Canon Saddle Finisher-T2, Service Manual

Page 1: ...Feb 21 2005 Service Manual Finisher Sorter DeliveryTray Saddle Finisher T2 ...

Page 2: ......

Page 3: ... need arises In the event of major changes in the contents of this manual over a long or short period Canon will issue a new edition of this manual The following paragraph does not apply to any countries where such provisions are inconsistent with local law Trademarks The product names and company names used in this manual are the registered trademarks of the individual companies Copyright This ma...

Page 4: ...quiring care to avoid combustion fire Indicates an item prohibiting disassembly to avoid electric shocks or problems Indicates an item requiring disconnection of the power plug from the electric outlet Indicates an item intended to provide notes assisting the understanding of the topic in question Indicates an item of reference assisting the understanding of the topic in question Provides a descri...

Page 5: ...sed to indicate Low The voltage value however differs from circuit to circuit In addition the asterisk as in DRMD indicates that the DRMD signal goes on when 0 In practically all cases the internal mechanisms of a microprocessor cannot be checked in the field Therefore the operations of the microprocessors used in the machines are not discussed they are explained in terms of from sensors to the in...

Page 6: ......

Page 7: ...raction of the Control System Saddle Stitcher Unit 2 13 2 2 5Paper Delivery Path Saddle Stitcher Unit 2 15 2 2 6Basic Operation Saddle Stitcher Unit 2 16 2 2 7Controlling the Inlet Flappers 2 20 2 2 8Controlling the Movement of Sheets 2 24 2 2 9Controlling the Aligning the Sheets 2 26 2 2 10Controlling the Phase of the Crescent Roller 2 28 2 2 11Overview of Folding Operation 2 30 2 2 12Controlling...

Page 8: ...ate shaped Upper Guide 3 2 3 1 4 Grate shaped Lower Guide 3 2 3 1 4 1 Removing the Front Door 3 2 3 1 4 2 Removing the Rear Upper Cover 3 2 3 1 4 3 Removing the Escape Tray Cover 3 2 3 1 4 4 Removing the Front Inside Upper Cover 3 3 3 1 4 5 Removing the Grate shaped Upper Guide 3 3 3 1 4 6 Removing the Tray 1 3 3 3 1 4 7 Removing the Tray 2 3 4 3 1 4 8 Removing the Grate shaped Lower Guide 3 6 3 1...

Page 9: ... Inside Upper Cover 3 18 3 2 3 6 Removing the Front Inside Lower Cover 3 18 3 2 3 7 Removing the Grate shaped Upper Guide 3 19 3 2 3 8 Removing the Tray 1 3 19 3 2 3 9 Removing the Tray 2 3 20 3 2 3 10 Removing the Grate shaped Lower Guide 3 21 3 2 3 11 Removing the Saddle Delivery Tray Unit 3 22 3 2 3 12 Removing the PCB Cover 3 22 3 2 3 13 Removing the Escape Unit 3 23 3 2 3 14 Removing the Sadd...

Page 10: ... 3 5 Removing the Grate shaped Upper Guide 3 38 3 3 3 6 Removing the Tray 1 3 38 3 3 3 7 Removing the Tray 2 3 40 3 3 4 Buffer Roller 3 41 3 3 4 1 Removing the Front Door 3 41 3 3 4 2 Removing the Escape Tray Cover 3 41 3 3 4 3 Removing the Buffer Roller 3 41 3 3 5 Return Roller 3 42 3 3 5 1 Removing the Front Door 3 42 3 3 5 2 Removing the Rear Upper Cover 3 42 3 3 5 3 Removing the Escape Tray Co...

Page 11: ...e Upper Cover 3 61 3 3 9 6 Removing the Front Inside Lower Cover 3 61 3 3 9 7 Removing the Grate shaped Upper Guide 3 61 3 3 9 8 Removing the Tray 1 3 61 3 3 9 9 Removing the Tray 2 3 63 3 3 9 10 Removing the Grate shaped Lower Guide 3 64 3 3 9 11 Removing the Upper Delivery Guide 3 64 3 3 9 12 Removing the PCB Cover 3 64 3 3 9 13 Removing the Paper Folding Roller 3 65 3 3 10 Escape Unit 3 67 3 3 ...

Page 12: ...aintenance 4 1 User Maintenance 4 1 4 1 1User Maintenance Finisher Unit 4 1 4 1 2User Maintenance Saddle Stitcher Unit 4 1 4 2 Maintenance and Inspection 4 2 4 2 1 Periodically Replaced Parts 4 2 4 2 1 1 Periodically Replaced Parts Finisher Unit 4 2 4 2 1 2 Periodically Replaced Parts Saddle Stitcher Unit 4 2 4 2 2 Durables 4 2 4 2 2 1 Durables Finisher Unit 4 2 4 2 2 2 Durables Saddle Stitcher Un...

Page 13: ...ror 4 17 4 4 1 17 E5F4 Stitcher rear error 4 17 4 4 1 18 E5F5 Stitcher front error 4 17 4 4 1 19 E5F6 Paper pushing plate motor error 4 18 4 4 1 20 E5F9 Micro switch error 4 18 4 5 Outline of Electrical Components 4 19 4 5 1Sensors Finisher Unit 4 19 4 5 2Microswitches Finisher Unit 4 22 4 5 3Solenoids Finisher Unit 4 23 4 5 4Motors Finisher Unit 4 24 4 5 5Clutches Finisher Unit 4 26 4 5 6PCBs Fin...

Page 14: ...exceeded Saddle Stitcher Unit 5 4 5 2 7Stitching capacity error Saddle Stitcher Unit 5 4 5 3 Service Error Code 5 5 5 3 1E500 5 5 5 3 2E503 5 5 5 3 3E505 5 5 5 3 4E514 5 6 5 3 5E530 5 6 5 3 6E531 5 7 5 3 7E532 5 7 5 3 8E535 5 8 5 3 9E537 5 8 5 3 10E540 5 9 5 3 11E542 5 10 5 3 12E584 5 11 5 3 13E5F0 5 11 5 3 14E5F1 5 12 5 3 15E5F2 5 12 5 3 16E5F3 5 13 5 3 17E5F4 5 13 5 3 18E5F5 5 13 5 3 19E5F6 5 14...

Page 15: ...Chapter 1 Specifications ...

Page 16: ......

Page 17: ...s 1 1 Product Specifications 1 1 1 1 1 Finisher Unit 1 1 1 1 2 Saddle Stitcher Unit 1 4 1 2 Names of Parts 1 7 1 2 1 External View 1 7 1 2 2 Cross Section Finisher Unit 1 8 1 2 3 Cross Section Saddle Stitcher Unit 1 9 ...

Page 18: ......

Page 19: ...eight 64g m2 to 200g m2 Modes Non sort Escape tray Trays 1 and 2 Sort Trays 1 and 2 Staple Trays 1 and 2 Stacking capacity 2 3 Escape tray Non sort Large size 43 mm high 125 sheets Small size 43 mm high 250 sheets Tray 1 Non sort Large size 96 mm high 650 sheets Small size 188 mm high 1300 sheets Tray 2 Non sort Large size 96 mm high 650 sheets Small size 243 mm high 1700 sheets Small size 347 mm ...

Page 20: ...ss T 1 2 Large size 96 mm high 50 sets Small size 188 mm high 100 sets Mixed stacking capac ity Size mixing Escape tray 43 mm high Tray 1 and 2 96 mm high 650 sheets Stapling 96 mm high 50 sets Mode mixing Large size 96 mm high 50 sets Small size 188 mm high 100 sets Stapling By rotating cam Stapling capacity Small size 50 sheets Large size 30 sheets Item Specifications Remarks Staple supply Speci...

Page 21: ... x 17 LGL LTR LTRR Paper detection Provided Control panel Not provided Display Not provided Dimensions W 649 761 x D 656 x H 1108mm If within parentheses with the tray extended Weight Approx 70 5 kg Power supply From host machine 24VDC Maximum power consumption 7 5 W or less during standby 114 W or less operating Item Specifications Remarks Front 1 point stapling 30deg A4R LGL and LTRR 5 2mm 5 2mm...

Page 22: ...o 80g m2 1 to 15 sheets Paper weight 2 Plain paper 64g m2 to 90g m2 Material for cover 64g m2 to 200g m2 Rear 1 point stapling 30deg A4R LGL and LTRR 5 2mm 5 2mm Rear 1 point stapling 45deg A3 A4 B4 B5 279mm x 432mm 11 x 17 and LTR 5 2mm 5 2mm 83 4mm 203 4mm 5 2mm 2 point stapling A3 and A4 63 4mm 183 4mm 5 2mm B4 and B5 279mm x 432mm 11 x 17 and LTR 74 4mm 194 4mm 5 2mm 159 5 4mm 5 2mm A4R LGL an...

Page 23: ...tion 2 points center distribution fixed interval Staple accommoda tion 2000 staples Staple supply Special cartridge Staples Special staple Staple D3 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 24VDC 1 Cover mode including 1 cover page 2 Spe...

Page 24: ...m 139 7 1 mm 42 2 mm 203 2 mm 210 1 mm 83 2 mm A3 183 2 mm 182 1 mm 63 2 mm B4 194 2 mm 216 1 mm 74 2 mm 162 2 mm 177 8 1 mm 42 2 mm LGL 159 5 2 mm 148 5 1 mm 39 5 2 mm A4R 279mm x 432mm 11 x 17 LTRR Staple position Folding position ...

Page 25: ...Parts 1 2 1 External View 0009 2529 F 1 5 T 1 4 1 Escape tray 6 Grate shaped upper guide 2 Escape door 7 Tray 1 3 Rear upper cover 8 Tray 2 4 Front door 9 Saddle delivery tray 5 Foot cover 10 Rear lower cover 5 7 8 6 4 9 2 1 3 10 ...

Page 26: ... roller 2 Tray 2 10 Buffer roller 3 Shutter 11 Feed roller 4 Stack delivery roller 12 Inlet roller 5 Aligning plate 13 Return roller 6 1st delivery roller 14 Rear end assist guide 7 Escape tray 15 Stapler 8 Escape delivery roller 16 Escape inlet flapper 3 12 11 14 13 10 4 5 15 7 8 9 9 2 1 6 16 ...

Page 27: ...1 6 1 Saddle inlet flapper 7 Holding roller 2 Saddle inlet roller 8 Paper pushing plate 3 No 1 flapper 9 Paper folding roller 4 No 2 flapper 10 Crescent roller 5 Stitcher front rear 11 Saddle delivery roller 6 Stitcher mount 12 Saddle delivery tray 2 3 4 5 6 7 8 9 10 11 12 1 ...

Page 28: ......

Page 29: ...Chapter 2 Functions ...

Page 30: ......

Page 31: ... Overview of Folding Operation 2 30 2 2 12 Controlling the Movement of Stacks 2 31 2 2 13 Folding a Stack 2 32 2 2 14 Double Folding a Stack 2 35 2 3 Intermediate Process Tray Assembly 2 38 2 3 1 Stack Job Offset 2 38 2 3 2 Processing Tray Paper Stacking Operation 2 39 2 3 3 Offset Operation 2 39 2 3 4 Rear End Assist Operation 2 40 2 3 5 Stack Delivery Operation 2 41 2 4 Staple Operation 2 42 2 4...

Page 32: ......

Page 33: ...ontroller 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 info...

Page 34: ...ow of signals between the finisher and the options controller F 2 2 2 1 3 Basic Operation Saddle Stitcher Unit 0009 2535 The unit stitches 2 points a stack of sheets delivered by the finisher unit and folds it in two for delivery All these operations are controlled by the saddle stitcher controller PCB in response to commands from the host machine via the finisher unit IC108 CPU IC105 EEP ROM Sadd...

Page 35: ...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 IC7 CPU Controls the sequence of operations Contains the sequence program IC8 communications IC Communicates with the finisher unit IC512 regulator IC Generates 5...

Page 36: ...F 2 4 Sensor Switch Saddle stitcher controller PCB IC7 CPU IC512 Regulator IC IC8 Communi cations IC Solenoid Motor Finisher controller PCB Host machine IC10 Regulator IC ...

Page 37: ...Saddle Stitcher unit carries in aligns and stitches sheets delivered from the host machine and then feeds the resulting stack After these operations it folds a stack of sheets and delivers it to the delivery trays of the Saddle Stitcher unit There are four delivery methods F 2 5 F 2 6 Method of delivery Normal delivery Simple stacking Stack job offset Staple Front 1 point stapling 2 point stapling...

Page 38: ...er PCB The following three sensors are provided in the copy delivery path to detect the arrival or passing of copies Inlet sensor PI103 Delivery path sensor PI104 Escape tray path sensor PI118 Also each ejection tray has sensors to detect the presence of copy on the tray First tray paper sensor PI111 Second tray paper sensor PI112 If the copy does not reaches or passes each sensor within prescribe...

Page 39: ...olding solenoid drive signal First tray shift motor drive signal Stapler drive motor drive signal Stapler motor drive signal Stack ejection motor drive signal inlet motor drive signal Finisher controller PCB 2 2 Second tray shift motor drive signal M112 SL103 M103 M104 Aligning plate front rear motor drive signal Feed motor drive signal Rear end assist motor drive signal Feed driver PCB Finisher c...

Page 40: ...e escape tray Straight Ejection Destination Tray 1 Tray 2 When the equipment is set to non sort all copies are ejected through the following path Stack ejection roller Second tray paper detection signal First tray paper detection signal Finisher controller PCB Escape tray path paper detection signal Feed driver PCB PI111 PI112 PI118 PI104 PI103 Feed path paper detetion signal Inlet paper detection...

Page 41: ...the equipment is set to sort for paper size other than A4 B5 or LTR or when set to staple sort Copies are delivered to the processing tray for aligning and stapling Then they are ejected using the rear end assist Tray Paper Feed roller Buffer roller Stack ejection roller 1st delivery roller Inlet roller ...

Page 42: ...and post processed stack in the processing tray is performed because copies are received continuously from the host machine The stack delivered from the buffer is ejected to the processing tray and the stack processed in the processing tray is ejected to the tray Simultaneous stack ejection operation is described below for two A4 copies between stacks when the equipment is set to sort 1 When the 1...

Page 43: ...d toward the delivery tray by the return roller and rear end assist guide F 2 13 4 When the stack in the processing tray is delivered to the delivery tray and the rear end of the 1st and 2nd paper exits the 1st delivery roller the 1st and 2nd paper are delivered toward the processing tray by the stack delivery roller and return roller Feed roller Buffer roller Switch back point 20mm Buffer guide S...

Page 44: ...ay When the escape tray is specified as the destination of paper ejection in the non sort mode the paper delivered from the host machine to the finisher is rerouted to the path shown below by the escape inlet flapper and ejected to the escape tray Stack ejection roller Return roller 1st delivery roller Processing tray Return roller Stack ejection roller Rear end assist guide ...

Page 45: ...d the crescent roller and held in a predetermined position The feed plate serve to move sheets by coming into contact with or moving away from sheets as needed The alignment plates put the stack into order each time a sheet is output The alignment plates are driven by the alignment motor M5 whose position is identified in reference to the number of motor pulses coming from the alignment plate home...

Page 46: ...ock signal LUNGECLK Flapper drive signal 1 FLPSL1 Flapper drive signal 2 FLPSL2 Feed p ate contact solenoid drive signal RLNIPSL Paper folding motor clock signal FLDCLK Paper folding motor drive signal Paper positioning plate motor drive signal Saddle stitcher controller PCB 2 2 SL5 M113 Inlet motor drive signal Saddle inlet solenoid drive signal SDLINSL Saddle stitcher controller PCB 1 2 Finisher...

Page 47: ...Paper folding home position detection signal PAFLDHP Vertical path paper detection signal VPJM PI19 PI18 PI15 PI14 Paper pushing plate leading edge position detection signal LUNGETOP Paper pushing plate home position detection signal LUNGEHP No2 paper detection signal 2NDPA No 1 paper detection signal 1STPA PI21 Paper positioning plate home position detection signal PAPPOS PI7 PI8 Paper postioning...

Page 48: ...The vertical path while sheets are being output is configured by two paper deflecting plates The position of the sheets being output is set by the paper positioning plate so that the center of the stack matches the stapling folding position Sheets coming later are output closer to the delivery slot and the volume of paper that may be output is as follows 15 sheets maximum of 14 sheets of 80g m2 1 ...

Page 49: ... When all sheets have been output the two stitchers stitch the stack The stitchers are positioned so that they face the center of a stack The two stitchers are not operated simultaneously so as to prevent the paper from wrinkling between two staples and to limit the load on the power supply If only one sheet of paper arrives from the host machine stitching does not take place and the sequence goes...

Page 50: ... the center of the stack i e stapling position matches the height of the paper pushing plate and the paper folding roller nip The stack is moved forward by operating the paper positioning plate When the plate is operated the guide plate which has been covering the paper folding rollers also moves down so that the paper folding rollers directly face the stack Stitcher Staple ...

Page 51: ... the direction of the paper folding rollers In response the paper folding rollers pick the stack along its center and fold it in two The paper folding rollers together with the delivery roller then move the stack along to output it on the delivery tray Paper folding roller Guide plate Paper positioning plate Paper pushing guide ...

Page 52: ... passage of the trailing edge of the paper being moved by an appropriate sensor 2 To prevent the following sheet from butting against the top of the existing stack The following table shows the relationship between sensors and paper sizes T 2 1 SENSOR A3 279mm x 432mm 11 x 17 B4 LGL A4R LTRR No 1 paper sensor PI18 Used Used Used No 2 paper sensor PI19 Not used Used Used No 3 paper sensor PI20 Not ...

Page 53: ...following table shows the relationship between solenoids and paper sizes T 2 2 A3 279mm x 432mm 11 x 17 Paper Path 3 sheets Solenoid A3 279mm x 432mm 11 x 17 B4 LGL A4R LTRR No 1 paper deflecting solenoid SL1 OFF ON ON No 2 paper deflecting solenoid SL2 OFF OFF ON ...

Page 54: ...ensor PI19 No 3 paper sensor PI20 No 1 paper deflecting plate solenoid No 2 paper deflecting plate solenoid Passage of paper Non passage of paper Non passage of paper Entry of First sheet Entry of Second sheet Entry of Third sheet SL1 SL2 OFF OFF PI18 PI19 PI20 PI18 PI19 PI20 Top edge ...

Page 55: ...heets No 1 paper sensor PI18 No 2 paper sensor PI19 No 3 paper sensor PI20 Passage of paper Passage of paper Non passage of paper Entry of First sheet Entry of Second sheet Entry of Third sheet Top edge SL1 SL2 ON OFF PI18 PI19 PI20 PI18 PI19 PI20 ...

Page 56: ... path bed so as to move the sheet The contact is broken as soon as the leading edge of the sheet reaches the paper positioning plate This series of operations is executed each time a sheet arrives When the leading edge of the first sheet reaches the paper positioning plate the paper positioning plate paper sensor PI8 turns ON The arrival of the second and subsequent sheets will not be checked sinc...

Page 57: ...sheet so as to put both left and right edges of the sheet in order 1 The solenoid turns ON while paper is being moved so that the feed plate comes into contact F 2 28 2 The solenoid turn OFF when the paper butts against the paper positioning plate The feed motor continues to rotate F 2 29 3 The solenoid turns ON when the next sheet arrives and the feed plate comes into contact SL4 ON Feed motor In...

Page 58: ...The following briefly describes what takes place when the saddle stitching mechanism operates on two sheets 1 When the first sheet has been output the alignment plates butt against the left and right edges of the stack first alignment The alignment plates leave the home position in advance and remain in wait at points 10 mm from the edges of the stack F 2 31 2 The alignment plates move away from t...

Page 59: ...t plates butt against the stack once again during which stitching takes place F 2 34 6 The alignment plates escape to points 10 mm from the edges of the stack after which folding and delivery take place F 2 35 7 When the first sheet of the following stack reaches the No 1 paper sensor the guide moves to a point 10 mm from the edge of the stack to be ready for the next alignment operation ...

Page 60: ...r Alignment plate Alignment plate Alignment plate home position sensor PI5 Stack Paper positioning plate Alignment plate home position sensor PI5 Paper positioning plate motor M4 Alignment motor M5 Alignment Escape Entry of 1st sheet Entry of 2nd sheet 1st sheet of follow ing stack entry In case of 2 sheets 1 Move to wait position 2 Stapling period 3 Paper folding delivery period 4 Move to followi...

Page 61: ...l leave the sensor while the roller shaft rotates turning the sensor ON or OFF enabling the assumption that the crescent roller is positioned at the opposite side of the stack The alignment plates are operated to correspond with this change in the state of the sensor F 2 39 F 2 40 Crescent roller phase sensor PI12 Flag Feed motor Stack Crescent roller Alignment plates M1 Alignment plates Crescent ...

Page 62: ...during output Before the stack is folded the guide plate moves down to enable the folding rollers to operate The following shows the names and the functions of the motors and sensors used by the paper folding mechanism T 2 3 Motor Function Paper folding motor M2 Drives the folding roller Paper pushing plate motor M8 Drives the paper pushing plate Alignment operation is started when the flag has co...

Page 63: ...s so that folding may take place Sensor Function Paper pushing plate motor clock sensor PI1 Detects the paper pushing plate motor clock Paper folding motor clock sensor PI4 Detects the paper paper folding motor clock Tray paper sensor PI6 Detects the presence absence of a stack of sheets in the saddle delivery tray Delivery sensor PI11 Detects the paper delivery Paper pushing plate home position s...

Page 64: ...til the stack has been drawn to the paper folding roller and is gripped for a length of 10 mm When the paper folding roller has gripped the stack for a length of about 10 mm the paper pushing plate motor starts to rotate once again and the paper pushing plate returns to its home Paper folding roller Guide plate Paper positioning plate Paper pushing guide PI7 Paper positioning plate home position s...

Page 65: ...he paper folding roller lower do not contact each other except at the center so they only feed paper to prevent paper from being wrinkled The paper folding start position and stop position of the paper folding rollers are controlled by the number of motor pulses delivered from the paper foldimg home position sensor P121 F 2 45 F 2 46 Paper folding roller lower Paper folding roller upper Sensor fla...

Page 66: ...position sensor PI21 Sensor flag Delivery outlet Paper feed inlet Paper pushing plate Stack of sheets Paper folding start position Paper folding feeding is performed Paper feeding is performed Paper folding home position sensor PI21 Sensor flag Delivery outlet Paper feed inlet Paper folding roller stop position ...

Page 67: ...ally and the paper pushing plate returns to its home position while the stack is being delivered This way a stack requiring a large force may properly be folded with less pressure 1 The paper pushing plate pushes the stack in the direction of the paper folding rollers F 2 50 2 The paper folding rollers grip the stack for a length of about 20 mm Paper folding motor M2 Paper pushing plate motor M8 P...

Page 68: ...r a length of about 20 mm reverse feeding F 2 52 4 The paper folding rollers rotate again feeding out the stack The paper pushing plate returns to its home position F 2 53 M2 Paper folding motor 20 mm approx M2 Paper folding motor 20 mm approx M2 Paper folding motor M8 Paper pushing plate motor ...

Page 69: ...ry sensor PI11 Paper pushing plate top position sensor PI15 Paper pushing plate home position sensor PI14 Tray paper sensor PI6 Equivalent of 20 mm Equivalent of 20 mm reverse feeding Gripping of paper stack Motor CW Motor CCW Paper folding home position sensor PI21 ...

Page 70: ...drives the aligning plate front motor M103 and aligning plate rear motor M104 to return the two aligning plates to home position The name and function of motors and sensors used by the stack job offset function are shown below F 2 55 F 2 56 T 2 5 Motor Function Aligning plate front motor M103 Aligns paper in processing tray to the front Paper Light shielding plate Rear aligning plate home position...

Page 71: ...each time a sheet is pulled onto the processing tray Aligning plate rear motor M104 Aligns paper in processing tray to the rear Swing motor M106 Moves the swing guide up down Rear end assist motor M109 Carry the stack end during stack ejection Sensor Function Swing guide HP sensor PI105 Detects the swing guide home position Aligning plate front HP sensor PI106 Detects the aligning plate front home...

Page 72: ...d in addition to the stack ejection roller to support the rear end of the stack during stack ejection F 2 59 Rear aligning plate Sheet to be offset Front aligning plate Tray Rear aligning plate Sheet to be offset Front aligning plate Tray Paper Processing tray stopper Rear end assist guide Rear end assist motor M109 Processing tray stopper Rear end assist guide home position sensor PI109 ...

Page 73: ... direction The rear end assist guide stops once it reaches the prescribed position and returns to home position when the rear end assist motor is reversed Then the stack delivery motor starts and ejects the stack with the upper lower stack delivery rollers F 2 60 1 Varies from 1 to 4 sheets depending on the number of original ex When the number of original is 10 copy stack are ejected in the order...

Page 74: ...rotates the cam one turn for stapling The home position of this cam is detected by the staple home position sensor PI50 The staple motor is rotated in the forward or reverse direction under the control of the macro computer IC108 on the finisher controller PCB When the staple home position sensor is OFF the finisher controller PCB rotates the staple motor in the forward direction until the sensor ...

Page 75: ... 4 3 Shifting the Stapler Unit 0009 2520 The stapler unit is shifted by the stapler shift motor M105 The home position is detected by the stapler shift home position sensor PI110 When there is a staple command from the host machine the stapler shifts to the staple ready position which depends on the stapling position and paper size The stapler unit waits at the following points when staple mode is...

Page 76: ...ear 1 Point Stapling The position is the same as the stapling position F 2 65 Front aligning plate Stopper Stapling position Wait position Feeding direction Rear aligning plate Front aligning plate Stopper Stapling position Wait position Feeding direction Rear aligning plate ...

Page 77: ...I110 The stapler unit is equipped with a stapler alignment interference sensor PI116 The staple motor M111 operation is prohibited when the stapler alignment interference sensor PI116 is ON This is to prevent stapling at the stopper and damaging the stopper when the stapler shift motor M105 is incorrectly adjusted When the power is turned on the finisher controller PCB drives the stapler shift mot...

Page 78: ...Symbol Connector Function Remark s Stapler shift home position sensor PI110 J721A 15 Detects the home position for the stapler moving back and forth Front diagonal stapling Rear diagonal stapling 2 point stapling Paper width 1 2 ...

Page 79: ...hen the swing guide home position sensor PI105 detects the rising of the swing guide the swing guide motor stops and holds the swing guide at the raised position After the processing tray paper sensor detects the paper the aligning motor M103 M104 starts and aligns the paper Stapler alignment interference sensor PI116 J720 3 Staple prohibited area detection Staple home position sensor PI50 J720 5 ...

Page 80: ...ler clutch CL102 is disengaged The paper in the processing tray is detected by the processing tray paper sensor PI108 When the paper is delivered to the processing tray the swing motor M106 starts and raises the swing guide When the swing guide home position sensor PI105 detects the rising of the swing guide the swing guide motor stops and holds the swing guide at the raised position Return roller...

Page 81: ...owers the swing guide Then the stack is ejected by the stack delivery roller return roller and rear endassist guide F 2 72 2 4 5 Stitcher Unit 0009 2552 The stitcher base unit consists of two stitchers and stitcher bases The stitchers are fixed in position and are not designed to slide or swing Stitching is executed by driving the rotary cam by the stitcher motor M7 M6 The front and rear stitcher ...

Page 82: ... sensor SW6 SW4 The alignment plates keep both edges of the stack in place while stitching takes place F 2 73 F 2 74 F 2 75 2 4 6 Stitching Operation 0009 2553 To enable stitching at two locations on a stack two stitcher units front rear are used Each stitcher unit is equipped with a stitcher motor M7 M6 for drive a stitcher home position sensor SW7 SW5 for detection of position and Stitcher home ...

Page 83: ...ddle stitcher for replacement of the staple cartridge or removal of a staple jam The stitcher unit in sensor PI16 is used to make sure that the stitcher base is properly fitted to the saddle stitcher Safety switches are not mounted for the stitcher unit front rear as the location does not allow access by the user F 2 76 Stitcher rear Stitcher front Stack ...

Page 84: ...ts are stacked in tray 2 When the power is turned on the finisher controller PCB drives the tray 1 shift motor M107 and tray 2 shift motor M108 to return the tray 1 and tray 2 to their home positions If either tray is already at the home position it is moved out of the home position once and then returned to the home position again If both tray 1 and tray 2 are at their home positions this operati...

Page 85: ...itch MSW103 Tray 1 shift motor M107 Rack Tray 1 shift area sensor PCB Tray 2 shift area sensor PCB Tray 1 paper surface sensor PI111 Tray 2 paper surface sensor PI112 Rack Light shielding plate Tray 2 shift motor M108 ...

Page 86: ... ON ON ON Detected items Tray 2 shift area sensor PCB Area sensor 1 PS983 Area sensor 2 PS982 Area sensor 3 PS981 Tray 2 upper limit OFF ON OFF Stack count 650 sheet limit exceeded ON OFF OFF Stack count 1700 sheet limit exceeded ON ON ON Stack count 2450 sheet limit exceeded OFF ON ON Tray 1 Tray 1 paper surface sensor PI114 Edge Tray 2 Tray 2 paper surface sensor 2 PI120 Edge Paper surface senso...

Page 87: ...en the shutter clutch CL101 and stack ejection lower roller clutch CL102 are ON the shutter moves up close when the stack ejection motor M102 turns forward and moves down open delivery enabled when the motor turns backward The open close of the shutter is detected by the shutter home position sensor PI113 F 2 79 Tray 2 lower limit finisher ON OFF ON Tray 2 lower limit saddle finisher OFF OFF ON De...

Page 88: ...sence of a jam When all doors are closed after the paper jam is removed the finisher checks whether paper is detected by the above three sensors inlet sensor and tray 1 delivery sensor If the sensors detect paper the finisher determines that paper jam is not completely removed and sends a jam removal signal to the host machine once more F 2 80 T 2 11 Jam Type Sensor Jam Condition Code Inlet sensor...

Page 89: ...s elapsed since this sensor detected paper 1103 Timing When the tray 1 or tray 2 loading position has not been changed at reception of a delivery signal from the host machine or when the reception interval of the delivery signal from the host machine is shorter than the paper processing time by 150 ms or more 1200 Staple PI50 When the staple motor M1111 is rotated forward the staple home position ...

Page 90: ...the vertical path paper sensor PI17 has detected the presence of paper If the sensor has detected paper the unit will identify the condition as being faulty jam removal and send the jam signal to the host machine once again F 2 81 T 2 12 No Sensor PI11 Delivery sensor PI17 Vertical path paper sensor PI18 No 1 paper sensor PI19 No 2 paper sensor PI20 No 3 paper sensor PI22 Saddle inlet sensor PI19 ...

Page 91: ...he feed motor M1 after the 1st paper sensor PI18 has detected the leading edge of the paper 17A1 Delivery delay PI11 When delivery sensor PI11 cannot detect the paper after feeding the stack for a prescribed amount with the paper folding motor M2 after completing paper pushing motion with the paper pushing plate 1792 Delivery stationary PI11 PI17 When stack does not exit the delivery sensor PI11 a...

Page 92: ...ivery sensor PI11 paper positioning plate paper sensor PI8 or saddle inlet sensor PI22 during power ON 1787 Door open PI3 PI9 PI102 When the delivery cover sensor PI13 or inlet cover sensor PI19 detects that the cover is opened during operation When the front cover sensor PI102 detects cover open with paper present on the processing tray while the device is not operating 1788 Jam Type Sensor Jam C...

Page 93: ...stalled they are supplied to the punch controller PCB as well 24VDC for specific motor drives is cut off when the front cover switch MSW101 is open This is not applied to the optional puncher unit and some other motors A block diagram of power supply is shown below F 2 82 2 7 2 Protection Function Finisher Unit 0009 2556 The 24 VDC for motor and solenoid drive has a fuse or motor driver with over ...

Page 94: ...ed into 3 3 VDC by the regulator IC IC10 on the saddle stitcher controller PCB and then used to drive the ICs on the PCB F 2 83 2 7 4 Protection Function Saddle Stitcher Unit 0009 2558 The 24 VDC power supply used for motors and solenoids is equipped with a circuit breaker CB1 The 24V power supply used to drive the guide motor M3 alignment motor M5 and the paper positioning plate motor M4 is equip...

Page 95: ...Chapter 3 Parts Replacement Procedure ...

Page 96: ......

Page 97: ...de Upper Cover 3 10 3 1 5 1 Removing the Front Door 3 10 3 1 5 2 Removing the Escape Tray Cover 3 11 3 1 5 3 Removing the Front Inside Upper Cover 3 11 3 1 6 Front Inside Lower Cover 3 12 3 1 6 1 Removing the Front Door 3 12 3 1 6 2 Removing the Escape Tray Cover 3 12 3 1 6 3 Removing the Front Inside Upper Cover 3 13 3 1 6 4 Removing the Front Inside Lower Cover 3 13 3 1 7 PCB Cover 3 14 3 1 7 1 ...

Page 98: ...3 14 Removing the Saddle Unit 3 43 3 2 4 Stitcher Mount Unit 3 45 3 2 4 1 Removing the Front Door 3 45 3 2 4 2 Removing the Escape Tray Cover 3 45 3 2 4 3 Removing the Front Inside Upper Cover 3 46 3 2 4 4 Removing the Front Inside Lower Cover 3 46 3 2 4 5 Removing the Stitcher Mount Unit 3 47 3 2 5 Positioning Plate Unit 3 47 3 2 5 1 Removing the Front Door 3 47 3 2 5 2 Removing the Rear Upper Co...

Page 99: ...3 3 5 4 Removing the Front Inside Upper Cover 3 76 3 3 5 5 Removing the Grate shaped Upper Guide 3 77 3 3 5 6 Removing the Tray 1 3 77 3 3 5 7 Removing the Tray 2 3 80 3 3 5 8 Removing the Grate shaped Lower Guide 3 82 3 3 5 9 Removing the Processing Tray 3 82 3 3 5 10 Removing the Return Roller 3 85 3 3 6 Return Roller Unit 3 86 3 3 6 1 Removing the Front Door 3 86 3 3 6 2 Removing the Rear Upper...

Page 100: ...oor 3 121 3 3 10 2 Removing the Rear Upper Cover 3 121 3 3 10 3 Removing the Rear Lower Cover 3 122 3 3 10 4 Removing the Escape Tray Cover 3 122 3 3 10 5 Removing the Front Inside Upper Cover 3 123 3 3 10 6 Removing the Escape Unit 3 123 3 3 11 Escape Door Unit 3 125 3 3 11 1 Removing the Front Door 3 125 3 3 11 2 Removing the Rear Upper Cover 3 126 3 3 11 3 Removing the Escape Tray Cover 3 126 3...

Page 101: ...the Escape Tray Cover 3 142 3 4 3 3 Removing the Inlet Static Charge Eliminator 3 142 3 4 4 Static Charge Eliminator 3 3 143 3 4 4 1 Removing the Escape Door 3 143 3 4 4 2 Removing the Escape Delivery Static Charge Eliminator 3 143 3 4 5 Saddle Stitcher Controller PCB 3 144 3 4 5 1 Removing the PCB Cover 3 144 3 4 5 2 Removing the Saddle Stitcher Controller PCB 3 144 ...

Page 102: ......

Page 103: ...ng the Rear Upper Cover 0009 3555 1 Remove four screws 1 and remove the rear upper cover 2 F 3 2 3 1 3 Grate shaped Upper Guide 3 1 3 1 Removing the Front Door 0009 4444 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 3 3 1 3 2 Removing the Escape Tray Cover 0009 4406 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 1 2 1 1 2...

Page 104: ...per guide 2 F 3 5 3 1 4 Grate shaped Lower Guide 3 1 4 1 Removing the Front Door 0009 4445 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 6 3 1 4 2 Removing the Rear Upper Cover 0009 3619 1 Remove four screws 1 and remove the rear upper cover 2 F 3 7 3 1 4 3 Removing the Escape Tray Cover 0009 4410 1 Remove four screws 1 open the escape door 2 and then remove t...

Page 105: ...teps under Removing the Tray 1 2 Remove five screws 3 and remove the grate shaped upper guide 2 F 3 10 3 1 4 6 Removing the Tray 1 0009 3624 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your han...

Page 106: ...ase from shifting due to the front and rear rails the tray must be attached horizontally Lower the tray 1 to the position shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 16 3 1 4 7 Remo...

Page 107: ...ect the connector 2 F 3 19 3 Lift tray 2 1 to remove it F 3 20 When installing the tray be careful not to twist the tray cable To prevent the gear phase from shifting due to the front and rear rails the tray must be attached horizontally Lower the tray 1 to the position shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front an...

Page 108: ...ped lower guide to the sensor flag arm on the delivery side F 3 22 3 1 5 Front Inside Upper Cover 3 1 5 1 Removing the Front Door 0009 4447 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 23 3 1 5 2 Removing the Escape Tray Cover 0009 4411 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 24 1 3 2 1 1 1 2 1 2 2 1 3 1 ...

Page 109: ...t door 1 to remove F 3 26 3 1 6 2 Removing the Escape Tray Cover 0009 4412 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 27 3 1 6 3 Removing the Front Inside Upper Cover 0009 3565 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 F 3 28 3 1 6 4 Removing the Front Inside Lower Cover 0009 3561 1 Remove screw 1 and...

Page 110: ...e Front Door 0009 4443 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 31 3 1 9 Escape Tray Cover 3 1 9 1 Removing the Escape Tray Cover 0009 4402 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 32 3 1 10 Escape Door 3 1 10 1 Removingh the Escape Door 0009 4397 1 Open the front door 3 1 2 3 4 7 1 1 2 2 1 3 1 ...

Page 111: ...2 Remove two screws 1 and remove the escape door 2 F 3 33 2 1 ...

Page 112: ...ay cover 3 F 3 35 3 2 1 3 Removing the Front Inside Upper Cover 0009 3634 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 F 3 36 3 2 1 4 Removing the Stapler 0009 3631 1 Pull out the stapler remove screw 1 and remove the PCB cover 2 F 3 37 2 Release the claw 1 and remove the PCB 2 3 Disconnect three connectors 3 4 Remove screw 4 and remove the stapler t...

Page 113: ...the Front Door 0009 4450 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 40 3 2 2 2 Removing the Rear Upper Cover 0009 3662 1 Remove four screws 1 and remove the rear upper cover 2 F 3 41 3 2 2 3 Removing the Escape Tray Cover 0009 4415 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 3 6 4 2 1 5 2 1 1 2 1 2 1 ...

Page 114: ... steps under Removing the Tray 1 2 Remove five screws 3 and remove the grate shaped upper guide 2 F 3 44 3 2 2 6 Removing the Tray 1 0009 3666 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your h...

Page 115: ...hase from shifting due to the front and rear rails the tray must be attached horizontally Lower the tray 1 to the position shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 50 3 2 2 7 Rem...

Page 116: ...ect the connector 2 F 3 53 3 Lift tray 2 1 to remove it F 3 54 When installing the tray be careful not to twist the tray cable To prevent the gear phase from shifting due to the front and rear rails the tray must be attached horizontally Lower the tray 1 to the position shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front an...

Page 117: ...flag 3 from the stack delivery roller 2 Hold the snap fastener at the base when unfastening because the sensor flag arm can break easily When fastening insert the boss of the sensor flag snap fastener in the hole on the processing tray side F 3 57 2 Remove the stack delivery roller front side E ring 1 gear 2 parallel pin 3 E ring 4 washer 5 and bearing 6 The parallel pin 3 drops when the gear 2 is...

Page 118: ...1 and remove harness from the clamp and edge saddle 2 8 Remove two screws 3 and pull out the processing tray 4 in the paper delivery direction When removing parts inside the processing tray be careful not to exert force on the aligning plate front rear or the rear end stopper plate F 3 61 3 2 2 10 Removing the Swing Unit 0009 3658 1 Remove two screws 1 and remove the solenoid cover 2 F 3 62 2 Remo...

Page 119: ...wing pressure rack 3 from the swing unit center hook F 3 64 5 Remove the belt 1 from the gear 2 remove the belt 3 from the gear 2 and gear 4 and pull out the swing unit 5 from the delivery direction F 3 65 3 2 3 Saddle Unit 3 2 3 1 Removing the Front Door 0009 4451 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 66 3 1 2 1 2 5 4 3 1 2 1 2 ...

Page 120: ... Tray Cover 0009 4416 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 69 3 2 3 5 Removing the Front Inside Upper Cover 0009 3769 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 F 3 70 3 2 3 6 Removing the Front Inside Lower Cover 0009 3770 1 Remove screw 1 and then remove the roller knob 2 2 Remove four screws 3...

Page 121: ...oving the Tray 1 0009 3772 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 73 1 Remove the screw 1 and remove the stopper 2 at the front F 3 74 2 Remove the ...

Page 122: ...ter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 78 3 2 3 9 Removing the Tray 2 0009 3773 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch H...

Page 123: ...sition shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 83 3 2 3 10 Removing the Grate shaped Lower Guide 0009 3774 1 Remove ten screws 1 and remove the grate shaped lower guide 2 When r...

Page 124: ...ray unit F 3 85 2 Remove the door axis 1 in the direction of the arrow and pull out the saddle delivery tray unit 2 toward the front F 3 86 3 Remove the harness from two clamps 1 4 Remove two connectors 2 and remove the saddle delivery tray unit 3 F 3 87 3 2 3 12 Removing the PCB Cover 0009 3776 1 Remove seven screws 1 and remove the PCB cover 2 1 1 1 2 1 2 1 2 2 1 3 ...

Page 125: ...two clamps 2 and harness guide F 3 89 2 Remove the spring 1 and three screws 2 and remove the saddle belt cover 3 F 3 90 3 Remove five screws 1 at the back of the escape unit F 3 91 4 Remove three screws 1 at the front of the escape unit F 3 92 5 Lift the escape unit 1 slightly and remove it 7 1 2 1 1 1 2 1 2 3 2 1 1 1 1 1 1 ...

Page 126: ... Disconnect two connectors 1 and remove the harness from three clamps 2 F 3 94 2 Remove two screws 1 F 3 95 3 Remove the screw 1 F 3 96 4 Open the saddle door 1 and remove two screws 2 F 3 97 5 Remove the saddle unit 1 from the paper feeding side F 3 98 1 1 2 1 1 1 2 1 ...

Page 127: ...r Mount Unit 3 2 4 1 Removing the Front Door 0009 4452 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 100 3 2 4 2 Removing the Escape Tray Cover 0009 4417 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 101 3 2 4 3 Removing the Front Inside Upper Cover 0009 4154 1 Remove four screws 1 open the escape door 2 and then rem...

Page 128: ...inside lower cover 4 F 3 103 3 2 4 5 Removing the Stitcher Mount Unit 0009 4151 1 Remove the E ring 1 shaft 2 and roller 3 F 3 104 2 Pull out the stitcher mount unit 1 to the front F 3 105 3 2 5 Positioning Plate Unit 3 2 5 1 Removing the Front Door 0009 4453 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 106 1 3 2 3 1 2 3 4 1 3 2 1 1 2 ...

Page 129: ... Tray Cover 0009 4418 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 109 3 2 5 5 Removing the Front Inside Upper Cover 0009 4131 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 F 3 110 3 2 5 6 Removing the Front Inside Lower Cover 0009 4132 1 Remove screw 1 and then remove the roller knob 2 2 Remove four screws...

Page 130: ...d four screws 2 and remove the saddle stitcher controller PCB 3 F 3 113 3 2 5 9 Removing the Positioning Plate Unit 0009 4125 1 Disconnect two connectors 1 and remove the harness from the two edge saddles 2 and two clamps 3 F 3 114 2 Disconnect two connectors 1 and remove the harnesses from five edge saddles 2 3 Remove three screws 3 and remove the paper folding pushing motor base 4 3 1 2 3 4 7 1 ...

Page 131: ...le harness of the stay need not be removed F 3 116 5 Disconnect two connectors 1 and remove the harness 2 from two clamps 3 6 Remove two screws 4 shift the positioning plate unit 5 forward once and then pull it out from the paper feeding side F 3 117 1 2 3 3 2 4 1 1 2 1 3 2 1 4 4 5 ...

Page 132: ...moving the Rear Upper Cover 0009 3646 1 Remove four screws 1 and remove the rear upper cover 2 F 3 119 3 3 1 3 Removing the Escape Tray Cover 0009 4419 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 120 3 3 1 4 Removing the Front Inside Upper Cover 0009 3648 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 1 2 1...

Page 133: ...moving the Tray 1 0009 3652 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 123 1 Remove the screw 1 and remove the stopper 2 at the front F 3 124 2 Remove t...

Page 134: ...ter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 128 3 3 1 7 Removing the Tray 2 0009 3653 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch ...

Page 135: ...osition shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 133 3 3 1 8 Removing the Grate shaped Lower Guide 0009 3654 1 Remove ten screws 1 and remove the grate shaped lower guide 2 When ...

Page 136: ...35 2 Remove the stack delivery roller front side E ring 1 gear 2 parallel pin 3 E ring 4 washer 5 and bearing 6 The parallel pin 3 drops when the gear 2 is removed Be careful not to loose it F 3 136 3 Remove all finisher controller PCB connectors 1 and remove the harness from two clamp 2 4 Remove four screws 3 and remove the finisher controller PCB 4 F 3 137 5 Release the claw 1 of the stack deliv...

Page 137: ...igning plate front rear or the rear end stopper plate F 3 139 3 3 2 Tray 1 3 3 2 1 Removing the Front Door 0009 4456 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 140 3 3 2 2 Removing the Rear Upper Cover 0009 3586 1 Remove four screws 1 and remove the rear upper cover 2 F 3 141 3 3 2 3 Removing the Escape Tray Cover 0009 4426 1 Remove four screws 1 open the e...

Page 138: ...oving the Tray 1 0009 3577 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 144 1 Remove the screw 1 and remove the stopper 2 at the front F 3 145 2 Remove th...

Page 139: ...osition shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 149 3 3 3 Tray 2 3 3 3 1 Removing the Front Door 0009 4457 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 ...

Page 140: ...er Guide 0009 3615 1 Lower tray 1 below the grate shaped upper guide 2 For how the tray is moved see the steps under Removing the Tray 1 2 Remove five screws 3 and remove the grate shaped upper guide 2 F 3 154 3 3 3 6 Removing the Tray 1 0009 3595 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch Ho...

Page 141: ...en installing the tray be careful not to twist the tray cable To prevent the gear phase from shifting due to the front and rear rails the tray must be attached horizontally Lower the tray 1 to the position shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their h...

Page 142: ...e to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 161 1 Remove screw 1 and remove the stopper 2 F 3 162 2 Remove the screw 1 and disconnect the connector 2 F 3 163 3 Lift tray 2 1 to remove it F 3 164 When installing the tray be careful not to twist the 1 3 2 2 1 1 2 2 1 1 ...

Page 143: ...ntally If their heights are not the same remove the tray and then attach it again F 3 165 3 3 4 Buffer Roller 3 3 4 1 Removing the Front Door 0009 4458 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 166 3 3 4 2 Removing the Escape Tray Cover 0009 4428 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 167 3 3 4 3 Removing ...

Page 144: ...r Cover 0009 3711 1 Remove four screws 1 and remove the rear upper cover 2 F 3 170 3 3 5 3 Removing the Escape Tray Cover 0009 4429 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 171 3 3 5 4 Removing the Front Inside Upper Cover 0009 3713 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 1 3 1 3 2 4 1 2 1 2 1 2 1...

Page 145: ...moving the Tray 1 0009 3715 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 174 1 Remove the screw 1 and remove the stopper 2 at the front F 3 175 2 Remove t...

Page 146: ...ter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 179 3 3 5 7 Removing the Tray 2 0009 3716 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch ...

Page 147: ...osition shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 184 3 3 5 8 Removing the Grate shaped Lower Guide 0009 3718 1 Remove ten screws 1 and remove the grate shaped lower guide 2 When ...

Page 148: ...86 2 Remove the stack delivery roller front side E ring 1 gear 2 parallel pin 3 E ring 4 washer 5 and bearing 6 The parallel pin 3 drops when the gear 2 is removed Be careful not to loose it F 3 187 3 Remove all finisher controller PCB connectors 1 and remove the harness from two clamp 2 4 Remove four screws 3 and remove the finisher controller PCB 4 F 3 188 5 Release the claw 1 of the stack deliv...

Page 149: ...n the return roller Cleaning with water for example will increase its feed power ultimately causing feeding faults Moreover be sure to avoid touching the surface of the return roller when mounting it to the machine 1 Remove two clips 1 of the return roller axis 2 Pull out the return roller axis and remove two return rollers 2 together with collar 3 Separate the return roller and collar Note the di...

Page 150: ...he escape tray cover 3 F 3 194 3 3 6 4 Removing the Front Inside Upper Cover 0009 3687 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 F 3 195 3 3 6 5 Removing the Grate shaped Upper Guide 0009 3688 1 Lower tray 1 below the grate shaped upper guide 2 For how the tray is moved see the steps under Removing the Tray 1 2 Remove five screws 3 and remove the ...

Page 151: ...hen the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 197 1 Remove the screw 1 and remove the stopper 2 at the front F 3 198 2 Remove the screw 1 and remove the stopper 2 at the back F 3 199 3 Remove two screws 1 open three harness retainers 2 and disconnect two connectors 3 F 3 200 4 Lift tray 1 1 to remove it 3 3 2 1 2...

Page 152: ...ck that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 202 3 3 6 7 Removing the Tray 2 0009 3690 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold ...

Page 153: ...h those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 207 3 3 6 8 Removing the Grate shaped Lower Guide 0009 3691 1 Remove ten screws 1 and remove the grate shaped lower guide 2 When replacing be careful not to hook the grate shaped lower guide to the sensor flag arm on ...

Page 154: ...ase F 3 211 3 3 6 10 Removing the Processing Tray 0009 3693 1 Unfasten four snap fasteners 1 and remove the sensor flag 3 from the stack delivery roller 2 Hold the snap fastener at the base when unfastening because the sensor flag arm can break easily When fastening insert the boss of the sensor flag snap fastener in the hole on the processing tray side F 3 212 2 Remove the stack delivery roller f...

Page 155: ...ng 3 washer 4 and bearing 5 and remove the stack delivery roller F 3 215 7 Disconnect two connectors 1 and remove harness from the clamp and edge saddle 2 8 Remove two screws 3 and pull out the processing tray 4 in the paper delivery direction When removing parts inside the processing tray be careful not to exert force on the aligning plate front rear or the rear end stopper plate F 3 216 3 3 6 11...

Page 156: ...unit and the return roller unit and then slide the two return roller unit collars 2 inside 4 Unhook the swing pressure rack 3 from the swing unit center hook F 3 219 5 Remove the belt 1 from the gear 2 remove the belt 3 from the gear 2 and gear 4 and pull out the swing unit 5 from the delivery direction F 3 220 2 1 1 2 1 3 1 2 1 2 5 4 3 1 2 ...

Page 157: ... Tray Unit 0009 3751 1 Lift the saddle delivery tray unit 1 open close lever 2 and open the saddle delivery tray unit F 3 222 2 Remove the door axis 1 in the direction of the arrow and pull out the saddle delivery tray unit 2 toward the front F 3 223 3 Remove the harness from two clamps 1 4 Remove two connectors 2 and remove the saddle delivery tray unit 3 F 3 224 3 3 8 Upper Delivery Guide 3 3 8 ...

Page 158: ...he escape tray cover 3 F 3 227 3 3 8 4 Removing the Front Inside Upper Cover 0009 4092 1 Remove four screws 1 open the escape door 2 and then remove the front inside upper cover 3 F 3 228 3 3 8 5 Removing the Grate shaped Upper Guide 0009 4093 1 Lower tray 1 below the grate shaped upper guide 2 For how the tray is moved see the steps under Removing the Tray 1 2 Remove five screws 3 and remove the ...

Page 159: ...hen the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 230 1 Remove the screw 1 and remove the stopper 2 at the front F 3 231 2 Remove the screw 1 and remove the stopper 2 at the back F 3 232 3 Remove two screws 1 open three harness retainers 2 and disconnect two connectors 3 F 3 233 4 Lift tray 1 1 to remove it 3 3 2 1 2...

Page 160: ...ck that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 235 3 3 8 7 Removing the Tray 2 0009 4095 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold ...

Page 161: ...e tray projections 3 at the front and rear to check that the tray is attached horizontally If their heights are not the same remove the tray and then attach it again F 3 240 3 3 8 8 Removing the Grate shaped Lower Guide 0009 4096 1 Remove ten screws 1 and remove the grate shaped lower guide 2 When replacing be careful not to hook the grate shaped lower guide to the sensor flag arm on the delivery ...

Page 162: ...3 3 9 2 Removing the Rear Upper Cover 0009 4099 1 Remove four screws 1 and remove the rear upper cover 2 F 3 244 3 3 9 3 Removing the Rear Lower Cover 0009 4100 1 Remove four screws 1 and remove the rear lower cover 2 F 3 245 3 3 9 4 Removing the Escape Tray Cover 0009 4439 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 1 2 3 1 2 1 2 1 1 2 1 ...

Page 163: ...Grate shaped Upper Guide 0009 4105 1 Lower tray 1 below the grate shaped upper guide 2 For how the tray is moved see the steps under Removing the Tray 1 2 Remove five screws 3 and remove the grate shaped upper guide 2 F 3 249 3 3 9 8 Removing the Tray 1 0009 4106 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to relea...

Page 164: ...en installing the tray be careful not to twist the tray cable To prevent the gear phase from shifting due to the front and rear rails the tray must be attached horizontally Lower the tray 1 to the position shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their h...

Page 165: ...e to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 256 1 Remove screw 1 and remove the stopper 2 F 3 257 2 Remove the screw 1 and disconnect the connector 2 F 3 258 3 Lift tray 2 1 to remove it F 3 259 When installing the tray be careful not to twist the 1 3 2 2 1 1 2 2 1 1 ...

Page 166: ...heights are not the same remove the tray and then attach it again F 3 260 3 3 9 10 Removing the Grate shaped Lower Guide 0009 4108 1 Remove ten screws 1 and remove the grate shaped lower guide 2 When replacing be careful not to hook the grate shaped lower guide to the sensor flag arm on the delivery side F 3 261 3 3 9 11 Removing the Upper Delivery Guide 0009 4109 1 Remove two screws 1 and ground ...

Page 167: ...the harness from five edge saddles 2 3 Remove three screws 3 and remove the paper folding paper pushing motor base 4 F 3 265 4 Remove the screw 1 remove the spring retaining plate 2 and remove the front tension spring 3 and the smaller tension spring 4 F 3 266 5 Remove the screw 1 remove the spring retaining plate 2 and remove the rear tension spring 3 and the smaller tension spring 4 7 1 3 1 2 1 ...

Page 168: ...emove the two bearings 1 F 3 270 9 Open the saddle delivery tray 1 10 Remove two screws 2 and remove the two aligning plates 3 11 Slide the two paper folding rollers 4 to the front and then pull it out in the delivery direction F 3 271 When installing attach the gear 2 so that the grooves 1 of the paper folding rollers face each other and align the phase F 3 272 4 3 1 2 3 1 2 2 1 1 1 3 2 2 4 1 2 ...

Page 169: ...ar upper cover 2 F 3 274 3 3 10 3 Removing the Rear Lower Cover 0009 4481 1 Remove four screws 1 and remove the rear lower cover 2 F 3 275 3 3 10 4 Removing the Escape Tray Cover 0009 4482 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 276 3 3 10 5 Removing the Front Inside Upper Cover 0009 4483 1 Remove four screws 1 open the escape door 2 and then remov...

Page 170: ... clamps 2 and harness guide F 3 278 2 Remove the spring 1 and three screws 2 and remove the saddle belt cover 3 F 3 279 3 Remove five screws 1 at the back of the escape unit F 3 280 4 Remove three screws 1 at the front of the escape unit F 3 281 5 Lift the escape unit 1 slightly and remove it 1 3 2 2 1 1 1 2 1 2 3 2 1 1 1 1 1 1 ...

Page 171: ...2 Removing the Rear Upper Cover 0009 4472 1 Remove four screws 1 and remove the rear upper cover 2 F 3 284 3 3 11 3 Removing the Escape Tray Cover 0009 4473 1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 285 3 3 11 4 Removing the Escape Door 0009 4474 1 Open the front door 2 Remove two screws 1 and remove the escape door 2 1 1 2 1 2 1 2 1 3 1 ...

Page 172: ...e Door Unit 0009 4477 1 Remove two E rings 1 2 Remove screw and remove the escape unit support plate 3 3 Open the escape door unit 4 and remove the escape door unit F 3 287 Do not remove the two screws 1 securing escape door shaft F 3 288 2 1 1 3 2 4 1 ...

Page 173: ...Controller PCB 0009 4159 1 Disconnect all connectors 1 on the finisher controller PCB 2 Remove four screws 2 and remove the finisher controller PCB 3 F 3 290 3 4 2 Static Charge Eliminator 1 3 4 2 1 Removing the Front Door 0009 4467 1 Open the front door 1 and remove the clip 2 2 Lift the front door 1 to remove F 3 291 3 4 2 2 Removing the Rear Upper Cover 0009 3700 1 Remove four screws 1 and remo...

Page 174: ...er Guide 0009 3703 1 Lower tray 1 below the grate shaped upper guide 2 For how the tray is moved see the steps under Removing the Tray 1 2 Remove five screws 3 and remove the grate shaped upper guide 2 F 3 295 3 4 2 6 Removing the Tray 1 0009 3704 When moving the tray down to attach it you need to push the tray lift motor gear 1 to the front using a screwdriver or the like to release the clutch Ho...

Page 175: ...en installing the tray be careful not to twist the tray cable To prevent the gear phase from shifting due to the front and rear rails the tray must be attached horizontally Lower the tray 1 to the position shown in the figure and compare the heights of the shutter guide top edges 2 with those of the tray projections 3 at the front and rear to check that the tray is attached horizontally If their h...

Page 176: ...e to release the clutch However when the clutch is released the tray 2 drops by its own weight Be sure to hold the tray with your hand when releasing the clutch F 3 302 1 Remove screw 1 and remove the stopper 2 F 3 303 2 Remove the screw 1 and disconnect the connector 2 F 3 304 3 Lift tray 2 1 to remove it F 3 305 When installing the tray be careful not to twist the 1 3 2 2 1 1 2 2 1 1 ...

Page 177: ...ray and then attach it again F 3 306 3 4 2 8 Removing the Grate shaped Lower Guide 0009 3706 1 Remove ten screws 1 and remove the grate shaped lower guide 2 When replacing be careful not to hook the grate shaped lower guide to the sensor flag arm on the delivery side F 3 307 3 4 2 9 Removing the Stapler 0009 3707 1 Pull out the stapler remove screw 1 and remove the PCB cover 2 F 3 308 2 Release th...

Page 178: ...g because the sensor flag arm can break easily When fastening insert the boss of the sensor flag snap fastener in the hole on the processing tray side F 3 311 2 Remove the stack delivery roller front side E ring 1 gear 2 parallel pin 3 E ring 4 washer 5 and bearing 6 The parallel pin 3 drops when the gear 2 is removed Be careful not to loose it F 3 312 3 Remove all finisher controller PCB connecto...

Page 179: ...sing tray be careful not to exert force on the aligning plate front rear or the rear end stopper plate F 3 315 3 4 2 11 Removing the Swing Unit Static Charge Eliminator 0009 3697 1 Remove the screw 1 securing the static charge eliminator at the center of the swing unit 2 Remove two screws 2 securing the ground of the delivery side static charge eliminator F 3 316 3 Pull out the static charge elimi...

Page 180: ...1 Remove four screws 1 open the escape door 2 and then remove the escape tray cover 3 F 3 319 3 4 3 3 Removing the Inlet Static Charge Eliminator 0009 4161 1 Remove three screws 1 open the delivery door 2 and remove the inlet static charge eliminator 3 F 3 320 3 4 4 Static Charge Eliminator 3 3 4 4 1 Removing the Escape Door 0009 4400 1 Open the front door 2 Remove two screws 1 and remove the esca...

Page 181: ...static charge eliminator 2 is mounted When mounting the escape delivery static charge eliminator 2 insert it in the lateral direction F 3 323 3 4 5 Saddle Stitcher Controller PCB 3 4 5 1 Removing the PCB Cover 0009 4124 1 Remove seven screws 1 and remove the PCB cover 2 F 3 324 3 4 5 2 Removing the Saddle Stitcher Controller PCB 0009 4123 1 Remove the all connectors 1 and four screws 2 and remove ...

Page 182: ...F 3 325 2 1 3 2 2 ...

Page 183: ...Chapter 4 Maintenance ...

Page 184: ......

Page 185: ...le Delivery Tray Limitless Mode 4 9 4 3 2 Adjustment at Time of Parts Replacement 4 9 4 3 2 1 Adjusting the Alignment Position 4 9 4 3 2 2 Adjusting the Staple Position 4 10 4 3 2 3 Adjusting the Folding Position 4 11 4 3 2 4 Adjusting the Stitching Position adjusting center stitching 4 14 4 3 2 5 Adjusting the Stitcher Unit 4 14 4 4 Troubleshooting 4 17 4 4 1 Error Code 4 17 4 4 1 1 E500 Communic...

Page 186: ... 5 4 Motors Finisher Unit 4 29 4 5 5 Clutches Finisher Unit 4 31 4 5 6 PCBs Finisher Unit 4 32 4 5 7 Sensors Saddle Stitcher Unit 4 33 4 5 8 Microswitches saddle Stitcher Unit 4 35 4 5 9 Motors Saddle Stitcher Unit 4 37 4 5 10 Solenoids Saddle Stitcher Unit 4 38 4 5 11 PCBs Saddle Stitcher Unit 4 39 4 6 Variable Resistors VR Light Emitting Diodes LED and 4 40 4 6 1 Overview 4 40 4 6 2 Finisher Con...

Page 187: ...009 2559 T 4 1 4 1 2 User Maintenance Saddle Stitcher Unit 0009 2570 T 4 2 No Item Timing 1 Staple cartridge replacement When prompted indicator on host machine control panel No Item Timing 1 Staple cartridge replacement When prompted indicator on host machine control panel ...

Page 188: ...sis 4 2 2 Durables 4 2 2 1 Durables Finisher Unit 0009 2561 Some of the parts of the machine may need to be replaced one or more times because of wear or tear during the machine s warranty period Replace them as necessary T 4 3 As of November 2004 No Name No Quantit y Approx life Remark 1 Stapler FM2 0665 000 1 500 000 times 1 cartridge lasts approximately 5 000 times 2 Delibery static chargeelimi...

Page 189: ...3 2 Periodical Servicing Saddle Stitcher Unit 0009 2573 Does not have parts that must be serviced on a periodical basis 5 Swing guide inside static charge eliminator FL2 0817 000 1 1 000 000 sheets 6 Buffer roller FC5 3442 000 2 1 000 000 sheets 7 Return roller Rear FC5 3457 000 1 1 000 000 sheets Color White 8 Return roller Front FC5 6873 000 1 1 000 000 sheets Color Black As of November 2004 No ...

Page 190: ...ing When this mode item has been enabled changes in conditions e g the use of paper with little curl or paper with downward curl can cause improper stacking In this regard it is very important to study the type of paper that is most often used by the user before enabling this mode item 4 3 1 2 Special Curl Mode 0009 2564 a Outline If paper with irregular curl is deposited its edges can block the d...

Page 191: ...aper still develops downward curl and thus fails to deposit itself normally try enabling the downward curl mode item b Enabling the Downward Curl Mode 1 Turn off the host machine 2 Set the bits of SW104 on the finisher controller PCB as follows F 4 6 3 Turn on the host machine When this mode item is enabled the machine changes the speed of its stack delivery roller to ensure proper stacking When t...

Page 192: ...er can rain against the stacking wall and prevent the machine from stacking it correctly also causing it to prematurely detect an over stack condition see the following figure For instance in stack delivery mode other than when the stack consists of 6 or fewer sheets of small size paper F 4 9 If this is the case 1 Turn over the stack of paper inside the source e g cassette If doing so has made upw...

Page 193: ...is exceeded b Enabling the Saddle Delivery Tray Limitless Mode 1 Turn off the host machine 2 Set the bits of SW104 on the finisher controller PCB as follows F 4 12 3 Turn on the host machine When this mode has been enabled stacking can be continued even after the number of saddles that can be stacked is exceeded 4 3 2 Adjustment at Time of Parts Replacement 4 3 2 1 Adjusting the Alignment Position...

Page 194: ...er between the aligning plates and push it against the stopper push the far end edge of the paper to the rear aligning plate and press SW103 once stapling action store adjustment value and proceed to step 11 9 To adjust the staple position press SW101 or SW102 on the finisher controller PCB and adjust the staple position When SW101 is pressed staple position moves 0 49 mm forward When SW102 is pre...

Page 195: ...itching position and the folding position If the stitching position is below the folding position perform positive width adjustment If the stitching position is above the folding position perform negative width adjustment F 4 17 11 Change the settings of bits 6 through 8 on SW504 referring to the following table If the width adjustment is 0 The stitching position and the folding position match req...

Page 196: ...remove the stitcher cover 3 F 4 18 4 Remove the stitcher positioning tool 4 from the back of the cover F 4 19 5 To adjust the front stitcher remove the front guide plate 4 and center guide plate 6 To adjust the rear stitcher remove the center guide plate 6 and the rear guide plate 7 one screw each F 4 20 6 To adjust the front stitcher loosen the two screws 9 on the stitcher mount 8 To adjust the r...

Page 197: ...he tool 12 into the staple slot of the stitcher 11 F 4 22 8 Tilt the stitcher and turn the stitcher gear 13 to match the recess of the tool 14 and the mount 15 and then tighten the screws on the mount 15 to secure F 4 23 10 9 8 11 12 15 14 13 ...

Page 198: ...he host machine power switch is turned OFF ON YES End Wiring 2 Is the wiring between the finisher controller PCB and saddle stitcher controller PCB normal NO Repair the wiring Finisher controller PCB Saddle stitcher controller PCB 3 Does it improve when the finisher controller PCB and saddle stitcher controller PCB are replaced YES End 4 4 1 3 E505 Backup RAM error 0009 2589 Finisher controller PC...

Page 199: ...ing plate 3 Is there any mechanical trapping in the path of the aligning plate YES Repair the mechanism Front aligning plate motor M103 Finisher controller PCB 4 Does it improve when the front aligning plate motor is replaced YES End NO Replace the finisher controller PCB 4 4 1 6 E531 Staple motor error 0009 2592 Wiring 1 Is the wiring between the finisher controller PCB and stapler normal NO Repa...

Page 200: ...mal NO Repair the wiring Swing mechanism 3 Is there any abnormality in the swing machanism YES Repair the swing mechanism Swing motor M106 Finisher controller PCB 4 Does it improve when the swing motor is replaced YES End NO Replace the finisher controller PCB 4 4 1 9 E537 Rear aligning plate motor error 0009 2595 Rear aligning plate home position sensor PI107 1 Check the rear aligning plate home ...

Page 201: ...2600 Saddle delivery tray unit 1 Is the saddle delivery tray unit closed properly not closed on one side NO Properly close the saddle delivery tray unit Tray 2 paper surface sensor 1 PI115 Tray 2 paper surface sensor 2 PI120 2 Check the tray 2 paper surface sensor 1 and the tray 2 paper surface sensor 2 Does it operate normally NO Replace the sensor Tray 2 shift area sensor PCB 3 Check the tray 2 ...

Page 202: ...Is the sensor normal NO Replace sensor Positioning plate drive mechanism 2 Is there a problem with the positioning plate drive mechanism YES Repair the positioning plate drive mechanism Paper positioning plate motor M4 Saddle stitcher controller PCB 3 Is the problem solved by replacing the paper positioning plate motor YES Complete NO Replace saddle stitcher controller PCB 4 4 1 14 E5F1 Paper fold...

Page 203: ...drive mechamism Aligning motor M5 Saddle stitcher controller PCB 3 Does it improve when the aligning motor is replaced YES End NO Replace the saddle stitcher controller PCB 4 4 1 17 E5F4 Stitcher rear error 0009 2605 Installing the stitcher rear 1 Are the stitcher rear and mount installed properly NO Install them properly Stitcher home position sensor rear SW5 2 Check the stitcher home position sw...

Page 204: ...r the paper pushing plate drive mechanism Paper pushing plate motor M8 Saddle stitcher controller PCB 3 Does it improve when the paper pushing plate motor is replaced YES End NO Replace the saddle stitcher controller PCB 4 4 1 20 E5F9 Micro switch error 0009 2610 Front cover switch MSW101 Inlet door switch MSW1 Delivery door switch MSW3 1 Check the switches Do the switches operate normally NO Repl...

Page 205: ...7 Ref Name Description Parts No Jam Error PI10 2 Front cover sensor Detects front cover open close WG8 5593 1400 1788 PI10 3 Inlet sensor Detects paper in inlet WG8 5509 1001 1101 1200 1300 PI105 PI103 PI109 PI106 PI104 PI108 PI119 PI115 PI113 PI111 PI112 PI107 PI110 PI116 PI102 PI114 PI120 PI121 PI118 ...

Page 206: ... sensor Detects paper on tray 1 WG8 5593 PI11 2 Tray 2 paper sensor Detects paper on tray 2 WG8 5593 PI11 3 Shutter HP sensor Detects shutter HP WG8 5509 E584 PI11 4 Tray 1 paper surface sensor Detects paper surface on tray 1 WG8 5593 PI11 5 Tray 2 paper surface sensor 1 Detects paper surface on tray 2 WG8 5593 PI11 6 Stapler alignment interference sensor Detects stapler alignment interference WG8...

Page 207: ...2 J887 J886A J708B PI103 J712 PI104 J731 PI105 J731 PI106 J721B PI107 J721B PI108 J721B PI109 J721B PI110 J721A PI111 J718B PI112 J719B PI113 J721A PI114 J721A PI115 J721A PI116 J994 J993 J992 J991 J720 PI118 J887 J886A J708B PI119 J887 J886A J708B PI120 J721A PI121 J887 J886A J708B ...

Page 208: ...e Description Parts No Jam Error Finisher controller PCB MS W1 01 Front cover switch Detects front cover close FH7 6379 1400 E5F9 J707 MS W1 02 Swing guide switch Detects swing guide open FH7 6379 J714 MS W1 03 Tray 1 switch Detects tray 1 FH7 6377 J715 MSW103 MSW101 MSW102 MSW104 ...

Page 209: ... Detects swing guide open FH7 6379 J714 Ref Name Parts No Feed driver PCB Finisher controller PCB SL 101 Feed roller separation solenoid FL2 0811 J713 SL 102 Buffer roller separation solenoid FL2 0813 J713 Ref Name Description Parts No Jam Error Finisher controller PCB SL101 SL102 SL103 SL104 SL105 ...

Page 210: ...0812 J713 SL 104 Buffer rear end holding solenoid FL2 0821 J713 SL 105 Escape solenoid FH6 5089 J889 J881B J705B Ref Name Parts No Error M101 Feed motor FH5 1034 M102 Stack ejection motor 4K1 1106 E584 Ref Name Parts No Feed driver PCB Finisher controller PCB M101 M107 M106 M102 M109 M105 M108 M111 M104 M103 M113 M112 ...

Page 211: ...4K1 1102 E542 M109 Rear end assist motor FH5 1039 E514 M111 Stapler motor FM2 0665 E531 M112 Escape feed motor 4K1 1105 M113 Inlet motor FH5 1043 Ref Stapler PCB 2 Stapler PCB 1 Feed driver PCB Finisher controller PCB M101 J709 M102 J717 M103 J722 M104 J722 M105 J995 J993 J992 J991 J720 M106 J711 M107 J718A M108 J719A M109 J722 M111 J994 995 J993 J992 J991 J720 M112 J888 J886A J708A M113 J883 J881...

Page 212: ... 4 5 5 Clutches Finisher Unit 0009 2617 F 4 28 T 4 13 Ref Name Parts No Error Finisher controller PCB CL10 1 Shutter clutch FH6 5101 E584 J732 CL10 2 Stack ejection lower roller clutch FH6 5101 E584 J716 CL101 CL102 ...

Page 213: ...CB 4G1 1487 2 Stapler PCB 1 FM2 1426 CABLE STAPLE CONNECTING ASS Y E531 E532 3 Stapler PCB 2 FM2 1426 CABLE STAPLE CONNECTING ASS Y E531 E532 4 Feed driver PCB 4G1 1488 5 Tray 1 shift area sensor PCB FG3 2886 E540 6 Tray 2 shift area sensor PCB FG3 2886 E542 7 Tray 1 shift motor PCB 4K1 1102 E540 1 4 2 3 6 5 7 8 ...

Page 214: ...arts No Jam Error Saddle stitcher controller PCB PI1 Paper pushing plate motor clock sensor Detects paper pushing plate motor clock FK2 0149 E5F6 J11 PI3 Delivery cover sensor Detects delivery cover open WG8 5593 1788 J11 Ref Name Parts No Error PI4 PI3 PI18 PI22 PI19 PI20 PI1 PI11 PI9 PI21 PI8 PI7 PI6 PI13 PI12 PI5 PI14 PI15 PI16 PI17 ...

Page 215: ...17A2 1787 J9 PI12 Crescent roller phase sensor Detects crescent roller phase WG8 5593 J9 PI13 Guide HP sensor Detects guide HP WG8 5593 E5F2 J9 PI14 Paper pushing plate HP sensor Detects paper pushing plate HP WG8 5593 E5F6 J9 PI15 Paper pushing plate top position sensor Detects paper pushing plate top position WG8 5593 E5F6 J9 PI16 Stitcher unit IN sensor Detects stitcher unit storage WG8 5593 J1...

Page 216: ...ects paper No 3 on paper sensor PCB FG3 3106 17A1 1787 J10 PI21 Paper folding HP sensor Detects paper fold HP WG8 5593 E5F1 J18 PI22 Saddle inlet sensor Detects saddle inlet paper WG8 5593 1793 17A3 1787 J21 Ref Name Description Parts No Jam Error Saddle stitcher controller PCB MSW1 MSW3 SW4 5 SW6 7 ...

Page 217: ...oor open WC4 5128 E5F9 J4 SW4 Staple sensor rear Detects presence of staples rear FL2 0846 000 STAPL ER UNIT J8 SW5 Stitcher HP sensor rear Detects stitching HP rear FL2 0846 000 STAPL ER UNIT 1786 E5F4 J8 SW6 Staple sensor front Detects presence of staples front FL2 0846 000 STAPL ER UNIT J8 SW7 Stitcher HP sensor front Detects stitching HP front FL2 0846 000 STAPL ER UNIT 1786 E5F5 J8 ...

Page 218: ...er PCB M1 Feed motor FH5 1042 J5 M2 Paper folding motor FH5 1068 E5F1 J23 M3 Guide motor 4K1 1103 E5F2 J12 M4 Paper positioning plate motor 4K1 1104 E5F0 J7 M5 Alignment motor 4K1 1103 E5F3 J7 M6 Stitcher motor rear FL2 0846 STAPLER UNIT E5F4 J8 M7 Stitcher motor front FL2 0846 STAPLER UNIT E5F5 J8 M7 M8 M2 M6 M1 M4 M5 M3 ...

Page 219: ...068 E5F6 J23 Ref Name Parts No Saddle stitcher controller PCB SL1 No 1 paper deflecting solenoid FH6 5089 J15 SL2 No 2 paper deflecting solenoid FH6 5089 J15 SL4 Feed plate contact solenoid FH6 5090 J15 SL5 Saddle inlet solenoid FH6 5089 J19 Ref Name Parts No Error Saddle stitcher controller PCB SL1 SL2 SL5 SL4 ...

Page 220: ...Chapter 4 4 34 4 5 11 PCBs Saddle Stitcher Unit 0009 2650 F 4 34 T 4 19 Ref Name Parts No 1 Saddle stitcher controller PCB 4G1 1489 2 Paper sensor PCB FG3 3106 1 2 ...

Page 221: ... Used for making adjustments to the alignment position stapling position SW102 Used for making adjustments to the alignment position stapling position SW103 Used to start operation for alignment position adjustment stapling position adjustment SW104 Used to start operation for alignment position adjustment stapling position adjustment J731 1 1 6 9 J709 J713 J721 J711 J715 J714 J717 J708 J702 J716 ...

Page 222: ...tching position and folding position SW504 Bit 6 to 8 Stores corrected settings for stitching position and folding position SW1 Starts correction of discrepancy between stitching position and folding position 1 7 1 3 J2 J21 1 6 1 3 J13 J18 6 2 1 4 12 1 1 14 1 1 J12 SW504 J11 1 8 J10 1 9 J6 1 15 J9 12 1 J7 J4 CB1 J1 SW1 J8 2 1 J19 4 1 J5 8 1 J15 J23 4 1 ...

Page 223: ...ember part of the downloader PCB F 4 37 T 4 22 No Description Function 1 START STOP key A key to be pressed when you start or stop download 2 LOAD LED To be lit when download is available 3 Model LED To be lit when the Finisher is connected 4 Power LED To be lit when power is supplied from the Finisher to the downloader PCB 5 RS 232C cable straight full wiring 9 pins A cable to connect the downloa...

Page 224: ...tore ROM data to be downloaded in the C ServTool NewROM folder 2 Start up the Service Support Tool C ProgramFiles Service Support Tool bpchost exe 3 Select Register System Software F 4 38 4 Select the data inside the NewROM folder 7 Cable B 9 pins Length approx 50cm A cable to connect the downloader PCB and the Finisher 8 RS 232C connector A connector to connect an RS 232C cable to the downloader ...

Page 225: ...Chapter 4 4 39 F 4 39 5 Select Register F 4 40 6 Select OK and register the data ...

Page 226: ...sher controller PCB 4 Connect the RS 232C cable to the RS 232C connectors of the circuit board and the PC 5 Turn on the power of the host machine c Download The error code E713 might occur during download It does not affect the download operation and its results 1 Start up the Service Support Tool C ProgramFiles Service Support Tool bpchost exe 2 Select the type of host machine ...

Page 227: ...Chapter 4 4 41 F 4 42 F 4 43 3 Press the START STOP key of the downloader PCB LOAD LED is lit 4 Select the data and press START ...

Page 228: ...Chapter 4 4 42 F 4 44 5 Follow the instructions on the screen to prepare for downloading A press on OK will bring up the next screen F 4 45 6 Select the data to download ...

Page 229: ...Chapter 4 4 43 F 4 46 7 Press START to start downloading F 4 47 8 Press START so that the computer and the downloader PCB will start downloading the program ...

Page 230: ...Chapter 4 4 44 F 4 48 9 If downloading ended normally press OK F 4 49 10 Return to the main menu and finish the download ...

Page 231: ...ng the Operation 1 Check to make sure that the finisher operates normal 4 7 2 Upgrading Saddle Stitcher Unit 0009 2652 Overview A flash ROM is used for the IC7 CPU of the Saddle stitcher unit To upgrade this IC the downloader PCB FY9 2034 is used The operating instructions for it are given below How to Use the Downloader PCB FY9 2034 1 When to Use the Downloader PCB The downloader PCB is used when...

Page 232: ...l LED To be lit when the Finisher is connected 4 Power LED To be lit when power is supplied from the Finisher to the downloader PCB 5 RS 232C cable straight full wiring 9 pins A cable to connect the downloader PCB and a PC Be sure to connect the cable in a way that its ferrite core comes to the PC side 6 Cable A 9 pins Length approx 70cm A cable to connect the downloader PCB and other products 7 C...

Page 233: ...e downloaded in the C ServTool NewROM folder 2 Start up the Service Support Tool C ProgramFiles Service Support Tool bpchost exe 3 Select Register System Software F 4 52 4 Select the data inside the NewROM folder F 4 53 5 Select Register ...

Page 234: ...he power of the host machine 2 Detach the finisher from the host machine and remove the PCB cover of the finisher 3 Insert the cable B to J22 on the Saddle stitcher controller PCB 4 Connect the RS 232C cable to the RS 232C connectors of the circuit board and the PC 5 Turn on the power of the host machine ...

Page 235: ...rror code E503 might occur during download It does not affect the download operation and its results 1 Start up the Service Support Tool C ProgramFiles Service Support Tool bpchost exe 2 Select the type of host machine F 4 56 F 4 57 ...

Page 236: ...ress the START STOP key of the downloader PCB LOAD LED is lit 4 Select the data and press START F 4 58 5 Follow the instructions on the screen to prepare for downloading A press on OK will bring up the next screen F 4 59 ...

Page 237: ...apter 4 4 51 6 Select the version of the ROM to download F 4 60 7 Press Start so that the computer and the downloaded PCB will start downloading the program F 4 61 8 If downloading ended normally press OK ...

Page 238: ...d the session as instructed on the screen F 4 63 5 Release of Connection 1 Press the START STOP key of the downloader PCB LOAD LED is turned off 2 Turn off the power of the host machine 3 Disconnect the cable B from the Finisher ...

Page 239: ... Put the PCB cover back to the finisher and attach the finisher to the host machine 5 Turn on the power of the host machine 6 Checking the Operation 1 Check to make sure that the finisher operates normal ...

Page 240: ...tion Composition Remarks 1 Vic Clean Cleaning e g glass plastic rubber parts external covers Hydrocarbon fluori ne family Alcohol Surface activating agent Water Do not bring near fire Procure locally Isopropyl alcohol may be substituted 2 Lubricant Sliding units Silicone oil MOLYKOTE EM30 L ...

Page 241: ...Chapter 5 Error Code ...

Page 242: ......

Page 243: ...4 5 2 6 Stack exceeded Saddle Stitcher Unit 5 4 5 2 7 Stitching capacity error Saddle Stitcher Unit 5 4 5 3 Service Error Code 5 5 5 3 1 E500 5 5 5 3 2 E503 5 5 5 3 3 E505 5 5 5 3 4 E514 5 6 5 3 5 E530 5 6 5 3 6 E531 5 7 5 3 7 E532 5 7 5 3 8 E535 5 8 5 3 9 E537 5 8 5 3 10 E540 5 9 5 3 11 E542 5 10 5 3 12 E584 5 11 5 3 13 E5F0 5 11 5 3 14 E5F1 5 12 5 3 15 E5F2 5 12 5 3 16 E5F3 5 13 5 3 17 E5F4 5 13...

Page 244: ......

Page 245: ...quipped with a mechanism to check the machine condition as needed when it detects a fault the machine communicates the fact to the host machine in the form of a code and a detail code The host machine indicates the code on its control panel The detail code may be checked in the host machine s service mode ...

Page 246: ... run out of staples Always monitored Normal operation can be continued However whether to operate or not depends on the instruction from the host machine Replace the staple cartridge or set it correctly Error Descrip tion Condition Detection timing Machine operation Resetting Stapler safety protectio n function activated Stapler safety protection function was activated When starting staple operati...

Page 247: ... tray has exceeded the stackable sheet or set count After ejecting the sheet set exceeding the limit Normal operation will continue Remove paper from ejection tray Error Descrip tion Condition Detection timing Machine operation Resetting Staple is absent The staple cartridge has run out of staples Always monitored Normal operation will continue However operation is subject to instruction from host...

Page 248: ...ited Remove the sheets from the holding area Error Descrip tion Condition Detection timing Machine operation Resetting Stack exceede d The stack of sheets on the output tray exceeds the maximum numberofsheets that can be stacked When output of the sheet that cause an excess is output on the output tray Normal operation is continued Remove the stack of sheets from the tray Error Descrip tion Condit...

Page 249: ...0 0001 Communication error The communication with the host machine is interrupted Code Detail Error Description Detection timing E503 0002 Communication error The communication with the saddle stitcher is interrupted Code Detail Error Description Detection timing E505 0001 Backup RAM The checksum for the finisher controller PCB has an error when the power is turned on ...

Page 250: ...not return to the rear end assist home position when the rear end assist motor has been driven for 3 seconds Code Detail Error Description Detection timing E530 8001 Aligning plate frontmotor M103 Aligning plate fronthome position sensor PI106 The aligning plate does not return to aligning plate front home position sensor when the alignment plate front motor has been driven for 4 seconds 8002 The ...

Page 251: ...nwhen the staple motor has been driven for 0 5 sec Code Detail Error Description Detection timing E532 8001 Stapler shift motor M105 Stapler shift homeposition sensor PI110 The stapler does not leave the stapler shifthome position when the stapler shift motor hasbeen driven for 5 seconds 8002 The stapler does not return to the stapler shift home position when the stapler shift motor has been drive...

Page 252: ...eave the swing home position when the swing motor has been driven for 3 seconds Code Detail Error Description Detection timing E537 8001 Aligning plate rear motor M104 Aligning plate rear home position sensor PI107 The aligning plate does not leave the aligning plate rear home position sensor when the alignment plate rear motor has been driven for 4 seconds 8002 The aligning plate does not return ...

Page 253: ...rface sensor detects paper surface during the paper surface detection operation A discontinuous area is detected during tray operation 8003 The tray 1 closing detect switch is activated while the tray 1 is operating 8004 Clock signal input cannot be detected when the tray 1 shift motor has been driven for 0 2 second 8005 The lock detection signal turns OFF 150 ms after the lock detection signal tu...

Page 254: ...er surface during paper surface detection operation A discontinuous area is detected during tray operation During evacuation operation arrival at the area beyond the tray 2 paper surface sensor 2 is detected before this sensor detects paper surface 8004 Clock signal input cannot be detected when the tray 2 shift motor has been driven for 0 2 second 8005 The lock detection signal turns OFF 150 ms a...

Page 255: ...riven for 3 seconds 0002 The stapler does not return to the shutter home position when the stack ejection motor has been driven for 3 seconds Code Detail Error Description Detection timing E5F0 8001 Paper positioning plate motor M4 Paper positioning plate home position sensor PI7 The paper positioning plate home positio sensor does not turn ON when the paper positioning plate motor has been driven...

Page 256: ...clock sensor is less than standard value 8002 The status of the paper fold home position sensor does not change when the paper fold motor has been driven for 3 seconds Code Detail Error Description Detection timing E5F2 8001 Guide motor M3 Guide home position sensor PI13 The guide home position sensor does not turn ON when the guide motor has been driven for 700 pulses 8002 The guide home position...

Page 257: ...on Detection timing E5F4 8001 Stitch motor rear M6 Stitching home position sensor rear SW5 The stitching home position sensor does not turn ON when the stitch motor rear has been driven backward for 0 5 sec 8002 The stitching home position sensor does not turn OFF when the stitch motor rear has been driven forward for 0 5 sec Code Detail Error Description Detection timing E5F5 8001 Stitch motor fr...

Page 258: ...ing plate motor has been driven for 0 3 sec 8002 The paper pushing plate home position sensor does not turn OFF when the paper pushing plate motor has been driven for 80 ms 8003 The number of pulses detected by the paper pushing plate motor clock sensor is less than standard value 8004 The paper pushing plate leading edge position sensor does not turn OFF when the paper pushing plate motor has bee...

Page 259: ...has appeared press yes 3 Turn off and then on the main power switch of the host machine 3 Communication with the Host Machine 1 When the main power switch is turned on the DC controller PCB will communicate to the main controller PCB that a functional limit has been imposed The control panel will indicate that a functional limit has been imposed on the finisher 2 The DC controller PCB backs up inf...

Page 260: ...ay 2 shift motor error E5F0 Paper positioning plate motor error E5F1 Paper folding motor error E5F2 Guide motor error E5F3 Aligning motor error E5F4 Stitcher rear error E5F5 Stitcher front error E5F6 Paper pushing plate motor error E5F9 Micro switch error E590 Punch motor error E591 Scrap full detector sensor error E592 Trailing edge Horizontal registration sensor error E593 Horizontal registratio...

Page 261: ...Feb 21 2005 ...

Page 262: ......