Mita-Kyocera F-4220 Service Manual

F-4220

SERVICE

MANUAL

Published in Jul.’00

845C1110

Safety precautions

This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

Safety warnings and precautions

Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:

DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance

with warning messages using this symbol.

CAUTION:Bodily injury or damage to property may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

Symbols

The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.

General warning.

Warning of risk of electric shock.

Warning of high temperature.

indicates a prohibited action. The specific prohibition is shown inside the symbol.

General prohibited action.

Disassembly prohibited.

indicates that action is required. The specific action required is shown inside the symbol.

General action required.

Remove the power plug from the wall outlet.

Always ground the copier.

1. Installation Precautions

WARNING

• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check

that it is adequate for the rated current. ............................................................................................

• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the

proper authorities. .............................................................................................................................

CAUTION:

• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .....

• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..............

• Do not install the copier near a radiator, heater, other heat source or near flammable material.

This may cause fire. ..........................................................................................................................

• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool

as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........

• Always handle the machine by the correct locations when moving it. ..............................................

• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may

cause the copier to move unexpectedly or topple, leading to injury..................................................

• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is
accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention
immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain

medical attention. ..............................................................................................................................

• Advice customers that they must always follow the safety warnings and precautions in the copier’s

instruction handbook. ........................................................................................................................

2. Precautions for Maintenance

WARNING

• Always remove the power plug from the wall outlet before starting machine disassembly...............

• Always follow the procedures for maintenance described in the service manual and other related

brochures. .........................................................................................................................................

• Under no circumstances attempt to bypass or disable safety features including safety

mechanisms and protective circuits. .................................................................................................

• Always use parts having the correct specifications...........................................................................

• Always use the thermostat or thermal fuse specified in the service manual or other related
brochure when replacing them. Using a piece of wire, for example, could lead to fire or other

serious accident. ...............................................................................................................................

• When the service manual or other serious brochure specifies a distance or gap for installation of a

part, always use the correct scale and measure carefully. ...............................................................

• Always check that the copier is correctly connected to an outlet with a ground connection. ............

• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If

it is dirty, clean it to remove the risk of fire or electric shock. ............................................................

• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may

damage eyesight...............................................................................................................................

• Handle the charger sections with care. They are charged to high potentials and may cause

electric shock if handled improperly. .................................................................................................

CAUTION

• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are

safely secured so they will not be caught in rotating sections...........................................................

• Use utmost caution when working on a powered machine. Keep away from chains and belts. .......

• Handle the fixing section with care to avoid burns as it can be extremely hot. .................................

• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause

abnormally high temperatures...........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement....................

• Do not pull on the AC power cord or connector wires on high-voltage components when removing

them; always hold the plug itself. ......................................................................................................

• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a

cable cover or other appropriate item. ..............................................................................................

• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........

• Remove toner completely from electronic components. ...................................................................

• Run wire harnesses carefully so that wires will not be trapped or damaged. ...................................

• After maintenance, always check that all the parts, screws, connectors and wires that were

removed, have been refitted correctly. Special attention should be paid to any forgotten

connector, trapped wire and missing screws. ..................................................................................

• Check that all the caution labels that should be present on the machine according to the

instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................

• Handle greases and solvents with care by following the instructions below: ....................................

· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.

· Ventilate the room well while using grease or solvents.

· Allow applied solvents to evaporate completely before refitting the covers or turning the main
switch on.

· Always wash hands afterwards.

• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to

fire in a furnace, etc...........................................................................................................................

• Should smoke be seen coming from the copier, remove the power plug from the wall outlet

immediately. ......................................................................................................................................

3. Miscellaneous

WARNING

• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than

the specified refiner; it may generate toxic gas.................................................................................

CONTENTS

INSTALLATION

CHAPTER 1 GENERAL DESCRIPTION

I. FEATURES ................................. 1-1

II. SPECIFICATIONS.......................1-2

A. Specifications...........................1-2

B. Cross Section...........................1-7

III. Using the Machine.......................1-9

A. Removing Paper Jams from the

Finisher Unit.............................1-9

B. Supplying the Finisher Unit with

Staples ................................... 1-10

C. Removing Staple Jams from the

Finisher Unit...........................1-12

D. Removing Paper Jams from the

Saddle Stitcher Unit ...............1-13

E. Supplying the Saddle Stitcher Unit

with Staples............................1-15

F. Removing Staple Jams from the

Saddle Stitcher.......................1-16

IV. MAINTENANCE BY THE

USER ........................................ 1-18

A. Maintenance by the User ....... 1-18

CHAPTER 2 FINISHER UNIT BASIC OPERATION

I. BASIC OPERATION....................2-1

A. Outline......................................2-1

B. Outline of Electrical

Circuitry....................................2-2

C. Inputs to and Outputs from the

Finisher Controller PCB ...........2-4

II. FEED/DRIVE SYSTEM ............. 2-10

A. Outline....................................2-10

B. Type of Delivery Paths ........... 2-15

C. Feeding and Delivering..........2-18

D. Job Offset...............................2-21

E. Staple Operation ....................2-24

F. Stapler Unit ............................ 2-32

G. Tray Operation ....................... 2-38

H. Detecting the Height of

Stack on the Tray...................2-40

I. Shutter Operation...................2-42

J. Buffer Path Operation ............ 2-46

K. Detecting Jams....................... 2-49

III. POWER SUPPLY SYSTEM ...... 2-54

CHAPTER 3 SADDLE STITCHER UNIT

BASIC OPERA TION

I. BASIC OPERATION .................... 3-1

A. Outline...................................... 3-1

B. Electrical Circuitry.................... 3-2

C. Inputs to and Outputs from the

Saddle Stitcher Controller

PCB .........................................3-3

II. FEEDING/DRIVE SYSTEM ........3-8

A. Outline...................................... 3-8

III. PAPER OUTPUT

MECHANISM ............................3-14

A. Outline.................................... 3-14

B. Controlling the Inlet

Flappers.................................3-17

CHAPTER 4 MECHANICAL CONSTRUCTION

I. FINISHER UNIT ..........................4-1

A. Externals and Controls.............4-1

B. FEEDING SYSTEM ................. 4-8

C. PCBs......................................4-12

C. Controlling the Movement of

Sheets.................................... 3-21

D. Aligning the Sheets................ 3-23

E. Controlling the Phase of the Cres-

cent Roller.............................. 3-26

IV. STITCHING SYSTEM...............3-28

V. FOLDING/DELIVERY

SYSTEM ...................................3-31

VI. CHECKING FOR A JAM ...........3-38

VII. POWER SUPPLY......................3-43

II. SADDLE STITCHER UNIT........4-13

A. Externals and Controls...........4-13

B. SADDLE UNIT ....................... 4-17

C. PCBs......................................4-27

CHAPTER 5 MAINTENANCE AND INSPECTION

I. PERIODICALLY REPLACED

PARTS.........................................5-1

A. Finisher Unit ............................. 5-1

B. Saddle Stitcher Unit ................. 5-1

II. CONSUMABLES AND

DURABLES ................................. 5-2

A. Finisher Unit ............................. 5-2

B. Saddle Stitcher Unit ................. 5-2

III. PERIODICAL SERVICING .......... 5-2

CHAPTER 6 TROUBLESHOOTING

I. ADJUSTMENTS..........................7-1

A. Electrical System

(finisher unit) ............................7-1

B. Electrical System

(saddle stitcher unit).................7-6

II. ARRANGEMENT OF

ELECTRICAL PARTS................7-10

A. Finisher Unit...........................7-10

B. Saddle Stitcher Unit ...............7-16

APPENDIX

A. FINISHER UNIT GENERAL TIMING

CHART ....................................... A-1

B. SADDLE STITCHER UNIT

GENERAL TIMMING CHART .....A-2

C. SIGNAL AND

ABBREVIATIONS........................A-3

D. FINISHER UNIT CIRCUIT

DIAGRAM....................................A-4

C. Light-Emitting Diodes (LED) and

Check Pins by PCB................7-22

III. TROUBLESHOOTING ..............7-23

A. Finisher Unit...........................7-23

B. Saddle Stitcher Unit ...............7-34

IV. SELF DISGNOSIS ....................7-38

A. Finisher Unit...........................7-38

B. Saddle Stitcher Unit ...............7-40

C. Alarm......................................7-42

E. SADDLE STITCHER UNIT

DIAGRAM....................................A-5

INSTALLATION

INSTALLATION

INSTALLATION

Removing the packaging

1) Open the top cover of the box and re­move the accessory box.

2) After removing the accessory box from
the finisher (step a), stand up the fin­isher upright with the four pads still at­tached (step b).

Note:

Do not remove the four pads from the
finisher at this time. Doing so will cause
the rail joint to come in direct contact with
the floor and become damaged.

3) Remove the tapes and packaging from
the tray side.

4) Remove the tapes holding the covers.

5) Remove the pads that have a red tab
attached to them and the securing ma­terial from inside the finisher.

Accessory box

Rail joint

a

b

Installing the eject tray

1) First install the upper eject tray and then
the lower eject tray. Insert the projec­tions on the eject tray into the holes in
the horizontal frame and lower the tray
into position. Make sure that the pro­jections on both sides of the tray fit into
the holes in the vertical frame.

Eject tray

Vertical frame

Horizontal frame

i

INSTALLATION

2) Secure the upper and lower eject trays
below on both sides using two black M4
× 6 TP screws for each tray.
First secure the rear side of the trays.

3) Firmly connect a sensor cable to the
sensor connector for both the upper and
lower eject trays.

Eject tray

Black M4 × 6TP screw

4) Install the lower relay cable cover on
the lower rear side and the upper relay
cable cover on the upper rear side.
*1:Insert the wiring into the cutouts of
the relay cable covers.
*2: Insert the claws of the relay cable
covers into the cutouts of the eject trays.

*2

*1

Sensor cable

*2

Lower relay
cable cover

Upper relay
cable cover

*1

ii

INSTALLATION

Installing the finisher on the copier

1) Remove the two screws securing the
paper conveying section cover of the
copier and fit the latch catch assembly
using four screws.

Note:

The screws used differ for the 42/52
copies per minute copiers and the 62
copies per minute copiers.

• 42/52 cpm copiers: Secure the upper
front and rear using two of the supplied
M4 × 8 binding screws. Secure the lower
front and rear using two of the supplied
M4 × 14 binding screws.

• 62 cpm copiers: Secure all four positions
using the supplied four M4 × 14 binding
screws.

2) Insert the shaft of the joint spacer U into
the U-shaped groove of the latch catch
assembly and secure the spacer using
the M4 × 6 screw.

Paper conveying section cover

Latch catch assembly

M4 × 6 screw

Latch catch assembly

3) Join the rail retainer unit with the guide
rail unit while aligning it with the groove
of the guide rail unit. Make sure that the
plate spring of the rail retainer unit fits
into the groove and the edges of the
guide rail unit fit between the pulleys
on the reverse side of the rail retainer
unit.

Joint spacer U

Guide rail unit

Plate spring

Rail retainer unit

iii

INSTALLATION

4) Orient the pulley of the guide rail unit
toward the copier and fit a caster rail
unit to each side of the rail retainer unit.

Guide rail unit

Caster rail unit

Pulley

Rail retainer unit

Caster rail unit

5) For the 62 copies per minute copier
only, remove the two screws securing
the bottom of the lower left cover of the
copier and slide the rail retainer unit in
the direction of the arrow.
Secure the lower left cover using two
screws so that the front and rear gaps
between the floor and rail retainer unit
is 10 mm*.

Note:

The screws used differ for the 42/52
copies per minute copiers and the 62
copies per minute copiers.

• 42/52 cpm copiers: Secure using two of
the supplied M4 × 8 binding screws. If a
paper feed desk is used, there are two
screw holes aligned vertically for each of
the front and rear sides of the left cover.
Use the lower screw holes.

• 62 cpm copiers: Secure using the two
M4 × 14 TP chrome screws that were
used to originally secure the lower left
cover.

Rail retainer unit

10 mm* 10 mm*

Rail retainer unit

Lower left cover

iv

INSTALLATION

6) Loosen the two screws securing the rail
fixing plate of the finisher and lower the
rail fixing plate to the floor. Slide the
guide rail unit toward the rail fixing plate
and pass it to the back of the finisher.

7) Secure the guide rail unit using the
M4 × 6 screw with lock at the position
where the round holes in it and the rail
fixing plate meet.

Screws

Rail fixing plate

Guide rail unit

M4 × 6 screw with lock

Rail fixing plate

8) Tighten the two screws for the rail fix­ing plate at the position where the guide
rail unit is horizontal.
Reference: Secure the rail fixing plate
at a height of 8.0 mm* from the floor.

Guide rail unit

Screws

8.0 mm*

Screws

Guide rail unit

v

INSTALLATION

y

9) Insert the top cover cap into the round
hole in the finisher.

10) Peel off the indication label sheet from
its backing paper and attach the sheet
to the upper front cover of the finisher
as shown in the diagram.

1 1) Connect the signal cable for the finisher

to the connector on the copier.

Indication label sheet

Top cover cap

5 mm

3 mm

Indication label sheet

12) Peel off the separate sheet stuck to the
double faced tape of the Sponge, Fin­isher A. Stick Sponge, Finisher A to the
paper conveying section cover along
the edge (X, Y).

13) Peel off the separate sheet stuck to the
two double faced tape of the Sponge,
Finisher B. Stick the narrow side tape
toward Sponge, Finisher A, and the
wide side tape to along the edge of the
latch catch assembly.
*Be sure that the short edge of the
Sponge, Finisher B align with the long
edge of the Sponge, Finisher A.

Paper conveying section cover

Latch catch assembl

Sponge finisher A

Paper conveying
section cover

X

Y

*

Sponge finisher B

vi

Latch catch assembly

Installing the relay cable and IPC PCB

For the 62 copies per minute copier

1) Remove the five screws securing the
rear cover of the copier and then the
rear cover .

2) Remove the fifteen screws securing the
main PCB cover and then the main PCB
cover.

INSTALLATION

Main PCB cover

3) Insert the board support into the round
hole in the main PCB shield.

4) Connect the 10-pin connector of the
relay cable to connector J2 on the IPC
PCB.

5) Connect connector J1 of the IPC PCB
to CN19 on the main PCB and insert
the board support into the round hole
in the IPC PCB to secure the IPC PCB
in place.

6) Pass the remaining portion of the relay
cable through the slot in the main PCB
shield.

Board support

IPC PCB

Main PCB shield

CN19

10-pin connector

J1

Board support

Slot

vii

INSTALLATION

7) Remove the two screws securing the
main PCB shield and open the main
PCB shield forward.

8) Detach the 6-pin connector of the main
wiring.

9) Connect the detached main wiring 6­pin plug and receptacle to the 6-pin
receptacle and plug of the relay cable
respectively.

Main PCB shield

Screw

6-pin connector

Screw

6-pin connector

10) Secure the wiring of the relay cable
using the two PLT1M bands.

Relay cable

PLT1M band PLT1M band

viii

INSTALLATION

Installing the relay cable and IPC PCB

For the 42/52 copies per minute copier

1) Remove the signal cable of the DF from
the copier. Remove the seven screws
securing the rear cover , the two screws
securing the controller cover and then
the rear cover and controller cover from
the copier.

2) Remove the eight screws securing the
main PCB cover, the six screws secur­ing the sequence cover and then the
main PCB cover and sequence cover
from the copier.

3) Insert the rocking support into the round
hole in the main PCB.

Main PCB cover

Sequence cover

Main PCB

Rocking support

4) Connect the 10-pin connector of the
relay cable to connector J2 on the IPC
PCB.

5) Connect J1 of the IPC PCB to CN15
on the main PCB and insert the rock­ing support into the round hole in the
IPC PCB to secure the IPC PCB in
place.

Main PCB

CN15

J1

IPC PCB

Rocking support

ix

INSTALLATION

6) Detach the 6-pin connector extending
from CN21 on the engine output PCB.

7) Connect the detached 6-pin plug and
receptacle to the 6-pin receptacle and
plug of the relay cable respectively.

8) Secure the wiring of the relay cable
using the wire saddle.

Adjusting height and slope

1) To correct the height, loosen the fixing
screw on the front and rear casters on
the pickup side of the finisher.

2) To increase the height of the finisher,
turn the adjusting bolt in the direction
of arrow A in the following figure; turn
the adjusting bolt as needed while re­ferring to the index on the caster . (Per­form this for both front and rear cast­ers.)

Engine output PCB

Wire saddle

6-pin connector

CN21

6-pin connector

Screws

Adjusting bolt

A

Index

3) To decrease the height of the finisher,
turn the adjusting bolt in the direction
of arrow B in the following figure; turn
the adjusting bolt as needed while re­ferring to the index on the caster . (Per­form this for both front and rear cast­ers.)

x

Screws

Adjusting bolt

B

Index

INSTALLATION

B

Adjusting bolt

Screws

Index

4) To correct any slope, loosen the fixing
screw on both front and rear casters on
the delivery side of the finisher.

5) To decrease the gap between the fin­isher and the copier, turn the adjusting
bolt in the direction of arrow A in the
following figure; turn the adjusting bolt
as needed while referring to the index
on the caster. (Perform this for both front
and rear casters.)

6) To increase the gap between the fin­isher and the copier, turn the adjusting
bolt in the direction of arrow B in the
following figure; turn the adjusting bolt
as needed while referring to the index
on the caster. (Perform this for both front
and rear casters.)

7) Connect the finisher to the copier, and
check to see that the difference in height
and the slope are within the indicated
tolerances; otherwise, make the adjust­ments once again.

8) When done, disconnect the finisher
from the copier, and tighten the fixing
screws on the casters.

Screws

Adjusting bolt

A

Index

9) To prevent loosening of the adjusting
bolts during relocation of the machine,
turn the adjusting bolts about 90° in the
direction of the arrow; be sure not to
over-tighten them, as such can lead to
displacement.

Adjusting bolt

90°

xi

CHAPTER 1

GENERAL DESCRIPTION

I. FEATURES ................................. 1-1

II. SPECIFICATIONS.......................1-2

A. Specifications ............................1-2

B. Cross Section ............................1-7

III. Using the Machine.......................1-9

A. Removing Paper Jams from the

Finisher Unit ..............................1-9

B. Supplying the Finisher Unit with

Staples..................................... 1-10

C. Removing Staple Jams from the

Finisher Unit ............................1-12

D. Removing Paper Jams from the

Saddle Stitcher Unit.................1-13

E. Supplying the Saddle Stitcher Unit

with Staples .............................1-15

F. Removing Staple Jams from the

Saddle Stitcher ........................1-16

IV. MAINTENANCE BY THE

USER ........................................ 1-18

A. Maintenance by the User.........1-18

CHAPTER 1 GENERAL DESCRIPTION

I. FEATURES

1. Accommodates large quantities of sheets.

●

Normally , the finisher holds a stack of sheets 147 mm in height in its two bins (small­size paper: equivalent to 1000 sheets)/74 mm in height (large-size paper: equiva­lent to 500 sheets)

2. Has high paper transportation performance.

●

The finisher is capable of handling papers between 64 and 200 gm/m2.

3. Offers a job offset function.

●

The finisher has a job offset function for sorting non-stapled stacks of copies.

4. Offers four types of auto stapling.

●

The finisher offers a choice of four stapling modes (1-point stapling at rear , diagonal
stapling at front, diagonal stapling at rear, 2-point stapling).

5. Uses a buffer roller.

●

The use of a buffer roller enables the finisher to accept copies without interruption
from the copier even during stapling or offset operation.

6. Has a saddle stitch function.

●

The finisher can staple along the center of paper and fold it in two (up to 15 sheets).

1-1

CHAPTER 1 GENERAL DESCRIPTION

II. SPECIFICATIONS

A. Specifications

1. Finisher Unit

Item

Stacking method
Stacking orientation

Stacking size

Paper weight
Bins
Modes

Stacking capacity

Description

Trays 1 and 2: by lifting tray
Face-down

Face-up
AB: A3, A4, A4R, A5, A5R, B4, B5, B5R, postcard

Inch: 279 x 432 mm (11″ x 17″), LGL, LTR, LTRR, STMT, STMTR
64 to 200 g/m

2

Trays 1 and 2
Non-sort:trays 1 and 2

Sort: trays 1 and 2
Staple: trays 1 and 2

Non staple sort

Small-size Tray 1: 147 mm high (1000 sheets)

(Note 1)

Tray 2: 147 mm high (1000 sheets)

Large-size Tray 1: 74 mm high (500 sheets)

(Note 1)

Staple sort Small-size Tray 1:

(Note 1)

Tray 2: 74 mm high (500 sheets)

110 mm high/30 sets (750 sheets)

Tray 2:

110 mm high/30 sets (750 sheets)

Large-size Tray 1: 74 mm high/30 sets (500 sheets)

(Note 1)

Tray 2: 74 mm high/30 sets (500 sheets)

(Note 2)
(Note 2)

(Note 2)
(Note 2)

Size mixing

Size mixing: 44 mm or less (300 sheets)
Stapling: 22 mm or less (150 sheets/30 sets)

Stacking mixing

Notes:

1. Approximate when computed with reference to 80 g/m

2. Alignment may not be correct if 750 or more small-size sheets are stacked.

3. The accuracy of the stack height is ± 7 mm.

Face-down/face-up

2

paper.

Table 1-201

1-2

CHAPTER 1 GENERAL DESCRIPTION

Item

Stapling
Stapling position
Stapling capacity

Staple supply
Staples
Staple detection
Manual stapling
Stapling size

Paper detection
Control panel
Display
Dimensions

Description

By rotating cam
See Figure 1-201.
Small-size 50 sheets
Large-size 30 sheets
Special staple cartridge (5000 staples)
Special (staple-E1)
Provided
Not provided
1-point diagonal Front A3, B4, A4, A4R, B5, 279 × 432 mm

stapling (diagonal) (11″ × 17″), LGL, LTR, LTRR

Rear A3, B4, A4, B5, 279 x 432 mm (11″ × 17″), LTR
1-point Rear A4R, LTRR, LGL
2-point A3, B4, A4, B5, 279 x 432 mm (11″ × 17″), LTR
Provided
Not provided
Not provided
669 x 582 x 1013 mm (W x D x H; including saddle stitcher unit)

Equivalent of 80 g/m2 paper
Including two sheets of thick stock
(covers).

Weight
Power supply
Maximum power

consumption

Saddle finisher: 52 kg
From host machine (24 VDC)
170 W or less

Table 1-202

Reference:

The term “small-size” stands for A4, A5, A5R, B5, postcard, LTR, STMT, STMTR, while
the term “large-size” stands for A3, B4, A4R, B5R, LTRR, 279 x 432 mm (11″ x 17″),
LGL.

1-3

CHAPTER 1 GENERAL DESCRIPTION

Stapling Positions (finisher unit)

1-point stapling (rear) 1-point stapling

Specified paper width

-

2-point stapling

1-point stapling

(diagonal; front)

Specified paper width

(diagonal; rear)

-

A3 and A4 B4 and B5 279 x 432 mm

(11'' x 17'')
and LTR

Figure 1-201

1-4

2. Saddle Stitcher Unit

CHAPTER 1 GENERAL DESCRIPTION

Item

Stapling method
Folding position
Paper size
Capacity

Paper weight
Stacking capacity

Stapling

Folding

Description

Center binding (double folding)
See Figure 1-202.
A3, B4, A4R, 297mm x 432mm (11″ x 17″), LTRR
W/binding: 1 sheet

W/out binding:2 to 15 sheets
64 to 80 g/m2 (cover page up to 200 g/m2)

(including single cover page)

(Note 1)

10 sets (stack of 11 to 15 sheets), 15 sets (stack of 6 to 10 sheets),
25 sets (stack of 5 sheets or less)

Stapling position

2 points (center distribution; fixed interval)
Staple accommodation 2000 staples
Staple supply Special cartridge
Staples Special staples (Staple-D1)
Staple detection Provided
Manual stapling Not provided
Folding method Roller contact
Folding mode Double folding
Folding position Paper center
Position adjustment Provided

Power supply

From finisher unit
(24 V line x 2)

Power consumption

160 W or less

Note1: Special paper, postcards, transparencies, reproducibles, label paper and hole­punched paper cannot be handled.

Table 1-203

1-5

CHAPTER 1 GENERAL DESCRIPTION

Staple and Folding Position (saddle finisher unit)

A3

Center
of staple

210±1.0mm

88.5±2.0mm

208.5±2.0mm

Stack front edge

279mm x 432mm
(11'' x 17'')

Staple position

Center of
staple

B4

182±1.0mm

LTRR

68.5±2.0mm

188.5±2.0mm

A4R

148.5±1.0mm

45±2.0mm

165±2.0mm

216±1.0mm

79.7±2.0mm

199.7±2.0mm

139.7±1.0mm

48±2.0mm

168±2.0mm

Figure 1-202

1-6

B. Cross Section

1. Finisher Unit

CHAPTER 1 GENERAL DESCRIPTION

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

[7] [10]

[9]

[11]

[1] Tray 1/2
[2] Shutter
[3] Delivery roller
[4] Swing guide
[5] Feed roller 2
[6] Height sensor
[7] Wrap flapper
[8] Buffer roller
[9] Buffer inlet flapper

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

[10] Saddle stitcher flapper
[11] Inlet feed roller
[12] Feed roller 1
[13] Vertical path
[14] Stapler
[15] Knurled belt
[16] Tray lift motor
[17] Saddle stitcher unit

Figure 1-204

1-7

CHAPTER 1 GENERAL DESCRIPTION

2. Saddle Stitcher Unit

[6]

[5]

[4]
[3]

[2]

[1]

[7]
[8]

[9]

[10]
[11]

[12]

[1] Guide plate
[2] Paper folding roller
[3] Delivery guide plate
[4] Holding roller
[5] Stitcher (front, rear)
[6] Inlet roller

[7] No.1 flapper
[8] No. 2 flapper
[9] Stitcher mount
[10] Butting plate
[11] Crescent roller
[12] Paper positioning plate

Figure 1-205

1-8

CHAPTER 1 GENERAL DESCRIPTION

III. Using the Machine

A. Removing Paper Jams

from the Finisher Unit

If the host machine indicates the fin­isher paper jam message, perform the fol­lowing to remove the jam.

Note, however, that paper jams at the
paper feed inlet on the finisher unit can be
removed by opening the front cover of the
host machine as the Finisher is fixed to host
machine.

1) Holding the finisher unit as shown,

move it to detach it from the host ma-

chine.

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

Figure 1-303

4) Lift the buffer roller cover , and remove
the jam.

Figure 1-301

2) Remove any jam visible from the out­side.

Figure 1-302

Figure 1-304

5) Lift the buffer roller, and remove the
jam.

Figure 1-305

1-9

CHAPTER 1 GENERAL DESCRIPTION

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

Figure 1-306

7) Connect the finisher to the host ma­chine.

B. Supplying the Finisher

If the host machine indicates the fin­isher unit staple supply message, perform
the following to supply it with staples.

1) Open the front cover.

Figure 1-308

2) Shift down the green lever.

Figure 1-307

8) Operate as instructed on the display.

Figure 1-309

3) When the staple cartridge has slightly

slid out, hold and pull it out.

Figure 1-310

1-10

CHAPTER 1 GENERAL DESCRIPTION

4) Hold the empty staple case on its sides,
and slide it out.

Figure 1-311

5) Set a new staple case.

6) Pull the length of tape (used to hold
the staples in place) straight out.

Figure 1-313

7) Push in the stapler unit until the green
lever returns to its original position.

Figure 1-312

Reference:

You may set no more than one staple
cartridge at a time.
Make sure that the new cartridge is one
specifically designed for the finisher unit.

Figure 1-314

8) Check to make sure that the stapler has
been locked in place, and close the
front cover.

Figure 1-315

1-11

CHAPTER 1 GENERAL DESCRIPTION

C. Removing Staple Jams

from the Finisher Unit

If the host machine indicates the fin­isher unit staple jam message, perform the
following to remove the jam.

1) Remove the stack waiting to be stapled

from the delivery tray.

Figure 1-316

4) When the staple cartridge has slightly
slid out, hold and pull it out.

Figure 1-319

5) Shift down the tab on the staple car­tridge.

2) Open the front cover.

Figure 1-317

3) Shift down the green lever.

Figure 1-320

6) Remove all staples that have slid out
of the staple case.

Figure 1-321

1-12

Figure 1-318

CHAPTER 1 GENERAL DESCRIPTION

7) Return the tab on the staple cartridge
to its original position.

8) Return the staple cartridge to its origi­nal position, and close the front cover .

Figure 1-322

Reference

When the cover has been closed, the
stapler unit will automatically execute idle
punching several times to advance the
staples.

D. Removing Paper Jams

from the Saddle Stitcher
Unit

If the host machine indicates the saddle
stitcher unit paper jam message, perform
the following to remove the jam.

1) Holding the saddle stitcher unit as

shown, move it to detach it from the

host machine.

Figure 1-323

2) Open the front lower cover.

Figure 1-324

1-13

CHAPTER 1 GENERAL DESCRIPTION

3) Turn the knob on the right side.

Figure 1-325

4) Turn the knob on the left side while
pushing it in.

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

Figure 1-328

7) Close the front lower cover.

Figure 1-326

5) Remove the jam.

Figure 1-327

Figure 1-329

8) Connect the finisher unit.

9) Operate as instructed on the display.

1-14

CHAPTER 1 GENERAL DESCRIPTION

E. Supplying the Saddle

Stitcher Unit with Staples

If the host machine indicates the saddle
stitcher unit staple supply message, per­form the following to supply it with staples.

1) Open the front lower cover.

Figure 1-330

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

Figure 1-332

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

2) Slide out the stitcher unit.

Figure 1-331

Figure 1-333

5) Fit the new cartridge.

Figure 1-334

Reference

You must always replace both cartridges
at the same time.

1-15

CHAPTER 1 GENERAL DESCRIPTION

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

Figure 1-335

7) Push in the stitcher unit, and close the
front cover.

F. Removing Staple Jams

from the Saddle Stitcher

If the host machine indicates the saddle
stitcher unit staple jam message, perform
the following to remove the jam.

1) Open the front lower cover.

Figure 1-337

Figure 1-336

2) Slide out the stitcher unit.

Figure 1-338

3) Pull the stapler of the stitcher unit to

the front once, and then shift it up.

1-16

Figure 1-339

CHAPTER 1 GENERAL DESCRIPTION

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

Figure 1-340

5) Push down on the area identified as A,
and pull up the tab identified as B.

7) Return the cartridge to its original po­sition.

Figure 1-343

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

Figure 1-341

6) Remove the staple jam, and return the
tab B to its original position.

Figure 1-342

Figure 1-344

9) Push the stitcher unit back to its origi­nal position, and close the front lower
cover.

Figure 1-345

Reference

Whenever you have removed a staple
jam, be sure to execute staple edging.

1-17

CHAPTER 1 GENERAL DESCRIPTION

IV. MAINTENANCE BY THE USER

A. Maintenance by the User

As of May 2000

No.

1
2

Item

Replacing the staple cartridge (finisher unit)
Replacing the staple cartridge (saddle

stitcher unit)

When the apropriate indication is made
on the copier’s display.

Timing

Caution:

The finisher unit and the saddle stitcher unit use different cartridge types. Be sure
that the appropriate type is used for each.

Table 1-401

1-18

CHAPTER 2

FINISHER UNIT BASIC OPERATION

1. This chapter discusses the purpose and role of each of the finisherís functions, and
the principles of operation used for the finisher mechanical and electrical systems. It
also explains the timing at which these systems are operated.The symbol in draw­ings indicates transmission of mechanical drive, and signals marked by together
with the signal name indicates the flow of electrical signals.

2. In descriptions of digital circuits on the finisher, “1” indicates a high signal voltage level,
while “0” indicates a low signal voltage level. Voltage values dif fer according to circuit.

A microprocessor is used on the finisher. A description of microprocessor operation is
omitted in this chapter as it is practically impossible to check internal operation of the
microprocessor.

Descriptions in this chapter also assume that PCBs will not be repaired at user sites.
For this reason, descriptions of circuits on PCBs is limited to block diagrams. Two
types of block diagrams are provided for separate functions: diagrams indicating de­tails from sensors up to input sections of major PCBs, and diagrams indicating details
from the output sections of major PCBs up the loads.

I. BASIC OPERATION..................2-1

A. Outline ................................. 2-1

B. Outline of Electrical

Circuitry................................2-2

C. Inputs to and Outputs from the

Finisher Controller PCB....... 2-4

II. FEED/DRIVE SYSTEM ...........2-10

A. Outline ............................... 2-10

B. Type of Delivery Paths....... 2-15

C. Feeding and Delivering...... 2-18

D. Job Offset .......................... 2-21

E. Staple Operation................ 2-24

F. Stapler Unit........................2-32

G. Tray Operation...................2-38

H. Detecting the Height of

Stack on the Tray...............2-40

I. Shutter Operation .............. 2-42

J. Buffer Path Operation ........2-46

K. Detecting Jams ..................2-49

III. POWER SUPPLY SYSTEM .... 2-54

I. BASIC OPERATION

A. Outline

CHAPTER 2 FINISHER UNIT BASIC OPERATION

It is designed to deliver copies arriving from its host copier, and its modes of delivery

include simple stacking, job offset

(Note)

, and staple.

All operations involved in these modes are controlled by the finisher controller PCB,

according to the appropriate commands from the host machine.

And copies from the host machine may be routed to the saddle stitcher unit.

Swing guide drive system

Alignment drive system

Stapler drive system

Delivery drive system

Control system

Feeder drive system

Shutter drive system

Tray drive system

Saddle stitcher unit control system

Figure 2-101

Note:

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

2-1

CHAPTER 2 FINISHER UNIT BASIC OPERATION

B. Outline of Electrical Circuitry

The finisher’s sequence of operation is controlled by the finisher controller PCB. The
finisher controller PCB is a 16-bit microprocessor (CPU), and is used for communication
with the host machine (serial) in addition to controlling the finisher’s sequence of opera­tions.

The finisher controller PCB responds to the various commands coming from the host
machine through a serial communications line to drive solenoids, motors, and other loads.
In addition, it communicates the finisher’s various states (information on sensors and
switches) to the host machine through a serial communications circuit.

The finisher controller PCB not only communicates with the saddle stitcher controller
PCB but also communicates the saddle stitcher unit’s various states (information on sen­sors and switches) to the host machine.

The ICs used on the finisher controller PCB are designed for the following:

●

Q1 (CPU)
Controls sequence of operations.

●

Q2 (EP-ROM)
Backs up adjustment values.

●

Q7
Contains sequence programs.

●

Q8/Q89 (RAM)
Backs up initial setting data.

●

Q4 (communications IC)
Communicates with the host machine and the saddle stitcher unit.

●

Q14 (regulator IC)
Generates 5V.

Figure 2-102 shows the flow of signals between the finisher and the options controller.

2-2

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Saddle stitcher
controller PCB

Host machine
(DC controller PCB CPU)

Finisher controller
PCB communication

Q1

CPU

Q2

EEP-ROM

Q4

IC

Q7

EP-ROM

Q8/Q89

RAM

Q14

Regulator IC

Figure 2-102

Motor

Solenoid

Switch

Sensor

2-3

CHAPTER 2 FINISHER UNIT BASIC OPERATION

C. Inputs to and Outputs from the Finisher Controller PCB

1. Inputs to the Finisher Controller PCB

Finisher controller PCB

Inlet sensor

Delivery sensor

Stapling tray
sensor

Shutter open
sensor

Alignment plate
home position
sensor

Stapler shift home
position sensor

PI1

PI3

PI4

PI5

PI6

PI7

J106-1

-3

-2

J134-1

-2

-3

J122-3

-1

-2

J118-3

-1

-2

J121-3

-1

-2

J129-3

-1

-2

-9

-7

-8

-3

-2

-1

-1

-3

-2

-1

-3

-2

-4

-6

-5

-1

-3

-2

-3

-1

-2

J202

-5

-6

-7

J208

-11

-9

-10

J207A

-3

-1

-2

J205

-8

-6

-7

J207A

-3

-1

-2

J210

J17-7

-9

-8

J11-3

-2

-1

J9A-1

-3

-2

J12B-4

-6

-5

J9A-4

-6

-5

J12A-7

-9

-8

+5V
PENT

+5V
PDEL

+5V
STPTY

+5V
STOPN

+5V
JOGHP

+5V
STPHP

When the sensor detects
paper, “1”.

When the sensor detects
paper, “1”.

When the sensor detects
paper, “1”.

When the shutter opens, “1”.

When the alignment plate
is at the home position, “1”.

When the stapler is at the
home position, “1”.

Tray home
position sensor

2-4

PI8

J130-3

-1

-2

Figure 2-103

J12A-4

-6

-5

+5V
TRYHP

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

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Inputs to the Finisher Controller PCB

PI10

Delivery motor
clock sensor

J120-1

-2

-3

-9

-8

-7

-3

-4

-5

J207A

J9A-9

-8

-7

Finisher controller PCB

+5V
DELCLK

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

Tray 1 paper
sensor

Tray 2 paper
sensor

Buffer path paper
sensor

Joint sensor

Door open
sensor

Buffer path inlet
paper sensor

PI11

PI12

PI14

PI15

PI16

PI17

J101-3

-1

-2

J102-3

-1

-2

J110-3

-1

-2

J117-3

-1

-2

J113-3

-1

-2

J105-3

-1

-2

-1

-3

-2

-1

-3

-2

-3

-1

-2

J1010

-3

-1

-2

J1020

-1

-3

-2

-4

-6

-5

J201

J201

-6

-4

-5

-3

-1

-2

J14-1

J14-4

J24-4

J12A-1

J12B-1

J24-1

+5V

-3

FSTTRAY*

-2

+5V

-6

SNDTRAY*

-5

+5V

-6

BUFPASS

-5

+5V

-3

JOINT

-2

+5V

-3

DROPN

-2

+5V

-3

BUFENTR

-2

When paper is present
on tray 1, “0”.

When paper is present
on tray 2, “0”.

When paper is in the
buffer path, “1”.

When the finisher is
joined with the copier, “1”.

When the front door is
open, “0”.

When paper is present at
the buffer path inlet, “1”.

Swing guide
open sensor

Tray lift motor
clock sensor 1

Tray lift motor
clock sensor 2

PI18

J127-3

PI9

PI19

Sensor PCB

-1

-2

J400-3

-1

-2

J400-6

-4

-5

-1

-3

-2

J204

-3

-1

-2

Figure 2-104

J11-8

-10

J14-10

-12

-11

J14-7

+5V
SWGOPN

-9

+5V
SFTCLK1

+5V

-9

SFTCLK2

-8

When the swing guide is
open, “1”.

When the tray lift motor
is rotating, alternately
between “1” and “0”.

When the tray lift motor
is rotating, alternately
between “1” and “0”.

2-5

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Inputs to the Finisher Controller PCB

PI20

PS1

J125-1

-2

-3

J114-3

-4

-2

Swing motor
clock sensor

Height sensor

Door switch

N. O.

MS1

Swing guide closed detecting switch 1

N. O.

MS2

-5

-4

-3

-7

-8

-9

J207B

-1

-2

J112

-1

-2

J209

J9B-5

J6-2

J5-1

J5-9

-10

Finisher controller PCB

+5V

-4

SWGCLK

-3

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

-1

-3

-4-1

-3

+5V
V0
Vin

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

+24V

+24VMOVE

DRSW

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

Swing guide closed detecting switch 2

N. O.

MS6

Safety zone switch

J131-3

MS3

N. C.

N. O.

C.

-2

-1

Shutter closed detecting switch

N. C.

N. O.

C.

MS4

Tray upper limit detecting switch

N. C.

MS5

J209

J206

J132

-3

-4

-3

-2

-1

-1

-2

J5-11

-12

J5-4

J7-3

J5-7

-5

-6

-2

-1

-8

+24VSTPL

+24VSHIFT

TRAYSAF

SHUTCLD

+24VSHIFT

TRYLMT

SWGGCLD

When the swing
guide is closed,
“1”.

When the tray is at
the delivery slot, “1”.

When the shutter is
closed, “1”.

When the tray is at
the upper limit, “0”.

2-6

Figure 2-105

CHAPTER 2 FINISHER UNIT BASIC OPERATION

4. Inputs to and Outputs from the Finisher Controller PCB

Staple edging
sensor

Staple home
position sensor

Cartridge switch

Staple switch

Stapler unit

Finisher controller PCB

When a staple is at the edge of

*

the stapler, “0”.

When the stapler is at the home

*

position, “0”.

*

When a cartridge is present, “0”.

When staples are present in

*

the cartridge, “0”.

*

When the stapler is connected,
“0”.

Saddle stitcher
controller PCB

Host machine

J131-8 J400-1

-7

-6

-5

-4

-3

-2

-3

-4

-5

-6

J500-1

-2

Communication line

J2-1

Communication line

Figure 2-106

2-7

CHAPTER 2 FINISHER UNIT BASIC OPERATION

5. Outputs from the Finisher Controller PCB

Finisher controller PCB

Flapper solenoid

SL1

Buffer inlet solenoid

SL2

Buffer outlet solenoid

SL3

Paddle solenoid

SL5

Escape solenoid

SL6

-1 -2

-2

-1 -3

-2

-1 -2

-2

-1 -2

-2

-1 -3

-2

J107

J108

J109

J128

J123

-1 -11

-2 -10

J207B

-10 -2

-11 -1

J207A

J12A-10

-11-1

J12B-9

-10-2

J24-7

-8-1

J9B-1

-2-1

J9A-10

-11-2

+24V

When "0", the solenoid turns on.

FLPSL*

+24V

When "0", the solenoid turns on.

ENTSL*

+24V

When "0", the solenoid turns on.

EXITSL*

+24V

When "0", the solenoid turns on.

PDLSL*

+24V

When "0", the solenoid turns on.

ESCPSL*

Belt escape solenoid

SL7

First feed motor

M1

2-8

-1 -2

-2

J500

-1

J12B-7

J10-1

Figure 2-107

-8

BESCPSL*

-2

-3

B*

-4

A*

-5

B

-6

A

+24V

When "0", the solenoid turns on.

+24V

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

CHAPTER 2 FINISHER UNIT BASIC OPERATION

6. Outputs from the Finisher Controller PCB

Delivery motor

Alignment motor

Stapler shift motor

Finisher controller PCB

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

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

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

Staple motor

Tray lift motor

Swing motor

Second feed motor

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

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

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

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

Inlet feed motor

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

Figure 2-108

2-9

CHAPTER 2 FINISHER UNIT BASIC OPERATION

II. FEED/DRIVE SYSTEM

A. Outline

The finisher is designed to operate according to the commands from its host machine
to deliver arriving copies to trays in the appropriate mode: simple stacking, job offset,
stapling.

See Figure 2-201 for a diagram of the four modes of delivery.

Method of delivery

Normal delivery tray

Normal
delivery

Saddle stitch delivery

Figure 2-201

Simple stacking

Job offset

Staple

Front diagonal
Rear 1-point
Rear diagonal
2-point

2-10

Normal delivery tray

To saddle stitcher unit

Figure 2-202

CHAPTER 2 FINISHER UNIT BASIC OPERATION

1. Normal Delivery
a. Simple Stacking

The finisher delivers copies directly to the tray.

Tray Tray

CopiesCopies

Delivery roller

Figure 2-203

Feed roller 1

Feed roller 2

2-11

CHAPTER 2 FINISHER UNIT BASIC OPERATION

b. Job Offset

The finisher forwards all copies of each sort job to the stapling tray . The first sort job on
the stapling tray is delivered with a shift to the front of about 30 mm, and the second sort
job is delivered without being shifted. Whether the first copy or the last copy of a sort job
should be shifted is determined by the host machine.

Tray

Each sort job is stacked
alternately.

Figure 2-204

Swing guide

Stapling tray

Results of Delivering 4 Sets

Direction of delivery

Stopper

Delivery roller

Figure 2-205

Figure 2-206

Feed roller 1

Copies handled
by job offset

2-12

CHAPTER 2 FINISHER UNIT BASIC OPERATION

c. Stapling

The finisher stacks copies arriving from its host machine on the stapling tray. Then, it

staples and delivers the copies to the appropriate tray.

Tray
Copies

Staple

Swing guide

Delivery roller

Front diagonal stapling

Rear diagonal stapling

Stapling
tray

Stopper

Figure 2-207

Rear 1-point stapling

Feed roller 2

Paper width/2

2-point stapling

Figure 2-208

2-13

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Saddle Stitch Delivery

A copy arriving in the finisher from the host machine is routed to the saddle stitcher by
the paper deflecting plate. The saddle stitcher executes stitching and saddling operations
on the copy and then delivers it to the saddle stitcher tray.

For discussions of stacks in the saddle stitcher, see Chapter 3.

To saddle stitcher

Figure 2-209

2-14

CHAPTER 2 FINISHER UNIT BASIC OPERATION

B. Type of Delivery Paths

The finisher has three different paper paths for delivery, each selected to suit paper

size and delivery mode.

1. Straight Path

When stacking copies shown in Table 2-201, the copies pass under the buffer roller.

Copy size Length or width 182 mm or less
Typical copy examples A5, A5R, STMT, STMTR, postcard, thick stock

Table 2-201

Delivery roller

Buffer roller

Figure 2-210

2. Buffer Paper Path 1

When stacking copies shown in Table 2-202, the copies pass over the buffer roller,

increasing the distance between copies.

Copy size Length and width 182 mm or more
Typical copy examples A3, B4, A4, A4R, B5, B5R, 279mm × 432mm (11″ × 17″), LGL, LTR,

LTRR, transparencies (excluding thick stock)

Table 2-202

Buffer roller

Delivery roller

Figure 2-211

Feed roller 2

2-15

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Buffer Paper Path 2

This is the paper path when copy sizes shown in Table 2-203 are stacked. A maximum
of two copies (two originals or more in the staple mode) are wrapped round the buffer
roller, during which job offset and stapling are performed on the stapling tray.

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

T able 2-203

The following shows paper delivery operation in the case of two originals in the staple
mode.

1) The first copy is moved in the direction of the buffer roller.

Buffer roller

1st copy

Figure 2-212

2) The first copy wraps around the buffer roller and, at the same time, the second copy

arrives from the host machine.

1st copy

2nd copy

Figure 2-213

2-16

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3) The second copy is laid over the first copy.

1st copy

2nd copy

Figure 2-214

4) The first and second copies are simultaneously pulled into the stapling tray.

2nd copy

1st copy

Figure 2-215

Cauiton:

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

2-17

CHAPTER 2 FINISHER UNIT BASIC OPERATION

C. Feeding and Delivering

1. Outline

The finisher moves copies arriving from the host machine to the delivery tray , stapling
tray , or the saddle stitcher unit according to the mode of delivery. On the stapling tray, the
copies are subjected to job offset or stapling as instructed by the host machine.

The first feed motor (M1), second feed motor (M8) and inlet feed motor (M9) are step­ping motors, and delivery motor (M2) is a DC motor. These motors are controlled by the
microprocessor (CPU) on the finisher controller PCB, and rotate either clockwise or coun­terclockwise.

The paper paths are equipped with the following four sensors for detection of paper
(arrival, passage):

●

Inlet sensor (PI1)

●

Delivery sensor (PI3)

●

Stapling tray sensor (PI4)

●

Buffer path paper sensor (PI14)

In addition, each delivery tray is equipped with a sensor designed to detect the pres­ence/absence of paper on it.

●

No.1 tray paper sensor (PI11)

●

No.2 tray paper sensor (PI12)

If a copy fails to reach or move past each sensor within a specific period of time, the
finisher controller PCB identifies the condition as a jam, and stops the ongoing operation
and at the same time informs the host machine of the condition. When all doors are closed
after the paper jam is removed, the buffer path inlet paper sensor (PI17) checks whether
or not copies are being detected in addition to the above four sensors (inlet sensor , deliv­ery sensor, stapling tray sensor and buffer path paper sensor). If the sensors detect a
copy, the finisher unit judges that paper jams have not completely been removed, and
sends the paper jam removal signal to the host machine again.

2-18

PI10

PI20

Escape solenoid drive signal ESCPSL

Alignment motor drive signal

Delivery motor drive signal

Delivery motor clock signal DELCLK

Swing motor drive signal

Swing motor clock signal SWGCLK

Shift motor clock detection signal 1 SFTCLK1

2-19

Figure 2-216

SL6

M4

M3

M6

SL7

M2

SL1

SL2

M7

SL3

SL5

PI9

Shift motor clock detection signal 2 SFTCLK2

PI19

M5

Tray lift motor drive signal

Paddle solenoid drive signal PDLSL

Second feed motor drive signal

M1M8 M9

First feed motor drive signal

Inlet feed motor drive signal

Buffer outlet solenoid drive signal EXITSL

Buffer inlet solenoid drive signal EXTSL

Flapper solenoid drive signal FLPSL

Belt escape solenoid drive signal BESCPSL

Stapler motor drive signal

Stapler shift motor drive signal

Finisher controller PCB

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2-20

CHAPTER 2 FINISHER UNIT BASIC OPERATION

No. 2 tray paper detection signal SNDTRAY

No. 1 tray paper detection signal FSTTRAY

Figure 2-217

PI12

PI4

PI1

PI11

Stapling tray paper detection signal STPTY

Buffer path paper
detection signal BUFPASS

PI3

Delivery detection signal PDEL

PI14

PI17

Buffer path inlet paper
detection signal BUFENTR

Inlet paper detection signal PENT

Finisher controller PCB

CHAPTER 2 FINISHER UNIT BASIC OPERATION

D. Job Offset

1. Outline

In the job offset mode, sort jobs and entire copy groups are shifted to the front for

delivery to the tray, and other copies are delivered to the tray without a shift.

The copies are shifted by the alignment plate. The alignment plate is checked by the

alignment home position sensor (PI6) to find out whether it is at the home position.

The finisher controller PCB drives the alignment plate motor (M3) at power-on to re-

turn the alignment plate to its home position.

The finisher controller PCB stops the delivery motor (M2) when the trailing edge of the
copy has moved past the feed roller 2. Then, the finisher controller PCB rotates the deliv­ery motor counterclockwise, and drives the swing motor (M7). As a result, the drive of the
delivery motor is transmitted to the swing guide to move up the guide. When the swing
guide open detection sensor (PI18) detects the swing guide, the delivery motor stops, and
the swing guide is held at the up position.

When the swing guide has moved up, the feed belts attached to the feed roller 2 move
the copy to the stapling tray. The presence of paper on the stapling tray is monitored by
the stapling tray paper sensor (PI4). (The first sheet is fed to the stapling tray while the
swing guide is moving up.)

The finisher controller PCB drives the alignment motor (M3) in advance, and keeps
the alignment plate in wait at a point 10 mm behind the trailing edge of a sheet. Whenever
one sheet is moved to the stapling tray, each sheet is aligned, and when the fifth or last
sheet in a sort job/group is fed to the stapling tray , the guide plate retaining solenoid (SL6)
moves the guide plate away and under the stapling tray. From then on, the alignment
motor shifts the sheets to the front by 30 mm.

When the copy has been shifted, the finisher controller PCB rotates the alignment
motor counterclockwise to move the alignment plate to a point 10 mm behind the trailing
edge of the sheet. This alignment operation is repeated until alignment of the fifth or last
sheet in a sort job is completed. At this time, the swing guide is moved down and is closed,
and the delivery motor rotates clockwise to deliver the sheet.

2-21

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Guide plate

Paper

Alignment plate

Alignment plate
home position sensor (PI6)

Alignment motor (M3)

Escape solenoid
(SL6)

Sequence of Operation (job offset)

Inlet sensor (PI1)
Delivery sensor (PI3)

Inlet feed motor (M9)
First feed motor (M1)

Second feed
motor (M8)

Delivery motor (M2)
Stapling tray

sensor (PI4)

Alignment motor (M3)
Alignment guide home
position sensor (PI6)

Swing guide (M7)
Swing guide closed
sensor (PI18)

Swing guide closed

detect switch 1 (MS2)

Escape solenoid (SL6)

Figure 2-218

Start signal
Host machine delivery signal

2-22

: Motor CW rotation : Motor CCW rotation

Figure 2-219

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Flow of Job Offset Operations

1) The swing guide moves up and, at the same time, the feed belts move the sheet to the
stapling tray.

Swing guide

Offset sheet

Feed roller 2

Feed belts

Tray 1/2

Delivery
roller

Stapling tray

Stopper

Figure 2-220

2) The alignment plate shifts the sheet to the front.

Existing stack

Alignment plate

Offset sheet

Figure 2-221

3) The swing guide moves down and, at the same time, the delivery roller delivers the
sheet.

Offset sheet

Swing guide

Tray 1/2

Delivery
roller

Stapling tray

Figure 2-222

Feed roller 2

Feed belts

Stopper

2-23

CHAPTER 2 FINISHER UNIT BASIC OPERATION

E. Staple Operation

1. Outline

The stapler unit staples a stack of as many sheets as specified.
The stapling position differs according to the selected staple mode and paper size.
The stapler unit is checked by the stapler shift home position sensor (PI7) to find out

whether it is at the home position.

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

Stapler shift
motor (M4)

Sheets

Stapler shift home
position sensor (PI7)

Stapler

Figure 2-223

2-24

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Paper width/2

Front diagonal stapling

Rear diagonal stapling

2-point stapling

Rear 1-point stapling

Figure 2-224

2-25

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. First Sheet

The finisher controller PCB stops the delivery motor (M2) as soon as the trailing edge
of the first sheet has moved past the feed roller 2. Then, it rotates the delivery motor
clockwise to switch the gear drive to the swing motor (M7), causing the swing guide to
move up. When the swing guide open sensor (PI18) finds the swing guide at the up posi­tion, the swing motor stops, maintaining the swing guide at the up position.

When the swing guide has moved up, the feed belts of the feed roller 2 move the sheet
to the stapling tray. (The first sheet is fed to the stapling tray while the swing guide is
moving up.) The presence of paper on the stapling tray is detected by the stapling tray
paper sensor (PI4).

The finisher controller PCB drives the alignment plate shift motor (M3) when the sta­pling tray paper sensor has detected paper to put sheets in order. The alignment plate is
kept in wait in advance at a point 10 mm behind the trailing edge of the paper.

The swing guide is kept in wait at the up position until the last sheet is output onto the
stapling tray.

Swing guide

1st sheet

Tray 1/2

Feed roller 2

Feed belts

Delivery roller

Stapling tray

Stapler

Figure 2-225

2-26

Swing guide

y

)

Swing guide open
sensor (PI18)

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Swing guide closed
detecting switches
(MS2/MS6)

Swing motor (M7)

Figure 2-226

Deliver

Delivery roller

Swing motor
clock sensor
(PI20)

Delivery motor
clock sensor
(PI10)

motor (M2

2-27

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. 2nd and Subsequent Sheets

The finisher controller PCB turns on the belt escape solenoid (SL7) before the trailing
edge of the second and subsequent sheets have moved past the feed roller 2 to make the
feed belt escape. This operation is performed to reduce the time it takes for the trailing
edge of the paper to fall on the stapling tray , and to improve the product duty. The finisher
controller PCB turns on the paddle solenoid (SL5) as soon as the trailing edge of the
second and subsequent sheets have moved past the feed roller 2, causing the drive of the
second feed motor (M8) to rotate the paddle. The sheets are pushed by the paddle and
moved to the stapling tray . Almost simultaneously with the trailing edge of the sheet falling
into the stapling tray , the belt escape solenoid turns off to return the feed belts that were in
the escape position to its original position, and feed the sheet onto the stapling tray . When
the sheet has been output onto the stapling tray, the finisher controller PCB rotates the
alignment motor (M3) to put the sheets in order.

Swing guide

2nd and
subsequent
sheets

Paddles

Tray 1/2

Delivery
roller

Stapling tray

Figure 2-227

Feed roller 2

Feed belts

SL7

Belt escape solenoid

Stapler

2-28

Feed belts

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Escape direction

Belt escape
solenoid (SL7)

Figure 2-228

Paddles

Paddle
solenoid (SL5)

Paddles

2nd and
subsequent sheets

1st sheet

Stapler

M8

2nd feed motor

Stopper

Figure 2-229

2-29

CHAPTER 2 FINISHER UNIT BASIC OPERATION

4. Last Sheet

When the last sheet has been put in order, the finisher controller PCB turns on the
alignment motor (M3) to move the alignment plate to the alignment position (to butt the
plate against the stack). Then, the finisher controller PCB rotates the swing motor (M7)
counterclockwise to move down the swing guide.

The finisher controller PCB moves the stapler according to the staple mode for sta­pling.

From then on, it rotates the delivery motor (M2) clockwise to delivery the stack to the
tray.

Swing guide

Sheets

Feed roller 2

Feed belts

Tray 1/2

Delivery
roller

Stapling tray

Stapler

Figure 2-230

2-30

Swing guide

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Delivery roller

Swing motor (M7)

Delivery motor (M2)

Figure 2-231

2-31

CHAPTER 2 FINISHER UNIT BASIC OPERATION

F. Stapler Unit

Stapling is executed by the stapler motor (M6). A single rotation of the cam by the
motor results in one stapling operation.

The cam is checked by the stapling home position sensor (PI22) to find out whether it
is at the home position.

The stapler motor is controlled by the microprocessor (Q1) on the finisher controller so
that it is rotated clockwise or counterclockwise.

When the stapling home position sensor is off, the finisher controller PCB rotates the
stapler motor clockwise until the sensor turns on so as to return the stapling cam to its
initial state.

The presence/absence of the staple cartridge is detected by the staple cartridge switch
(MS8). The presence/absence of staples inside the staple cartridge is detected by the
staple detecting switch (MS9). The staple edge sensor (PI21) is used to find out whether
a staple has been edged out to the end of the cartridge.

The finisher controller PCB does not drive the stapler motor (M6) unless the swing
guide closed detecting switch 2 (MS6) is on (i.e., the swing guide is closed). This is to
protect against injuries that could occur when a finger is stuck inside the stapler.

2-32

Finisher controller PCB

Figure 2-233

Staple edge detection signal

Staple motor drive
signal

Stapling home
position detection signal

Cartridge detection signal

Staple detection signal

M6

Figure 2-232

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2-33

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Start signal
Host machine delivery signal

Stacking sheets Delivery

Inlet sensor (PI1)

Delivery sensor (PI3)

Inlet feed motor (M9)

First feed motor (M1)

Second feed motor (M8)

Delivery motor (M2)
Stapling tray

sensor (PI4)
Alignment motor (M3)

Alignment guide home
position sensor (PI6)

Swing guide closed
sensor (PI18)

Swing guide closed
detect switch 1 (MS2)

Paddle solenoid (SL5)
Belt escape

solenoid (SL7)
Staple motor (M6)

Staple drive home
position sensor (PI22)

Stapler shift
motor (M4)

1st sheet 2nd sheet

Stapling

: Motor CW rotation : Motor CCW rotation

Figure 2-234

2-34

CHAPTER 2 FINISHER UNIT BASIC OPERATION

5. Shifting the Stapler Unit

The stapler unit is moved by the stapler shift motor (M4). Its home position is detected
by the stapler shift home position sensor (PI7). When the start signal arrives from the host
machine, the stapler moves to the center of its movement range. This movement occurs
regardless of the selected mode of delivery , as no specific mode is recognized at this point
in time. When the command for stapling arrives from the host machine after the first sheet
has reached the host machine pre-registration sensor, the stapler moves to the staple wait
position to suit the appropriate stapling position and paper size.

See Figures 2-235 and later for an idea of the wait position according to the stapling
mode.

a. Front Diagonal Stapling

The position is the same as the stapling position.

Stapling tray delivery
direction

Stopper

Stopper

Guide plate

Stapler

Figure 2-235

2-35

CHAPTER 2 FINISHER UNIT BASIC OPERATION

b. Rear 1-Point Stapling

The stapler is kept in wait at the center position. The stapler is moved to and from the

stapling position for each stapling operation.

Stopper

Stapling position

Wait position

Stapling tray delivery
direction

Stopper

Stapler

Guide plate

Figure 2-236

c. Rear Diagonal Stapling

For A4, LTR and B5 sizes, the stapler is kept in wait toward the rear away from the
stapling position. The stapler is moved to and from the stapling position for each stapling
operation.

Stapler

Wait position

Stapling position

Stopper

Stapling tray delivery
direction

2-36

Stopper

Guide plate

Figure 2-237

CHAPTER 2 FINISHER UNIT BASIC OPERATION

d. 2-Point Stapling

The stapler is kept in wait at the center of paper . Stapling occurs at two points, first at

the rear and then at the front.

Stopper

Stapling position
Wait position

Stapler

Stapling tray delivery
direction

Stapling position

Guide plate

Figure 2-238

Stopper

2-37

CHAPTER 2 FINISHER UNIT BASIC OPERATION

G. Tray Operation

The finisher has two delivery trays for normal delivery, each accepting sheets.

Each tray is moved up and down by the tray lift motor (M5).

The position of tray is identified with reference to the number of clock pulses of the tray
lift motor clock sensor 1/2 (PI9/PI19) coming from the tray home position sensor (PI8).
The finisher controller PCB finds out in which direction (up or down) the tray is moving
based on combinations of pulses from the two clock sensors.

The finisher controller PCB drives the tray lift motor (M5) to return the tray to the home
position at power-on. If the tray is already at the home position, it is kept in wait as it is.

The finisher controller PCB moves up and down the tray selected by the copier so that
it is positioned at the delivery slot.

The upper limit of the tray is detected by the tray upper limit detecting switch (MS5).
The finisher controller PCB stops the drive (up) of the tray lift motor (M5) as soon as the
tray upper limit detecting switch turns on.

The height of the stack on the tray is identified by the height sensor (PS1), which
measures its distance from the top of the stack. The tray is moved down when the dis­tance between the top of the stack and the delivery assembly drops to a specific measure­ment.

The finisher controller PCB cuts off the +24V power of the tray lift motor (M5) as soon
as the safety zone detecting switch (MS3) turns on while the shutter and the swing guide
are open, stopping the operation of the finisher.

2-38

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Tray 1

Tray 2

Tray guide

Tray upper limit detecting
switch (MS5)

Encoder

Tray lift motor clock
sensor 2 (PI19)

Tray lift motor
clock sensor 1 (PI19)

Tray lift motor (M5)

Safety zone switch (MS3)

Tray home position sensor (PI8)

Figure 2-239

2-39

CHAPTER 2 FINISHER UNIT BASIC OPERATION

H. Detecting the Height of Stack on the Tray

1. Outline

The number of sheets delivered to the tray and the number of sets (number of stapling
operations) are stored in memory by the finisher controller PCB. The height of the stack is
checked by the height sensor (PS1). See Table 2-201 for the maximum loading capacity of
each tray.

The finisher controller PCB stops operation when the conditions in Table 2-201 occur,
informing the host machine that the tray is full.

Stacking

mode

Tray

Tray 1

Tray 2

Notes: 1. The capacity for the non-staple sort mode is approximate and computed based on 80 g/m2 paper .

2. Alignment for stacks containing of 750 sheets or more is not guaranteed.

3. Stacking height precision is ±7 mm.

Small-size
147 mm high

(1000 sheets)

147 mm high
(1000 sheets)

Non-staple sort Staple sort

Large-size
44 mm high

(500 sheets)

74 mm high
(500 sheets)

Mixed sizes
44 mm high

(300 sheets)

44 mm high
(300 sheets)

Small-size
110 mm high

(750 sheets/
30 sets)

110 mm high
(750 sheets/
30 sets)

Large-size
74 mm high

(500 sheets/
30 sets)

74 mm high
(500 sheets/
30 sets)

Mixed sizes
22 mm high

(150 sheets/
30 sets)

22 mm high
(150 sheets/
30 sets)

Table 2-201

Caution:

1. The term “small-size” stands for A4, LTR, and B5.

2. The term “large-size” stands for A3, A4R, B4, LGL, 279 x 432 mm (11″ x 17″),
and LTRR.

2-40

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Height sensor (PS1)

Paper

Figure 2-240

2-41

CHAPTER 2 FINISHER UNIT BASIC OPERATION

I. Shutter Operation

Before the tray on which sheets are output is shifted by the tray lift motor (M5) to
another tray, the finisher controller PCB closes the shutter mounted on the delivery slot
before moving the tray, preventing the existing stack on the tray by the delivery slot and
intrusion of the hands.

The shutter moves up (to close) when the second feed motor (M8) rotates counter­clockwise, and is held in position when the motor stops. When the second feed motor
rotates counterclockwise once again, it moves down (to open) to enable delivery.

When the shutter is held at the up position, claws slide out of the swing guide to
engage the back of the shutter. This way, the existing slack and the swing guide engage
while the tray is moved, preventing the guide from opening. The claws slide in when the
shutter is moved down to release the engagement.

The upward movement of the shutter is monitored by the shutter closed detecting
switch (MS4), and the downward movement is monitored by the shutter open sensor (PI5).

See the following diagrams for how these operations take place.

1) The second feed motor rotates counterclockwise to move the shutter up.

2-42

M8

Figure 2-241

Second feed motor

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2) The tray lift motor rotates, and the new tray moves to the stacking lower limit. The
distance of movement is detected by the tray shift motor clock sensor 1/2 (PI9/19).

M5

Tray lift motor

Figure 2-242

3) The second feed motor rotates counterclockwise, and the shutter moves down.

M

M8

Second feed motor

Figure 2-243

2-43

CHAPTER 2 FINISHER UNIT BASIC OPERATION

4) The tray lift motor rotates, and the tray moves to suit the height of the stack. The
appropriate height in relation to the existing stack is checked by the height sensor
(PS1).

Height sensor (PS1)

M5

Tray lift motor

Claw

Shutter closed
detecting
switch (MS4)

Shutter open
sensor (PI5)

Figure 2-244

Shutter

Claw

2-44

Figure 2-245

M8

One-way cam

Second feed motor

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Sequence Operations (shutter drive)

Move from Tray 1 to Tray 2

Second feed motor (M8)

Tray lift motor (M5)
Shutter closed detecting

switch (MS4)
Shutter open sensor

(PI5)

Height sensor (PS1)

Shutter
closed

Tray
moved

Motor CW rotation Motor CCW rotation

Shutter
opened

Tray
moved

Correct height detected

Figure 2-246

2-45

CHAPTER 2 FINISHER UNIT BASIC OPERATION

J. Buffer Path Operation

1. Outline

This machine is provided with a buffer paper path for continuously receiving paper

from the copier during stapling and stack job offset operation on the stapling tray. A maxi­mum of three copies (three originals or more in the staple mode) are wrapped around the
buffer roller. During this time, stack job offset and stapling are performed on the stapling
tray.

The following shows operation on the buffer paper path.

1) When the first sheet arrives, the buffer inlet solenoid (SL2) remains off. The first sheet
enters the buffer path.

OFF

SL2

1st sheet

Buffer inlet solenoid

Figure 2-247

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

Buffer outlet
solenoid

ON

SL3

Buffer path inlet paper
sensor (PI17)

2-46

Figure 2-248

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3) When the leading edge of the sheet has moved past the buffer path paper sensor
(PI14), the buffer roller stops and waits for the second sheet.

1st sheet

2nd sheet

Buffer path paper
sensor (PI14)

Figure 2-249

4) When the second sheet arrives and its leading edge reaches the inlet sensor (PI1),
the buffer roller starts to operate once again.

1st sheet

2nd sheet

Inlet sensor (PI1)

Figure 2-250

2-47

CHAPTER 2 FINISHER UNIT BASIC OPERATION

5) When the buffer roller starts to operate, the buffer outlet solenoid (SL3) turns off so
that the path is directed in the direction of delivery. (The actual switch-over will occur
after the trailing edge of the first sheet has moved past the flapper.)

Buffer outlet
solenoid

SL3

OFF

1st sheet

2nd sheet

Inlet sensor (PI1)

Figure 2-254

6) The buffer roller continues to rotate, the third second sheets the first sheet, and the
second sheets are fed together towards the delivery roller.

2-48

Figure 2-255

CHAPTER 2 FINISHER UNIT BASIC OPERATION

K. Detecting Jams

The following sensors are used to detect the presence/absence of paper and to make

sure that sheets are moved properly:

●

Inlet sensor (PI1)

●

Delivery sensor (PI3)

●

Stapling tray sensor (PI4)

●

Buffer path paper sensor (PI14)

A jam is identified with reference to the presence/absence of paper at each specific
sensor at the times programmed in the memory of the microprocessor (CPU) on the fin­isher controller PCB.

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

The tray 1 paper sensor (PI11) and tray 2 paper sensor (PI12) are not used to detect
jams.

PI3

PI14

PI1

PI4

No. Sensor names

PI1 Inlet sensor
PI3 Delivery sensor
PI4 Stapler tray sensor

PI14 Buffer path paper sensor

Figure 2-256 Table 2-202

2-49

CHAPTER 2 FINISHER UNIT BASIC OPERATION

1. Feeding Delay Jam (JAM90)

The inlet sensor does not detect paper when feeding an equivalent of 400 mm from

when the host machine delivery signal has been issued.

Host machine delivery signal Host machine delivery signal

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

Equivalent of 400 mm

Normal

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

Equivalent of 400 mm

Jam

Figure 2-257

2. Feeding Delay Jam (JAM90)

The buffer inlet sensor does not detect paper when an equivalent of 540 mm has been

fed after the inlet sensor turned on.

Equivalent of 540 mmEquivalent of 540 mm

Jam check

Inlet sensor (PI1)
Buffer path paper

sensor (PI14)

Normal

Jam check

Inlet sensor (PI1)
Buffer path paper

sensor (PI14)

Jam

First feed motor (M1)

2-50

First feed motor (M1)

Figure 2-258

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Feeding Delay Jam (JAM90)
a. Straight Path

The delivery sensor does not detect paper when an equivalent of 285 mm has been
fed after the inlet sensor turned on.

Jam check
Inlet sensor (PI1)
Delivery sensor (PI3)
First feed motor (M1)

Second feed motor
(M8)

Equivalent of 285 mm

Normal

Jam check
Inlet sensor (PI1)
Delivery sensor (PI3)
First feed motor (M1)

Second feed motor
(M8)

Equivalent of 285 mm

Figure 2-259

b. Buffer Path

The delivery sensor does not detect paper when an equivalent of 480 mm has been
fed after the inlet sensor turned on.

Equivalent of 480 mm Equivalent of 480 mm

Jam check
Inlet sensor (PI1)

Normal

Jam check
Inlet sensor (PI1)

Jam

Jam

Delivery sensor (PI3)
First feed motor (M1)

Second feed motor
(M8)

Delivery sensor (PI3)
First feed motor (M1)

Second feed motor
(M8)

Figure 2-260

2-51

CHAPTER 2 FINISHER UNIT BASIC OPERATION

4. Feeding Stationary Jam (JAM91)

The sheet does not move past the inlet sensor when an equivalent of twice the feeding

length of the sheet has been fed after the sensor turned on.

Equivalent of size x 2

Jam

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

Equivalent of size x 2

Normal

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

Figure 2-261

5. Feeding Stationary Jam (JAM91)

The sheet does not move past the buffer inlet sensor when an equivalent of twice the

feeding length of the sheet has been fed after the sensor turned on.

Jam check
Buffer path paper

sensor (PI14)
First feed motor (M1)

Equivalent of size x 2

Normal

Jam check
Buffer path paper

sensor (PI14)
First feed motor (M1)

Equivalent of size x 2

Jam

Figure 2-262

6. Feeding Stationary Jam (JAM91)

The sheet does not move past the delivery sensor when an equivalent of twice the

feeding length of the sheet has been fed after the delivery sensor turned on.

Equivalent of size × 2 Equivalent of size × 2

Jam check

Delivery sensor (PI3)
Second feed motor

(M8)
Delivery motor (M2)

Normal

Jam check

Delivery sensor (PI3)
Second feed motor

(M8)
Delivery motor (M2)

Jam

Figure 2-263

2-52

CHAPTER 2 FINISHER UNIT BASIC OPERATION

7. Feeding Stationary Jam (JAM91)

The sheet does not move past the stapling tray sensor 1 sec after the delivery motor
(M2) turned on.

1 sec 1 sec

Jam check
Stapling tray

sensor (PI4)
Delivery motor (M2)

Normal

Jam check
Stapling tray

sensor (PI4)
Delivery motor (M2)

Jam

Figure 2-264

8. Timing Jam (JAM92)

The inlet sensor (PI1) detects a sheet before the delivery signal is received from the
host machine.

9. Staple Jam (JAM95)

When the staple motor (M6) is rotating clockwise, the staple home position sensor
(PI22) does not turn on within 0.5 sec. after it has turned off. However , the sensor turns on
within 0.5 sec. after the motor has been rotated counterclockwise.

10. Power-On Jam (JAM97)

One of the inlet sensor (PI1), delivery sensor (PI3), buffer path paper sensor (PI4) and
buffer path inlet paper sensor (PI17) detects paper at power-on.

11. Door Open Jam (JAM98)

One of the joint sensor (PI15), door open sensor (PI16) or door switch (MS1) detects
the cover open during operation (including the upper door switch (MS1P) and front door
switch (MS2P) when the optional puncher unit is mounted).

2-53

CHAPTER 2 FINISHER UNIT BASIC OPERATION

III. POWER SUPPLY SYSTEM

1. Outline

The finisher controller PCB is supplied with 24 VDC power (two lines) when the host
machine is turned on: of the two lines, one is used to drive the motor solenoids, while the
other is used for sensors and ICs on PCBs after being converted to 5 VDC by the regulator
IC (Q14) on the finisher controller PCB. Both lines are also used to feed power from the
finisher controller PCB to the saddle stitcher controller PCB. Power is also supplied to the
punch driver PCB when the optional puncher unit is mounted.

Some of the 24 VDC power used to drive motors is cut off when the door switch (MS1)
is open. The power to the saddle stitcher controller PCB, however, will not be cut off.

Figure 2-301 is a block diagram showing the power supply system.

Saddle stitcher
controller PCB

Circuit breaker

(CB1)

Finisher controller PCB

Host
machine

(Q14)

Regulator IC

Door switch

(MS1)

Motor

Motor

Solenoid

Sensors

Logic

Figure 2-301

2. Protection Functions

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

2-54

CHAPTER 3

SADDLE STITCHER UNIT

BASIC OPERATION

1. This chapter discusses the purpose and role of each of the stitcher’s functions, and
the principles of operation used for the stitcher mechanical and electrical systems. It
also explains the timing at which these systems are operated.

The symbol in drawings indicates transmission of mechanical drive, and signals
marked by together with the signal name indicates the flow of electrical signals.

2. In descriptions of digital circuits on the stitcher, “1” indicates a high signal voltage level,
while “0” indicates a low signal voltage level. Voltage values dif fer according to circuit.

A microprocessor is used on the stitcher. A description of microprocessor operation is
omitted in this chapter as it is practically impossible to check internal operation of the
microprocessor.

Descriptions in this chapter also assume that PCBs will not be repaired at user sites.
For this reason, descriptions of circuits on PCBs is limited to block diagrams. Two
types of block diagrams are provided for separate functions: diagrams indicating de­tails from sensors up to input sections of major PCBs, and diagrams indicating details
from the output sections of major PCBs up the loads.

I. BASIC OPERATION..................3-1

A. Outline ................................. 3-1

B. Electrical Circuitry................ 3-2

C. Inputs to and Outputs from the

Saddle Stitcher Controller

PCB ..................................... 3-3

II. FEEDING/DRIVE SYSTEM.......3-8

A. Outline ................................. 3-8

III. PAPER OUTPUT

MECHANISM........................... 3-14

A. Outline ............................... 3-14

B. Controlling the Inlet

Flappers............................. 3-17

C. Controlling the Movement of

Sheets................................3-21

D. Aligning the Sheets............ 3-23

E. Controlling the Phase of the

Crescent Roller.................. 3-26

IV. STITCHING SYSTEM ............. 3-28

V. FOLDING/DELIVERY

SYSTEM..................................3-31

VI. CHECKING FOR A JAM.......... 3-38

VII. POWER SUPPLY ....................3-43

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

I. BASIC OPERATION

A. Outline

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

Finisher unit control system

Guide plate drive system

Paper positioning plate

Alignment drive system

Stitcher drive system

Control system

Delivery drive system

drive system

Feed drive system

Paper pushing plate

drive system

Paper folding roller

drive system

Figure 3-101

3-1

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

B. Electrical Circuitry

The sequence of operations used for the saddle stitcher is controlled by the saddle
stitcher controller PCB. The saddle stitcher controller PCB has a microprocessor. This
microprocessor is used to control the sequence of operations and to handle serial com­munications with the finisher controller PCB, driving solenoids and motors in response to
the various commands from the finisher controller PCB.

The saddle stitcher controller PCB is also used to communicate the state of various
sensors and switches to the finisher controller PCB in serial.

The functions of the major ICs mounted on the saddle stitcher controller PCB are as
follows:

●

Q1
Controls the sequence of operations.

●

Q2
Contains the sequence program.

●

Q3
Controls the sequence of operations.

●

Q4
Handles IPC communications.

Electrical circuitry block diagram

Sensor

Switch

Saddle stitcher

controller PCB

Q1 CPU

Communi­cations IC

Finisher controller

PCB

Motor

Solenoid

Q2

ROM

Q3

RAM

Q4

Host machine

Figure 3-102

3-2

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

C. Inputs to and Outputs from the Saddle Stitcher Controller PCB

1. Inputs to the Saddle Stitcher Controller PCB

Saddle stitcher controller PCB

PI1S

Paper pushing
plate motor
clock sensor

Front door
open/closed
sensor

Delivery cover
sensor

Paper folding
motor clock
sensor

Alignment
plate home
position sensor

PI2S

PI3S

PI4S

PI5S

J107-1

-3

-2

J104-3

-1

-2

J103-3

-1

-2

J102-1

-3

-2

J101-3

-1

-2

J303-1

-3

-2

J309-1

-3

-2

J203-3

J209-3

-1

-2

-1

-2

J11-15

-14

-13

J11-10

-12

-11

J11-7

J11-6

J11-1

+5V
LUNGECLK

+5V
FDR

+5V

-9

EJCVR

-8

+5V

-5

FLDCLK

-4

+5V

-3

JOGHP

-2

When the paper pushing
plate motor is rotating,
alternately between “1”
and “0”.

When the front door is
open, “0”.

When the delivery cover
is open, “0”.

When the paper folding
motor is rotating,
alternately between “1”
and “0”.

When the alignment
plate is at home position,
“1”.

Tray paper
sensor

Paper
positioning
plate home
position sensor

PI6S

PI7S

J100-3

-1

-2

J106-3

-1

-2

-1

-3

-2

J502

J209A

-3

-1

-2

J402

-4

-6

-5

J302

J202A

-1

-3

-2

-3

-1

-2

J202

-6

-4

-5

J6-7

J6-4

-9

-8

-6

-5

+5V
TRYPAR

+5V
PAPPOS

When paper is present
on the tray, “1”.

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

Figure 3-103

3-3

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

2. Inputs to the Saddle Stitcher Controller PCB

PI8S

Paper positioning
plate paper sensor

Inlet cover sensor

PI9S

J105-3

-1

-2

J124-3

-1

-2

-1

-3

-2

J301

-3

-1

-2

J201

J201A

J6-1

-3

-2

J10-6

-8

-7

Saddle stitcher controller PCB

+5V
PPOSPAR

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

+5V
INLTCVR

When the inlet cover is
closed, “1”.

Delivery sensor

Crescent roller
phase sensor

Guide home
position sensor

Paper pushing
plate home
position sensor

Paper pushing
plate top position
sensor

Stitcher unit IN
sensor

PI11S

PI12S

PI13S

PI14S

PI15S

PI16S

J525-3

-1

-2

J126-3

-1

-2

J127-3

-1

-2

J128-3

-1

-2

J129-3

-1

-2

J131-3

-1

-2

-2

-4

-3

J425

J325

-3

-1

-2

-2

-4

-3

J225

-3

-1

-2

J125

J9-1

-3

-2

J9-4

-6

-5

J9-7

-9

-8

J9-10

-12

-11

J9-13

-15

-14

J13-1

-3

-2

+5V
DELV

+5V
FDRLHP

+5V
GIDHP

+5V
LUNGEHP

+5V
LUNGETOP

+5V
STPLHP*

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

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

When the guide is at
home position, “1”.

When the paper
pushing plate is at
home position, “1”.

When the paper
pushing plate is at the
leading edge, “1”.

When the stitcher unit
is housed, “0”.

Vertical path
paper sensor

Paper folding
home position
sensor

3-4

PI17S

PI21S

J132-3

-1

-2

J130-3

-2

-1

-1

-3

-2

J308

J208

J208A

Figure 3-104

-4

-2

-3

J13-4

-6

-5

J18-1

-2

-3

+5V
VPJM

+5V
PAFLDHP*

When paper is present
in the vertical path, “1”.

When the paper folding
roller is at home
position, “0”.