April 24, 2013 Revision 0. Staple Finisher-R1 Service Manual

1 2 3 4 5 6 April 24, 2013 Revision 0 Staple Finisher-R1 Service Manual

0 0-2 Application This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair of products. This manual covers all localities where the products are sold. For this reason, there may be information in this manual that does not apply to your locality. Corrections This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When changes occur in applicable products or in the contents of this manual, Canon will release technical information as the 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 manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or translated into another language, in whole or in part, without the consent of Canon Inc. Coryright CANON INC. 2013 Caution Use of this manual should be strictly supervised to avoid disclosure of confidential information. 0 0-2

0 0-3 Explanation of Symbols The following symbols are used throughout this Service Manual. Symbols Explanation Symbols Explanation The following rules apply throughout this Service Manual: 1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with reference to the timing of operation. Check Check visually Remove the claw. Insert the claw. In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol, the arrow indicates the direction of the electric signal. The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results in supplying the machine with power. Check the noise. Disconnect the connector. Connect the connector. Remove the cable/wire from the cable guide or wire saddle. Set the cable/wire to the cable guide or wire saddle. Use the bundled part. Push the part. Plug the power cable. Turn on the power. 2. In the digital circuits, '1' is used to indicate that the voltage level of a given signal is "High", while '0' is used 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 input of the DC controller PCB and from the output of the DC controller PCB to the loads. The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins. All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and be able to identify and isolate faults in the machine. Remove the screw. Tighten the screw. 0 0-3

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0 0-5 Safety Precautions Contents Notes Before Servicing-------------------------------------------------------0-9 Points to Note at Cleaning---------------------------------------------------0-9 Product Outline Features--------------------------------------------------------------------------1-2 Specifications-------------------------------------------------------------------1-3 Names of Parts-----------------------------------------------------------------1-4 External View------------------------------------------------------------------------ 1-4 Cross Section------------------------------------------------------------------------ 1-4 Technology Basic Configuration-----------------------------------------------------------2-2 Functional Configuration---------------------------------------------------------- 2-2 Overview of Electrical Circuitry-------------------------------------------------- 2-2 Controls--------------------------------------------------------------------------2-3 Controls------------------------------------------------------------------------------- 2-3 Basic Operation----------------------------------------------------------------2-4 Outline--------------------------------------------------------------------------------- 2-4 Feed Unit------------------------------------------------------------------------2-6 Outline--------------------------------------------------------------------------------- 2-6 Feeding Paper to Processing Tray Unit--------------------------------------- 2-6 Processing Tray Unit----------------------------------------------------------2-7 Outline--------------------------------------------------------------------------------- 2-7 Stacking Operation----------------------------------------------------------------- 2-8 Tray Auxiliary Guide Operation------------------------------------------------- 2-9 Alignment / Shifting Operation-------------------------------------------------2-10 Staple Operation-------------------------------------------------------------------2-16 Stack Delivery Operation--------------------------------------------------------2-16 Stack Tray Paper Retainer Operation----------------------------------------2-17 Stack Tray Unit--------------------------------------------------------------- 2-18 Stack Tray Shift Operation------------------------------------------------------2-18 Stack Tray Paper Height Detection Control---------------------------------2-18 Stack Tray Paper Full Detection Control-------------------------------------2-19 Controller Unit---------------------------------------------------------------- 2-20 Outline--------------------------------------------------------------------------------2-20 Detecting Jams--------------------------------------------------------------- 2-21 Outline--------------------------------------------------------------------------------2-21 Power Supply----------------------------------------------------------------- 2-23 Outline--------------------------------------------------------------------------------2-23 Protective Functions--------------------------------------------------------------2-23 Work of Service-------------------------------------------------------------- 2-24 When replacing the parts--------------------------------------------------------2-24 Periodical Servicing---------------------------------------------------------------2-24 Upgrading---------------------------------------------------------------------------2-24 Periodic Servicing List of Work for Scheduled Servicing-------------------------------------3-2 Parts Replacement and Cleaning Procedure Finisher---------------------------------------------------------------------------4-2 Detaching the Finisher from the Host Machine----------------------------- 4-2 List of Parts----------------------------------------------------------------------4-4 External / Internal Covers-------------------------------------------------------- 4-4 Front-------------------------------------------------------------------------------------------- 4-4 Rear--------------------------------------------------------------------------------------------- 4-4 Main Units---------------------------------------------------------------------------- 4-5 List of Motors------------------------------------------------------------------------ 4-5 List of Sensors and Switches---------------------------------------------------- 4-6 List of PCBs-------------------------------------------------------------------------- 4-6 External / Internal Covers----------------------------------------------------4-7 Removing the Front Cover------------------------------------------------------- 4-7 Removing the Rear Cover-------------------------------------------------------- 4-7 Removing the Upper Feed Guide Unit---------------------------------------- 4-8 Removing the Upper Cover------------------------------------------------------ 4-9 Removing the PCB Cover-------------------------------------------------------- 4-9 Main Units--------------------------------------------------------------------- 4-10 0 0-5

0 0-6 Removing the Grate-shaped Guide-------------------------------------------4-10 Removing the Staple Unit------------------------------------------------------- 4-11 Removing the Upper Processing Tray Unit (Front / Rear)--------------4-12 Removing the Lower Processing Tray Unit---------------------------------4-15 Motors-------------------------------------------------------------------------- 4-16 Removing the Feed Motor (M1)------------------------------------------------4-16 Removing the Delivery Motor (M2)--------------------------------------------4-17 Removing the Paddle Motor (M3)---------------------------------------------4-18 Removing the Front Alignment Motor (M4)---------------------------------4-18 Removing the Rear Alignment Motor (M5)----------------------------------4-19 Removing the Tray Auxiliary Guide Motor (M6)----------------------------4-19 Removing the Stack Tray Shift Motor (M8)---------------------------------4-20 Switches----------------------------------------------------------------------- 4-22 Removing the Front Door Switch----------------------------------------------4-22 Removing the Stack Tray Lower Limit Switch------------------------------4-23 PCBs---------------------------------------------------------------------------- 4-24 Removing the Finisher Controller PCB--------------------------------------4-24 Carton)-------------------------------------------------------------------------------- 6-2 Symbols in the Illustration-------------------------------------------------------- 6-2 Unpacking Procedure---------------------------------------------------------6-3 Unpacking Procedure------------------------------------------------------------- 6-3 Installation Procedure--------------------------------------------------------6-4 Preparation for Installation on Host Machine-------------------------------- 6-4 Connecting to Host Machine----------------------------------------------------- 6-5 Appendix Service Tools--------------------------------------------------------------------7-2 Solvents and Oils------------------------------------------------------------------- 7-2 Applying the Grease------------------------------------------------------------------------ 7-3 Special Tools------------------------------------------------------------------------- 7-5 General Circuit Diagram-----------------------------------------------------7-6 General Circuit Diagram---------------------------------------------------------- 7-6 Adjustment Adjustment Item----------------------------------------------------------------5-2 Overview------------------------------------------------------------------------------ 5-2 Dip Switch Function-----------------------------------------------------------5-3 Sensor Detection Check Mode-------------------------------------------------- 5-3 Entering the Sensor Detection Check Mode----------------------------------------- 5-3 List of Sensor Detection Check States------------------------------------------------ 5-3 Motor Operation Check Mode--------------------------------------------------- 5-4 Entering the Motor Operation Check Mode------------------------------------------- 5-4 List of Motor Operation Check States-------------------------------------------------- 5-4 Shifting Operation ON/OFF Setting in Staple Mode----------------------- 5-5 Tray Auxiliary Guide Operation ON/OFF Setting when delivering a sheet of paper------------------------------------------------------------------------------- 5-5 Installation How to Utilize This Installation Procedure-------------------------------6-2 Descriptions Used in This Procedure------------------------------------------ 6-2 When Using the Contained Parts (Bundled Components in the Shipping 0 0-6

Safety Precautions Notes Before Servicing Points to Note at Cleaning

0 Safety Precautions > Points to Note at Cleaning Notes Before Servicing 0-8 Caution: At servicing, be sure to turn off the power source according to the specified steps and disconnect the power plug. Caution: Do not turn off the power switch when downloading is under way. Turning off the main power switch while downloading is under way can disable the machine. Points to Note at Cleaning Caution: When performing cleaning using organic solvent such as alcohol, be sure to check that the component of solvent is vaporized completely before assembling. 0 Safety Precautions > Points to Note at Cleaning 0-8

1 Product Outline Features Specifications Names of Parts 1 Product Outline

1 Product Outline > Features 1-2 Features Compact, semi-inner finisher which corresponds to A4 black-and-white, high-speed MFP. Gripper mechanism for delivering paper to the stack tray. And the paper stacking of the high consistency is possible by the mechanism. Stack tray capacity of approximate 500 sheets. Easy to install on the host machine. 1 Product Outline > Features 1-2

1 Product Outline > Specifications Specifications Finisher Unit Item Specifications Remarks Stacking method Stack tray: moving up and down Stacking orientation Stacking paper size Alignment stacking paper size Paper weight Stacking capacity Mixed stacking capacity Dimensions Weight Power supply Power consumption Face down Feed direction: 139 to 356 mm (extra-length paper: 139 to 630 mm) Cross feed direction: 98 to 216 mm [Non sort] Cross feed direction: 98 to 216 mm [Sort] Cross feed direction: 138 to 216 mm [Staple sort] Cross feed direction: 182 to 216 mm 64 to 128 g/m2 - Processing tray [Non sort / sort] 6 sheets or less [Staple sort] 50 sheets or less - Stack tray - Equivalent of 80 g/m2 [Non sort / sort] paper 73.5 mm or less in height (equivalent of 500 sheets) [Staple sort] 73.5 mm or less in height, or 22 sets or less [Non sort / sort] - Equivalent of 80 g/m2 73.5 mm or less in height paper [Staple sort] 73.5 mm or less in height, or 22 sets or less 263 mm (H) 798 mm (W) 395 mm (D) Approx. 10.5 kg From host machine: 24V, 5V Standby: 2.5 W or less Operating: 50 W or less T-1-1 Staple Unit Item Specifications Remarks Stapling method Punching by rotating cam - Flat clinch Stapling capacity 50 sheets Paper thickness: 5.7 mm or less - Equivalent of 80 g/m2 paper - Including 2 sheets of 128 g/m2 paper Stapling paper size A4R, B5R, LGL, LTRR, EXECR, 16KR Staple supply Staple detection Manual stapling Initial feed of staple head Special staple cartridge (5000 staples) Provided Not provided Provided Staple Position Front 1-point stapling (45 degrees) 5.0 ± 2.0 mm 5.0 ± 2.0 mm F-1-1 1-3 T-1-2 1 Product Outline > Specifications 1-3

1 Product Outline > Names of Parts > Cross Section 1-4 Names of Parts Cross Section External View Stack Tray Alignment Plate Delivery Roller Paddle Paper Return Paddle Feed Roller Inlet Roller Stack Tray Stack Tray Paper Retainer Tray Auxiliary Guide Gripper Stapler F-1-3 Front Door F-1-2 1 Product Outline > Names of Parts > Cross Section 1-4

2 Technology Basic Configuration Controls Basic Operation Feed Unit Processing Tray Unit Stack Tray Unit Controller Unit Detecting Jams Power Supply Work of Service 2 Technology

2 Technology > Basic Configuration > Overview of Electrical Circuitry 2-2 Basic Configuration Functional Configuration The components of this finisher are organized into 3 major blocks; feed unit, processing tray unit and stack tray unit. Processing Tray Unit Stack Tray Unit Feed Unit Overview of Electrical Circuitry The finisher's sequence of the operation is controlled by its finisher controller PCB. The finisher controller PCB has the 16-bit CPU, and the controller also controls the communication with the host machine in addition to controlling the finisher's operation sequence. The CPU on the finisher controller PCB contains a flash ROM used to store the operating sequence program. The finisher controller PCB uses the serial communication line to receive various commands from its host to drive the motors. It also uses serial communications to send information on the sensors and switches to its host. Motor Finisher Controller PCB Sensor CPU F-2-1 Switch Motor Driver Serial Communication Host Machine (DC Controller PCB) F-2-2 2 Technology > Basic Configuration > Overview of Electrical Circuitry 2-2

2 Controls Technology > Controls > Controls 2-3 Controls Items Reference Basic Operation Outline Refer to page 2-4 Feed Unit Outline Refer to page 2-6 Feeding Paper to Processing Tray Refer to page 2-6 Unit Processing Tray Unit Outline Refer to page 2-7 Stacking Operation Refer to page 2-8 Tray Auxiliary Guide Operation Refer to page 2-9 Alignment / Shifting Operation Refer to page 2-10 Staple Operation Refer to page 2-16 Stack Delivery Operation Refer to page 2-16 Stack Tray Paper Retainer Refer to page 2-17 Operation Stack Tray Unit Stack Tray Shift Operation Refer to page 2-18 Stack Tray Paper Height Detection Refer to page 2-18 Control Stack Tray Paper Full Detection Refer to page 2-19 Control Controller Unit Outline Refer to page 2-20 Detecting Jams Outline Refer to page 2-21 Power Supply Outline Refer to page 2-23 Protective Functions Refer to page 2-23 Work of Service When replacing the parts Refer to page 2-24 Periodical Servicing Refer to page 2-24 Upgrading Refer to page 2-24 T-2-1 2 Technology > Controls > Controls 2-3

2 Technology > Basic Operation > Outline 2-4 Basic Operation Outline (3) The alignment plates are used to align paper in the width direction. (In the illustration below, paper is aligned with reference to the central reference position.) Rear Alignment Plate Basic operations of this finisher are described below. (1) The paper delivered from the host machine is fed by the inlet roller, feed roller, and delivery roller. Feed Roller Inlet Roller Front Alignment Plate F-2-5 Delivery Roller F-2-3 (4) The operations described in (1) to (3) are repeated for each sheet to be stacked on the processing tray. (5) The stacked sheets are stapled (only in the staple mode). (2) The paper delivered by the delivery roller is stacked on the processing tray by the paddle. A paddle and a paper return paddle are used to align paper in the feed direction. If two or more sheets with a length of 150 mm or more are stacked, the tray auxiliary guides slide out. Stapler Stack Tray Paper Retainer Paddle Paper Return Paddle F-2-6 F-2-4 2 Technology > Basic Operation > Outline 2-4

2 Technology > Basic Operation > Outline 2-5 (6) After being shifted, the sheets stacked on the processing tray are delivered to the stack tray. If the tray auxiliary guides have slid out, they slide back before the sheets are delivered to the stack tray. Gripper F-2-7 2 Technology > Basic Operation > Outline 2-5

2 Feed Unit Outline Technology > Feed Unit > Feeding Paper to Processing Tray Unit The feed unit feeds the paper delivered from the host machine and feeds it to the processing tray unit. Two sensors, an inlet sensor (S1) and a delivery sensor (S2), are provided along the paper feed path in the feed unit to detect the paper feed state and jam. M4/5 M3 M2 M1 2-6 Feeding Paper to Processing Tray Unit The paper delivered from the host machine is fed by the inlet roller, feed roller, and delivery roller. The paper delivered by the delivery roller is stacked on the processing tray by the paddle. M3 Paddle Motor M1 Feed Motor Paddle Delivery Sensor (S2) Inlet Sensor (S1) S2 S1 Feed Roller Inlet Roller Delivery Roller M2 Delivery Motor F-2-9 M8 M7 M6 M9 M1 Feed Motor M7 Gripper Motor M2 Delivery Motor M8 Stack Tray Shift Motor M3 Paddle Motor M9 Staple Motor M4 Front Alignment Motor S1 Inlet Sensor M5 Rear Alignment Motor S2 Delivery Sensor M6 Tray Auxiliary Guide Motor T-2-2 F-2-8 2 Technology > Feed Unit > Feeding Paper to Processing Tray Unit 2-6

2 Technology > Processing Tray Unit > Outline Processing Tray Unit Outline The processing tray unit aligns, shifts, and staples the delivered paper, and then delivers the paper onto the stack tray using a gripper. Names and roles of the components of the processing tray are as follows: M4 Front Alignment Plate Paddle Rear Alignment Plate M3 Paddle Motor M5 Rear Alignment Motor M2 Delivery Motor No. Name Function [1] Paddle Stacks the paper delivered from the delivery roller on the processing tray. [2] Paper Return Paddle Presses the paper stacked on the processing tray against the stopper (alignment in the feed direction) and prevents the previously stacked paper from being fed/delivered. [3] Front / Rear Alignment Plate Aligns the paper stacked on the processing tray in the width direction and shifts the paper. [4] Gripper Grips the paper stack on the processing tray, and then delivers it to the stack tray. [5] Tray Auxiliary Guide When two or more sheets with a length of 150 mm or more are stacked on the processing tray unit, prevents misalignment of paper due to curl. [6] Stopper Allows the paper stacked on the processing tray to be pressed against itself to align the paper in the feed direction. [7] Stapler Staples sheets of paper. 2-7 T-2-3 Front Alignment Motor Paper Return Paddle Stopper Gripper Paper Return Paddle M7 Tray Auxiliary Guide Stapler Tray Auxiliary Guide Gripper Motor M6 Tray Auxiliary Guide Motor F-2-10 2 Technology > Processing Tray Unit > Outline 2-7

2 Technology > Processing Tray Unit > Stacking Operation 2-8 Stacking Operation The paper delivered from the delivery roller is stacked on the processing tray and the paper is aligned in the feed direction. How paper is delivered from the delivery roller and stacked on the processing tray is described below. (2) After the specified time has lapsed since paper has passed through the delivery sensor (S2), the paddle motor (M3) operates to rotate the paddle once to stack the paper on the processing tray. The stacked paper is pressed against the stopper by the paper return paddle which is driven by the delivery motor (M2), thus aligning the paper in the feed direction. (1) When two or more sheets with a length of 150 mm or more are stacked, the tray auxiliary guide motor (M6) operates after lapse of the specified time since detection of paper by the inlet sensor (S1), thus sliding out the tray auxiliary guides. Paddle M3 Paddle Motor Paper Return Paddle Delivery Sensor (S2) Tray Auxiliary Guide Inlet Sensor (S1) Stopper M2 Delivery Motor F-2-12 NOTE: M6 Tray Auxiliary Guide Motor F-2-11 When a postcard or a sheet shorter than 150 mm is stacked, the paddle does not rotate. 2 Technology > Processing Tray Unit > Stacking Operation 2-8

2 Technology > Processing Tray Unit > Tray Auxiliary Guide Operation 2-9 (3) The front and rear alignment motors (M4 and M5) operate to move the front and rear alignment plates, thus aligning the paper in the width direction. (In the illustration below, the paper is aligned with reference to the central reference position.) Operations described in (2) and (3) are repeated for each sheet. Rear Alignment Plate Tray Auxiliary Guide Operation When two or more sheets with a length of 150 mm or more are stacked on the processing tray, the tray auxiliary guides slide out to prevent misalignment of paper due to curl. The tray auxiliary guides are driven by the tray auxiliary guide motor (M6). They slide out when the inlet sensor (S1) detects paper and they slide back when paper is delivered by the gripper. The home position of each tray auxiliary guide is detected by the tray auxiliary guide HP sensor (S6). Tray Auxiliary Guide Tray Auxiliary Guide HP Sensor (S6) Front Alignment Plate F-2-13 Tray Auxiliary Guide M6 Tray Auxiliary Guide Motor F-2-14 2 Technology > Processing Tray Unit > Tray Auxiliary Guide Operation 2-9

2 Technology > Processing Tray Unit > Alignment / Shifting Operation The tray auxiliary guide slide-out amount varies depending on the operation mode and paper length as follows: Operation Mode Paper Length Amount of Slide Out Non-Sort / Sort 150 mm or more to less than 55 mm 217 mm 217 mm or more to less than 55 + ("Paper Length" - 216) mm 300 mm 300 mm or more 120 mm Staple 150 mm or more to less than 50 mm 217 mm 217 mm or more 55 + ("Paper Length" - 216) mm T-2-4 2-10 Alignment / Shifting Operation The paper stacked on the processing tray is aligned in the width direction by the front and rear alignment plates. Then, the paper is shifted to the position where it is delivered to the stack tray. The front alignment plate is driven by the front alignment motor (M4) and the rear alignment plate is driven by the rear alignment motor (M5). The home positions of the front and rear alignment plates are detected by the front alignment plate HP sensor (S4) and rear alignment plate HP sensor (S5). Front Alignment Plate Rear Alignment Plate Front Alignment Plate HP Sensor (S4) Front Alignment Motor (M4) Rear Alignment Plate HP Sensor (S5) Rear Alignment Motor (M5) F-2-15 2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-10

2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-11 The relationship between operation modes and alignment positions is summarized in the following table: Operation Mode Paper Width Alignment Position Non-Sort / Sort 180 mm or more Front alignment position: 10 mm frontward from the central reference position Rear alignment position: 10 mm backward from the central reference position less than 180 mm Central reference position Staple 200 mm or more Stapling position less than 200 mm 10 mm frontward from the central reference position T-2-5 The relationship between operation modes and shifting positions is summarized in the following table: Operation Mode Paper Width Shifting Position Non-Sort / Sort 210 mm or more Front shift position: 10 mm frontward from the central reference position (Same as the alignment position) Rear shift position 10 mm backward from the central reference position (Same as the alignment position) *: Shift amount: 20 mm 180 mm or more to less than 210 mm Front shift position: F mm frontward from the central reference position F = 110 - ("Paper width" / 2) Rear shift position: R mm frontward from the central reference position R = 85 - ("Paper width" / 2) *: Shift amount: 25 mm less than 180 mm Front shift position: 10 mm frontward from the central reference position Rear shift position: 10 mm backward from the central reference position *: Shift amount: 20 mm Staple 210 mm or more Front shift position: 10 mm frontward from the central reference position Rear shift position: 10 mm backward from the central reference position *: Shift amount: 20 mm less than 210 mm Front shift position: F mm frontward from the central reference position F = 110 - ("Paper width" / 2) Rear shift position: R mm frontward from the central reference position R = 85 - ("Paper width" / 2) *: Shift amount: 25 mm T-2-6 NOTE: In the non-sort mode, paper is aligned/shifted at the position which is different from the position where paper was aligned/shifted at the end of the previous copy job. 2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-11

2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-12 Alignment Operation in Non-sort / Sort Mode (1) After lapse of the specified time since detection of paper by the delivery sensor (S2), the front and rear alignment plates move to the standby position (paper width + 10 mm). Rear Alignment Plate (2) After lapse of the specified time since detection of the trailing edge of paper by the delivery sensor (S2), the front and rear alignment plates move for paper alignment. Front / Rear alignment position (when the paper width is 180 mm or more) Paper (when aligning in the rear) Rear Alignment Position Half of Paper Width +10mm Middle of Feeding Path Half of Paper Width +10mm 20mm 20mm Front Alignment Plate F-2-16 Front Alignment Position Paper (when aligning in the front) F-2-17 Alignment position of central reference (when the paper width is less than 180 mm) 10mm Middle of Feeding Path 10mm Paper F-2-18 2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-12

2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-13 Alignment Operation in Staple Mode (1) After lapse of the specified time since detection of paper by the delivery sensor (S2), the front and rear alignment plates move to the standby position (Front alignment plate: Home position + 2 mm; Rear alignment plate: Paper width + 10 mm). (2) After lapse of the specified time since detection of the paper s trailing edge by the delivery sensor (S2), the front and rear alignment plates move to align paper. Staple alignment position (when the paper width is 200 mm or more) Standby position of central reference (when the paper width is 200 mm or more) The position that aligns paper by the front and rear alignment plates Half of Paper Width +10mm Middle of Feeding Path 2mm 2mm Paper Front Alignment Plate Home Position F-2-21 Front Alignment Plate Home Position F-2-19 Front alignment position (when the paper width is less than 200 mm) Front standby position (when the paper width is less than 200 mm) 20mm Half of Paper Width +10mm Middle of Feeding Path Half of Paper Width +10mm Paper F-2-22 F-2-20 2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-13

2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-14 Shifting Operation in Non-sort / Sort Mode (1) After alignment of the sheet stacked on the processing tray lastly, it is shifted according to the paper width. Front / Rear shift position (when the paper width is 210 mm or more) The shift position is the same as the alignment position Front shift position (when the paper width is from 180 mm or more to less than 210 mm) Front shift position (when the paper width is less than 180 mm) Alignment position +10mm front side Middle of Feeding Path Alignment position +10mm front side The position that aligns paper by the front and rear alignment plates Middle of Feeding Path 110mm Paper (when aligning in the front) Rear shift position (when the paper width is less than 180 mm) F-2-25 Alignment position +10mm rear side Paper (when aligning in the front) F-2-23 Rear shift position (when the paper width is from 180 mm or more to less than 210 mm) Middle of Feeding Path Alignment position +10mm rear side Paper (when aligning in the rear) Paper (when aligning in the rear) The position that aligns paper by the front and rear alignment plates F-2-26 Middle of Feeding Path 85mm F-2-24 2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-14

2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-15 Shifting Operation in Staple Mode (1) After completion of stapling, the paper stack is shifted according to the paper width. Front shift position (when the paper width is 210 mm or more) Front shift position (when the paper width is less than 210 mm) The position that aligns paper by the front and rear alignment plates The position that aligns paper by the front and rear alignment plates Middle of Feeding Path 110mm Middle of Feeding Path Half of Paper Width +10mm Paper (when aligning in the front) F-2-29 Rear shift position (when the paper width is 210 mm or more) F-2-27 Front shift position (when the paper width is less than 210 mm) Paper (when aligning in the rear) Half of Paper Width +10mm Middle of Feeding Path The position that aligns paper by the front and rear alignment plates The position that aligns paper by the front and rear alignment plates Middle of Feeding Path 85mm F-2-28 F-2-30 2 Technology > Processing Tray Unit > Alignment / Shifting Operation 2-15

2 Technology > Processing Tray Unit > Stack Delivery Operation 2-16 Staple Operation When the staple mode is selected, paper is stapled by the stapler after it has been stacked on the processing tray and aligned. The stapler is provided at the front of the finisher. Paper is stapled at only one position at the front. A maximum of 50 sheets can be stapled. Stack Delivery Operation The paper stacked on the processing tray is delivered to the stack tray by the gripper after being shifted and stapled. The gripper is driven by the gripper motor (M7) via the gripper drive belt. The home position of the gripper is detected by the gripper HP sensor (S7). Gripper HP Sensor (S7) Stapler Gripper Drive Belt Gripper Paper M7 Gripper Motor F-2-31 F-2-32 2 Technology > Processing Tray Unit > Stack Delivery Operation 2-16

2 Technology > Processing Tray Unit > Stack Tray Paper Retainer Operation 2-17 Stack Tray Paper Retainer Operation The paper delivered to the stack tray is retained by the stack tray paper retainer to prevent wrong detection of paper height and misalignment caused by curl. The tray paper retainer is released when the gripper presses portion A of the gear stopper after it has delivered paper to the stack tray. Then, it is rotated by the driving force of the gripper motor (M7). Gear Stopper Stack Tray Paper Retainer M7 Gripper Motor A F-2-33 2 Technology > Processing Tray Unit > Stack Tray Paper Retainer Operation 2-17

2 Technology > Stack Tray Unit > Stack Tray Paper Height Detection Control 2-18 Stack Tray Unit Stack Tray Shift Operation The paper delivered from the processing tray by the gripper is then stacked on the stack tray. The stack tray is moved up and down by the stack tray shift motor (M8). When the power is turned on or before start of printing, the stack tray shift motor (M8) is driven to move the stack tray up/down to the position where the stack tray paper height sensor (S9) detects the stack tray top surface. After the paper has been delivered from the processing tray, the stack tray moves down by the specified amount. Then, the stack tray moves up until the stack tray paper height sensor (S9) detects the stack tray top surface (top surface of the stacked paper) with the stack tray paper height sensor flag. Stack Tray Paper Height Detection Control The height of the paper stack on the stack tray is detected by the stack tray paper height sensor (S9). After paper has been delivered to the stack tray, the stack tray moves down by the specified amount. Next, the stack tray paper height sensor (S9) turns on (the top surface of the paper on the stack tray is detected). The above operations are repeated each time paper is delivered to the stack tray. Stack Tray Paper Height Sensor Flag Stack Tray Paper Height Sensor (S9) Stack Tray Paper Height Sensor (S9) OFF ON Stack Tray Paper Height Sensor Flag Stack Tray F-2-35 M8 Stack Tray Shift Motor Stack Tray Lower Limit Switch (SW2) F-2-34 2 Technology > Stack Tray Unit > Stack Tray Paper Height Detection Control 2-18

2 Technology > Stack Tray Unit > Stack Tray Paper Full Detection Control 2-19 Stack Tray Paper Full Detection Control The paper full state of the stack tray is detected by the stack tray paper height sensor (S9) and stack tray lower limit switch (SW2). Stack Tray Paper Height Sensor (S9) ON ON Stack Tray Lower Limit Switch (SW2) F-2-36 The paper full state of the stack tray is detected in the following cases: When the power is turned on or during initialization before start of printing When the ON states of both the stack tray paper height sensor (S9) and stack tray lower limit switch (SW2) are detected When paper is delivered When the ON state of the stack tray lower limit switch is detected two successive times because the height of the paper delivered to the stack tray has become lower than the specified level NOTE: After the stack tray full state has been detected, a maximum of 50 sheets can be stacked on the stack tray. 2 Technology > Stack Tray Unit > Stack Tray Paper Full Detection Control 2-19

2 Controller Unit Technology > Controller Unit > Outline 2-20 Outline The controller unit controls the entire portion of this machine. Its finisher controller PCB controls the feed unit, processing tray unit, and stack tray unit. The finisher controller PCB controls operations of motors and detects the states of sensors and switches according to the instruction from the host machine. Finisher Controller PCB Host Machine CPU(U1) Motor Driver (U5) to (U14) Switch Sensor Motor F-2-37 Roles of major ICs mounted on the finisher controller PCB are summarized below. Name Function CPU (U1) Controls communications between this finisher and host machine. Stores firmware. Controls operations of this finisher. Motor Driver (U5) Controls the driver of feed motor (M1) Motor Driver (U6) Controls the driver of delivery motor (M2) Motor Driver (U7) Controls the driver of front alignment motor (M4) Motor Driver (U8) Controls the driver of rear alignment motor (M5) Motor Driver (U9) Controls the driver of tray auxiliary guide motor (M6) Motor Driver (U10) Controls the driver of paddle motor (M3) Motor Driver (U11) Controls the driver of gripper motor (M7) Motor Driver (U12) Controls the driver of staple motor (M9) Motor Driver (U13/14) Controls the driver of stack tray shift motor (M8) T-2-7 2 Technology > Controller Unit > Outline 2-20

2 Detecting Jams Outline Technology > Detecting Jams > Outline The following sensors are provided to check whether paper is present and whether the stapler is operating normally. Inllet sensor (S1) Delivery sensor (S2) Staple HP sensor (S11) Staple edging sensor (S12) S2 S1 S11 S12 Stapler F-2-38 2-21 Occurrence of a jam is checked (at the check timing) according to the sensor detection state stored in the CPU on the finisher controller PCB. When the finisher controller PCB judges that a jam has occurred, it stops feeding/delivering paper and notifies occurrence of the jam to the host machine. Jam type Sensor Jam description Inlet sensor delay jam S1 Detected when the inlet sensor (S1) does not detect paper after lapse of the specified time since reception of a paper delivery signal from the host machine. Delivery sensor delay jam S2 Detected when the delivery sensor (S2) does not detect paper after lapse of the specified time since detection of paper by the inlet sensor (S1). Delivery sensor staionary jam S2 Detected when the delivery sensor (S2) does not turn off after lapse of the specified time since detection of paper by the delivery sensor (S2). Inlet sensor early arrival jam S1 Detected when the inlet sensor (S1) detects paper without receiving a delivery signal from the host machine. Or detected when the inlet sensor (S1) detects paper earlier than the specified timing after reception of a delivery signal from the host machine. Stapler jam S11/S12 Detected when the staple HP sensor (S11) cannot detect the stapler again even after the specified time has lapsed since the stapler passed through the staple HP sensor (S11) when stapling is executed. Or detected when the staple edging sensor (S12) cannot detect a staple even when recovery operation is performed ten times when staple edging is executed. Door open jam S1/S2 Detected when the front door is opened while paper is being fed (the inlet sensor (S1) or delivery sensor (S2) detects paper). Power-on jam S1/S2 Detected when the inlet sensor (S1) or delivery sensor (S2) detects paper during power-on. 2 Technology > Detecting Jams > Outline 2-21

2 Technology > Detecting Jams > Outline 2-22 Jam type Sensor Jam description Error avoidance jam - When the controller detected the following errors during feeding operation. Error in the paddle motor (E577) Error in the front alignment motor (E530) Error in the rear alignment motor (E537) Error in the tray auxiliary guide motor (E583) Error in the gripper motor (E575) Error in the stack tray shift motor (E540) Error in the staple motor (E531) T-2-8 2 Technology > Detecting Jams > Outline 2-22

2 Technology > Power Supply > Protective Functions 2-23 Power Supply Outline When the host machine is turned on, it supplies the finisher controller PCB with 24VDC and 5VDC; the 24VDC power is used to drive the motors and the switches, while the 5VDC power is used for the sensors and the ICs. Finisher Controller PCB 5VDC Sensors Host Machine CPU(U1) 24VDC F1 Motor Driver (U5) to (U12) M Motors SW1 Front Door Switch F2, F3, F5 to 10 F4 Motor Driver (U13, 14) SW2 M8 Stack Tray Lower Limit Switch Stack Tray Shift Motor F-2-39 Protective Functions The finisher is provided with fuses (F1 through 10) which blow in response to overcurrent. 2 Technology > Power Supply > Protective Functions 2-23

2 Technology > Work of Service > Upgrading 2-24 Work of Service When replacing the parts When you have replaced the finisher controller PCB with the service parts, check that the firmware is the latest version. If it is not the latest version, upgrade it. Periodical Servicing This finisher has no periodic service items. Upgrading When upgrading the firmware of the finisher controller PCB, upgrade from the host machine. (Refer to the service manual for the host machine as to the detail.) 2 Technology > Work of Service > Upgrading 2-24

3 Periodic Servicing List of Work for Scheduled Servicing 3 Periodic Servicing

3 Periodic Servicing > List of Work for Scheduled Servicing List of Work for Scheduled Servicing 3-2 There is no item that requires the scheduled service in this finisher.. 3 Periodic Servicing > List of Work for Scheduled Servicing 3-2

4 Parts Replacement and Cleaning Procedure Finisher List of Parts External / Internal Covers Main Units Motors Switches PCBs 4 Parts Replacement and Cleaning Procedure

Finisher 4 Parts Replacement and Cleaning Procedure > Finisher > Detaching the Finisher from the Host Machine 4-2 Detaching the Finisher from the Host Machine CAUTION: 1) Lift the control panel and open the front door. When detaching this finisher from the host machine, be sure to check that the host machine has been turned off and its power plug has been disconnected from the outlet. When disassembling or assembling this finisher, remove it from the host machine following the specified procedure. F-4-1 2) Release the hook to remove the front door. 3) Release the hook to remove the stack tray. x1 F-4-2 x1 F-4-3 4 Parts Replacement and Cleaning Procedure > Finisher > Detaching the Finisher from the Host Machine 4-2

4 Parts Replacement and Cleaning Procedure > Finisher > Detaching the Finisher from the Host Machine 4-3 4) Insert a screwdriver or the like in the hole [A] to release the hook, and then slide the finisher leftward until it stops. A NOTE: After releasing the hook by sliding the finisher 2-3 cm, you can remove the screwdriver or the like. F-4-4 NOTE: 5) While releasing the hook by raising the lever, remove the finisher from the host machine. The hook may not be released completely with the finisher at the leftmost position. In this case, slide the finisher 1-2 cm back and raise the lever to release the hook. F-4-5 4 Parts Replacement and Cleaning Procedure > Finisher > Detaching the Finisher from the Host Machine 4-3

4 Parts Replacement and Cleaning Procedure > List of Parts > External / Internal Covers > Rear 4-4 List of Parts Rear Front External / Internal Covers Grate-shaped Guide Upper Cover Upper Feed Guide Unit Rear Cover PCB Cover F-4-8 Stack Tray Front Door F-4-6 No. Name Part No. Reference [1] Front Door FM0-4874 - [2] Front Cover FM0-4872 Refer to page 4-7 [3] Rear Cover FE2-3660 Refer to page 4-7 [4] Upper Feed Guide Unit FM4-8176 Refer to page 4-8 [5] Upper Cover FE2-3661 Refer to page 4-9 [6] PCB Cover FE2-3658 Refer to page 4-9 [7] Staple Unit FM4-8187 Refer to page 4-11 [8] Grate-shaped Guide FM0-4871 Refer to page 4-10 [9] Stack Tray FE2-3662 - T-4-1 Staple Unit Front Cover F-4-7 4 Parts Replacement and Cleaning Procedure > List of Parts > External / Internal Covers > Rear 4-4

4 Parts Replacement and Cleaning Procedure > List of Parts > List of Motors 4-5 Main Units List of Motors Upper Processing Tray Unit (Rear) M1 M3 M5 M2 M8 M7 M4 M9 Lower Processing Tray Unit Upper Processing Tray Unit (Front) M6 F-4-9 F-4-10 No. Name Part No. Reference [1] Upper Processing Tray Unit (Front) FM0-4865 Refer to page 4-12 [2] Upper Processing Tray Unit (Rear) FM0-4866 Refer to page 4-12 [3] Lower Processing Tray Unit - Refer to page 4-15 T-4-2 No. Name Part No. Reference M1 Feed Motor FM4-8171 Refer to page 4-16 M2 Delivery Motor FK3-1668 Refer to page 4-17 M3 Paddle Motor FM4-8183 Refer to page 4-18 M4 Front Alignment Motor FM4-8181 Refer to page 4-18 M5 Rear Alignment Motor FM4-8181 Refer to page 4-19 M6 Tray Auxiliary Guide Motor FM4-8183 Refer to page 4-19 M7 Gripper Motor - - M8 Stack Tray Shift Motor FM4-8201 Refer to page 4-20 M9 Staple Motor - - T-4-3 4 Parts Replacement and Cleaning Procedure > List of Parts > List of Motors 4-5

4 List of Sensors and Switches Parts Replacement and Cleaning Procedure > List of Parts > List of PCBs List of PCBs 4-6 S1 S5 S7 S2 SW1 S10 S3 S11/S12/S13 S9 S4 S6 PCB1 S8 SW2 F-4-11 F-4-12 No. Name Part No. Reference S1 Inlet Sensor WG8-5776 - S2 Delivery Sensor WG8-5776 - S3 Paddle HP Sensor WG8-5776 - S4 Front Alignment Plate HP Sensor WG8-5776 - S5 Rear Alignment Plate HP Sensor WG8-5776 - S6 Tray Auxiliary Guide HP Sensor WG8-5776 - S7 Gripper HP Sensor WG8-5776 - S8 Gripper Encoder Sensor WG8-5776 - S9 Stack Tray Paper Height Sensor WG8-5776 - S10 Staple Paper Detection Sensor FK2-1772 - S11 Staple HP Sensor - - S12 Staple Edging Sensor - - S13 Staple Sensor - - SW1 Front Door Switch FK3-1665 Refer to page 4-22 SW2 Stack Tray Lower Limit Switch FK3-1664 Refer to page 4-23 T-4-4 No. Name Part No. Reference PCB1 Finisher Controller PCB FM4-8199 Refer to page 4-24 T-4-5 4 Parts Replacement and Cleaning Procedure > List of Parts > List of PCBs 4-6

4 External / Internal Covers Parts Replacement and Cleaning Procedure > External / Internal Covers > Removing the Rear Cover 4-7 Removing the Front Cover 1) Remove the 4 screws and release the hook, and then remove the front cover. x1 x4 F-4-13 Removing the Rear Cover 1) Remove the 3 screws and release the hook, and then remove the rear cover. x3 x1 F-4-14 4 Parts Replacement and Cleaning Procedure > External / Internal Covers > Removing the Rear Cover 4-7

4 Parts Replacement and Cleaning Procedure > External / Internal Covers > Removing the Upper Feed Guide Unit 4-8 Removing the Upper Feed Guide Unit 1) Remove the front and rear covers. (Refer to page 4-7) 2) Open the paper delivery guide, holding it by the front tab. Then remove the 3 screws. x3 F-4-15 3) Remove the 3 screws and disconnect the connector from the rearward, and then loosen the screw [A] of the belt tensioner to remove the belt. Then remove the upper feed guide unit. x3 x1 A F-4-16 4 Parts Replacement and Cleaning Procedure > External / Internal Covers > Removing the Upper Feed Guide Unit 4-8

4 Parts Replacement and Cleaning Procedure > External / Internal Covers > Removing the PCB Cover 4-9 Removing the Upper Cover 1) Remove the front and rear covers. (Refer to page 4-7) 2) Remove the 4 screws, and then remove the upper cover. x4 F-4-17 Removing the PCB Cover 1) Remove the screw, and then remove the PCB cover. x1 F-4-18 4 Parts Replacement and Cleaning Procedure > External / Internal Covers > Removing the PCB Cover 4-9

4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Grate-shaped Guide 4-10 Main Units Removing the Grate-shaped Guide 1) Remove the front and rear covers. (Refer to page 4-7) 2) Loosen the 2 screws [A], and then remove the stack tray support plate by loosening the 2 screws. x2 A A F-4-19 4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Grate-shaped Guide 4-10

4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Staple Unit 4-11 3) Remove the 4 screws and disconnect the connector, and then remove the grate-shaped guide. x1 x2 x2 F-4-20 Removing the Staple Unit 1) Removing the front cover (Refer to page 4-7) 2) Remove the 2 screws and disconnect the 2 connectors, and then remove the staple unit. x2 x2 F-4-21 4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Staple Unit 4-11

4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Upper Processing Tray Unit (Front / Rear) 4-12 Removing the Upper Processing Tray Unit (Front / Rear) 1) Remove the front and rear covers. (Refer to page 4-7) 2) Remove the upper feed guide unit. (Refer to page 4-8) 3) Remove the upper cover. (Refer to page 4-9) 4) Remove the grate-shaped guide. (Refer to page 4-10) 5) Remove the 2 screws and disconnect the connector, and then release the harness from the harness guide to remove the paddle motor unit. x2 x1 x1 F-4-22 6) Remove the 2 E-rings and gear and bushing, and then remove the paddle unit. F-4-23 4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Upper Processing Tray Unit (Front / Rear) 4-12

4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Upper Processing Tray Unit (Front / Rear) 4-13 7) Remove the 4 screws, and then remove the support plate. 8) Remove the 4 screws, and then remove the delivery guide. x4 x4 F-4-24 F-4-25 9) Remove the 5 screws and disconnect the connector, and remove the belt by loosening the 2 screws [A] securing the delivery motor unit, and then remove the delivery unit. CAUTION: When tightening the screws securing the delivery motor unit, attach the belt and then tighten them at the position where tension is applied to the belt due to the motor's own weight. x5 x1 A A F-4-26 F-4-27 4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Upper Processing Tray Unit (Front / Rear) 4-13

4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Upper Processing Tray Unit (Front / Rear) 4-14 10) Remove the 3 screws and disconnect the 2 connectors, and then release the harness from the harness guide to remove the upper processing tray unit (front). x3 x2 x1 F-4-28 11) Remove the 3 screws and disconnect the 2 connectors, and then release the harness from the harness guide to remove the upper processing tray unit (rear). x3 x2 x1 F-4-29 4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Upper Processing Tray Unit (Front / Rear) 4-14