Toshiba MJ1017, MJ1018 User Manual

File No. 31100204
R02032112400-TTEC
Ver01 2002-09

General Precautions for Installation/Servicing/Maintenance for the Finisher MJ-1017/1018,

Hole punch unit MJ-6003, Inserter MJ-7001

The installation and service should be done by a qualified service technician.

1. When installing the Finisher MJ-1017/1018, Hole punch unit MJ-6003, Inserter MJ­7001 to the Plain Paper Copier, be sure to follow the instructions described in the
“Unpacking/Set-Up Procedure for the MJ-1017/1018/MJ-6003/MJ-7001” booklet which
comes with each unit of the MJ-1017/1018/MJ-6003/MJ-7001.

2. The MJ-1017/1018, MJ-6003, MJ-7001 should be installed by an authorized/qualified
person.

3. Before starting installation, servicing or maintenance work, be sure to turn off and
unplug the copier first.

4. When selecting the installation site, avoid placing the MJ-1017/1018/MJ-7001 and
copier on different levels or inclined floors.

5. When servicing or maintaining the MJ-1017/1018/MJ-6003/MJ-7001, be careful about
the rotating or operation sections such as gears, pulleys, sprockets, cams, belts, etc.

6. When parts are disassembled, reassembly is basically the reverse of disassembly
unless otherwise noted in this manual or other related materials. Be careful not to
reassemble small parts such as screws, washers, pins, E-rings, toothed washers to
the wrong places.

7. Basically, the machine should not be operated with any parts removed or disassembled.

8. Delicate parts for preventing safety hazard problems (such as breakers, thermofuses,
fuses, door switches, sensors, etc. if any) should be handled/installed/adjusted cor­rectly.

9. Use suitable measuring instruments and tools.

10. During servicing or maintenance work, be sure to check the serial No. plate and other
cautionary labels (if any) to see if they are clean and firmly fixed. If not, take appropri­ate actions.

11. The PC board must be stored in an anti-electrostatic bag and handled carefully using
a wristband, because the ICs on it may be damaged due to static electricity. Before
using the wrist band, pull out the power cord plug of the copier and make sure that
there is no uninsulated charged objects in the vicinity.

12. For the recovery and disposal of used MJ-1017/1018/MJ-6003/MJ-7001s, consum­able parts, packing materials, used batteries, and RAM-ICs including litium batteries,
it is recommended that the relevant local regulations/rules.

13. After completing installation, servicing and maintenance of the MJ-1017/1018/MJ-6003/
MJ-7001, return the MJ-1017/1018/MJ-6003/MJ-7001 to its original state, and check
operation.

14. When you move the finisher, do not move it in the direction of the arrow as shown in
the figure [A] below otherwise it might fall down. Also, when installing the inserter MJ­7001, hold it as the figure [B] below shows in order for your hands not to be caught.

[A] [B]

Copyright © 2002

TOSHIBA TEC Corporation

INTRODUCTION

This Service Manual contains basic data and figures for the Finisher (MJ-1017)/Saddle

Finisher (MJ-1018) needed to service the machine in the field.

This manual comprises the following chapters:

Chapter 1 “General Description” introduces the finisher’s features, specifications, and

names of parts, and shows how to operate the finisher.

Chapter 2 “Finisher Unit Basic Operation” discusses the principles of operation used for

the finisher mechanical and electrical systems. It also explains the timing at
which these systems are operated.

Chapter 3 “Saddle Finisher Unit Basic Operation” discusses the principles of operation

used for the saddle stitcher unit’s mechanical and electrical systems. It also
explains the timing at which these systems are operated.

Chapter 4 “Puncher (option) Unit Basic Operation” discusses the principles of operation

used for the puncher unit’s mechanical and electrical systems. It also explains
the timing at which these systems are operated.

Chapter 5 “Inserter (option) Unit Basic Operation” discusses the principles of operation

used for the inserter units mechanical and electrical systems. It also explains
the timing at which these systems are operated.

Chapter 6 “Mechanical System” discusses how the finisher is constructed mechanically,

and shows how it may be disassembled/assembled and adjusted.

Chapter 7 “Maintenance and Inspection” provides tables of periodically replaced parts

and consumables and durables, together with a scheduled servicing chart.

Chapter 8 “Troubleshooting” shows how to troubleshoot possible faults and gives electri-

cal parts arrangement diagrams, LED/check pin diagrams by PCB, and self
diagnosis tables.

“Appendix” contains diagrams showing tables of signals, overall circuit dia­grams and tables of solvents/oils.

Descriptions regarding installation are not mentioned in this Service Manual as the
Finisher (MJ-1017)/Saddle Finisher (MJ-1018)’s packing boxes contain Installation Proce­dures.

The descriptions in this Service Manual are subject to change without notice for prod­uct improvement or other purposes, and major changes will be communicated in the form
of Service Information bulletins.

All service persons are expected to have a good understanding of the contents of this
Service Manual and all relevant Service Information bulletins, and be able to identify and
isolate faults in the machine.

i

ii

CONTENTS

CHAPTER 1 GENERAL DESCRIPTION

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

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

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

B. Cross Section .........................1-10

III. Using the Machine .....................1-14

A. Removing Paper Jams from the

Finisher Unit ........................... 1-14

B. Supplying the Finisher Unit with

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

C. Removing Staple Jams from the

Finisher Unit ........................... 1-17

D. Removing Paper Jams from the

Saddle Stitcher Unit

(Saddle Finisher) ....................1-18

E. Supplying the Saddle Stitcher

Unit with Staples

(Saddle Finisher) ....................1-20

F. Removing Staple Jams from the

Saddle Stitcher Unit

(Saddle Finisher) ....................1-21

G. Removing Paper Jams from the

Puncher Unit (option) .............1-23

H. Removing Punched Scrap from

the Puncher Unit (option) .......1-25

IV. MAINTENANCE BY THE

USER ........................................1-26

A. Maintenance by the User .......1-26

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 ...................... 2-51

III. POWER SUPPLY SYSTEM .......2-56

iii

CHAPTER 3 SADDLE STITCHER UNIT

BASIC OPERATION

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

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

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

C. Inputs to and Outputs from the

Saddle Stitcher Controller

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

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

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

III. PAPER OUTPUT

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

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

B. Controlling the Inlet

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

CHAPTER 4 PUNCHER UNIT (OPTION)

BASIC OPERATION

I. BASIC OPERATION ....................4-1

A. Outline...................................... 4-1

B. Inputs to and Outputs from

Punch Driver PCB .................... 4-2

II. PUNCH OPERATION ..................4-5

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

A. Outline ......................................4-5

B. PUNCH OPERATION ...............4-7

C. Horizontal Registration

Operation ............................... 4-11

III. POWER SUPPLY SYSTEM .......4-14

CHAPTER 5 INSERTER UNIT (OPTION)

BASIC OPERATION

I. BASIC OPERATION ....................5-1

A. Outline ......................................5-1

B. Symbols and Layout of

Electric Parts/Diagram of

Signal Blocks............................ 5-2

iv

C. Drive System ............................ 5-6

D. Operation .................................5-8

E. JAM/ERROR DETECTION AND

LED DISPLAY ........................ 5-32

F. CIRCUIT................................. 5-36

CHAPTER 6 MECHANICAL CONSTRUCTION

I. FINISHER UNIT .......................... 6-1

A. Externals and Controls .............6-1

B. FEEDING SYSTEM ................. 6-9

C. PCBs ......................................6-13

II. SADDLE STITCHER UNIT ........6-14

A. Externals and Controls ...........6-14

B. SADDLE UNIT ....................... 6-17

C. PCBs ......................................6-27

D. Accessory .............................. 6-28

III. PUNCHER UNIT (OPTION) ...... 6-29

CHAPTER 7 MAINTENANCE AND INSPECTION

I. PERIODICALLY REPLACED

PARTS ......................................... 7-1

A. Finisher Unit ............................. 7-1

B. Saddle Stitcher Unit ................. 7-1

C. Puncher Unit (option) ............... 7-1

D. Inserter (option)........................ 7-1

II. CONSUMABLES AND

DURABLES .................................7-2

A. Externals and Controls ........... 6-29

B. Puncher Driver System .......... 6-30

C. PCBs ......................................6-41

IV. INSERTER UNIT (OPTION) ...... 6-43

A. Exterior Parts ......................... 6-43

B. Feeding Section .....................6-44

C. Drive Section .......................... 6-46

D. Upper Inserter Unit .................6-49

E. Tray Unit .................................6-50

F. Notes for Installing ................. 6-52

A. Finisher Unit ............................. 7-2

B. Saddle Stitcher Unit ................. 7-2

C. Puncher Unit (option) ............... 7-2

D. Inserter (option)........................ 7-2

III. PERIODICAL SERVICING .......... 7-2

IV. FIRMWARE UPDATING

(only for inserter section) .............7-3

CHAPTER 8 TROUBLESHOOTING

I. ADJUSTMENTS .......................... 8-1

A. Electrical System

(finisher unit) ............................ 8-1

B. Electrical System

(saddle stitcher unit) .................8-5

C. Electrical System

(puncher unit (option)) ..............8-7

D. Electric Unit/(Inserter Section

(Optional)) ................................8-9

E. Inserter Section ...................... 8-10

II. ARRANGEMENT OF

ELECTRICAL PARTS ................8-12

A. Finisher Unit ...........................8-12

B. Saddle Stitcher Unit ............... 8-19

C. Puncher Unit (option) .............8-25

D. Light-Emitting Diodes (LED)

and Check Pins by PCB .........8-29

III. TROUBLESHOOTING ............... 8-31

A. Finisher Unit ...........................8-31

B. Saddle Stitcher Unit ............... 8-41

C. Puncher Unit (option) .............8-48

D. Inserter Section (Option) ........ 8-49

v

APPENDIX

A. FINISHER UNIT GENERAL

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

B. SADDLE STITCHER UNIT

GENERAL TIMING CHART........ A-2

C. PUNCHER UNIT (option)

GENERAL TIMING CHART........ A-3

D. INSERTER UNIT (option)

GENERAL TIMING CHART........ A-4

E. SIGNAL AND

ABBREVIATIONS ..................... A-14

F. FINISHER UNIT CIRCUIT

DIAGRAM ................................. A-15

G. SADDLE STITCHER UNIT

CIRCUIT DIAGRAM ................. A-26

H. PUNCHER UNIT (option)

CIRCUIT DIAGRAM ................. A-34

I. INSERTER UNIT (option)

CIRCUIT DIAGRAM ................. A-41

J. SOLVENTS AND OILS ............. A-45

vi

CHAPTER 1

GENERAL DESCRIPTION

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

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

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

B. Cross Section .......................... 1-10

III. Using the Machine .....................1-14

A. Removing Paper Jams from the

Finisher Unit............................. 1-14

B. Supplying the Finisher Unit with

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

C. Removing Staple Jams from the

Finisher Unit............................. 1-17

D. Removing Paper Jams from the

Saddle Stitcher Unit

(Saddle Finisher) .....................1-18

E. Supplying the Saddle Stitcher

Unit with Staples

(Saddle Finisher) ..................... 1-20

F. Removing Staple Jams from the

Saddle Stitcher Unit

(Saddle Finisher) ..................... 1-21

G. Removing Paper Jams from the

Puncher Unit (option) ............... 1-23

H. Removing Punched Scrap from

the Puncher Unit (option) ......... 1-25

IV. MAINTENANCE BY THE

USER ........................................1-26

A. Maintenance by the User ......... 1-26

CHAPTER 1 GENERAL DESCRIPTION

I. FEATURES

1. Accommodates large quantities of sheets

●

Normally, the finisher holds a stack of sheets 250 mm in height in its two bins (small-size
paper: equivalent to 2000 sheets)/140 mm in height (large-size paper: equivalent to 1000
sheets)

2. Has high paper transportation performance

●

The finisher is capable of handling papers between 60 and 256 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 f inisher to accept copies without interruption from the
host machine even during stapling or offset operation.

6. Has a saddle stitch function (Saddle Finisher MJ-1018)

●

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

7. Offers a punch function (option)

●

The use of the puncher unit enables the finisher to punch sheets for binders before they are
output. (The puncher unit is capable of handling papers between 60 and 256 gm/m2. It can­not handle special paper, postcards and transparencies.)

8. Insert function (option)

●

Enable the use of special type of paper and printed paper in addition to the staple sorting or
the hole punching mode (Available when the optional staple sorting and the hole punching
mode units are installed.) This paper is not run through fuser (heat).

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

Size mixing

Description

Trays 1 and 2: by lifting tray
Face-down
AB: A3, A4, A4-R, A5-R, B4, B5, B5-R, FOLIO

Inch: LD, LG, LT, LT-R, ST-R, COMPUTER
60 to 256 g/m

2

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

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

Non sort Small-size
Non staple sort

(Note 1)

Large-size

(Note 1)

Staple sort Small-size

(Note 1)

Large-size

(Note 1)

Size mixing: 74 mm or less (500 sheets)
Staple mixing: 74 mm or less (500 sheets)

250 mm (2000 sheets)

140 mm (1000 sheets)

110 mm/50 sets (750 sheets)

74 mm/50 sets (500 sheets)

(Note 1)
(Note 1)

(Note 2)

(Note 2)

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/0.28 in.

Face-down

2

paper.

Table 1-201

1-2

CHAPTER 1 GENERAL DESCRIPTION

Item

Stapling
Stapling position
Stapling capacity

(Note1)

Staple supply
Staples
Staple detection
Manual stapling
Stapling size

Paper detection
Control panel
Display

Description

By rotating cam
See Figure 1-201.
Small-size
Large-size
Special staple cartridge (5000 staples)
Special (STAPLE-700: 3 cartridges of 5000 staples in a package)
Provided
Not provided
1-point diagonal Front A3, B4, A4, A4-R, B5, LD, LG, LT, LT-R,

stapling (diagonal) FOLIO, COMPUTER

1-point Rear A4-R, LT-R, LG, FOLIO
2-point A3, B4, A4, B5, A4-R, LD, LG, LT-R, FOLIO,

Provided
Not provided
Not provided

50 sheets (60 ~ 80 g/m2)
30 sheets (60 ~ 80 g/m2)

Rear A3, B4, A4, B5, LD, LT

COMPUTER

30 sheets (90 g/m2)
15 sheets (90 g/m2)

30 sheets (105 g/m2)
15 sheets (105 g/m2)

Dimensions
(W × D × H)

Weight

Power supply
Maximum power

consumption

740 × 630 × 1023 mm/29.25 × 24.88 × 40.38 in
813 × 630 × 1023 mm/32.13 × 24.88 × 40.38 in
922 × 630 × 1023 mm/36.38 × 24.88 × 40.38 in
995 × 630 × 1023 mm/39.25 × 24.88 × 41.38 in (with Puncher Unit and
Inserter Unit attached)

Finisher (MJ-1017): 42 kg/92.59 lb
Saddle finisher (MJ-1018): 62 kg/136.68 lb
Puncher unit (option): 5.4 kg/11.68 lb
Inserter unit (option): 20 kg/44.09 lb

From host machine (24 VDC, 5 VDC)
170 W or less

(with Puncher Unit attached)
(with Inserter Unit attached)

Note1: Equiv alent of 80 g/m2 paper . Including two sheets of thick stock or cov er (200 ~ 256 g/m2)

Table 1-202

Reference:

The term “small-size” stands for A4, A5-R, B5, LT, ST-R, while the term “large-size” stands for
A3, B4, A4-R, B5-R, LT-R, LD, LG, FOLIO, COMPUTER.

1-3

CHAPTER 1 GENERAL DESCRIPTION

Stapling Positions (finisher unit)

1-point stapling (rear)

Specified paper width

-0.24±0.16in

2-point stapling

A3 and A4

83±4mm/

3.26±0.16in

203±4mm/

5±4mm/

7.98±0.16in

0.2±0.16in

-6±4mm/

5±4mm/

0.2±0.16in

1-point stapling
(diagonal; front)

30˚

4.4±4mm/

-0.17±0.16in

4.4±4mm/

0.17±0.16in

B4 and B5

63±4mm/

2.47±0.16in

183±4mm/

5±4mm/

7.19±0.16in

0.2±0.16in

Specified paper width

-0.24±0.16in

5±4mm/

1-point stapling
(diagonal; rear)

-6±4mm/

LD and LT

74±4mm/

2.9±0.16in

194±4mm/

7.63±0.16in

0.2±0.16in

30˚

4±4mm/

0.16±0.16in

A4-R and FOLIO LT-R and LG

62.5±4mm/

2.46±0.16in

5±4mm/

0.2±0.16in

138.5±4mm/

5.45±0.16in

5±4mm/

0.2±0.16in

62.5±4mm/

2.46±0.16in

144.5±4mm/

5.69±0.16in

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, A4-R, LD, LT-R
W/binding: 1 sheet

W/out binding: 2 to 15 sheets
60 to 105 g/m2 (cover page up to 256 g/m2)

(including single cover page)

(Note 1)

10 sets (stack of 11 to 15 sheets), 20 sets (stack of 6 to 10 sheets),
25 sets (stack of 5 sheets or less)

Stapling position 2 points (center distribution; fixed interval)
Staple accommodation 2000 staples
Staple supply Special cartridge
Staples Special staples (STAPLE-600: 3 cartridges

of 2000 staples in a package)
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
DC24V, DC5V

Power consumption

160 W or less

Note1: Special paper, postcards, transparencies, reproducibles, label paper and hole-punched paper

cannot be handled.

Table 1-203

1-5

CHAPTER 1 GENERAL DESCRIPTION

Staple and Folding Position (saddle stitcher unit)

A3

210±1mm/

8.27±0.04in

203±2mm/

8.21±0.08in

Stack front edge

LD

Edge
of staple

83±2mm/

3.48

±0.08in

Staple position

Edge of
staple

B4

182±1mm/

7.17±0.04in

LT-R

63±2mm/

2.7

±0.08in

183±2mm/

7.42±0.08in

A4-R

5.85±0.04in

148.5±1mm/

159.5±2mm/

39.5±2mm/

1.77±0.08in

6.5±0.08in

8.5±0.04in

216±1mm/

74±2mm/

3.14

±0.08in

194±2mm/

7.86±0.08in

5.5±0.04in

139.7±1mm/

42mm/

1.89±0.08in

162±2mm/

6.61±0.08in

Figure 1-202

1-6

3. Puncher Unit (Option)

12±3 mm/

0.47±0.12 in

80±1 mm/

3.15±0.04 in

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

CHAPTER 1 GENERAL DESCRIPTION

Item

Punching method
Paper size

Paper weight
Punched hole diameter

Punched scrap capacity

Power supply
Power consumption

Description

Sequential punching
2 holes (puncher unit MJ-6003E): A3, A4, A4-R, B4, B5, B5-R

2 or 3 holes (puncher unit MJ-6003N): 2 holes/LG, LT-R

3 holes/LD, LT

4 holes (puncher unit MJ-6003F/ 6003S): A3, A4, A4-R (MJ-6003S)
60 to 256 g/m2

(Note 1)

2 holes (puncher unit MJ-6003E): 6.5mm
2 or 3 holes (puncher unit MJ-6003N): 2 holes/8.0mm

2 holes/0.31in
3 holes/8.0mm
3 holes/0.31in

4 holes (puncher unit MJ-6003F/ 6003S): 6.5mm
2 holes (puncher unit MJ-6003E): 5,000 sheets or more (64g/m

equivalent)

2 or 3 holes (puncher unit MJ-6003N): 3,000 sheets or more (75 g/m

equivalent)

4 holes (puncher unit MJ-6003F/6003S): 5,000 sheets or more (80 g/m

equivalent)
From finisher unit (24 VDC, 5 VDC)
120 W or less

2

2

2

Note1: Transparencies, reproducibles, label paper, postcards and hole-punched paper cannot be handled.

Hole position (Puncher Unit)

Figure 1-203-1

1-7

CHAPTER 1 GENERAL DESCRIPTION

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

70±1 mm/

2.76±0.04 in

12±3 mm/

0.47±0.12 in

108±1 mm/

4.25±0.04 in

108±1 mm/

4.25±0.04 in

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

80±1 mm/

3.1 5±0.04in

80±1 mm/

3.1 5±0.04in

80±1 mm/

3.1 5±0.04in

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

12±3 mm/

0.47±0.12 in

12±3 mm/

0.47±0.12 in

1-8

21±1 mm/

0.83±0.04 in

70±1 mm/

2.76±0.04 in

21±1 mm/

0.83±0.04 in

12±3 mm/

0.47±0.12 in

Figure 1-203-2

Specifications are subject to change without notice.

4. Inserter section

CHAPTER 1 GENERAL DESCRIPTION

Item

Paper size
Paper weight
Special papers
Laded number of

papers

A3, A4, A4-R, B4, B5, FOLIO, LD, LG, L T, LT -R
60g/m2 ~ 256g/m2 (16 lb. ~ 140 lb. Index)
OHP film, color paper (coated paper), hole-punched paper
100 at maximum for papers less than 80g/m2, number of papers up to 12mm

of laden height for papers more than 80g/m

* less than 60% of the above quantities for special papers
Inserter size
Inserter weight

533 × 612 × 1072mm (21 × 24.13 × 42.38 in) (W × D × H)

Approx. 20kg

* NOTE: Refer to 1-7, 8 for the hole position

Details

(*NOTE)

2

Table 1-204

1-9

CHAPTER 1 GENERAL DESCRIPTION

B. Cross Section

1. Finisher Unit

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

[7] [10] [11][9]

1-10

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

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

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

(saddle finisher MJ-1018)

Figure 1-204

2. Saddle Stitcher Unit

CHAPTER 1 GENERAL DESCRIPTION

[6]

[5]

[4]
[3]

[2]

[1]

[7]
[8]

[9]

[10]
[11]

[12]

[1] Guide plate
[2] Pa per folding roller
[3] Deli v ery guide plate
[4] Holding roller
[5] Stitcher (front, rear)
[6] Inlet roller

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

Figure 1-205

1-11

CHAPTER 1 GENERAL DESCRIPTION

3. Puncher Unit (option)

[1]

[2]

[3]

[4]

[1] Punch motor
[2] Cam
[3] Hole puncher (Punch blade)
[4] Die
[5] Photosensor PCB

[5]
[6]

[7]
[8]

[9]

[6] LED PCB
[7] Horizontal registration motor
[8] Scrap full detector PCB unit
[9] Punched scrap container

1-12

Figure 1-206

4. Inserter section (optional)

[1]

[10]

[9]

CHAPTER 1 GENERAL DESCRIPTION

[3]

[2]

[4]
[5]

[6]

[7]

[8]

[1] Tray
[2] Pickup roller
[3] Feed roller
[4] Transport roller 1
[5] Transport roller 2

[6] Transport roller 3
[7] Transport roller 4
[8] Transport roller 5
[9] Transport roller 6
[10] Reverse roller

Figure 1-207

1-13

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.

1) Holding the finisher unit as shown, move

it to detach it from the host machine.

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

Figure 1-303

4) Lift the buffer roller co ver , 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

1-14

CHAPTER 1 GENERAL DESCRIPTION

6) Return the buffer roller and the b uffer 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

Unit with Staples

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

1) Open the front cover.

Figure 1-308

2) Shift down the blue lever.

Figure 1-307

8) Operate as instructed on the display.

Figure 1-309

3) When the staple cartridge has slightly slid

out, hold and pull it out.

Figure 1-310

1-15

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 blue 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

1-16

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 blue lever.

Figure 1-320

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

Figure 1-321

Figure 1-318

1-17

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 (Saddle Finisher)

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

1) Holding the saddle stitcher unit as shown,

move it to detach it from the host machine.

Figure 1-323

2) Open the front lower cover.

Figure 1-324

1-18

CHAPTER 1 GENERAL DESCRIPTION

3) Turn the knob on the left side.

Figure 1-325

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

6) Open the inlet cover, and remov e 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.

1-19

CHAPTER 1 GENERAL DESCRIPTION

E. Supplying the Saddle

Stitcher Unit with Staples
(Saddle Finisher)

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) Set a new cartridge.

Figure 1-334

Reference

You must always replace both cartridges at
the same time.

1-20

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
Unit (Saddle Finisher)

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

Figure 1-339

1-21

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 cov er.

Figure 1-345

Reference

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

1-22

CHAPTER 1 GENERAL DESCRIPTION

G. Removing Paper Jams

from the Puncher Unit
(option)

If the display indicates a paper jam on the
puncher unit, perform the following to remov e
the jam:

1) Open the front cover of the puncher unit.

4) Holding the finisher unit as shown, move
it to detach it from the most machine.

Figure 1-349

5) Remove any jam visible from the outside.

Figure 1-346

2) Align the triangle mark on the knob within
the range marked by .

Figure 1-347

3) Close the front cover of the puncher unit.

Figure 1-350

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

Figure 1-351

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

Figure 1-348

Figure 1-352

1-23

CHAPTER 1 GENERAL DESCRIPTION

8) Return the buffer roller and the b uffer roller
cover to their original position, and close
the upper cover.

Figure 1-353

9) Connect the finisher to the host machine.

Figure 1-354

10) Operate as instructed on the display.

1-24

CHAPTER 1 GENERAL DESCRIPTION

H. Removing Punched Scrap

from the Puncher Unit
(option)

If the display indicates a punched scrap full
state on the puncher unit, perform the follow­ing to remove the punched scrap:

1) Open the front cover of the puncher unit.

Figure 1-355

2) Slide out the punched scrap container.

4) Return the punched scrap container to its
original position.

Figure 1-358

Figure 1-356

3) Discard the punched scrap.

Figure 1-357

1-25

CHAPTER 1 GENERAL DESCRIPTION

IV. MAINTENANCE BY THE USER

A. Maintenance by the User

No.

1

2

Item

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

unit)

When the appropriate indication is made on
the host machine’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

1-26

CHAPTER 2

FINISHER UNIT BASIC OPERATION

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

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

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

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

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

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

B. Outline of Electrical Circuitry...... 2-2

C. Inputs to and Outputs from the

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

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

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

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

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

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

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 ........................2-51

III. POWER SUPPLY SYSTEM .......2-56

I. BASIC OPERATION

A. Outline

CHAPTER 2 FINISHER UNIT BASIC OPERATION

The finisher is designed to deliver copies arriving from its host machine, and its modes of

delivery include simple stacking, job offset

(Note)

, and staple.

All operations inv olved in these modes are controlled by the finisher controller PCB, according

to the appropriate commands from the host machine.

In the case of the Saddle Finisher, copies from the host machine may be routed to the saddle

stitcher unit.

Swing guide drive system

Alignment drive system

Stapler drive system

Delivery drive system

Feeder drive system

Tray drive system

Control system

Shutter drive system

Saddle stitcher unit control system
(Saddle Finisher)

Tray drive system

Figure 2-101

Note:

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

2-1

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.

In the case of the Saddle Finisher, the f inisher 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:

●

IC1 (CPU)
Controls sequence of operations.

●

IC2 (EP-ROM)
Backs up adjustment values.

●

IC3
Contains sequence programs.

●

IC6/IC7 (RAM)
Backs up initial setting data.

●

IC4 (communications IC)
Communicates with the host machine and the saddle stitcher unit.

●

IC9 (regulator IC)
Generates PWM.

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
(Saddle Finisher)

Punch driver PCB
(Puncher unit (option))

Host machine
(DC controller PCB CPU)

Connecting with inserter

Saddle stitcher
controller PCB
(Saddle Finisher)

Finisher controller
PCB communication

IC1

CPU

IC2

EEP-ROM

IC4

IC

IC3

EP-ROM

IC6/IC7

RAM

IC9

Regulator IC

Finisher controller
PCB communication

IC1

CPU

Motor

Solenoid

Switch

Sensor

Motor

Solenoid

Host machine
(DC controller PCB CPU)

Punch driver PCB
(Puncher unit (option))

Inserter

driver PCB

(Inserter unit

(option)

)

Figure 2-102

IC2

EEP-ROM

IC4

IC

IC3

EP-ROM

IC6/IC7

RAM

IC9

Regulator IC

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

J106-3

J134-1

J122-3

J118-3

J121-3

J129-3

-7

-1

-2

-2

-3

-1

-2

-1

-2

-1

-2

-1

-2

-9

-8

-3

-2

-1

-1

-3

-2

-1

-3

-2

-4

-6

-5

-1

-3

-2

J202

J208

J207A

J205

J207A

J210

-3

-1

-2

-5

-6

-7

-11

-9

-10

-3

-1

-2

-8

-6

-7

-3

-1

-2

J17-7

J11-3

J9A-1

J12B-4

J9A-4

J12A-4

-9

-8

-2

-1

-3

-2

-6

-5

-6

-5

-6

-5

+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 1 home
position sensor

2-4

PI8

J130-3

J14A-1

-1

-2

-3

-2

+5V
TRYHP 1

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

Figure 2-103

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Inputs to the Finisher Controller PCB

Finisher controller PCB

Delivery motor
clock sensor

Tray 1 paper
sensor

Tray 2 paper
sensor

Buffer path paper
sensor

Joint sensor

Door open
sensor

PI10

PI11

PI12

PI14

PI15

PI16

J120-1

J2011-3

J8011-3

J110-3

J117-3

J1130-3

-9

-2

-3

-1

-1

-3

-2

-2

-1

-1

-3

-2

-2

-1

-2

-1

-2

-1

-2

-8

-7

J2010

J8010

-1

-3

-2

-3

-1

-2

-3

-1

-2

-3

-4

-5

J207A

-1

-3

-2

-7

-9

-8

J113

J9A-9

+5V

-8

DELCLK

-7

-3

J14A-4

-1

-2

J201

J14B-7

-3

-1

-2

J801

J12A-1

-3

-1

-2

J12B-1

J24-4

+5V

-6

FSTTRAY*

-5

+5V

-9

SNDTRAY*

-8

+5V

-6

BUFPASS

-5

+5V

-3

JOINT

-2

+5V

-3

DROPN

-2

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

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 host machine, “1”.

When the front door is
open, “0”.

Buffer path inlet
paper sensor

Swing guide
open sensor

Tray 1 lift
motor clock
sensor 1

Tray 1 lift
motor clock
sensor 2

Tray 2 lift
motor clock
sensor 1

Tray 2 lift
motor clock
sensor 2

PI17

PI18

PI9

PI19

PI23

PI24

J105-3

J127-3

J6011-3

J6011-6

J8021-3

J24-1

J11-8

-10

-12

-11

+5V

-3

BUFENTR

-2

+5V
SWGOPN

-9

+5V
SFTCLK11

+5V

-9

SFTCLK12

-8

+5V

-6

SFTCLK21

-5

+5V

-3

SFTCLK22

-2

-1

-2

-1

-1

-2

-1

-2

-4

-5

-3

-2

-4

-6

-5

J6010

-1

-3

-2

-4

-6

-1

-5

-2

J8020

-1

-6

-3

-4

-2

-5

-3

-1

-2

-6

-4

-5

-3

-1

-2

-6

-4

-5

J204

-3

-1

-2

J601

J801

J14A-10

-3

-1

-2

-6

-4

-5

-6

-4

-5

-9

-7

-8

J14A-7

J14B-4

J14B-1

-4

-6

-5

-1

-3

-2

-4

-6

-5

-1

-3

-2

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

When the swing guide is
open, “1”.

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

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

When the tray 2 lift motor
is rotating, alternately
between “1” and “0”.

When the tray 2 lift motor
is rotating, alternately
between “1” and “0”.

Figure 2-104

2-5

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Inputs to the Finisher Controller PCB

PI20

Swing motor
clock sensor

PI25

Tray 2 home
position sensor

Height sensor

Door switch

N. O.

MS1

C.

J112-1

Swing guide closed detecting switch 1

N. O.

C.

MS2

PS1

J125-1

-2

-3

J135-3

-1

-2

J114-3

-2

-2

-4

-1

-2

-3

-4

J112-1

-2

-5

-4

-3

J212

-1

-2

-1

-2

J207B

-3

-2

-4

-1

-2

-3

-1

-4

J112

J209

-7

-8

-9

-1

-2

-1

-2

J14B-10

J213

J9B-5

J6-2

-3

-4

-2

-1

J5-1

J5-6

-4

-3

-12

-11

-1

-3

-4-1

-2

-7

Finisher controller PCB

+5V
SWGCLK

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

+5V
TRYHP2

+5V
Height
PWR

When the tray 2 is home
position, “1”.

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

+24V

+24VMOVE

DRSW

+24V SHIFT

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

Swing guide closed detecting switch 2

N. O.

C.

MS6

Safety zone switch

J131-1

MS3

C.

N. C.
N. O.

-3

-2

Shutter closed detecting switch

MS4

N. C.
N. O.

C.

J140-3

-2

-1

J206-1

Tray coming close detection switch

J138

MS9

N. C.

N. O.

C.

-3

-1

J1151

-3

-2

-1

J1151

-4

-3

J5-8

-9

J5-3

-5

-4

J7-7

-6

-5

J5-11

-10

+24VSTPL

+24VSHIFT

TRAYSAF

SHUTCLD

TRYLMT
+24VSHIFT

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 1 gets
close to the tray 2: "0"

J209

J206-1

-4

-3

-3

-4

-2

-3

J115

-3

-4

-2

-3

-3
J115

-2

-1

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

J400-9 J400-1

-8

-7

-6

-5

-4

J51-3

-4

-1

-2

-8

-9

-11

-12

-6

-7

-5

CONNECT

-2

-3

-4

-5

-6

Communication line

J2-1

Communication line

JS1

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

J107

-2

-1 -3

J108

-2

-1 -2

J109

-2

-1 -2

J128

-2

-1 -3

J123

-2

-1 -2

J701

-2 -1

-1 -11

-2 -10

J207B

-10 -2

-11 -1

J207A

J12A-7

J12B-9

-10-2

J24-7

J9B-1

J9A-10

-11-2

-8-1

-8-1

-2-1

+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

Delivery motor

Alignment motor

-1 -2

-2

J10-6

-1

-2

-4

-3

-5

J501

J10-6

-1

-1

-2

-4

-3

-5

-1 -2

J500

-2 -1

J12B-7

J10-1

-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.

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

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

2-8

Figure 2-107

CHAPTER 2 FINISHER UNIT BASIC OPERATION

6. Outputs from the Finisher Controller PCB

Stapler shift motor

Staple motor

Tray 1 lift motor

J115-1

-2

-1

-2

Finisher controller PCB

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

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

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

Tray 2 lift motor

Swing motor

Second feed motor

Inlet 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 -.

Figure 2-108

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

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 deli ver

arriving copies to trays in the appropriate mode: simple stacking, job offset, stapling.

See Figure 2-201 for a diagram of the three modes of delivery (four for the Saddle Finisher).

Method of delivery

Normal
delivery

Saddle stitch delivery (Saddle Finisher only)

Simple stacking

Job offset

Staple

Figure 2-201

Front diagonal
Rear 1-point
Rear diagonal
2-point

Normal delivery tray

Normal delivery tray

To saddle stitcher unit
(Saddle Finisher)

Figure 2-202

2-10

1. Normal Delivery

a. Simple Stacking

The finisher delivers copies directly to the tray.

Tray Tray

CHAPTER 2 FINISHER UNIT BASIC OPERATION

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 deli v­ered without being shifted. Whether the fi rst copy or the last cop y 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

Delivery roller

Figure 2-205

Figure 2-206

Stopper

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 1

Paper width/2

2-point stapling

Figure 2-208

2-13

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2. Saddle Stitch Delivery (Saddle Finisher)

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

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

To saddle stitcher

Figure 2-209

2-14

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-R, ST-R, thick paper

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, A4-R, B5, B5-R, LD, LG, LT, LT-R, (excluding

transparencies and 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 three
copies (three originals or more in the staple mode) are wrapped round the buffer roller, during
which job offset and stapling are performed on the stapling tray.

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

Table 2-203

The following sho ws paper deli very operation in the case of three originals in the staple mode.

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

Buffer roller

First copy

Figure 2-212

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

from the host machine.

First copy

Second copy

Figure 2-213

2-16

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3) The second copy is laid ov er the first copy and, at the same time, the third copy arri ves from the
host machine.

First copy

Second copy

Third copy

Figure 2-214

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

Second copy

Third copy

First copy

Figure 2-215

Cauiton:

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

2-17

CHAPTER 2 FINISHER UNIT BASIC OPERATION

C. Feeding and Delivering

1. Outline

The finisher moves copies ar ri ving from the host mac hine to the deli very tray, stapling tray, or
the saddle stitcher unit (Saddle Finisher) according to the mode of delivery. On the stapling tray, the
copies are subjected to job offset or stapling as instructed by the host machine.

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

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

●

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 buf fer 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 remov al signal to the host machine again.

2-18

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Finisher controller PCB

Swing motor drive signal

Tray 2 lift motor drive signal

Escape solenoid drive signal ESCPSL

Shift motor clock signal 1 SFTCLK 21

Shift motor clock signal 2 SFTCLK 22

Delivery motor drive signal

Alignment motor drive signal

Swing motor clock signal SWGCLK

Delivery motor clock signal DELCLK

Shift motor clock detection signal 1 SFTCLK11

PI20

PI10

Tray 1 lift motor drive signal

Paddle solenoid drive signal PDLSL

PI19

Shift motor clock detection signal 2 SFTCLK12

M5

PI9

M7

M2

Second feed motor drive signal

SL5

First feed motor drive signal

M1M8 M9

Inlet feed motor drive signal

Buffer outlet solenoid drive signal EXITSL

SL3
SL2
SL1
SL7

M6

Stapler motor drive signal

Stapler shift motor drive signal

Flapper solenoid drive signal FLPSL

Buffer inlet solenoid drive signal EXTSL

Belt escape solenoid drive signal BESCPSL

M3

PI24

PI23

M

10

Figure 2-216

M4

SL6

2-19

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Finisher controller PCB

detection signal BUFPASS

Buffer path paper

detection signal BUFENTR

Delivery detection signal PDEL

Buffer path inlet paper

No. 1 tray paper detection signal FSTTRAY

No. 2 tray paper detection signal SNDTRAY

Stapling tray paper detection signal STPTY

PI3

PI14

PI11

PI4

PI12

PI17

Inlet paper detection signal PENT

PI1

2-20

Figure 2-217

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

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

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

ment 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 f inisher controller PCB rotates the deliv ery motor coun­terclockwise, and drives the swing motor (M7). As a result, the drive of the delivery motor is trans­mitted to the swing guide to move up the guide. When the swing guide open sensor (PI18) detects
the swing guide, the delivery motor stops, and the swing guide is held at the up position.

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

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

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

2-21

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Guide plate

Alignment plate

Alignment plate
home position sensor (PI6)

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)

Paper

Alignment motor (M3)

Figure 2-218

Start signal
Host machine delivery signal

2-22

Staple tray sensor (PI4)
Alignment motor (M3)

Alignment plate home
position sensor (PI6)

Swing motor (M7)
Swing guide open

sensor (PI18)
Swing guide closed

detecting switch 1 (MS2)
Escape solenoid (SL6)

: Motor CW rotation : Motor CCW rotation

Figure 2-219

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

Knurled belts

Tray 1/2

Delivery
roller

Stapling tray

Stopper

Figure 2-220

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

Existing stack

Alignment plate

Offset sheet

Figure 2-221

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

Offset sheet

Swing guide

Tray 1/2

Feed roller 2

Knurled belts

Delivery
roller

Stapling tray

Stopper

Figure 2-222

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 mo ve up. When the swing guide
open sensor (PI18) finds the swing guide at the up position, the swing motor stops, maintaining the
swing guide at the up position.

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

The finisher controller PCB drives the alignment motor (M3) when the stapling tray paper
sensor has detected paper to put sheets in order . The alignment plate is k ept in w ait in adv ance at a
point 10 mm behind the trailing edge of the paper.

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

Swing guide

First sheet

Tray 1/2

Feed roller 2

Knurled belts

Delivery roller

Stapling tray

Stapler

Figure 2-225

2-26

Swing guide

Swing guide open
sensor (PI18)

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Swing guide closed
detecting switch 1,2
(MS2/MS6)

Delivery roller

Swing motor
clock sensor
(PI20)

Delivery motor
clock sensor
(PI10)

Swing motor (M7)

Delivery motor (M2)

Figure 2-226

2-27

CHAPTER 2 FINISHER UNIT BASIC OPERATION

3. Second and Subsequent Sheets

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

Swing guide

Second and
subsequent
sheets

Paddles

Feed roller 2

Tray 1/2

Delivery
roller

Stapling tray

Figure 2-227

Knurled belts

SL7

Belt escape solenoid

Stapler

2-28

Knurled belts

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Escape direction

Belt escape
solenoid (SL7)

Figure 2-228

Paddles

Paddle
solenoid (SL5)

Paddles

Second and
subsequent sheets

First sheet

Stapler

M8

Second 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 deliver the stack to the tray.

Swing guide

Sheets

Feed roller 2

Knurled belts

Tray 1/2

Delivery
roller

Stapling tray

Stapler

Figure 2-230

2-30

Swing guide

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 staple motor (M6). A single rotation of the cam by the motor results
in one stapling operation.

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

The stapler motor is controlled by the microprocessor (IC1) on the finisher controller so that it
is rotated clockwise or counterclockwise.

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

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

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

2-32

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Figure 2-232

M6

Staple motor drive

signal

Staple edge detection signal

Finisher controller PCB

Stapling home

position detection signal

Figure 2-233

Cartridge detection signal

Staple detection signal

2-33

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Start signal
Host machine delivery signal

Inlet sensor (PI1)

Delivery sensor (PI3)

Inlet feed motor (M9)

First feed motor (M1)

Second feed motor (M8)

Delivery motor (M2)

Stapling tray sensor (PI4)

Alignment motor (M3)
Alignment guide home

position sensor (PI6)
Swing guide open

sensor (PI18)
Swing guide closed

detecting switch 1 (MS2)
Paddle solenoid (SL5)
Belt escape solenoid

(SL7)
Staple motor (M6)

First sheet

Stacking

Second sheet

Stapling

Delivery

Staple home position
sensor (PI22)

Stapler shift motor (M4)

: 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 mov ement range. This mov ement 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 f irst sheet has reached the host machine pre-regis­tration sensor, the stapler mo v es to the staple w ait 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 mov ed 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, LT and B5 sizes, the stapler is kept in wait toward the rear away from the stapling

position. The stapler is moved to and from the stapling position for each stapling operation.

Stapler

Wait position

Stapling position

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 the paper. Stapling occurs at two points, first at the
rear and then at the front.

Stopper

Stapling position

Wait position

Stapler

Stapling tray delivery
direction

Stapling position

Guide plate

Figure 2-238

Stopper

2-37

CHAPTER 2 FINISHER UNIT BASIC OPERATION

G. Tray Operation

The finisher has two delivery trays-upper tray 1 and lower tray 2. The upper and lower trays

move up and down independently.

Tray 1 is moved up and down by the tray 1 lift motor (M5), and tray 2 by the tray 2 lift motor

(M10).

The tray 1 position is detected by counting the clock pulses of tray 1 lift motor clock sensors 1
and 2 (PI9 and PI19) in relation to the tray 1 home position sensor (P18). The tray 2 position is
detected by counting the clock pulses of tray 2 lift motor clock sensors 1 and 2 (PI23 and PI24) in
relation to the tray 2 home position sensor (PI25).

When the tray is already at the home position, it is moved aw ay fr om the home position once,
then returned to that position.

When both tray 1 and tray 2 are at the home position, the above operation is performed for tray
1 and tray 2 in this order.

The finisher controller PCB moves up and do wn the tray selected by the host machine so that it
is positioned at the delivery slot.

The upper limit of the tray is detected by the tray coming close detecting switch (MS9). The
finisher controller PCB stops the drive (up) of the tray 1 lift motor (M5) as soon as the tray upper
limit detecting switch turns on.

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

The finisher controller PCB cuts off the +24V po wer of the tray 1 lift motor (M5) as soon as the
safety zone switch (MS3) turns on while the shutter and the swing guide are open, stopping the
operation of the finisher.

2-38

Tray 1 lift
motor

One way
gear

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Tray 1 lift
motor clock
sensor / and 2

Tray coming close
detection switch

Rack

Tray 2 lift
motor

One way
gear

Tray 2 lift motor
clock sensor / and 2

Figure 2-239

2-39

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 check ed by the
height sensor (PS1). See Table 2-204 for the maximum loading capacity of each tray.

The finisher controller PCB stops operation when the conditions in Table 2-204 occur, inform­ing the host machine that the tray is full.

Non-staple sort Staple sort

Stacking

mode

Small-size

Large-size

Mixed sizes

Small-size

Large-size

Mixed sizes

Height

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

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

3. Stacking height precision is ±7 mm.

250 mm high
(2000 sheets)

140 mm high
(1000 sheets)

74 mm high
(500 sheets)

110 mm high
(750 sheets/
50 sets)

74 mm high
(500 sheets/
50 sets)

22 mm high
(500 sheets/
50 sets)

Table 2-204

Caution:

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

2. The term “large-size” stands for A3, A4-R, B4, LG, LD, LT-R, FOLIO and COMUTER.

2-40

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Height sensor (PS1)

Paper

Figure 2-240

2-41

CHAPTER 2 FINISHER UNIT BASIC OPERATION

I. Shutter Operation

When the tray 1 passes the delivery slot, the f inisher controller PCB closes the shutter mounted
on the delivery slot before moving the tray, preventing the existing stack on the tray by the deli v ery
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 s wing 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

Second feed motor

Figure 2-241

CHAPTER 2 FINISHER UNIT BASIC OPERATION

2) The tray 1,2 lift motor rotates, and the new tray moves to the stacking lower limit. The distance
of movement is detected by1 the tray 1 lift motor clock sensor 1/2 (PI9/19) or tray 2 lift motor
clock sensor 1/2 (PI22/PI24).

Tray 1 lift motor

Tray 2 lift motor

M5

M10

Figure 2-242

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

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)

M10

Tray 2 lift motor

Shutter closed
detecting
switch (MS4)

Shutter open
sensor (PI5)

Figure 2-244

Claw

Shutter

Claw

2-44

Figure 2-245

M8

Second feed motor

One-way cam

Second feed motor (M8)

Tray 1 lift motor (M5)

Tray 2 lift motor (M10)
Shutter closed detecting

switch (MS4)
Shutter open

sensor (PI5)

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Sequence Operations (shutter drive)

Move from Tray 1 to Tray 2

Tray moved

Shutter
closed

Shutter
opened

Height sensor (PS1)

Correct height detected

Motor CW rotation Motor CCW rotation

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

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

The following sho ws 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

First sheet

Buffer inlet solenoid

Figure 2-247

2) When the leading edge of the sheet has moved past the buf fer path inlet paper sensor (PI17), the
buff er 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.

First sheet

Second sheet

Buffer path paper
sensor (PI14)

Figure 2-249

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

First sheet

Second sheet

Inlet sensor (PI1)

Figure 2-250

2-47

CHAPTER 2 FINISHER UNIT BASIC OPERATION

5) The buffer roller continues to rotate, and the second sheet overlaps the first sheet.

Second sheet

First sheet

Figure 2-251

6) When the trailing edge of the second sheet has moved past the b uf fer path paper sensor (PI14),
the buff er roller stops and waits for the third sheet.

Second sheet

First sheet

Third sheet

Buffer path paper
sensor (PI14)

2-48

Figure 2-252

CHAPTER 2 FINISHER UNIT BASIC OPERATION

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

Second sheet

First sheet

Third sheet

Inlet sensor (PI1)

Figure 2-253

8) W hen the leading edge of the third sheet reaches the inlet sensor (PI1), the buffer outlet sole­noid (SL3) turns off so that the path is directed in the direction of deliv ery. (The actual switch­over will occur after the trailing edge of the first sheet has moved past the flapper.)

Second sheet

Buffer outlet
solenoid

SL3

OFF

First sheet

Third sheet

Inlet sensor (PI1)

Figure 2-254

2-49

CHAPTER 2 FINISHER UNIT BASIC OPERATION

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

Figure 2-255

2-50

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 a jam. After the paper jam is removed, the buf fer path
inlet paper sensor (PI17) checks whether or not copies are being detected in addition to the above
four sensors (inlet sensor, deli v ery sensor, stapling tray sensor and buffer path paper sensor). If the
sensors detect a copy when all doors are closed, the finisher unit judges that paper jams have not
completely been removed, and sends the paper jam remov al 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 Stapling tray sensor

PI14 Buffer path paper sensor

Figure 2-256 Table 2-205

2-51

CHAPTER 2 FINISHER UNIT BASIC OPERATION

1. Inlet Sensor Delay Jam

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

host machine delivery signal has been issued.

Host machine delivery signal Host machine delivery signal

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. Inlet Sensor Stationary Jam

The sheet does not move past the inlet sensor when an equi valent 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 2-258

3. Buffer Path Paper Sensor Delay Jam

The buffer inlet sensor does not detect paper when an equi v alent of 550 mm has been fed after

the inlet sensor turned on.

Equivalent of 550 mmEquivalent of 550 mm

Jam check

Inlet sensor (PI1)
Buffer path paper

sensor (PI14)
First feed motor (M1)

Normal

Jam check

Inlet sensor (PI1)
Buffer path paper

sensor (PI14)
First feed motor (M1)

Jam

Figure 2-259

2-52

CHAPTER 2 FINISHER UNIT BASIC OPERATION

Jam check

Equivalent of size x 2

Buffer path paper
sensor (PI14)

Normal

First feed motor (M1)

Jam check

Equivalent of size x 2

Buffer path paper
sensor (PI14)

Jam

First feed motor (M1)

4. Buffer Path Paper Sensor Stationary Jam

The sheet does not move past the buffer inlet sensor when an equivalent of twice the feeding
length of the sheet has been fed after the sensor turned on.

Figure 2-260

5. Delivery Sensor Delay Jam

a. Straight Path

The delivery sensor does not detect paper when an equi v alent of 476 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 476 mm

Normal

Figure 2-261

Jam check

Inlet sensor (PI1)

Delivery sensor (PI3)

First feed motor (M1)
Second feed motor

(M8)

Equivalent of 476 mm

Jam

2-53

CHAPTER 2 FINISHER UNIT BASIC OPERATION

b. Buffer Path

The delivery sensor does not detect paper when an equi v alent of 772 mm has been fed after the

inlet sensor turned on.

Equivalent of 772 mm Equivalent of 772 mm

Jam check

Jam check

Inlet sensor (PI1)

Delivery sensor (PI3)

First feed motor (M1)
Second feed motor

(M8)

Normal

Inlet sensor (PI1)

Delivery sensor (PI3)

First feed motor (M1)
Second feed motor

(M8)

Figure 2-262

6. Delivery Sensor Stationary Jam

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

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

Equivalent of size x 2 Equivalent of size x 2

Jam check

Delivery sensor (PI3)
Second feed motor

(M8)

Normal

Jam check

Delivery sensor (PI3)
Second feed motor

(M8)

Jam

Jam

Delivery motor (M2)

Delivery motor (M2)

Figure 2-263

2-54

CHAPTER 2 FINISHER UNIT BASIC OPERATION

7. Stapling Tray Sensor Stationary Jam

The sheet does not move past the stapling tray sensor 1 sec after the deli very 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

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

9. Staple Jam

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

10. Power-On Jam

One of the inlet sensor (PI1), delivery sensor (PI3), b uffer path paper sensor (PI4) or buf fer path
inlet paper sensor (PI17) detects paper at power-on.

11. Door Open Jam

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

12. Punch Jam

The punch home sensor (PI3P) does not turn on again within 200 msec after turning off.

13. Stay Jam Caused By Finisher Start Signal OFF

The finisher start signal is turned OFF in the host machine while paper is being fed in the
finisher.

2-55

CHAPTER 2 FINISHER UNIT BASIC OPERATION

III. POWER SUPPLY SYSTEM

1. Outline

The finisher controller PCB is supplied with 24 VDC po wer (and 5 VDC power) when the host
machine is turned on. 24 VDC one is used to drive the motor solenoids, while 5 VDC is used for
sensors and ICs on PCBs. Both lines are also used to feed power from the finisher controller PCB
to the saddle stitcher controller PCB. Power is also supplied to the punch driver PCB when the
optional puncher unit is mounted.

Some of the 24 VDC power used to driv e 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.

Host
machine

J1-1

J2-6

Saddle stitcher
controller PCB
(Saddle Finisher)

Circuit breaker

(CB1)

Finisher controller PCB

Door switch

(MS1)

Motor

Motor

Solenoid

Sensors

Logic

Punch driver PCB
(Puncher Unit (option))

Figure 2-301

2. Protection Functions

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

2-56

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 differ according to circuit.

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

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

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

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

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

C. Inputs to and Outputs from the

Saddle Stitcher Controller

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

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

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

III. PAPER OUTPUT

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

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

B. Controlling the Inlet

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

C. Controlling the Movement of

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

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

E. Controlling the Phase of the

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

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

V. FOLDING/DELIVERY

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

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

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

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

I. BASIC OPERATION

A. Outline

The unit “stitches” (2 points) a stack of sheets delivered by the f inisher 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

Control system

Paper positioning plate

drive system

Alignment drive system

Stitcher drive system

Delivery drive system

Feed drive system

Paper pushing plate

drive system

Paper folding roller

drive system

Figure 3-101

3-1

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

Sensors

Switches

Saddle stitcher
controller PCB

Q1 CPU

Q2

ROM

Q3

RAM

Q4

Communi-

cations IC

Finisher controller

PCB

Figure 3-102

Motors

Solenoids

Host machine

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

Paper pushing
plate motor
clock sensor

Front door
open/closed
sensor

Delivery cover
sensor

Paper folding
motor clock
sensor

Alignment
plate home
position sensor

Tray paper
sensor

PI1S

PI2S

PI3S

PI4S

PI5S

PI6S

J107-1

J104-3

J103-3

J102-1

J101-3

J100-3

J11-15

-2

-3

-14

-13

+5V
LUNGECLK

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

J11-10

-1

-2

J303-1

-1

-2

-2

-3

-1

-2

-1

-1

-3

-2

-2

J309-1

J502

J402A

-3

-2

-3

-2

J402

-3

-1

-2

J203-3

J209-3

-4

-6

-5

J11-7

-1

-2

J11-6

J11-1

-1

-2

-3

-1

-2

-12

-11

J6-7

-9

-8

-5

-4

-3

-2

-9

-8

+5V
FDR

+5V
EJCVR

+5V
FLDCLK

+5V
JOGHP

+5V
TRYPAR

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”.

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

Paper
positioning
plate home
position sensor

PI7S

J106-3

J302

J202

J202A

-1

-1

-2

-3

-2

-6

J6-4

-4

-5

-6

-5

+5V
PAPPOS

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

Saddle stitcher controller PCB

Paper positioning
plate paper sensor

Inlet cover sensor

Delivery sensor

Crescent roller
phase sensor

Guide home
position sensor

Paper pushing
plate home
position sensor

PI8S

PI9S

PI11S

PI12S

PI13S

PI14S

J105-3

J124-3

J525-3

J126-3

J127-3

J128-3

-1

-1

-2

-1

-2

-1

-2

-1

-2

-1

-2

-1

-2

-3

-2

-2

-4

-3

J425

J425

J325

J301

-3

-1

-2

J201

J301A

-2

-4

-3

-3

-1

-2

J225

J225

-3

-1

-2

J125

J6-1

J10-6

J9-1

J9-4

J9-7

J9-10

-12

-11

+5V

-3

PPOSPAR

-2

+5V

-8

INLTCVR

-7

+5V

-3

DELV

-2

+5V

-6

FDRLHP

-5

+5V

-9

GIDHP

-8

+5V
LUNGEHP

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

When the inlet cover is
closed, “1”.

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”.

Paper pushing
plate top position
sensor

Stitcher unit IN
sensor

Vertical path
paper sensor

Paper folding
home position
sensor

PI15S

PI16S

PI17S

PI21S

J129-3

J131-3

J132-3

J130-3

J9-13

+5V

-1

-2

-1

-2

-1

-2

-2

-1

-1

-3

-2

J308

J208

J308A

-4

-2

-3

-15

-14

J13-1

J13-4

J18-1

LUNGETOP

+5V

-3

STPLHP*

-2

+5V

-6

VPJM

-5

+5V

-3

PAFLDHP*

-2

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

When the stitcher unit is
housed, “0”.

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

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

Figure 3-104

3-4

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

3. Inputs to the Saddle Stitcher Controller PCB

Paper sensor PCB

PI18S

Saddle stitcher controller PCB

No.1 paper sensor

No.2 paper sensor

No.3 paper sensor

Stitcher
home
position
sensor (front)

Staple
sensor (front)

Stitcher
home
position
sensor (rear)

Staple
sensor (rear)

PI19S

PI20S

Stitcher unit (front)

MS7S

MS6S

Stitcher unit (rear)

MS5S

MS4S

J123-5

J315-5

J316-5

When paper is present at
the No.1 paper sensor, “1”.
When paper is present at
the No.2 paper sensor, “1”.
When paper is present at
the No.3 paper sensor, “1”.

When the stitcher unit is

J304

J204

J304A

-5

-4

-3

-2

-1

-1

-4

-3

-2

-1

-2

-3

-4

-5

-3

J10-1

+5V

-2

1STPA

-3

2NDPA

-4
3RDPA

-5

J8-3

-5
STCHHP1*

at the home position for
stitching, “0”.

J305

-1

-7

-6

-2

-3

JD2

JD1

J120

-7

-6

-5

J8-10

-1
HKEMP1

-2

STCHHP2*

When no staple is present,
“0”.

When the stitcher unit is
at the home position for

J306

-1

-7

-6

-2

J121

-7

-6

-8

-9

HKEMP2

stitching, “0”.
When no staple is present,

“0”.

Inlet door switch

N.O.

MS1S

J109-3

Front door switch

N.O.

MS2S

J110-3

Delivery door switch

N.O.

MS3S

J111-2

+24V

J4-1

-2

-2

INLTCVRMS

When the inlet door is
closed, “1”.

J4-3

-2

-4

FDROPN

When the front door is
closed, “1”.

-1

-3

-2

J305

-1

-2

J205

J4-5

+24U

-6

DELVMS

When the delivery door
is closed, “1”.

Figure 3-105

3-5

CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION

4. Outputs from the Saddle Stitcher Controller PCB

Saddle stitcher controller PCB

No.1 paper deflecting solenoid

-1 -2

SL1S

-2

No.2 paper deflecting solenoid

-1 -2

SL2S

-2

Feed plate contact solenoid

-1 -2

SL4S

Feed motor

M1S

-2

-1 -4

-2 -3

-3 -2

-4 -1

J118

J117

J116

J115A

J15-1

J15-3

J15-5

J5-1

-2-1

FLPSL1*

-4-1

FLPSL2*

-6-1

RLNIPSL*

A

-2

A*

-3

B

-4

B*

+24V

When “0”, the solenoid turns ON.

+24V

When “0”, the solenoid turns ON.

+24V

When “0”, the solenoid turns ON.

The pulse signals change according
to the rotation of the motor.

Paper folding motor

M2S

Guide motor

M3S

Paper positioning plate motor

M4S

Alignment motor

M5S

J112-2

J119-5

J114-5

J113-5

J4-8

The states (+ and -) change according
to the rotation of the motor.

+24V

The pulse signals change according
to the rotation of the motor.

+24V

The pulse signals change according
to the rotation of the motor.

+24V

The pulse signals change according
to the rotation of the motor.

J12-1

J7-6

-10

J7-1

-7

-2

B*

-3

A*

-4

B

-5

A

-7

B*

-8

A*

-9

B
A

-2

B*

-3

A*

-4

B

-5

A

-1

-4

-3

-2

-1

-4

-3

-2

-1

-4

-3

-2

-1

3-6

Figure 3-106