3190 ms
Off
On
Timing chart 1-3-3
1-3-2
Page 10
(3) Paper misfeeds
Problem Causes Check procedures/corrective measures
(1)
Paper jams in the
finisher when the
main switch is turned
on.
A piece of paper torn from
copy paper is caught
around the paper
conveying switch.
Defective paper conveying
switch.
Remove any found.
With 5 V DC present at CN4-9 on the main PCB, check if CN4-10
on the main PCB remains low when the paper conveying switch
is turned on and off. If it does, replace the paper conveying
switch.
3B5
(2)
Paper jams in the
finisher during
copying (intake jam).
Jam code 82
(3)
Paper jams in the
finisher during
copying (jam during
paper conveying for
batch ejection 1).
Jam code 83
(4)
Paper jams in the
finisher during
copying (jam during
paper conveying for
batch ejection 2).
Jam code 84
Defective paper conveying
switch.
Check if the feedshift roller
or feedshift pulley is
deformed.
Defective paper conveying
switch.
Check if the feedshift roller
or press roller is deformed.
Defective paper conveying
switch.
Check if the eject roller or
eject pulley is deformed.
With 5 V DC present at CN4-9 on the main PCB, check if CN4-10
on the main PCB remains high or low when the paper conveying
switch is turned on and off. If it does, replace the paper
conveying switch.
Check visually and replace the pulley or roller if deformed.
With 5 V DC present at CN4-9 on the main PCB, check if CN4-10
on the main PCB remains high or low when the paper conveying
switch is turned on and off. If it does, replace the paper
conveying switch.
Check visually and replace the pulley or roller if deformed.
With 5 V DC present at CN4-9 on the main PCB, check if CN4-10
on the main PCB remains high or low when the paper conveying
switch is turned on and off. If it does, replace the paper
conveying switch.
Check visually and replace the pulley or roller if deformed.
1-3-3
Page 11
3B5
1-3-2 Self-diagnosis
(1) Self-diagnostic function
This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled and the problem
displayed as a code consisting of “C” followed by a number between 0440 and 8220, indicating the nature of the problem.
A message is also displayed requesting the user to call for service.
After removing the problem, the self-diagnostic function can be reset by turning the tray open/close switch or copier safety
switch 1 or 2 off and back on.
(2) Self-diagnostic codes
Code Contents
C0440 Finisher communication problem
An error code from the side deck is
detected eight times in succession.
No communication: there is no reply
after 3 retries.
Abnormal communication: a
communication error (parity or
checksum error) is detected five times in
succession.
C8170 Finisher front side registration motor
problem
If the front side registration home
position sensor is on in initialization, the
sensor does not turn off within 570 ms
of starting initialization.
If the front side registration home
position sensor is off in initialization, the
sensor does not turn on within 3180 ms
of starting initialization.
Remarks
Causes Check procedure/corrective measures
Poor contact in the
connector
terminals.
Defective copier
main PCB.
Defective finisher
main PCB.
The front side
registration motor
connector makes
poor contact.
The front side
registration motor
malfunctions.
The front side
registration home
position sensor
connector makes
poor contact.
Check the connection of connectors CN4,
CN5 on the copier main PCB and CN2 on
the finisher main PCB, and the continuity
across the connector terminals. Repair or
replace if necessary.
Replace the copier main PCB and check for
correct operation.
Replace the finisher main PCB and check
for correct operation.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
Replace the front side registration motor
and check for correct operation.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
C8180 Finisher rear side registration motor
problem
If the rear side registration home
position sensor is on in initialization, the
sensor does not turn off within 570 ms
of starting initialization.
If the rear side registration home
position sensor is off in initialization, the
sensor does not turn on within 2880 ms
of starting initialization.
The front side
registration home
position sensor
malfunctions.
Defective finisher
main PCB.
The rear side
registration motor
connector makes
poor contact.
The rear side
registration motor
malfunctions.
The rear side
registration home
position sensor
connector makes
poor contact.
The rear side
registration home
position sensor
malfunctions.
Replace the front side registration home
position sensor and check for correct
operation.
Replace the finisher main PCB and check
for correct operation.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
Replace the rear side registration motor and
check for correct operation.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
Replace the rear side registration home
position sensor and check for correct
operation.
1-3-4
Page 12
3B5
Code Contents
C8180 Finisher rear side registration motor
problem
If the rear side registration home
position sensor is on in initialization, the
sensor does not turn off within 570 ms
of starting initialization.
If the rear side registration home
position sensor is off in initialization, the
sensor does not turn on within 2880 ms
of starting initialization.
C8190 Finisher trailing edge registration
motor problem
If the trailing edge registration home
position sensor is on in initialization, the
sensor does not turn off within 570 ms
of starting initialization.
If the trailing edge registration home
position sensor is off in initialization, the
sensor does not turn on within 4550 ms
of starting initialization.
Remarks
Causes Check procedure/corrective measures
Defective finisher
main PCB.
The trailing edge
registration motor
connector makes
poor contact.
The trailing edge
registration motor
malfunctions.
The trailing edge
registration home
position sensor
connector makes
poor contact.
Replace the finisher main PCB and check
for correct operation.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
Replace the trailing edge registration motor
and check for correct operation.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
C8210 Finisher front stapler problem
The front stapler home position sensor
does not change state from nondetection to detection within 200 ms of
the start of front stapler motor
counterclockwise (forward) rotation.
During initialization, the front stapler
home position sensor does not change
state from non-detection to detection
within 600 ms of the start of front stapler
motor clockwise (reverse) rotation.
The trailing edge
registration home
position sensor
malfunctions.
Defective finisher
main PCB.
The front stapler
connector makes
poor contact.
The front stapler
malfunctions.
a) The front stapler
is blocked with a
staple.
b) The front stapler
is broken.
Defective finisher
main PCB.
Replace the trailing edge registration home
position sensor and check for correct
operation.
Replace the finisher main PCB and check
for correct operation.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
a) Remove the front stapler cartridge, and
check the cartridge and the stapling section
of the stapler.
b) Replace the front stapler and check for
correct operation.
Replace the finisher main PCB and check
for correct operation.
1-3-5
Page 13
3B5
Code Contents
C8220 Finisher rear stapler problem
The rear stapler home position sensor
does not change state from nondetection to detection within 200 ms of
the start of rear stapler motor
counterclockwise (forward) rotation.
During initialization, the rear stapler
home position sensor does not change
state from non-detection to detection
within 600 ms of the start of rear stapler
motor clockwise (reverse) rotation.
Remarks
Causes Check procedure/corrective measures
The rear stapler
connector makes
poor contact.
The rear stapler
malfunctions.
a) The rear stapler
is blocked with a
staple.
b) The rear stapler
is broken.
Defective finisher
main PCB.
Reinsert the connector. Also check for
continuity within the connector cable. If
none, remedy or replace the cable.
a) Remove the front stapler cartridge, and
check the cartridge and the stapling section
of the stapler.
b) Replace the front stapler and check for
correct operation.
Replace the finisher main PCB and check
for correct operation.
1-3-6
Page 14
1-3-3 Electrical problems
Problem Causes Check procedures/corrective measures
(1)
The paper conveying
motor does not
operate.
(2)
The feedshift
solenoid does not
operate.
Broken paper conveying
motor coil.
Poor contact of the paper
conveying motor connector
terminals.
Defective finisher main
PCB.
Broken feedshift solenoid
coil.
Poor contact of the
feedshift solenoid
connector terminals.
Check for continuity across the coil. If none, replace the paper
conveying motor.
Reinsert the connector. Also check for continuity within the
connector cable. If none, remedy or replace the cable.
Check if a motor drive coil energization signal is output at CN9-9,
CN9-10, CN9-11 and CN9-12 on the finisher main PCB. If not,
replace the finisher main PCB.
Check for continuity across the coil. If none, replace the feedshift
solenoid.
Reinsert the connector. Also check for continuity within the
connector cable. If none, remedy or replace the cable.
3B5
(3)
The pickup solenoid
does not operate.
(4)
The front side
registration motor
does not operate.
(5)
The rear side
registration motor
does not operate.
Defective finisher main
PCB.
Broken pickup solenoid
coil.
Poor contact of the pickup
solenoid connector
terminals.
Defective finisher main
PCB.
Broken front side
registration motor coil.
Poor contact of the front
side registration motor
connector terminals.
Defective finisher main
PCB.
Broken rear side
registration motor coil.
Poor contact of the rear
side registration motor
connector terminals.
Check if CN4-2 and CN4-4 on the finisher main PCB go low. If
not, replace the finisher main PCB.
Check for continuity across the coil. If none, replace the pickup
solenoid.
Reinsert the connector. Also check for continuity within the
connector cable. If none, remedy or replace the cable.
Check if CN4-7 on the finisher main PCB goes low. If not, replace
the finisher main PCB.
Check for continuity across the coil. If none, replace the front side
registration motor.
Reinsert the connector. Also check for continuity within the
connector cable. If none, remedy or replace the cable.
Check if a motor drive coil energization signal is output at CN5-1,
CN5-3, CN5-4 and CN5-5 on the finisher main PCB. If not,
replace the finisher main PCB.
Check for continuity across the coil. If none, replace the rear side
registration motor.
Reinsert the connector. Also check for continuity within the
connector cable. If none, remedy or replace the cable.
(6)
The trailing edge
registration motor
does not operate.
Defective finisher main
PCB.
Broken trailing edge
registration motor coil.
Poor contact of the trailing
edge registration motor
connector terminals.
Defective finisher main
PCB.
Check if a motor drive coil energization signal is output at CN5-6,
CN5-8, CN5-9 and CN5-10 on the finisher main PCB. If not,
replace the finisher main PCB.
Check for continuity across the coil. If none, replace the trailing
edge registration motor.
Reinsert the connector. Also check for continuity within the
connector cable. If none, remedy or replace the cable.
Check if a motor drive coil energization signal is output at CN6-1,
CN6-2, CN6-3 and CN6-4 on the finisher main PCB. If not,
replace the finisher main PCB.
1-3-7
Page 15
3B5
Problem Causes Check procedures/corrective measures
(7)
The cooling fan
motor does not
operate.
Broken cooling fan motor
coil.
Poor contact of the cooling
fan motor connector
terminals.
Check for continuity across the coil. If none, replace the cooling
fan motor.
Reinsert the connector. Also check for continuity within the
connector cable. If none, remedy or replace the cable.
Defective finisher main
PCB.
Check if CN4-6 on the finisher main PCB goes low. If not, replace
the finisher main PCB.
1-3-8
Page 16
1-3-4 Mechanical problems
Problem Causes/check procedures Corrective measures
(1)
Paper jams.
Check if the contact between the feedshift
roller and feedshift pulley is correct.
Check if the contact between the feedshift
roller and press roller is correct.
3B5
Check and remedy.
Check and remedy.
(2)
Abnormal noise is
heard.
Check if the contact between the eject roller
and eject pulley is correct.
Check if the rollers and gears operate
smoothly.
Check and remedy.
Grease the bushings and gears.
1-3-9
Page 17
1-4-1 Precautions for assembly and disassembly
(1) Precautions
• Be sure to turn the main switch off and disconnect the power plug before starting disassembly.
• When handling PCBs, do not touch connectors with bare hands or damage the board.
• Do not touch any PCB containing ICs with bare hands or any object prone to static charge.
• Use the following testers when measuring voltages:
Hioki 3200
Sanwa MD-180C
Sanwa YX-360TR
Beckman TECH300
Beckman DM45
Beckman 330*
Beckman 3030*
Beckman DM850*
Fluke 8060A*
Arlec DMM1050
Arlec YF1030C
* Capable of measuring RMS values.
• Prepare the following as test originals:
1. NTC (new test chart)
2. NPTC (newspaper test chart)
3B5
1-4-1
Page 18
3B5
Stapler
5 ± 3.0 mm
5 ± 3.0 mm
(2) Adjusting the positions of the front side registration cursor, rear side registration cursor and trailing edge
registration cursor (reference)
Perform the following adjustment if paper registration is poor or stapling is made outside the specified area.
Procedure
Start
Make a test copy
in staple-sort mode.
Is the paper registration
good?
Yes
Is the stapling
position correct?
See Figure 1-4-1.
Yes
End
No
No
Enter maintenance mode.
Enter “246” using the numeric
keys.
Press the start key.
Select the item to be adjusted .
Change the setting using the
cursor up/down keys.
Press the start key.
The new setting
is stored.
Press the stop/clear key.
Exit maintenance mode.
Figure 1-4-1 Stapling position
ADJUST FRONT JOGGER: Stop position of the
front side registration cursor
ADJUST REAR JOGGER: Stop position of the rear
side registration cursor
ADJUST END JOGGER: Stop position of the
trailing edge registration cursor
Setting range: 0 to 8
Reference: 4
Changing the value by 1 changes the position by
0.5 mm.
Increasing the value moves the front or rear side
registration cursor or trailing edge registration
cursor outward (a); decreasing the value moves
each cursor inward (e). See Figure 1-4-2.
Trailing edge
registration cursor
Rear side
registration cursor
Front side
registration cursor
Figure 1-4-2
1-4-2
Page 19
(3) Cleaning the stapler
During periodic maintenance, remove all the staples remaining inside the machine due to failure of stapling.
Procedure
1. Open the front and conveying covers of the
copier.
2. Remove the staple cartridge.
3. Remove the four screws securing the stapler
cover and then the cover.
4. Remove the staples attracted to the magnet
on the inside of the stapler cover.
5. Refit all the removed parts.
Staple
Stapler cover
3B5
Staple cartridge
Figure 1-4-3
Magnet
1-4-3
Page 20
3B5
(4) Adjusting the pressure of curl eliminator mechanism
Increase the pressure of the curl eliminator mechanism to reduce upward curling of paper stacked on the intermediate tray
if a paper jam occurs when batch ejection is performed because of strong upward curling.
Procedure
1. Remove the paper conveying unit from the
copier.
2. Loosen the two screws from the front and
rear curl eliminator pressure adjusting plates
respectively and then remove the plates.
3. Refit the all removed parts.
Curl eliminator pressure
adjusting plate
Paper conveying unit
Curl eliminator pressure
adjusting plate
Figure 1-4-4
1-4-4
Page 21
3B5
2-1-1 Construction of each section
The paper conveying section consists of the components shown in Figure 2-1-1. It switches the path for the paper conveyed
from the copier in sort mode. Also the paper conv eying section contains a curl eliminator mechanism, which reduces curling
of paper with curl eliminator rollers.
Figure 2-1-1 Paper conveying section
1 Feedshift pulley
2 Feedshift roller
3 Press roller
4 Press roller lift
5 Stopper
6 Upper curl eliminator roller
7 Lower curl eliminator roller
FSSOL
PCSW
8 Feedshift claw
9 Small feedshift claw
0 Eject roller
! Eject pulley
@ Paper conveying switch (PCSW)
# Upper guide plate
$ Lower guide plate
PUSOL
PCM
CN6-7-
CN4-10
CN4-2,4
CN6-12
MPCB
Figure 2-1-2 Paper conveying section block diagram
CN4-7
2-1-1
Page 22
3B5
(1) Paper conveying operation in sort mode
When a copy is made in the sort mode, the feedshift solenoid (FSSOL) turns on and the feedshift guide of the copier
operates to switch the paper path to the paper conveying unit. After curling of the conveyed paper is eliminated by the curl
eliminator rollers, the paper is conveyed to the intermediate tray by the feedshift roller. When the trailing edge registration
cursor of the intermediate tray shifts the paper stocked in the intermediate tray to the stopper, the pickup solenoid (PUSOL)
turns on to lift the press roller and release the stopper. The stack of paper on the intermediate tray is ejected to the eject tray
by the feedshift roller and eject roller.
Feedshift guide
(FSSOL:ON)
Feedshift solenoid
Upper curl
eliminator
roller
Lower curl
eliminator roller
Feedshift pulley
Feedshift roller
To intermediate tray
Press roller
Stopper (PUSOL:OFF)
To eject tray
Eject pulley
Eject roller
Small feedshift claw
Feedshift claw
Figure 2-1-3
Feedshift pulley
Feedshift roller
Stopper (PUSOL:ON)
Pick up solenoid
Press roller
2-1-2
Page 23
3B5
2-1-2 Intermediate tray section
The intermediate tray section consists of the components shown in Figure 2-1-4. It stores and evens up the paper conveyed
from the paper conveying section and returns the stack of paper to the paper conveying section.
Intermediate tray
Trailing edge registration cursor
Rear side registration cursor
Front side registration cursor
Figure 2-1-4 Intermediate tray section
SRFHPS
FSRM RSRM TERM
CN5-5
CN5-1-
CN4-12
SRRHPS
CN5-6-
CN5-10
CN4-14
CN6-4
CN6-1-
TERHPS
MPCB
Figure 2-1-5 Intermediate tray section block diagram
CN4-26
2-1-3
Page 24
3B5
(1) Paper registration on the intermediate tray
In sort mode, the front and rear side registration cursors move to the size of the paper used to even up the sides of the stack
of paper and the trailing edge registration cursor shifts the paper to the paper conveying section.
In staple-sort mode, the front and rear side registration cursors even up the sides of the stack of paper and shift the stack
toward the machine front, and then the trailing edge registration cursor shifts the stack to the stapling position.
Home positions
Rear side registration cursor
Paper registration
Trailing edge registration cursor
Front side registration cursor
2-1-4
Shifting the paper to
the stapling position
Figure 2-1-6
Page 25
2-1-3 Stapler section
In staple-sort mode, paper stocked on the intermediate tray is stapled by the stapler.
The stapler motor (STM) drives the stapler cam via the stapler drive gear to staple paper.
3B5
Stapler self-priming
sensor
Figure 2-1-7 Stapler section
Stapler drive gear
Stapler cam
Stapler motor
Stapler cam
STES STCS
STHPS
STM
STSPS
Figure 2-1-8 Stapler section block diagram
CN4-20
CN4-22
CN4-16
CN6-13 –
CN6-16
CN4-24
MPCB
2-1-5
Page 26
2-2-1 Electrical parts layout
(1) Paper conveying section
3B5
3
6
1
4
2
Machine front
Machine inside
5
Machine rear
Figure 2-2-1 Paper conveying section
1. Paper conveying motor (PCM) .................... Drives the paper conveying section.
2. Paper conveying switch (PCSW) ................. Detects a paper jam in the finisher.
3. Feedshift solenoid (FSSOL) ........................ Operates the feedshift guide of the copier.
4. Pickup solenoid (PUSOL) ............................ Operates the press roller.
5. Tray open/close switch (TOCSW)................ Detects if the intermediate tray is opened or closed.
6. Cooling fan motor (CFM) ............................. Cools the stapler section.
2-2-1
Page 27
3B5
(2) Intermediate tray section
2
1
5
7,8
3,4
Machine front
Machine inside
Machine rear
6
Figure 2-2-2 Intermediate tray section
1. Main PCB (MPCB)....................................... Controls electrical components.
2. Intermediate tray sensor (ITS) ..................... Detects the presence of paper on the intermediate tray.
3. Trailing edge registration motor (TERM)...... Drives the trailing edge registration cursor.
4. Front side registration motor (FSRM) .......... Drives the front side registration cursor.
5. Rear side registration motor (RSRM) .......... Drives the rear side registration cursor.
6. Trailing edge registration home position
sensor (TERHPS) ........................................ Detects the trailing edge registration cursor in the home position.
7. Side registration front home position
sensor (SRFHPS) ........................................ Detects the front side registration cursor in the home position.
8. Side registration rear home position
sensor (SRRHPS)........................................ Detects the rear side registration cursor in the home position.
2-2-2
Page 28
(3) Stapler section
3B5
1
5
Machine front Machine inside
2
3
4
Machine rear
Figure 2-2-3 Stapler section
1. Stapler empty sensor (STES) ...................... Detects the presence of staples.
2. Staple cartridge sensor (STCS)................... Detects the presence of the staple cartridge.
3. Stapler home position sensor (STHPS) ....... Detects the stapler in the home position.
4. Stapler self-priming sensor (STSPS) ........... Detects the pre-stapling state of the stapler.
5. Stapler motor (STM) .................................... Drives the stapler.
2-2-3
Page 29
2-3-1 Main PCB
3B5
Feedshift solenoid
Pickup solenoid
CPU (IC5)
Buffer IC12,
IC13, IC14
Main PCB
Motor
drive
circuit
Motor
drive
circuit
Paper conveying
motor
Motors
Switches
and
sensors
TXD
RXD
Copier
Figure 2-3-1 Main PCB block diagram
The main PCB (MPCB) consists mainly of the CPU IC5 and motor drive circuit.
The CPU IC5 detects the condition of the switches and sensors and controls the motors and solenoids by serially
communicating with the copier. The feedshift solenoid (FSSOL) operates with the control signals from the copier.
2-3-1
Page 30
3B5
18CN8
IC1
1
R1
CN5
110
32
1
1
131
2
11 1
C1
1
R8 R9
C11
IC9
IC10
CN4
CN3
C12
IC4
IC11
D1
9
9
Figure 2-3-2 Main PCB silk-screen diagram
R2
IC13
ZD1
C13
IC5
TP1
TP2
TP4
8
8
L3F1
C2
100
IC12
TP5
81
C3
CN2
80
C4
1
IC6
1
IC14
1
12
D3
10
1
CN1
18
JP1
IC3
18
1
1
D2
JP2
1
51
50
R3
R4
31
30
TP3
TR1
D4
1
IC16
IC7
IC15
1
IC17
TR2
8
TR3
8
8
1
C6
C5 C7
L1
X1
R5 R6
18
8
IC18
CN7
8
7
L2
IC19
IC2
TR6
C14
R7
C8
CN6
C10
1
16 2
15 1
8
IC20
12 1
16
IC8
5
1
C9
1
TR5
1
TR4
2
2-3-2
Page 31
Terminals (CN) V olta ge Remarks
2-1 2-3 0/5 V DC RESET signal, input
2-2 2-3 0/5 V DC Finisher SET signal, input
2-4 2-5 0/5 V DC (pulse) Serial signal TXD, input
2-6 2-7 0/5 V DC (pulse) Serial signal RXD, output
2-8 2-7 5 V DC 5 V DC supply, input
2-11 2-9 24 V DC 24 V DC supply, input
2-12 2-10 24 V DC 24 V DC supply, input
3-7 3-4 0/24 V DC FSSOL release signal, input
3-8 3-4 0/24 V DC FSSOL latch-on signal, input
3-9 3-4 24 V DC 24 V DC supply for FSSOL, input
4-1 4-29 24 V DC 24 V DC supply for FSSOL, output
4-2 4-29 0/24 V DC FSSOL latch-on signal, output
4-3 4-29 24 V DC 24 V DC supply for CFM, output
4-4 4-29 0/24 V DC FSSOL release signal, output
4-5 4-29 24 V DC 24 V DC supply for PUSOL, output
4-6 4-29 0/24 V DC CFM on/off signal, output
4-7 4-29 0/24 V DC PUSOL on/off, output
4-9 4-29 5 V DC 5 V DC supply for PCSW, output
4-10 4-29 0/5 V DC PCSW on/off, input
4-11 4-23 5 V DC 5 V DC supply for SRFHPS, output
4-12 4-23 0/5 V DC SRFHPS on/off, input
4-13 4-25 5 V DC 5 V DC supply for SRRHPS, output
4-14 4-25 0/5 V DC SRRHPS on/off, input
4-15 4-27 5 V DC 5 V DC supply for stapler, output
4-16 4-27 0/5 V DC STHPS on/off, input
4-17 4-21 5 V DC 5 V DC supply for ITS, output
4-18 4-21 0/5 V DC ITS on/off, input
4-19 4-28 5 V DC 5 V DC supply for TERHPS, output
4-20 4-27 0/5 V DC STCS on/off, input
4-22 4-27 0/5 V DC STES on/off, input
4-24 4-27 0/5 V DC STSPS on/off, input
4-26 4-28 0/5 V DC TERHPS on/off, input
5-1 2-9 0/24 V DC (pulse) FSRM motor coil energization pulse, output (A)
5-2 2-9 24 V DC 24 V DC supply for FSRM, output
5-3 2-9 0/24 V DC (pulse) FSRM motor coil energization pulse, output (B)
5-4 2-9 0/24 V DC (pulse) FSRM motor coil energization pulse, output (B)
5-5 2-9 0/24 V DC (pulse) FSRM motor coil energization pulse, output (A)
5-6 2-9 0/24 V DC (pulse) RSRM motor coil energization pulse, output (A)
5-7 2-9 24 V DC 24 V DC supply for RSRM, output
5-8 2-9 0/24 V DC (pulse) RSRM motor coil energization pulse, output (B)
5-9 2-9 0/24 V DC (pulse) RSRM motor coil energization pulse, output (B)
5-10 2-9 0/24 V DC (pulse) RSRM motor coil energization pulse, output (A)
6-1 2-9 0/24 V DC (pulse) TERM motor coil energization pulse, output (A)
6-2 2-9 0/24 V DC (pulse) TERM motor coil energization pulse, output (B)
6-3 2-9 0/24 V DC (pulse) TERM motor coil energization pulse, output (B)
6-4 2-9 0/24 V DC (pulse) TERM motor coil energization pulse, output (A)
6-5 2-9 24 V DC 24 V DC supply for TERM, output
6-7 2-9 24 V DC 24 V DC supply for PCM, output
6-8 2-9 24 V DC 24 V DC supply for PCM, output
6-9 2-9 0/24 V DC (pulse) PCM motor coil energization pulse, output (A)
6-10 2-9 0/24 V DC (pulse) PCM motor coil energization pulse, output (A)
6-11 2-9 0/24 V DC (pulse) PCM motor coil energization pulse, output (B)
6-12 2-9 0/24 V DC (pulse) PCM motor coil energization pulse, output (B)
6-13 2-9 0/24 V DC STM forward rotation drive signal (F), output
6-14 2-9 0/24 V DC STM forward rotation drive signal (F), output
6-15 2-9 0/24 V DC STM reverse rotation drive signal (R), output
6-16 2-9 0/24 V DC STM reverse rotation drive signal (R), output
3B5
2-3-3
Page 32
3B5
Terminals (CN) Voltage Remarks
7-3 2-9 24 V DC 24 V DC supply for LCSW, output
7-6 2-9 24/0 V DC LCSW on/off, input
2-3-4
Page 33
PCM CN6-9, 10, 11, 12
SRFHPS CN4-12
FSRM CN5-1, 2, 3, 5
SRRHPS CN4-14
RSRM CN5-6, 8, 9, 10
TERHPS CN4-26
TERM CN6-1, 2, 3, 4
PCSW CN4-10
Initialization start Sort
end
Standby for paper entry
Paper entry
Positioning for side registration
117 ms 117 ms100 ms
100 ms 100 ms
100 ms
178 mm/s
Operation start
3B5
Timing chart No. 1
2-4-1
Page 34
SRFHPS CN4-12
FSRM CN5-1,
2, 3, 5
SRRHPS CN4-14
RSRM CN5-6,
8, 9, 10
TERHPS CN4-26
TERM CN6-1,
2, 3, 4
STM CN6-13,
14, 15, 16
STHPS CN4-16
SRFHPS CN4-12
FSRM CN5-1,
2, 3, 5
SRRHPS CN4-14
RSRM CN5-6,
8, 9, 10
TERHPS CN4-26
TERM CN6-1,
2, 3, 4
SRFHPS CN4-12
FSRM CN5-1,
2, 3, 5
SRRHPS CN4-14
RSRM CN5-6,
8, 9, 10
TERHPS CN4-26
TERM CN6-1,
2, 3, 4
Sort end
Moving to stapling position
Stapling
Moving to
shift-eject
position
To batch
ejection
Sort end To batch
ejection
135 ms 135 ms
135 ms
Moving to
shift-eject
position
Sort end To batch
ejection
Moving to
shift-eject
position
300 ms
Stapling operation
Non-stapling operation (for front-shift ejection)
Non-stapling operation (for rear-shift ejection)
3B5
Timing chart No. 2
2-4-2
Page 35
3B5
SRFHPS CN4-12
FSRM CN5-1,
2, 3, 5
SRRHPS CN4-14
RSRM CN5-6,
8, 9, 10
TERHPS CN4-26
TERM CN6-1,
2, 3, 4
PCSW CN4-10
PCM CN6-9,
10, 11, 12
PUSOL CN4-7
250 ms
178 mm/s
257 mm/s
Batch ejection start
Batch ejection
Timing chart No. 3
2-4-3
Page 36
3B5
Periodic maintenance procedures
• Finisher
Section
Stapler section Magnet Clean Every service Remove the staples attracted to 1-4-3
Maintenance
part/location
Method Maintenance cycle Points and cautions Page
the magnet inside the stapler
cover.
2-4-4
Page 37
3B5
ABCDEFGHI J
ABCDEFGHI J
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
3
2
1
3
2
1
N.C
N.C
N.C
N.C
2
RD C201-1
RD C201-2
YW C201-25
OE C201-24
BE C201-26
BE C201-21
OE C201-22
YW C201-23
YW C201-20
YW C201-19
YW C201-18
GY C201-17
GY C201-16
GY C201-15
GY C201-14
GY C201-13
GY C201-10
GY C201-8
GY C208-2
RD C208-1
BE C207-11
BE C205-3
YW C205-2
DE C205-1
YW C207-13
YW C207-9
OE C207-12
YW C207-8
YW C207-7
GY C207-5
GY C207-4
GY C207-2
GY C207-1
GY C202-6
RD C202-5
GY C202-4
GY C202-3
RD C202-2
GY C202-1
GY C203-2
RD C203-1
RD C204-1
RD C206-1
GY C203-3
GY C204-3
RD C206-3
GY C001-6
RD C001-3
BE C001-27
BE C001-29
YW C001-10
OE C001-9
YW C001-24
YW C001-16
OE C001-15
YW C001-22
YW C001-20
GY C006-14
GY C006-13
GY C006-16
GY C006-15
GY C006-10
RD C006-7
GY C006-9
GY C006-11
RD C006-8
GY C006-12
GY C001-2
RD C001-1
RD C001-5
RD C005-2
GY C001-4
GY C001-7
RD C005-1
RD C006-5
GY C006-4
GY C006-3
GY C006-2
GY C006-1
GY C002-10
GY C002-9
GY C002-8
GY C002-6
GY C002-5
GY C002-4
GY C002-3
RD C002-7
RD C002-2
GY C002-1
YW C110-2
YW C108-2
YW C109-2
YW C107-2
BE C110-3
BE C108-3
BE C109-3
BE C107-3
OE C110-1
OE C108-1
OE C107-1
OE C109-1
GY C106-5
GY C106-4
GY C106-3
GY C106-1
RD C106-2
RD C101-1
RD C101-2
GY C104-5
GY C104-4
GY C104-3
GY C104-1
RD C104-2
RD C105-2
GY C105-5
GY C105-4
GY C105-3
GY C105-1
GY C101-15
GY C101-14
GY C101-17
GY C101-16
GY C101-8
GY C101-10
GY C101-13
GY C101-11
RD
RD
RD
RD
RD C101-9
RD C101-12
BE C101-21
BE C101-26
YW C101-23
YW C101-19
YW C101-18
YW C101-20
OE C101-22
YW C101-25
OE C101-24
GY C101-4
GY C101-28
RD C101-3
RD C101-27
GY C101-7
GY C101-6
RD C101-5
GY C103-13
GY C103-12
GY C103-11
GY C003-9
GY C003-8
GY C003-7
GY C102-1
GY C102-2
GY C102-3
GY C102-4
GY C102-5
GY C102-6
GY C102-7
GY C102-8
GY C102-9
GY C102-10
GY C102-11
GY C102-12
GY C004-1
GY C004-2
GY C004-3
GY C004-4
GY C004-5
GY C004-6
GY C004-7
GY C004-8
GY C004-9
GY C004-10
GY C004-11
GY C004-12
N.C
N.C
LCSW
LCSW 24V
RSRM A
RSRM B
RSRM B
RSRM 24V
RSRM A
FSRM A
FSRM B
FSRM B
FSRM 24V
FSRM A
STM R
STM R
STM F
STM F
PCM B
PCM B
PCM A
PCM A
PCM 24V
PCM 24V
N.C
TERM 24V
TERM B
TERM A
TERM B
TERM A
N.C
TERHPS SG
ST SG
TERHPS
SRRHPS SG
STSPS
STES
ITS SG
STCS
TERHPS 5V
ITS
ITS 5V
STHS
ST 5V
SRRHPS
SRRHPS 5V
3
2
1
1
2
3
TERM
RSRM FSRM
TERHPS SRRHPS SRFHPS
ITS
PCSW
LCSW
PUSOLPCM
FSRM B
FSRM A
FSRM B
R24V
FSRM A
RSRM B
RSRM A
RSRM B
R24V
RSRM A
PUSOL
Stapler
5V
STSPS
FSSOL
CFM
SRFHPS SG
SRFHPS
SRFHPS 5V
PCSW SG
PCSW
PCSW 5V
PUSOL
PUSOL 24V
N.C
CFM R
CFM 24V
FSSOL R
FSSOL A
FSSOL 24V
5V
PCSW
SG3
2
1
13
12
11
10
9
8
7
6
5
4
3
2
1
STM F
STCS
STES
SG
STHS
STM F
STM R
STM R
LCSW
24V
RD C201-4
YW C001-18
OE C001-17
BE C001-21
5V
SIG
SG
3
2
1
YW C001-12
OE C001-11
BE C001-23
5V
SIG
SG
3
2
1
5
4
3
2
1
5
4
3
2
1
GY C201-28
RD C201-27
GY C201-5
GY C201-4
RD C201-3
RD C201-3
FSSOL A
FSSOL R
CFM
R24V
R24V
R24V
3
2
1
3
1
2
1
YW C001-14
YW C001-26
OE C001-13
OE C001-19
BE C001-25
BE C001-28
RD C201-12
GY C201-11
RD C201-9
5V
SIG
SG
5V
SIG
SG
5
4
3
2
1
TERM B
TERM A
TERM B
R24V
TERM A
5
4
3
2
1
3
5
2
4
1
6
5
4
3
2
1
3
2
1
3
2
1
PCM B
PCM B
PCM A
PCM A
R24V
R24V
30 29 28 27
26 25 24 23 22 21
2019181716151413121110987654321
302928272625242322212019181716151413121110987654321
13
12
11
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
N.C
N.C
N.C
N.C
FSSOL R
N.C
N.C
N.C
N.C
24V
24V
FIN DET
SG
RXD
TXD
SG
5V
PG
PG
RESET
SG
11
10
9
2 FSSOL A12
1 FSSOL 24V13
8
7
6
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
11
10
9
N.C
FSSOL R
FSSOL A
8
7
6
5
4
3
2
1
PG
PG
24V
24V
12
11
10
9
RESET
SG
RXD
SG
TXD
SG
5V
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
27
28
29
30
N.C 31
N.C 32
FSSOL 24V
N.C
N.C
N.C
N.C
N.C
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
MPCB
C301C302
C208
C203
C207
C206
C205
C204
C202
C201C101
C110
C401
C108
C109
C105
C107
C104
C402C106
C103
C102
CN-7: C005
CN-5: C002
CN-3: C003
CN-6: C006
CN-4: C001
CN-2: C004
FIN SET
Wire Color
YELLOW
BLUE
RED
ORANGE
GRAY
Mark
YW
BE
RD
OE
GY
Wiring diagram
2-4-5
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