Page 1
500-SHEET FINISHER
(Machine Code: G302/B442)
Page 2
10 August, 2001 EXTERIOR
1. REPLACEMENT AND ADJUSTMENT
1.1 EXTERIOR
NOTE: This manual uses several symbols. The meanings for these symbols are
as follows:
☛: See or refer to !: screw ": connector #: clip
Front cover
[A]: : Front cover (!1)
Rear cover
[A]: Rear cover (!1)
[A]
B442R101.WMF
Options
[A]
B442R102.WMF
B442-1
Page 3
EXTERIOR 10 August, 2001
Top cover
[A]: Top cover (2 links)
[A]
Front lower guide
B442R105.WMF
[A]
B442R116.WMF
[B]
B442R104.WMF
[A]: Output tray (#2)
[B]: Front lower guide (!2)
NOTE: 1) When re-attaching th e lower guide, be sure that it is not in contact with
the exit lower guide and that the exit lower guide moves smoothly.
2) Make sure that the blue and black cables are in the correct position, as
engraved on the inside of the front lower guide.
B442-2
Page 4
10 August, 2001 EXTERIOR
Right cover
[A]: Grounding plate (!1)
[B]: Right cover (!2)
[B]
[A]
B442R103.WMF
B442-3
Options
Page 5
ENTRANCE UPPER GUIDE / PAPER EXIT UNIT 10 August, 2001
1.2 ENTRANCE UPPER GUIDE / PAPER EXIT UNIT
[H]
[A]
[G]
[F]
[D]
[E]
[C]
B442R106.WMF
• Front, rear, and top covers and front lower guide (☛ 1.1 Exterior)
[A]: Entrance upper guide (!2, "1)
[B]: Paddle gear spring
[C]: Paddle gear (#1)
[D]: Paddle gear holder
[E]: Bushing (#1)
[F]: Paper exit unit holder (!1)
[G]: Rear paper exit unit holder (!1)
[H]: Exit unit
NOTE: Keep the paper exit unit stays in
the upper position. Rotate the
paddle roller into the position
shown in the illustration [a]. Then,
insert the paddle gear, making
sure that the pawl on the gear’s
[b]
outer frame is resting on the clutch
link [b].
[B]
[a]
B442R107.WMF
B442-4
Page 6
10 August, 2001 ENTRANCE LOWER GUIDE
1.3 ENTRANCE LOWER GUIDE
• Entrance upper guide (☛ 1.2 Entrance
upper guide / Exit unit)
• Exit unit (☛1.2 Entrance upper guide /
Exit unit)
[A]: Release tension bracket (!1)
[B]: Reverse roller gear bracket (!2)
[C]: Timing belt
[D]: Entrance lower guide
NOTE: When re-assembling the tension
bracket, rotate the main motor
[B]
counter clockwise to tighten the
timing belt.
1.4 PAPER EXIT UNIT GEAR / PADDLE ROLLER
SOLENOID
[D]
[A]
[C]
B442R108.WMF
• Front cover (☛ 1.1 Exterior)
[A]: Gear bracket (!3)
[B]: Paper exit unit gear
[C]: Paddle roller solenoid (!1)
B442R109.WMF
[C]
[B]
[A]
Options
B442-5
Page 7
STAPLER UNIT 10 August, 2001
1.5 STAPLER UNIT
• Rear cover (☛1.1 Exterior)
[A]: Stapler unit bracket (!2, "1)
[B]: Stapler unit (!3)
[A]
[B]
B442R115.WMF
1.6 JOGGER TRAY UNIT
• Entrance upper guide and paper exit unit
(☛1.2 Entrance upper guide / paper exit
unit)
• Entrance lower guide (☛1.2 Entrance
lower guide)
• Paper exit unit gear and Paddle roller
solenoid (☛1.4 Paper exit unit gear /
Paddle roller solenoid)
• Stapler unit (☛ 1.5 Stapler unit)
[A]: Jogger tray unit holders (!2)
[B]: Jogger tray unit (!1, "3)
NOTE: Be sure to connect the black cable
to the paper exit sensor and the
blue one to the jogger home
position sensor.
[B]
[A]
B442R110.WMF
B442-6
Page 8
10 August, 2001 PAPER EXIT SENSOR FEELER
1.7 PAPER EXIT SENSOR FEELER
• Jogger tray unit (☛1.6 Jogger tray unit)
• Jogger motor (☛1.9 Jogger motor)
[A]: Paper exit sensor feeler
[A]
B442R121.WMF
1.8 MAIN MOTOR
• Right cover (☛1.1 Exterior)
[A]: Release tension bracket (!1)
[B]: Main motor (!2, "1)
[A]
[B]
B442R113.WMF
B442-7
Options
Page 9
JOGGER MOTOR 10 August, 2001
1.9 JOGGER MOTOR
• Front lower guide (☛1.1 Exterior)
[A]: Jogger motor (!2, "3)
[A]
B442R114.WMF
1.10 CONTROL BOARD
• Front lower guide (☛1.1 Exterior)
[A]: Control board (!1, "12)
B442R112.WMF
[A]
B442-8
Page 10
10 August, 2001 OUTPUT TRAY UNIT
1.11 OUTPUT TRAY UNIT
[D]
[A]
[E]
[B]
[F]
[A]: Output tray cover (!2)
[B]: Tray holder (!1)
[C]
B442R117.WMF
[G]
B442R118.WMF
B442R119.WMF
[C]: Links
[D]: Connector cover
[E]: Output tray motor link unit (!1)
[F]: Rear cover (!1)
[G]: Output tray motor ("1)
NOTE: When re-attaching the moto r link
unit, the arrows on each of the
gears need to face each other as
shown in the illustration.
B442-9
Options
B442R120.WMF
Page 11
OVERALL MACHINE INFORMATION 10 August, 2001
2. DETAILED DESCRIPTIONS
2.1 OVERALL MACHINE INFORMATION
2.1.1 COMPONENT LAYOUT
Mechanical component layout
89
10
1
2
1. Output tray
2. Stack height detection lever
B442D101.WMF
3
6. Lower entrance guide
7. Upper entrance guide
7
6
5
4
3. Paper exit roller
4. Jogger tray
5. Reverse roller
8. Paper exit unit
9. Paddle roller
10. Lower exit guide
B442-10
Page 12
10 August, 2001 OVERALL MACHINE INFORMATION
Drive layout
7
2
8
3
4
1. Main motor
2. Exit roller timing belt
3. Main motor timing belt
4. Output tray motor
1
B442D103.WMF
65
5. Output tray link gears
6. Paper exit unit drive gear
7. Reverse roller
8. Paper exit roller
B442-11
Options
Page 13
OVERALL MACHINE INFORMATION 10 August, 2001
2.1.2 ELECTRICAL COMPONENT DESCRIPTIONS
14
13
16
15
17
18
12
1
11
10
2
3
4
5
6
7
B442D102.WMF
9
8
See the next page for the component description table.
B442-12
Page 14
10 August, 2001 OVERALL MACHINE INFORMATION
Symbols Name Function Index No.
Motors
M1 Main Drives all the rollers 6
M2 Jogger Drives the jogger fence 9
M3 Output Tray Drives the tray up and down 12
Stapler Drives the stapler 16
Sensors
S1 Entrance Detects paper at the entrance 3
S2 Exit Detects paper at the exit 15
S3 Stack height Detects the top of the paper stack 13
S4 Lever Detects the position of stack height lever 14
S5
Jogger home
position
Detects the position of the jogg er fe nce
2
S6 Top cover Detects if the top cover is ope n 1
S7
S8
Tray upper limit Detects when the tray is lifted to the upper
limit
Stack near-limit Detects w hen the tray is at its lowest limit
(almost full)
11
10
Solenoids
SOL1 Exit unit gear Moves the paper exit unit up and down 7
SOL2 Paddle roller Switches paddle roller rotatio n on and off. 5
SOL3
Stack height
lever
Moves the stack height lever int o cont act
with the top of the stack.
PCBs
PCB1 Main control Controls all finisher functions 4
Switches
SW1 Paper exit unit Switches DC for the stapler unit on and off. 18
SW2 Staple unit cover Cuts DC when staple unit cover is open.
8
17
B442-13
Options
Page 15
DETAILED SECTION DESCRIPTIONS 10 August, 2001
2.2 DETAILED SECTION DESCRIPTIONS
2.2.1 OUTPUT TRAY MECHANISM
Stack height detection
[D]
[C]
[B]
[A]
B442D104.WMF
Stack height detection lever [A]: Driven by stack height lever solenoid [B].
Two sensors detect the height of the stack in the output tray: the stack height [C]
and lever [D] sensors.
Stack height
sensor
Off Off
Off On Target position
On On
On Off The stac k height detection lever is at home position.
Off: Actuator not in sensor
Lever sensor Status
The stack height is below t he target. The output tray is
lifted to the target positi on.
The stack height is more the target . The output tray is
lowered to the target position.
At the start of a print job, the solenoid turns off. The stack height detection lever
comes down, to detect the current stack level.
When a sheet of paper is being fed out, the solenoid turns on and the lever goes
back up to home position (inside the unit).
After paper has been fed out, the solenoid turns on again, and the lever detects the
level of the stack.
B442-14
Page 16
10 August, 2001 DETAILED SECTION DESCRIPTIONS
Output tray up/down mechanism
[D]
[E]
[B]
[A]
[C]
B442D105.WMF
Overview
The output tray motor [A] lifts/lowers the tray if the stack height is not at the target
position.
Gears [B] and [C] keep the angle of the tray constant at any tray position.
Output Tray Downward Movement
The top of the paper stack is checked after every page (or set of pages) has been
fed out. If the top of the stack is higher than the target level, the output tray motor
moves the tray down.
When the stack near-limit sensor [D] detects the actuator on gear [C], a stack nearlimit signal is transferred to the main frame. The tray cannot move any lower. The
next time the top of the stack height is above the target level, printing stops.
Output Tray Upward Movement
If paper is removed from the stack, the top of the stack will be lower than the target
level, and the output tray motor moves the tray up.
When the tray upper limit sensor [E] detects the actuator on gear [B], the tra y
cannot be moved up any more, so the motor stops.
B442-15
Options
Page 17
DETAILED SECTION DESCRIPTIONS 10 August, 2001
2.2.2 PAPER FEED
Overview
The following paper feed out modes can be selected at the printer driver.
Mode Description
Straight feed out mode Paper is fed directly to the output tray without shifting or sta pl ing.
Shift sorting mode Alternate sets are shifted before being fed to the output tray.
Stapling mode All sets are shifted and stapled, then fed to the output t r ay.
Straight feed out mode
Before the job, the exit unit [A] is up, and the exit unit gear solenoid [B] is on,
pulling lever [C] away from the exit unit gear [D].
At the start of the job, the stack height detection lever detects the top of the stack.
The tray moves up or down if the top of the stack is not at the correct level.
[A]
[F]
[J]
[E]
[H]
[I]
[G]
[D]
[B]
[C]
[G]
[C]
B442D106.WMF
B442D109.WMF
When the paper exit sensor in the main frame turns on, the finisher ma in m otor
starts. It drives the exit unit gear [D] through idle gear [E]. The gear pulls paper exit
unit [A] down, using the paper exit link [F]. The link also moves the paper exit roller
[H] up through the exit roller drive gear [G].
When the motor starts, the solenoid switch es off and a spring pushes lever [C] into
contact with the exit unit gear [D].
When a part of the exit unit gear without threads [I] faces the idle gear, the gear
stops turning (see the left-hand diagram). The lever [C] catches a peg on the exit
unit gear, to make sure that it stops at the correct position. The paper exit rollers
[H] now contact each other and the main motor feeds out the paper.
When the last page has been fed out, the solenoid turns on to pull the lever away
from the gear. The gear starts turning, to lift the exit unit to the standby position.
When the other part of the exit unit gear without threads [J] faces the idle gear, the
exit unit gear stops. Then, the main motor stops and the solenoid turns off.
B442-16
Page 18
10 August, 2001 DETAILED SECTION DESCRIPTIONS
Shift sorting mode
[D]
[C]
[B]
B442D111.WMF
[A]
[E]
B442D113.WMF
[F]
At the start of the job, and for odd numbered sets of copies, the mechanism is the
same as the straight feed out mode. However, even numbered sets are fed back to
the jogger tray, which shifts the sets to one side before feeding them out.
This section describes what happens for even-numbered sets (sets 2, 4, 6 etc) of
the job.
A short time after the entrance sensor [A] detects the first page of the set, the
paper exit unit solenoid turns on to restart the rotation of the paper exit unit gear,
raising the paper exit unit to the standby position. It stays there until after the last
page of the set.
The paper cannot feed out, so it drops into the jogger tray [B]. The paddle roller
solenoid [C] turns on and the paddle roller [D] feeds the paper to the reverse roller
[E]. The reverse roller feeds the paper to the end fence [F] of the jogger tray.
Options
B442-17
Page 19
DETAILED SECTION DESCRIPTIONS 10 August, 2001
[B]
[A]
[C]
[D]
B442D107.WMF
After the paper reaches the end fence [A], the jogger fence [B] shifts the paper
across. The jogger motor [C] drives the jogger fence. The home position sensor [D]
detects when the jogger fence has returned to home position.
When the ne xt set begins, the paper exit unit moves down, and the machine
operates the same way as straight feed out mode. At this time, the entire set in the
jogger tray is fed out at the same time as the first page of the next set. However,
the set coming from the jogger tray has been shifted to one side.
If the last set is an even-numbered set, the paper exit unit must be pulled down to
feed the final set out of the jogger tray. Then the exit unit moves back up to the
standby position.
The capacity of the jogger tray is 30 sheets. If the set contains more than 30
sheets, the machine feeds out the first 30 from the jogger tray, then continues with
the rest of the set, using the jogger tray.
B442-18
Page 20
10 August, 2001 DETAILED SECTION DESCRIPTIONS
Stapling mode
[B]
[D]
[F]
[E]
[C]
B442D112.WMF
[B]
B442D114.WMF
[A]
[G]
B442D106.WMF
The stapler is attached to the jogger tray, so all sets go to the jogger tray.
After all pages of a set have entered the jogger tray and been shifted across, the
paper exit link [A] pulls the paper exit unit [B] down until knob [C] on the exit unit
pushes the link lever [D] for the exit unit switch [E]. This turns on the exit unit
switch. When this switch is on, dc is supplied to the stapler unit [F] and the main
motor is turned off.
The exit unit switch is activated when the exit unit is pulled part-way down. After
stapling the set of prints, the paper exit unit is pulled down again until the unit
comes in contact with the paper exit roller [G], and the stapled set is fed out.
B442-19
Options
Page 21
DETAILED SECTION DESCRIPTIONS 10 August, 2001
2.2.3 JAM CONDITIONS
Sensors Conditions
Remaining paper detection Entrance
Exit
Non-feed at the entrance
Entrance
Jamming at the entrance
Entrance
Non-feed inside the unit
(Straight feed out mode only) Exit
Jamming at the exit
Jogger tray
Exit
Exit
Either the entrance or exit sensor detects
paper just after the unit is in it ialized.
The entrance sensor is not activ at ed within a
certain period after the paper exit sensor
detects paper.
The entrance sensor is not de-activated after
paper is fed 1.3 times the length of the
paper.
The exit sensor is not activ at ed within a
certain period after the entrance sensor
detects paper.
The exit sensor is not de-activated after
paper is fed for a certain period.
The exit sensor is de-activated during paper
shifting or stapling.
2.2.4 ERROR DETECTION
Conditions
Jogger motor error Jogger home position sensor does n ot shut of f a fter jog ger
motor starts.
Jogger motor home position
detection error
Stapler error
Output tray upper limit error Tray upper limit sensor i s act iv at ed.
Output tray motor error The output tray is away from the target position for more
Stack height detection error The stack height detection lever does not return to its home
Jogger home position sensor does n ot t urn on after paper
shifting.
Stapler home position sensor (inside stapler unit) does not
turn on after stapling.
than 10 seconds.
position before going to detect the stack height.
NOTE: The above errors are indicated as “Finisher jam” at the first occurrence.
If the same error happens again in the next job, “finisher error” is indicated.
B442-20
Page 22
10 August, 2001 SPECIFICATIONS
3. OVERALL MACHINE INFORMATION
3.1 SPECIFICATIONS
Paper Size: A3, B4, A4, B5 sideways (Metric)
DLT, LG, LT (Inch)
Paper Weight 52 ~ 128 g/m2, 14 ~ 34 lb.
Staple Capacity: 20 sheets (A3, B4, DLT, LG : 80 g/m2, 20 lb)
30 sheets (A4, B5 sideways, LT : 80 g/m2, 20 lb)
Stack Capacity (Maximum): 500 sheets (A4/LT or smaller: 80 g/m2, 20 lb.)
250 sheets (A3, B4, DLT and LG: 80 g/m2, 20 lb.)
Stapling Positions: 1
Staple Replenishment: Cartridge (3,000 staples/cartridge)
Power Source: 24 V DC, 5 V DC (from the copier/printer)
Power Consumption: 48 W
Weight: 8.3 kg (18.4 lbs.)
Dimensions (W x D x H): 350 x 490 x 230 mm
B442-21
Options
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