mj1023 SM v03

FINISHER
MJ-1023/1024/1030
HOLE PUNCH UNIT MJ-6004
BRIDGE KIT KN-3511/3520
File No. SME030019C0

R03042131901-TTEC
Ver03_2007-09
Trademarks
Molykote is a registered trademark of Dow Corning Corporation.
Other company names and product names in this manual are the trademarks of their respective
companies.
c 2003 TOSHIBA TEC CORPORATION All rights reserved
Under the copyright laws, this manual cannot be reproduced in any form without prior
written permission of TOSHIBA TEC CORPORATION. No patent liability is assumed,
however, with respect to the use of the information contained herein.
06/04
General Precautions for Installation/Servicing/Maintenance for the Finisher MJ-1023/1024/

1030, Hole Punch Unit MJ-6004, Bridge Kit KN-3511/3520
The installation and service should be done by a qualified service technician.
1. When installing the Finisher MJ-1023/1024/1030, Hole punch unit MJ-6004, Bridge kit
KN-3511/3520 to the equipment, be sure to follow the instructions described in the
Unpacking/Set-Up Procedure for the MJ-1023/1024/1030/6004 booklet which comes
with each unit of the MJ-1023/1024/1030/6004.
2. The MJ-1023/1024/1030, MJ-6004, KN-3511/3520 should be installed by an authorized/qualified person.
3. The MJ-1023/1024/1030/6004 are quite heavy and each weighs approximately 39kg
(85.98 lb) /70kg (154.32lb) /70kg (154.32lb) /9kg (19.84lb), therefore pay full attention
when handling it.
4. Before starting installation, servicing or maintenance work, be sure to turn off and
unplug the equipment first.
5. Be sure to fix and plug in the power cord securely after the installation so that no one
trips over it.
6. When servicing the machines with the power turned ON, be sure not touch live sections and rotating/operating sections.
7. When selecting the installation site, avoid placing the MJ-1023/1024/1030 and equipment on different levels or inclined floors.
8. When servicing or maintaining the MJ-1023/1024/1030, MJ-6004, KN-3511/3520, be
careful about the rotating or operation sections such as gears, pulleys, sprockets,
cams, belts, etc.
9. When parts are disassembled, reassembly is basically the reverse of disassembly
unless otherwise noted in this manual or other related materials. Be careful not to
reassemble small parts such as screws, washers, pins, E-rings, toothed washers to
the wrong places.
10. Basically, the machine should not be operated with any parts removed or disassembled.
11. Delicate parts for preventing safety hazard problems (such as breakers, thermofuses,
fuses, door switches, sensors, etc. if any) should be handled/installed/adjusted correctly.
12. Use suitable measuring instruments and tools.
13. During servicing or maintenance work, be sure to check the serial No. plate and other
cautionary labels (if any) to see if they are clean and firmly fixed. If not, take appropriate actions.
14. The PC board must be stored in an anti-electrostatic bag and handled carefully using
a wristband, because the ICs on it may be damaged due to static electricity. Before
using the wrist band, pull out the power cord plug of the equipment and make sure that
there is no uninsulated charged objects in the vicinity.
15. For the recovery and disposal of used MJ-1023/1024/1030, MJ-6004, KN-3511/3520s,
consumable parts and packing materials, it is recommended that the relevant local
regulations/rules.
16. After completing installation, servicing and maintenance of the MJ-1023/1024/1030,
MJ-6004, KN-3511/3520, return the MJ-1023/1024/1030, MJ-6004, KN-3511/3520 to
its original state, and check operation.
06/04
17. When you move the finisher, do not move it in the direction of the arrow as shown in
the figure [A] below otherwise it might fall down.
[A]
06/04
INTRODUCTION
1 Symbols Used
This documentation uses the following symbols to indicate special information:
Symbol
Description
Indicates an item of a non-specific nature, possibly classified as Note, Caution, or
Warning.
Indicates an item requiring care to avoid electric shocks.
Indicates an item requiring 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.
INTRODUCTION
2 Outline of the Manual

This Service Manual contains basic facts and figures needed to service the Finisher/Saddle Finisher in the field, and it consists of the following chapters:
Chapter 1
Chapter 2
General Description: features, specifications

Finisher Unit Outline of Operation:
mechanical systems by function, electrical systems in reference to principles of operation, timing of operation; construction and outline of electrical circuitry
Chapter 3 Saddle Stitcher Unit Outline of Operation:
Chapter 4 Puncher Unit (Option) Outline of Operation:
Chapter 5 Bridge Kit (Option): basic operation, disassembly and adjustment, maintenance
Chapter 6 Mechanical Systems: construction of mechanical systems; disassembly, assembly, and adjustments
Chapter 7 Maintenance and Inspection:
periodically replacement parts, durables and consumables;
scheduled servicing chart
Chapter 8 Troubleshooting:
standards, adjustments, troubleshooting tables
Appendix:
general timing chart, list of signals/abbreviations, general
circuit diagrams, etc
For installation, refer to the Installation Procedure found in the shipping box; this manual omits
descriptions of the installation work.
ii
INTRODUCTION
The descriptions in this Service Manual are based on he following rules:

1. In each chapter, the uses of the function in question and its relationship to electrical and mechanical systems are discussed and the timing of operation of its associated parts is explained
by means of outlines and diagrams.
represents a mechanical path, while the symbol
In the diagrams, the symbol
with a name next to it indicates the flow of an electric signal.
The expression turn on the power means turning on the power switch, closing the front
door, and closing the delivery door so that the machine will be supplied with power.
2. In circuit diagrams (digital), a signal whose level is High is expressed as being 1, while a
single whose level is Low is expressed as being 0; the level of voltage, however, varies from
circuit to circuit.
The machine uses CPUs, whose internal mechanisms cannot be checked in the field, and,
therefore, are not explained. In addition, the machines PCBs are not intended for repairs at
the users and, therefore, are explained by means of block diagrams: two types are used, i.e.,
between sensors and inputs of PCBs equipped with a control or drive function and between
outputs equipped with a control or drive function and loads; in addition, functional block diagrams are used at times.
Changes made to the machine for product improvement are communicated in the form of a Service Information bulletin as needed. All service persons are expected to go through all service
documentation including the bulletins and be equipped to respond to the needs of the field (as by
being able to identify possible causes of problems).
iii
CONTENTS
Contents
CHAPTER 1 GENERAL DESCRIPTION
1 Features ................................................. 1-1
2 Specifications ........................................ 1-2
2.1 Specifications ............................... 1-2
2.1.1 Finisher Unit .......................... 1-2
2.1.2 Saddle Stitcher Unit ............... 1-6
2.1.3 Puncher Unit (Option) ........... 1-7
3 Names of Parts....................................... 1-9

3.1 Cross Section ................................ 1-9
3.1.1 Finisher Unit .......................... 1-9
3.1.2 Saddle Stitcher Unit ............. 1-10
3.1.3 Puncher Unit (option) .......... 1-11
4 Routine Maintenance by the User ....... 1-12
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION

1 Basic Operations ................................... 2-1
1.1 Specifications ............................... 2-1
1.2 Outline of the Electrical
Circuitry ....................................... 2-2
1.3 Inputs to and Outputs from the
Finisher Controller PCB ............... 2-3
1.3.1 Inputs to the Finisher Controller
PCB (1/4) ............................... 2-4
PCB (2/4) ............................... 2-5
PCB (3/4) ............................... 2-6
PCB (4/4) ............................... 2-7
1.3.5 Outputs to the Finisher Controller
PCB (1/2) ............................... 2-8
1.3.6 Outputs to the Finisher Controller
PCB (2/2) ............................... 2-9
1.3.7 Inputs to and Outputs from the
Finisher Controller PCB ...... 2-10
Finisher Controller(1/2) ....... 2-11
Finisher Controller(2/2) ....... 2-12
2 Feed/Drive System .............................. 2-13
2.1 Outline ........................................ 2-13
2.1.1 Normal Delivery .................. 2-14
iv
2.1.2
Saddle Stitcher Delivery

(Saddle Finisher) .................. 2-18
2.2 Ejection Path Types .................... 2-19
2.2.1 Outline ................................. 2-19
2.2.2
Straight Ejection ................. 2-19
2.2.3 Processing Tray Path ............ 2-20
2.2.4 Buffer/Processing Tray
Path ...................................... 2-21
2.3 Delivery/Ejection ........................ 2-23
2.3.1 Outline ................................. 2-23
2.3.2 Rear End Assist Operation ... 2-26
2.4 Stack Job Offset .......................... 2-27
2.4.1 Outline ................................. 2-27
2.4.2 Processing Tray Paper Stacking
Operation ............................. 2-29
2.4.3 Offset Operation .................. 2-30
2.4.4 Stack Delivery Operation ..... 2-31
2.5 Stapling Operation ...................... 2-32
2.5.1 Outline ................................. 2-32
2.5.2 First Sheet ............................ 2-34
2.5.3 Second and Subsequent Sheets
............................................. 2-36
2.5.4 Last Sheet............................. 2-37
2.6 Stapler Unit ................................ 2-38
2.6.1 Shifting the Stapler Unit ...... 2-40
2.7 Tray Operation ............................ 2-43
2.7.1
Outline ................................ 2-43
CONTENTS
2.8 Shutter Operation ....................... 2-46

2.8.1
Outline ................................ 2-46
2.9 Detecting Jams ........................... 2-47
3 Power Supply System .......................... 2-49

3.1 Outline ........................................ 2-49
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF

OPERATION
1 Basic Operations ................................... 3-1
1.1 Outline .......................................... 3-1
1.2 Electrical Circuitry ....................... 3-2
1.3 Inputs to and Outputs from the
Saddle Stitcher Controller PCB
...................................................... 3-3
1.3.1 Inputs to the Saddle Stitcher
Controller PCB (1/3).............. 3-3
Controller PCB (2/3).............. 3-4
Controller PCB (3/3).............. 3-5
1.3.4 Outputs from the Saddle Stitcher
Controller PCB (1/2).............. 3-6
1.3.5 Outputs from the Saddle Stitcher
Controller PCB (2/2).............. 3-7
2 Feeding/Drive System ........................... 3-8
2.1 Outline .......................................... 3-8
2.1.1 Receiving Sheets .................... 3-9
2.1.2 Aligning the Sheets .............. 3-10
2.1.3 Stitching ............................... 3-11
2.1.4 Feeding the Stack ................. 3-12
2.1.5 Folding/Delivering the Stack
............................................. 3-13
3 Paper Output Mechanism .................... 3-14
3.1 Outline ........................................ 3-14
3.2 Controlling the Inlet Flappers .... 3-17
3.2.1 Outline ................................. 3-17
3.2.2
6
7
A3/LD Paper Path (3 sheets)

............................................. 3-18
3.2.3 B4 Paper Path (3 sheets) ...... 3-19
3.2.4 A4-R/LT-R Paper Path
(3 sheets) .............................. 3-20
3.3 Controlling the Movement of
Sheets ......................................... 3-21
3.3.1 Outline ................................. 3-21
3.4 Controlling the Aligning the Sheets
.................................................... 3-23
3.5 Controlling the Phase of the
Crescent Roller ........................... 3-26
3.5.1 Outline ................................. 3-26
Stitching System .................................. 3-28
4.1 Outline ........................................ 3-28
4.2 Stitcher Unit Operation .............. 3-29
Folding/Delivery System ..................... 3-31
5.1 Outline ........................................ 3-31
5.2 Controlling the Movement of
Stacks ......................................... 3-32
5.3 Folding a Stack ........................... 3-33
5.4 Double Folding a Stack .............. 3-36
Checking For a Jam ............................. 3-38
6.1 Outline ........................................ 3-38
Power Supply ...................................... 3-40
7.1 Outline ........................................ 3-40
7.2 Protection Function .................... 3-40
CONTENTS
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF

OPERATION
1 Basic Operation ..................................... 4-1
1.1 Outline .......................................... 4-1
1.2 Inputs to and Outputs from Punch
Driver PCB ................................... 4-2
1.2.1 Inputs to Punch Driver PCB
(1/1)........................................ 4-2
1.2.2 Outputs from Punch Driver
PCB (1/2) ............................... 4-3
1.2.3 Outputs from Punch Driver
PCB (2/2) ............................... 4-4
2 Punch Operation .................................... 4-5

2.1 Outline .......................................... 4-5
2.2 Punch Operation ........................... 4-7
2.2.1 2-/4-hole Type ........................ 4-8
2.2.2 2-/3-hole Dual Use Type ........ 4-9
2.3 Horizontal Registration Operation
.................................................... 4-12
3 Power Supply System .......................... 4-15
3.1 Outline ........................................ 4-15
3.2 Protection Function .................... 4-15
CHAPTER 5 BRIDGE KIT (OPTION)BASIC OPERATION

1 Basic Operation ..................................... 5-1
1.1 Outline .......................................... 5-1
1.2 Construction ................................. 5-2
1.2.1 Front side sectional view ....... 5-2
1.2.2 Rear side view ........................ 5-2
1.3
Arrangement of Electrical
Parts ....................................... 5-3
2 Disassembly and Adjustment ................ 5-4

2.1 Electrical Parts ................................. 5-4
3 Maintenance .......................................... 5-7
3.1 Periodically Replaced Parts .......... 5-7
3.2 Scheduled Maintenance ................ 5-7
CHAPTER 6 MECHANICAL SYSTEMS

1 Finisher Unit .......................................... 6-1
1.1 Externals and Controls ................. 6-1
1.1.1 Removing the Front Cover..... 6-2
1.1.2 Removing the Rear Cover
............................................... 6-3
1.1.3 Removing the Left Upper
Cover ...................................... 6-3
1.1.4 Removing the Upper Door ..... 6-4
1.1.5 Removing Tray1 .................... 6-5
1.1.6 Removing Tray2 .................... 6-6
1.1.7 Removing the Grate-Shaped
Upper Guide ........................... 6-8
1.1.8 Removing the Grate-Shaped
Lower Guide .......................... 6-8
vi
1.2 Delivery System ........................... 6-9

1.2.1 Removing the Stapler ............ 6-9
1.2.2 Removing the Processing
Tray ...................................... 6-10
1.2.3 Removing the Buffer roller
............................................. 6-13
1.2.4 Removing the Return roller
............................................. 6-13
1.2.5 Removing the Swing Unit ... 6-14
1.2.6 Removing the Return Roller
Unit ...................................... 6-15
1.2.7 Removing the Swing Unit
Static Charge Eliminator ...... 6-15
CONTENTS
1.2.8
Removing the Inlet Static

Charge Eliminator ................ 6-17
1.3 PCBs ........................................... 6-18
1.3.1 Removing the Finisher
Controller PCB .................... 6-18
2 Saddle Stitcher Unit ............................ 6-19
2.1 Exterior Control Components .... 6-19
2.1.1 Removing the Front Cover... 6-20
2.1.2 Removing the Rear Cover .... 6-20
2.1.3 Removing the Front Inside
Upper Cover ......................... 6-21
2.1.4 Removing the Front Inside
Lower Cover ........................ 6-21
2.1.5 Removing the Saddle Delivery
Tray Unit .............................. 6-22
2.1.6 Removing the Upper Delivery
Guide.................................... 6-23
2.1.7 Removing the PCB Cover.... 6-24
2.1.8 Removing the Inlet Delivery
Unit ...................................... 6-24
2.2 Saddle Unit ................................. 6-26
2.2.1 Removing the Saddle Unit
............................................. 6-26
2.2.2 Removing the Paper Folding
Roller ................................... 6-28
2.2.3 Removing the Stitcher
Mount Unit........................... 6-33
2.2.4 Adjusting the Stitcher
Position ................................ 6-33
2.2.5 Removing the Positioning
Plate Unit ............................. 6-36
2.2.6
Removing the No.1 and No.2

Flappers................................ 6-37
2.3 PCBs ........................................... 6-38
2.3.1 Removing the Saddle
Stitcher Controller PCB ....... 6-38
3 Puncher Unit (option) .......................... 6-39
3.1 Externals and Controls ............... 6-39
3.1.1 Removing the Rear Cover .... 6-39
3.1.2 Removing the Right Guide
Unit ...................................... 6-40
3.1.3 Removing the Upper Cover
............................................. 6-40
3.2 Puncher Driver System ............... 6-41
3.2.1 Removing the Punch Motor
............................................. 6-41
3.2.2 Removing the Horizontal
Registration Motor ............... 6-41
3.2.3 Removing the Punch Unit .... 6-42
3.2.4 Removing the Punch Unit
Harness ................................ 6-46
3.2.5 Installing the Punch Unit
Harness ................................ 6-49
3.3 PCBs ........................................... 6-50
3.3.1 Removing the LED PCB ..... 6-50
3.3.2 Removing the Photosensor
PCB ...................................... 6-51
3.3.3 Removing the Scrap Full
Detector PCB Unit ............... 6-51
3.3.4 Removing the Punch
Controller PCB .................... 6-51
vii
CONTENTS
CHAPTER 7 MAINTENANCE AND INSPECTION

1 Periodically Replaced Parts ................... 7-1
1.1 Finisher Unit ................................. 7-1
1.2 Saddle Stitcher Unit ..................... 7-1
1.3 Puncher Unit (option) ................... 7-1
2 Consumables and Durables ................... 7-2
2.1 Finisher Unit ................................. 7-2

2.2 Saddle Stitcher Unit ..................... 7-2
2.3 Puncher Unit (option) ................... 7-2
3 Periodic Maintenance ............................ 7-2
3. Updating Finisher ROM ........................ 7-3
CHAPTER 8 TROUBLESHOOTING
1 Adjustments ........................................... 8-1
1.1 Electrical System (finisher unit) ... 8-1
1.1.1 Adjusting the Alignment
Position .................................. 8-1
1.1.2 Adjusting the Staple Position
............................................... 8-2
1.2 Electrical System
(Saddle stitcher unit) .................... 8-4
1.2.1 Adjusting the Folding
Position .................................. 8-4
1.2.2 Adjusting the Stitching
Position (adjusting center
stitching) ................................ 8-6
1.3 Electrical System (Puncher unit
(option)) ........................................ 8-7
1.3.1 Sensor Output Adjustment
............................................... 8-7
1.3.2 Registering the Number of
Punch Holes ........................... 8-8
2 Arrangement of Electric Components
............................................................... 8-9
2.1 Finisher Unit ................................. 8-9
2.1.1 Sensors ................................... 8-9
2.1.2 Microswitches ...................... 8-11
2.1.3 Solenoids.............................. 8-12
2.1.4 Motors .................................. 8-13
2.1.5 Clutches ............................... 8-15
2.1.6 PCBs .................................... 8-16
2.2. Saddle Stitcher Unit ................... 8-17
2.2.1 Sensors ................................. 8-17
2.2.2 Microswitches ...................... 8-19
viii
2.2.3 Motors .................................. 8-20

2.2.4 Solenoids.............................. 8-21
2.2.5 PCBs .................................... 8-22
2.3 Punch Unit (option) .................... 8-23
2.3.1 Sensors ................................. 8-23
2.3.2 Microswitches ...................... 8-24
2.3.3 Motors .................................. 8-25
2.3.4 PCBs .................................... 8-26
3 LEDs and Check Pins by PCB ............ 8-27
3.1 Finisher Controller PCB ............. 8-27
3.2 Saddle Stitcher Controller PCB
.................................................... 8-28
3.3 Punch Controller PCB ................ 8-29
4 Troubleshooting ................................... 8-30
4.1 Troubleshooting (finisher unit)
.................................................... 8-30
4.1.1 Saddle stitcher controller PCB
communication error ............ 8-30
4.1.2 Puncher unit (option)
communication error ............ 8-30
4.1.3 Backup RAM error .............. 8-31
4.1.4 Front aligning plate motor
error ...................................... 8-31
4.1.5 Rear aligning plate motor
error ...................................... 8-32
4.1.6 Staple motor error ................ 8-32
4.1.7 Stapler shift motor error ....... 8-33
4.1.8 Swing motor error ................ 8-33
4.1.9 Tray 1 shift motor error ........ 8-34
4.1.10 Tray 2 shift motor error ........ 8-34
4.1.11 Stack ejection motor error.... 8-35
CONTENTS
4.1.12 Rear end assist motor error .. 8-35

4.1.13 Gear change motor error ...... 8-36
4.2 Troubleshooting Procedure
(Saddle Stitcher Unit) ................. 8-37
4.2.1
Paper positioning plate motor
error ...................................... 8-37
4.2.2 Paper folding motor error .... 8-37
4.2.3 Guide motor error ................ 8-38
4.2.4 Aligning motor error ............ 8-38
4.2.5 Stitcher (rear) error .............. 8-39
4.2.6 Stitcher (front) error ............. 8-39
4.2.7 Paper pushing plate motor
error ...................................... 8-40
4.2.8 Sensor connector error ............. 8-40
4.2.9 Micro switch error ............... 8-41
4.3 Troubleshooting Procedure
(Puncher unit (option)) ............... 8-42
4.3.1
Puncher unit backup RAM

error ...................................... 8-42
4.3.2 Punch motor error ................ 8-42
4.3.3 Horizontal registration motor
error ...................................... 8-43
5 Self Diagnosis ..................................... 8-44
5.1 Outline ........................................ 8-44
5.2 Errors .......................................... 8-44
5.2.1 Finisher Unit ........................ 8-44
5.3 Alarm .......................................... 8-50
5.3.1 Finisher Unit ........................ 8-50
ix
CONTENTS
APPENDIX
1 General Timing Chart ........................... A-1
1.1 Finisher Unit ................................ A-1
1.2 Saddle Stitcher Unit .................... A-2
1.3 Puncher Unit (option) .................. A-3
2 List of Signal Names/Abbreviations .... A-5
2.1 Finisher Unit ................................ A-5
2.2 Saddle Stitcher Unit .................... A-6
2.3 Puncher Unit (option) .................. A-7
3 Finisher Unit General Circuit Diagram
.............................................................. A-9
3.1 Finisher Controller PCB (A501)
................................................... A-11
................................................... A-12
................................................... A-13
................................................... A-14
................................................... A-15
................................................... A-16
................................................... A-17
................................................... A-18
................................................... A-19
................................................... A-20
................................................... A-21
................................................... A-22
................................................... A-23
................................................... A-24
3.15 Stapler PCB1 ............................. A-25
3.16 Stapler PCB2 ............................. A-26

3.17 Tray1/Tray2 Shift Area Sensor
PCB ........................................... A-27
3.18 Tray1/Tray2 Driver PCB ........... A-29
4 Saddle Stitcher Unit Circuit Diagram
............................................................ A-30
(A501) ....................................... A-31
(A502) ....................................... A-32
(A503) ....................................... A-33
(A504) ....................................... A-34
(A505) ....................................... A-35
(A506) ....................................... A-36
(A507) ....................................... A-37
(A508) ....................................... A-38
(A509) ....................................... A-39
(A510) ....................................... A-40
4.11 Saddle Driver PCB .................... A-41
4.12 Paper Sensor PCB ..................... A-43
5 Puncher Unit General Circuit Diagram
............................................................ A-45
5.1 Punch Controller PCB (A501) .. A-46
5.5 Scrap Full Detector PCB ........... A-51
5.6 LED PCB ................................... A-52
5.7 Photosensor PCB ....................... A-53
6 Solvents and Oils ................................ A-55
CHAPTER 1
GENERAL DESCRIPTION
#ChapterCover_b.p65
03/05/13, 20:48
1 Features
a. Use of straight buffering*1
Use of straight buffering (rear copy edge restraining type at straight path) enables the Finisher/
Saddle Finisher to continuously receive copy from the host machine during stapling or offset operation.
b. Use of simultaneous stack delivery/ejection*1
Conventional models delivered buffered copy stack to the processing tray after ejecting copy
stack to the delivery tray. This Finisher/Saddle Finisher can simultaneously eject copy stack to
the delivery tray while delivering copy stack from the processing tray and continuously receive
copy from the host machine during stapling or offset operation thus increasing productivity.
c. Use of full front processing mechanism
Installation space is reduced with the use of full front processing mechanism (placing jam handling mechanism on top and front side enables processing without separating from the host machine).
d. Increased stacking capacity
Capable of stacking up to 147 mm of small size paper (equivalent to 1000 sheets) or 73.5 mm
of large size paper (equivalent to 500 sheets) on upper and lower trays. (Basis weight 80 g/m2)
e. Wide range of delivery capability
Capable of handling paper basis weight from 60 to 256 g/m2.
f. Three different auto stapling functions
There are three different stapling positions (Front 1-point stapling (30 deg./45 deg.), Rear 1point stapling (30 deg./45 deg.), 2-point center stapling)
g. Saddle stitch function (Saddle Finisher)
Capable of ejecting up to 15 sheets center stapled and center folded. (Basis weight 80 g/m2)
h. Punch function (optional)
Capable of ejecting copy with binding holes punched with the use of Puncher Unit. (possible
with 60 to 256g/m2 paper, not possible with reproducibles or transparencies)
* Available only when sort/staple sort/group sort is set for A4, B5, or LT paper.
1-1
2 Specifications
2.1 Specifications
2.1.1 Finisher Unit
Item
Specification
Trays 1 and 2: by lifting tray

Face down
A3, A4, A4-R, A5-R, B4, B5, B5-R, LD, LG,
LT, LT-R, ST-R, FOLIO, COMPUTER
Basis weight
60 g/m2 to 256 g/m2 (16 lb. Bond to 140 lb. Index)
Bins
Trays 1 and 2
Modes
Non sort: Trays 1 and 2
Sort: Trays 1 and 2
Staple: Trays 1 and 2
Stacking capacity
Tray 1: Non staple sort
Large size: 500 sheets (73.5 mm)
Small size: 1,000 sheets (147 mm)
Tray 2: Non staple sort
Large size: 500 sheets (73.5 mm)
Small size: 1,000 sheets (147 mm)
Tray 1: Staple sort
Large size: 500 sheets/30 sets/73.5 mm
Small size: 1,000 sheets/30 sets/147 mm
Tray 2: Staple sort
Large size: 500 sheets/30 sets/73.5 mm
Small size: 1,000 sheets/30 sets/147 mm
Mixed stacking capacity Size mixing: 500 sheets (73.5 mm)
Stapling: 500 sheets/30 sets/73.5 mm
By rotating cam
Stapling
Stapling position
See Figure F01-201-01
Stapling capacity
MJ-1023/1024
Small size: 50 sheets, Large size: 30 sheets
Remarks
Stacking method
Stacking orientation
Stacking size

MJ-1030
1-2
06/04
Equivalent of 80 g/m2 (21.3

lb. Bond) paper.
Whichever the stack reaches first.


lb. Bond) paper.
Equivalent of 90 g/m2 (24 lb.
Bond) paper.
Equivalent of 105 g/m2 (28
lb. Bond) paper.
lb. Bond) paper.
Equivalent of 90 g/m2 (24 lb.
Bond) paper.
Equivalent of 105 g/m2 (28
lb. Bond) paper.
Item
Specification
Staple supply
Staples
Special staple cartridge (5000 staples)

Special (STAPLE-2000 : 3 cartridges of 5000
staples in a package)
Provided
Not provided
Front 1-point stapling (30 deg.)
A4-R, LG, LT-R, FOLIO
Front 1-point stapling (45 deg.)
A3, B4, A4, B5, LD, LT, COMPUTER
Rear 1-point stapling (30 deg.)
A4-R, LG, LT-R, FOLIO
Rear 1-point stapling (45 deg.)
A3, B4, A4, B5, LD, LT, COMPUTER
2-point stapling
A3, B4, A4, B5, LD, LT, FOLIO, COMUTER,
A4-R, LT-R, LG
Provided
Not provided
Not provided
Finisher:
536 (649) x 657 x 1086 mm (W (tray extended) x D x H)
Saddle Finisher:
649 (762) x 657 x 1086 mm (W (tray extended) x D x H)
Finisher: Approx. 39 kg (86 lb.)
Saddle Finisher: Approx. 70kg (154.32 lb.)
From host machine (24VDC, 5VDC)
170 W or less operating
Staple detection
Manual stapling
Stapling size
Paper detection
Control panel
Display
Dimensions
Weight
Power supply
Maximum power consumption
Remarks
Stacking capacity is equivalent of 80 g/m2 (21.3 lb. Bond) paper.

Alignment may not be correct if 750 or more small-size sheets are stacked.
Stacking capability is not guaranteed for mixed size stacking.
The term small-size stands for A4, A5-R, B5, LT, ST-R, while the term large-size stands for
A3, B4, A4-R, B5-R, LD, LG, LT-R, FOLIO, COMPUTER.
Note 5 : Basis weight: Over 105g/m2 (28 lb. Bond) cannot be stapled.
Note 6 : Grouping, sorting and stapling are not allowed for A5-R, B5-R and ST-R.
Note 1 :
Note 2 :
Note 3 :
Note 4 :
T01-201-01
1-3
06/04
Stapling Positions (Finisher Unit)

Front 1-point stapling (30deg.)
Front 1-point stapling (45deg.)
A4-R, LG, LT-R and FOLIO
A3, B4, A4, B5,

LD, LT and COMPUTER
Rear 1-point stapling (45deg.)
A4-R, LG, LT-R and FOLIO
A3, B4,A4,B5,
LD, LT and COMPUTER
5mm
5mm
F01-201-01
5mm
Rear 1-point stapling (30deg.)
5mm
1-4
5mm
5mm
5mm
5mm
2-point stapling
unit : mm
Paper size
5mm
A3, A4
A4-R, FOLIO
B4, B5, COMPUTER
LD, LT
LT-R, LG
83
39.5
63
74
42.5
203
159.5
183
194
162.5
F01-201-02
1-5
2.1.2 Saddle Stitcher Unit

Item
Specification
Stapling method
Folding position
Paper size
Capacity
Center binding (double folding)

See Figure F01-201-02
A3, B4, A4-R, LD, LT-R
W/binding: 1 sheet
W/out binding: 2 to 15 sheets
Paper weight
Stapling position
Staple accommodation
Staple supply
Staples
Staple detection
Manual stapling
Folding method
Folding mode
Folding position
Position adjustment
Power supply
Power consumption
Remarks
Including 1 cover page.

Maximum is 1 sheet of 256
g/m2 paper + 14 sheets of 80
g/m2 paper.
60 g/m2 to 256 g/m2 (17 lb. Bond to 140 lb. In- Special paper, postcards,
transparencies,
dex)
reproducibles, label paper, or
hole-punched paper cannot
be handled
2 points (center distribution; fixed interval)
2000 staples
Special cartridge (3 cartridges of 2000 staples
in a package)
Special staple (STAPLE-600)
Provided
Not provided
Roller contact
Double folding
Paper center
Provided
From finisher unit (24 VDC, 5 VDC)
170 W or less
T01-201-02
1-6
Staple and Folding Position (Saddle Finisher Unit)

unit : mm
1mm or less
Paper size
A3
B4
A4-R
LD
LT-R
83.0
63.0
39.5
74.0
42.0
203.0
183.0
159.5
194.0
162.0
F01-201-03
1-7
2.1.3 Puncher Unit (Option)

Item
Specification
Remarks
Punching method
Paper size
Reciprocating punching (Sequential punching)

2 holes:
A3, A4, A4-R, B4, B5, B5-R, FOLIO, LD, LG,
LT-R, LT, COMPUTER
2 or 3 holes:
2 holes/LG, LT-R, A4-R
3 holes/LD, LT, A3, A4
4 holes:
(F):A3, A4, LD, LT
(S):A3, B4, A4-R, A4, B5-R, B5, FOLIO, LD,
LG, LT-R, LT, COMPUTER
Basis weight
60 g/m2 to 256 g/m2 (17 lb. Bond to 140 lb. In- Transparencies not allowed
dex)
Punched hole diameter 2 holes: 6.5 mm
2 or 3 holes: 8 mm
4 holes: 6.5 mm
Punched scrap capacity 2 holes: 5,000 sheets or more
64 g/m2 or equivalent
2 or 3 holes: 3,000 sheets or more
4 holes: 5,000 sheets or more
W 112 x D 502 x H 298 (940.5*) mm
*Including the lower cover
Dimensions
Approx. 9kg (19.84 lb.)
Weight
Power supply
From finisher unit (24 VDC, 5 VDC)
120 W or less operating
Power consumption
T01-201-03
1-8
Hole position (Puncher Unit)

4-Hole(6.5) : MJ-6004F
2-Hole(6.5) : MJ-6004E
123
123
(801)
403
403
801
(801)
(801)
4-Hole(6.5) : MJ-6004S
2-Hole(8.0) : MJ-6004N
123
123
(211)
353
353
701
(701)
(211)
3-Hole(8.0) : MJ-6004N
123
1083
1081
1081
F01-201-04
Specifications are subject to change without notice.
1-9
3 Names of Parts
3.1 Cross Section
3.1.1 Finisher Unit
[2] [3]
[4]
[6] [5]
[10]
[8]
[9]
[1]
[1] Delivery tray

[2] Stack ejection roller
[3] Aligning plate
[4] 1st delivery roller
[5] Buffer roller
[6] Return roller

[7] Inlet roller
[8] Rear end assist guide
[9] Shutter
[10] Stapler
F01-301-01
1-10
[7]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[12]
[1]Saddle stitcher flapper

[2]Inlet roller 1
[3]Inlet roller 2
[4]No.1 flapper
[5]No.2 flapper
[6]Stitcher (front, rear)
[11]
[10]
[7] Stitcher mount

[8] Holding roller
[9] Paper pushing plate
[10] Paper folding roller
[11] Crescent roller
[12] Saddle delivery roller
F01-301-02
1-11
3.1.3 Puncher Unit (Option)
[1]
[2]
[3]
[4]
[1] Cam
[2] Hole puncher (Punch blade)
[3] Punch feed roller

[4] Punched scrap container
F01-301-03
1-12
4 Routine Maintenance by the User

No.
Item
Timing
Staple cartridge replacement

(Finisher unit)
Staple cartridge replacement
(Saddle stitcher unit)
Punched scrap removal
(Puncher unit (option))
When prompted (indicator on host machine control

panel)
panel)
panel)
2
3
T01-400-01
1-13
CHAPTER 2
FINISHER UNIT OUTLINE OF OPERATION
#ChapterCover_b.p65
03/05/13, 20:48
1 Basic Operations
1.1 Specifications
The finisher is designed to deliver sheets arriving from its host machine, and its modes of delivery include simple stacking, job offset (Note), and staple.
All operations involved in these modes are controlled by the finisher controller PCB, according
to the appropriate commands from the host machine.
In the case of the Saddle Finisher, sheets from the host machine may be routed to the saddle
stitcher unit.
Swing guide drive system
Tray drive system
Control system
Alignment drive system

Stapler drive system
Delivery drive system
Feeder drive system
Shutter drive system
Tray drive system
Saddle stitcher unit control system

(Saddle Finisher)
F02-101-01
Note:
The term job offset refers to shifting each sorting job, separating a single stack into several stacks.
2-1
1.2 Outline of the Electrical Circuitry

The finishers sequence of operation is controlled by the finisher controller PCB. The finisher
controller PCB is a 16-bit microprocessor (CPU), and is used for communication with the host
machine (serial) in addition to controlling the finishers 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 finishers various states (information on sensors and switches) to the host machine through a serial communications circuit.
In the case of the Saddle Finisher, the finisher controller PCB not only communicates with the
saddle stitcher controller PCB but also communicates the saddle stitcher units various states (information on sensors and switches) to the host machine.
The ICs used on the finisher controller PCB are designed for the following:
IC101 (CPU)
Controls sequence of operations.
Contains sequence programs.
IC106 (EP-ROM)
Backs up adjustment values.
Backs up initial setting data.
IC102 (communications IC)
Communicates with the host machine and the saddle stitcher unit.
IC108 (regulator IC)
Generates 3.3V.
F02-102-01 shows the flow of signals between the finisher and the options controller.
2-2
Saddle stitcher
controller PCB
(Saddle Finisher)
Punch Controller PCB

(Puncher unit (option))
Host machine
(DC controller PCB CPU)
Finisher controller
PCB communication
Motor
IC101
CPU
Solenoid
IC106
EEP-ROM
Switch
IC102
Communications
IC
Sensor
IC108
Regulator IC
F02-102-01
2-3
1.3 Inputs to and Outputs from the Finisher Controller PCB

1.3.1 Inputs to the Finisher Controller PCB (1/4)
Finisher controller PCB
J1006-3
-1
-2
J708-8 +5V
-10 UP-COVER When the upper cover is
-9
open, 1.
PI32
J1003-3
-1
-2
J707-7 +5V
-9
F-COVER
-8
Front cover
sensor
PI33
-1
-3
-2
-3
-1
-2
J708-11 +5V
-13
INLET
-12
When the sensor detects

paper, 1.
PI34
J1002-3
-1
-2
J707-4 +5V
-6 TIMMING When the sensor detects
-5
paper, 1.
Swing guide
home position
sensor
PI35
J1001-3
-1
-2
J707-1 +5V
-3 SWG-HP
-2
When the swing guide is at

the home position, 1.
Front aligning plate

home position
sensor
PI36
J1032
J1008-3
-1
-2
When the front cover is

open, 1.
-6
-4
-5
J722B-7 +5V
-9
FJOG-HP
-8
When the aligning plate

is at the home position, 1.
Rear aligning plate

home position
sensor
PI37
J1032
Inlet sensor
J1007
PI31
Upper cover
sensor
-9
-7
-8
J722B-4 +5V
-6 RJOG-HP
-5
When the aligning plate

is at the home position, 1.
Feed path
sensor
J1038-3
-1
-2
-7
-9
-8
J1037-3
-1
-2
-4
-6
-5
F02-103-01
2-4
-10
-12
-11
PI39
J1036-3
-1
-2
-1
-3
-2
PI41
J1043-3 -4
-1 -6
-2 -5
-4
-6
-5
J722B-1 +5V
When the rear end assist
-3
ASSIST-HP guide is at the home
-2
-3 -4
-1 -6
-2 -5
J721B-4
+5V
When the stapler unit is
-6
STPSFT-HP
-5
at the home position, 1.
-5
-3
-4
J1040
J1045-3
-1
-2
J1040
PI40
-5 J721A-4 +5V
-6 UPPER-P
-3
-5
-4

paper, 1.
PI42
J1021-3
-1
-2
J711B-6 +5V
-8
TRY1-P
-7

paper, 1.
PI43
J1026-3
-1
-2
J716B-1
+5V
-3
TRY2-P
-2

paper, 1.
Tray 1 paper
sensor
Tray 2 paper
sensor
-12
-10
-11
position, 1.
Stapler shift home

position sensor
Paper surface
sensor
-3
-1
-2
J1041
Rear end assist

guide home
position sensor
J722B-10 +5V
-12 JOGTRY-P When the sensor detects
-11
paper, 1.
J1032
J1039-3
-1
-2
J1032
PI38
Processing Tray
sensor
F02-103-02
2-5

PI46
Stapler alignment
interference sensor
J1044-3
-1
-2
-1
-3
-2
J993
-19
-17
-18
J994
J1029-3 -1
-1 -3
-2 -2
-8
-6
-7
J721B-1 +5V
-3 SHUT-HP
-2
When the shutter is at the

home position, 1.
J992
-19
-17
-18
J991 J717
-1
-1 +5V
-3
-3
STP-INFERE
-2
-2
When the stapler is at the

staple prohibited area, 1.
J1040
PI45
Shutter home
position sensor
PI49
Gear change home

position sensor
J1042-3 -1
-1 -3
-2 -2
J1005-3
-1
-2
-6 -1
-4 -3
-5 -2
J1040
Tray 2 paper
surface sensor
J1041
Stapler PCB 2 Stapler PCB 1

PI48
-8 J721A-1
+5V
-6
-3
LOWER2-P
-7
-2

paper, 1.
J708-5 +5V
-7 G-CHANGE-HP When the gear change
-6
lack gear is at the home
position, 1.
Tray 1 shift area

sensor PCB
PS983
Tray 1 area
sensor 1
PS982
Tray 1 area
sensor 2
J981-1
-2
-3
-4
-5
J711B-5
-4
-3
-2
-1
PS981
Tray 1 area
sensor 3
F02-103-03
2-6
+5V
TRY1-AREA3
TRY1-AREA2
TRY1-AREA1
When the sensor detects the

edge of the frame, 0.

Tray 2 shift area
sensor PCB
PS983
Tray 2 area
sensor 1
PS982
Tray 2 area
sensor 2
J1981-1
-2
-3
-4
-5
J716B-8
-7
-6
-5
-4
+5V
TRY2-AREA3
TRY2-AREA2
TRY2-AREA1

the edge of the frame, 0.
PS981
Tray 2 area
sensor 3
Swing guide
switch
MS31
J1031
N. O.
N. O.
MS32
J1019
Front cover
switch
MS33
N. O.
MS34
J1018
Staple safety
switch
J1020
N. O.
Tray 1 switch
-1
J719-1
-2
-2
-1
J715-3
-2
-4
-1
J714-1
F-COVER-SW When the front cover is

+24V
closed, 1.
+24V
When the swing guide is

at prescribed position, 1.
SWG-SW
+24V
-2 UPPER-TRY
-SW
-2
-1
J715-1
-2
-2
+24V
STP-SW
When the tray 1 and tray 2

are too close to each other, 1.
When the swing guide is at

prescribed position, 1.
F02-103-04
2-7
1.3.5 Outputs to the Finisher Controller PCB (1/2)

+24V
Inlet roller separation solenoid
-1
-1
-2
-2
-1
-1
J1015
SL31
J1016
-2
J710-8
-2
-7 INLET-ROL-SL*
+24V
Buffer roller separation solenoid

SL32
-1
-1
J1014
-2
J710-6
-2
-5 BUFF-ROL-SL*
-1
-1
J1013
SL33
J710-4
-2
+24V
-1
-1
J1012
SL34
When 0 ,the solenoid

turns on.
-3 DELIV-ROL-SL*
Buffer rear end holding solenoid

-2
J710-2
-2
-1 BUFF-P-SL*
Shutter clutch

turns on.
-1
J1046
CL31
-1
-8
-2
-7
J1040
+24V
-2
-1
J721B-8
-2
-7
Stack ejection lower

roller clutch
SHUT-CL*
When 0 ,the clutch

turns on.
+24V
-1
J712-2
-2
-1
CL32
F02-103-05
2-8

turns on.
+24V
1st delivery roller separation solenoid

-2

turns on.
BIND-CL*
When 0 ,the clutch

turns on.
1.3.6 Outputs to the Finisher Controller PCB (2/2)

-6
-4
-3
-1
J718-1
A*
-2
A
-3
B
-4
B*
According to rotation
direction/speed, changes
between + and - in sequence.
-6
-4
-3
-1
J713-1
A*
-2
A
-3
B
-4
B*
J1032
M31
J1010-1
-2
-3
-4
-4
-3
-2
-1
J722A-9
A
-10
A*
-11
B
-12
B*
J1032
Inlet motor
-8
-7
-6
-5
J722A-5
A
-6
A*
-7
B
-8
B*
J991J717-11
-11
A*
-10
-10
A
-9
-9
B
-8
-8
B*
Stack ejection motor

M32
J1011-1
-2
-3
-4
Front aligning plate motor

M33
J1035-4
-3
-2
-1
-4
-3
-2
-1
-9
-10
-11
-12
-4
-3
-2
-1
-5
-6
-7
-8
J993-8
-9
-10
-11
J992-8
-9
-10
-11
Rear aligning plate motor
M34
J1034-4
-3
-2
-1
J995-4
-3
-2
-1
Stapler PCB 2
Stapler PCB 1
Stapler shift motor

M35
J1027-4
-3
-2
-1
-1
-3
-4
-6
J1009-1
-2
-3
-4
-6
-4
-3
-1
Swing motor
M36
J709-1
A*
-2
A
-3
B*
-4
B
F02-103-06
2-9
1.3.7 Inputs to and Outputs from the Finisher Controller PCB

+24V
Tray 1 shift motor

-2
M37
J1024
-2
-5
-1
-3
-4
-6
-5
-1
-3
-4
-6
J952
-1
-2
-3
-4
-5
-6
J951 J711A
-1
-11
+24V
-2
-10
-3
-9
According to
+5V
-4
-8
rotation
-5
-7
A direction/speed,
-6
-6
A*
changes
B
-7
-5
B* between
TRY1-I
When 1 ,the motor turns on.
-8
-4
TRY1-CLK When the tray motor is rotating,
+ and - in
sequence.
Tray 2 shift motor
M38
-5
-2
-6
-4
-3
-1
J1025
-2
-5
-1
-3
-4
-6
J953
-1
-2
-3
-4
-5
-6
-9
-10
-3 TRY1-CW
-2 TRY1-EN
+24V
J1951 J716A
-1
-10
+24V
-2
-9
-3
-8
According to
+5V
-4
-7
rotation
-5
-6
A direction/speed,
-6
-5
A* changes
B
-7
-4
B* between
TRY2-I
-8
-3
+ and - in
TRY2-CLK
sequence.
-9
-2 TRY2-CW
-10
-1 TRY2-EN
alternately between 1 and 0.

Tray descends when 1 and ascends
when 0.
When 1, the motor turns on.
When 1 ,the motor turns on.

When the tray motor is rotating,
alternately between 1 and 0.
Tray descends when 1 and ascends
when 0.
When 1, the motor turns on.
M39
J1033-4
-3
-2
-1
-6
-4
-3
-1
-1
-2
-3
-4
J1032A
Rear end assist motor

-12
-11
-10
-9
J722A-1
A*
-2
A
-3
B
-4
B*
J708-1
A
-2
A*
-3
B
-4
B*
Gear change motor
M40
J1004-4
-3
-2
-1
-4
-3
-2
-1
F02-103-07
2-10
1.3.8 Inputs to and Outputs from the Finisher Controller PCB (1/2)
J995
-6
-7
-8
-9
J994
-4
-5
-6
-7
-8
J993
-6
-5
-4
-3
-2
-1
J992
-6
-5
-4
-3
-2
-1
J991
-12
-13
J993
-16
-15
-14
-13
-12
J992
-16
-15
-14
-13
-12
J991
-4
-5
-6
-7
-2
Stapler PCB 2
J717
-12
-13
-14
-15
+5V
When the stapler is at the
J717
-4
home position, 0 .
-5
STP-HP
When the staple is at the
-6
STP-READY
-7
edge of the stapler, 0 .
STP-LS
-2
Stapler PCB 1
When the staples are present

in the cartridge, 0 .
Stapler unit
Staple motor
M41
Staple home
position sensor
PI50
Staple edging
sensor
PI51
J1028-4
-3
-2
-1
J1030-5
-4
-3
-2
-1
Staple sensor
PI52
F02-103-08
2-11
1.3.9 Inputs to and Outputs from the Finisher Controller PCB (2/2)
Saddle stitcher
controller PCB
J2
-5
-6
-3
-1
-2
-4
J138
-3
-2
-5
-7
-6
-4
J1
-1
J139
-1
-2
-2
J1017
-8
-3
-1
-4
-2
-9
J138
-10
-11
-8
-6
-7
-9
J139
-1
+5V
J703-2
-1
-4
RXD
-6
TXD
-5
-3
+24V
J704-1
-2
-2
+5V
J702-6
-3 COPY-RXD
-4 COPY-TXD Communication line
-1
-5
-7
Host machine
J1017
-11
+24V
J701-1
-2
-12
F02-103-09
2-12
Communication line
2 Feed/Drive System
2.1 Outline
The finisher is designed to operate according to the commands from its host machine to deliver
arriving copies to delivery trays in the appropriate mode: simple stacking, job offset, stapling.
See F02-201-01 for a diagram of the three modes of delivery (four for the Saddle Finisher).
Method of delivery
Normal
delivery
Simple stacking
Stack job offset
Staple
Front 1-point stapling

Rear 1-point stapling
2-point stapling
Saddle stitch delivery (Saddle Finisher only)
F02-201-01
Delivery tray
Delivery tray
To saddle stitcher unit

(Saddle Finisher)
F02-201-02
2-13
2.1.1 Normal Delivery

a. Simple Stacking
The finisher delivers copies directly to the delivery tray.
Tray
Paper
F02-201-03
2-14
b. Stack Job Offset

Before ejection, the sheet is first pulled into the processing tray. Then the sheet is aligned to the
front or rear by the aligning plate. The stack ejected when the number of sheets in the processing
tray reaches a certain amount.
Tray
Paper is stacked alternately
Paper
F02-201-04
Paper Processing tray
F02-201-05
Results Delivering 4 sets
4th set
3rd set
2nd set
1st set
Direction of delivery
F02-201-06
2-15
c.Stapling
The finisher stacks sheets arriving from its host machine on the processing tray. Then, it staples
and delivers the sheets to the delivery tray.
Tray
Paper
Staple
Processing tray
Staple
Stapler unit
F02-201-07
Paper width 1/2

Front diagonal stapling
2-point stapling
Rear diagonal stapling
F02-201-08
2-16
d. Buffering
This function is available when set to sort or staple sort for A4, B5, or LT size paper. Since
sheet is received continuously from the host machine during print processing, buffering is performed to push and hold the rear end of the paper inside the delivery path. Buffering is performed
by overlaying the first two sheets (three sheets for 2-point binding) between stacks, and job offset
and stapling are performed in the processing tray during this time.
F02-201-09
2-17
2.1.2 Saddle Stitcher Delivery(Saddle Finisher)

A copy arriving in the finisher from the host machine is routed to the saddle stitcher by the
saddle stitcher flapper. The saddle stitcher executes center binding and double folding operations
on the sheets and then delivers it to the saddle stitcher tray.
For discussions of stacks in the saddle stitcher, see Chapter 3.
To saddle stitcher unit
F02-201-10
2-18
2.2 Ejection Path Types

2.2.1 Outline
There are three ejection paths to tray 1 and 2 depending on the ejection processing.
2.2.2 Straight Ejection
When the equipment is set to non-sort, all sheets are ejected through the following path.
Stack ejection roller
1st delivery roller

Buffer roller
Inlet roller
F02-202-01
2-19
2.2.3 Processing Tray Path

This is the sheet ejection path when the equipment is set to sort for paper size other than A4,
B5, or LT or when set to staple sort. Sheets are delivered to the processing tray for aligning and
stapling. Then they are ejected using the rear end assist.
1st delivery roller
Paper
Buffer roller
Paper
Inlet roller
Processing tray
Rear end assist
F02-202-02
2-20
2.2.4 Buffer/Processing Tray Path

This is the copy ejection path when the equipment is set to sort or staple sort for A4, B5, or LT
paper size. Two sheets (3 sheets if 2-point stapling) are delivered to the buffer. Then they are
aligned and stapled in the processing tray and ejected. Even while stapling or offset is being performed, simultaneous stack ejection, which simultaneously ejects sheets delivered to the buffer
and post processed stack in the processing tray, is performed because sheets 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 sheets between stacks
when the equipment is set to sort.
1) When the first sheet reaches the switch back point, it is sent to the buffer unit and the rear end
of the paper is held by the buffer guide.
Buffer roller
Buffer guide
Inlet roller
20mm
Switch back
point
F02-202-03
2) When the first sheet is delivered to the buffer, the second sheet is delivered from the host machine.
Buffer roller
Inlet roller
F02-202-04
2-21
3) The first delivery roller descends and works together with the stack delivery roller to deliver
the 1st and 2nd sheets toward the processing tray. At the same time, the stack in the processing
tray is delivered toward the delivery tray by the return roller and rear end assist guide.
Buffer roller
Buffer guide
1st delivery roller
Inlet roller
20mm
Switch back
point
Rear end
assist guide
Return roller
F02-202-05
4) When the stack in the processing tray is delivered to the delivery tray and the rear end of the
1st and 2nd sheets exits the 1st delivery roller, the 1st and 2nd sheet are delivered toward the
processing tray by the stack delivery roller and return roller.
1st delivery roller
Return roller
Processing tray
F02-202-06
5) The 1st and 2nd sheets delivered to the processing tray are aligned and then delivered to the
delivery tray.
Return roller
Rear end
assist guide
F02-202-07
2-22
2.3 Delivery/Ejection
2.3.1 Outline
The sheets sent from the host machine is delivered to the ejection tray, processing tray, or
saddle stitcher (saddle finisher) according to the ejection type. Job offset or stapling is performed, according to the instruction from the host machine, for sheets delivered to the staple tray.
When ejecting from the processing tray, rear end assist guide is used in addition to the stack
ejection roller to eject the stack.
The inlet motor (M31), stack ejection motor (M32), and rear end assist motor (M39) are step
motors. These motors are rotated forward or backward by the microcomputer (CPU) in the finisher controller PCB. The following two sensors are provided in the copy delivery path to detect
the arrival or passing of sheets.
Inlet sensor (PI33)
Feed path sensor (PI34)
Also, each ejection tray has sensors to detect the presence of sheet on the tray.
Tray 1 paper sensor (PI42)
If the sheet does not reaches or passes each sensor within prescribed time, the finisher controller PCB determines that the jam has occurred and stops the operation. Then it notifies the host
machine that a jam has occurred. When all of the doors are closed after fixing the jam, the finisher checks whether sheet is detected by any of the above two sensors (inlet sensor, delivery
path sensor). If any of the sensors detects a sheet, the finisher determines that the jam is not fixed
and sends jam processing signal to the host machine once more.
2-23
2-24
SL33
SL32
SL31
SL34
SL5
1st delivery roller separation solenoid drive

signal DELIV-ROL-SL
Buffer roller separation solenoid drive signal

BUFF-ROL-SL
Inlet roller separation solenoid drive signal

INLET-ROL-SL
Buffer rear end holding solenoid drive signal

BUFF-P-SL
Saddle inlet solenoid drive signal

SDL-INLET-SL
M38
M32
M39
M31
Finisher controller PCB (2/2)
F02-203-01
Saddle driver
PCB
Stapler motor drive signal
Stapler shift motor drive signal
Saddle inlet
motor drive signal
Inlet motor drive signal
M33
M34
Rear end assist motor drive signal
Aligning plate front/rear

motor drive signal
Stack ejection motor drive signal
Tray 1 shift motor drive signal
Tray 2 shift motor drive signal
M9
M37
M35
M41
Inlet paper detection sensor INLET
Feed path paper detection sensor TIMING
Tray 1 paper detection sensor TRY1-P
Tray 2 paper detection sensor TRY2-P
F02-203-02
2-25
2.3.2 Rear End Assist Operation

In order to improve stacking performance when ejecting sheets delivered to the processing tray,
a rear end assist guide is used in addition to the stack ejection roller to support the rear end of the
stack during stack ejection.
Paper
Rear end assist guide
home position sensor (PI39)
Processing tray stopper

Rear end assist motor (M39)
[FRONT SIDE]
F02-203-03
2-26
2.4 Stack Job Offset

2.4.1 Outline
Job offset operation offsets paper stack to the front or rear when ejecting to sort the paper stack.
The forward/backward movement of the copy delivered to the processing tray is controlled by
the front aligning plate and rear aligning plate.
The aligned copies are stapled or ejected according to the signal from the host machine.
When the power is turned on, the finisher controller PCB drives the Front aligning plate motor
(M33) and Rear aligning plate motor (M34) 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.
Motor
Front aligning plate motor (M33)
Rear aligning plate motor (M34)
Swing motor (M36)
Aligns paper in processing tray to the front

Aligns paper in processing tray to the rear
Moves the swing guide up/down
Aligns the stack end during stack ejection
Sensor
Swing guide home position sensor (PI35)
Front aligning plate home position sensor (PI36)
Rear aligning plate home position sensor (PI37)
Rear end assist guide home position sensor (PI39)
Detects the swing guide home position

Detects the aligning plate front home position
Detects the aligning plate rear home position
Detects the rear end assist home position
2-27
Rear aligning plate

Rear aligning plate
Light-shielding plate
Front aligning
plate
Paper

[FRONT SIDE]
F02-204-01
2-28
2.4.2 Processing Tray Paper Stacking Operation

When the rear end of the paper exits the 1st delivery roller, the sheet is delivered to the processing tray by the stack delivery roller and return roller and then pushed against the processing tray
stopper.

1st delivery roller
Return roller
F02-204-02
2-29
2.4.3 Offset Operation

Each sheet is pulled forward or backward using the front aligning plate and the rear aligning
plate.
The offset operation is performed each time a sheet is pulled onto the processing tray.
Offsetting in the forward direction
Rear aligning plate
Sheet to be offset

Tray
F02-204-03
Offsetting in the backward direction
Rear aligning plate
Sheet to be offset

Tray
F02-204-04
2-30
2.4.4 Stack Delivery Operation

The stack is ejected each time three large size sheets 1 or five small size sheets 2 are offset
on the processing tray.
The swing motor turns and the swing guide descends. This causes the upper/lower stack delivery rollers to hold the stack. The stack delivery motor turns the stack delivery roller and return
roller. At the same time, the rear end assist guide is started by the rear end assist motor and the
stack held by the stack delivery rollers is delivered in the ejection 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.
Swing guide
Return roller
Rear end
assist guide
F02-204-05
*1 Varies between 2 to 4 sheets depending on the number of paper. (Example: When the number
of paper is 10, stacks are ejected in the order of 3 sheets, 3 sheets, and 4 sheets.)
*2 Varies between 2 to 6 sheets depending on the number of paper. (Example: When the number
of paper is 7, stacks are ejected in the order of 5 sheets and 2 sheets.)
2-31
2.5 Stapling Operation

2.5.1 Outline
Stapling operation staples the prescribed number of sheets with the stapler unit.
The staple position depends on the staple mode and paper size.
Whether the staple unit is at home position or not is detected by the stapler shift home position
sensor (PI40).
When the power is turned on, the finisher controller PCB drives the stapler shift motor (M35)
to return the stapler unit to home position. If the stapler unit is already at home position, it waits
in that state.
Sensor
Stapler shift home
position sensor
Staple home
position sensor
Staple edging
sensor
Staple sensor
Symbol
PI40
Connector
J721B-6
PI50
J717-5
PI51
J717-6
PI52
J717-7
Motor
Stapler shift motor
Staple motor
Symbol
M35
M41
Function
Detects the home position for the
stapler moving back and forth.
Detects the home position for the
stapling operation.
Detects the staple top position.
Detects presence or absence of staples
in the cartridge.
Function
Moves the stapler.
Performs stapling operation.
T02-205-01
2-32
Remarks
In the stapler
In the stapler
In the stapler
Remarks
-
Paper
Stapler shift motor (M35)
Stapler
Stapler shift home position sensor (PI40)
F02-205-01
2-33
2.5.2 First Sheet

The finisher controller PCB moves the stapler according to the specified stapling position.
When the rear end of the first sheet passes the 1st delivery roller, the finisher controller PCB
stops the stack ejection motor (M32) and then rotates it in reverse. The stack delivery motor rotates the stack delivery roller and return roller and delivers the sheet to the processing tray. The
paper in the processing tray is detected by the processing tray sensor (PI38).
When the sheet is delivered to the processing tray, the swing motor (M36) starts and raises the
swing guide. When the swing guide home position sensor (PI35) 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 sensor detects the paper, the front and rear aligning plate motors
(M33/M34) start and align the sheet.
Swing guide
1st delivery roller
Return roller
Processing tray
F02-205-02
2-34
Stapler
Stack ejection roller (upper)

Stack ejection roller (lower)
Swing guide
Swing motor (M36)
Stack ejection lower roller cluch (CL32)

Stack ejection motor (M32)
F02-205-03
2-35
2.5.3 Second and Subsequent Sheets

The finisher controller PCB starts the swing motor (M36) and lowers the swing guide when the
rear end of the 2nd paper passes the 1st delivery roller. The stack delivery motor is reversed. The
stack delivery motor rotates the stack delivery roller (upper) and return roller and sends the paper
to the processing tray. At this point, the stack delivery roller (lower) does not rotate because the
stack ejection lower roller clutch (CL32) is disengaged. The paper in the processing tray is detected by the processing tray sensor (PI38).
When the paper is delivered to the processing tray, the swing motor (M36) starts and raises the
swing guide. When the swing guide home position sensor (PI35) 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 front and rear aligning plate motors
(M33/M34) start and align the paper.

Swing guide
1st delivery roller
Return roller
Processing tray
F02-205-04
2-36
Stapler
2.5.4 Last Sheet

When alignment of the last sheet completes, the finisher controller PCB moves the aligning
plate to alignment position with the aligning plate motor (M33/M34) (with the paper held with
the aligning plate). Then the finisher controller PCB staples at the specified staple position.
After stapling, the finisher controller PCB starts the swing motor (M36) and lowers the swing
guide. Then the stack is ejected by the stack delivery roller, return roller, and rear end assist
guide.
Swing guide
Return roller
Rear end
assist guide
Stapler
F02-205-05
2-37
2.6 Stapler Unit

The staple motor (M41) is used to perform stapling operation. This motor 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 micro
computer (IC101) 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 turns ON, allowing the staple cam to the original position.
The staple sensor (PI52) is used to detect presence/absence of a staple cartridge in the machine
and presence/absence of staples in the cartridge.
The staple edging sensor (PI51) is used to determine whether staples are pushed up to the top
of the staple cartridge.
The finisher controller circuit does not drive the staple motor (M41) unless the staple safety
switch (MS34) is ON. This assures safety in case where you happen to put your finger in the stapler.
2-38
Staple motor drive signal
Hook top position detect signal
Hook empty detect signal
Stapler HP detect signal
F02-206-01
M41
F02-206-02
2-39
2.6.1 Shifting the Stapler Unit

The stapler unit is shifted by the stapler shift motor (M35). The home position is detected by
the stapler shift home position sensor (PI40). 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 staple ready positions corresponding to staple mode are shown starting from F02-206-03.
a. Front 1-Point Stapling
The position is the same as the stapling position.
Rear aligning plate
Stopper
Feeding direction
Stapling position/
Wait position
F02-206-03
2-40
b. Rear 1-Point Stapling

The position is the same as the stapling position.
Rear aligning plate
Stapling position/
Wait position
Stopper
Feeding direction
F02-206-04
2-41
c. 2-Point Stapling
The stapler waits at the paper front end side staple position. The stapling sequence is first near
side and then far side.
Rear aligning plate

Stopper
Stapling position
Stopper
Feeding direction
Stapling position/
Wait position
Stopper
F02-206-05
2-42
2.7 Tray Operation

2.7.1 Outline
This equipment has two delivery trays. The upper tray is called tray 1 and the lower tray is
called tray 2. The upper and lower tray can move up and down independently.
The trays are moved up and down by the tray 1 shift motor (M37) and tray 2 shift motor (M38).
Tray 1 paper sensor (PI42) and tray 2 paper sensor (PI43) are provided to detect the presence of
the paper stacked on the tray.
The home position of tray 1 is detected by the paper surface sensor (PI41) and the home position of tray 2 is detected by the tray 2 paper surface sensor (PI48). The home position is the top
surface of the paper if papers are already stacked on the tray, or the position where the edge of
the tray is detected if no paper is stacked. When the power is turned on, the finisher controller
PCB drives the tray 1 shift motor (M37) and tray 2 shift motor (M38) to return the tray to home
position. If the tray is already at home position, it is moved out of the home position once and
then returned to the home position once more. If both tray 1 and tray 2 are at home position, this
is performed for tray 1 and then for tray 2. If the tray specified by the host machine is tray 2, the
finisher controller PCB shifts the tray so that tray 2 is at delivery port.
When paper is stacked on the tray, a prescribed number of pulses drive tray 1 shift motor (M37)
or tray 2 shift motor (M38) and the tray is lowered. Then the tray returns to home position to prepare for the next stack.
The upper and lower limits of the tray are detected by three area sensors (PS981, PS982, and
PS983) on tray 1 and tray 2 shift area sensor PCB. The finisher controller PCB stops driving the
tray 1 shift motor (M37) and tray 2 shift motor (M38) when it detects the upper or lower limit of
the tray. Also, the ON/OFF combinations of the area sensors (PS981, PS982 and PS983) are
used to detect over-stacking according to the stack height for large size and mixed stacking. T02207-01 shows the items detected with the ON/OFF combinations of the area sensors (PS981,
PS982 and PS983).
The finisher controller PCB stops supplying +24V to the tray 1 shift motor (M37) and stops the
finisher operation when tray 1 switch (MS33) turns ON.
2-43
Rack
Tray 1 switch (MS33)
Tray 1 shift motor

(M37)
Tray 1 shift area sensor PCB
(PS981, PS982, PS983)
Tray 2 shift motor

(M38)
Tray 2 paper
sensor (PI43)

(PS981, PS982, PS983)
Rack
F02-207-01
2-44
Paper surface sensor (PI41)

Paper surface sensor flag
Edge
Tray 1
Tray 2 paper surface

sensor (PI48)
Paper surface sensor flag

Edge
Tray 2
F02-207-02
Detected items
Tray 1 upper limit
Stack count 500 sheets limit exceeded
Tray 1 lower limit

Area sensor 1 Area sensor 2 Area sensor 3
(PS983)
(PS982)
(PS981)
OFF
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
OFF
ON
Detected items
Tray 2 upper limit
Tray 2 lower limit (finisher)
Tray 2 lower limit (saddle finisher)

Area sensor 1 Area sensor 2 Area sensor 3
(PS983)
(PS982)
(PS981)
OFF
ON
OFF
ON
ON
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
T02-207-01
2-45
2.8 Shutter Operation

2.8.1 Outline
When tray 1 passes the delivery section with paper already stacked, the stacked paper may get
caught by the delivery section. A shutter is provided at the delivery section to prevent this. The
shutter closes when tray 1 passes the delivery section. This is performed even when no paper is
stacked.
When the shutter clutch (CL31) and stack ejection lower roller clutch (CL32) are ON, the shutter moves up (close) when the stack ejection motor (M32) 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 (PI45).
Stack ejection lower roller clutch (CL32)
Stack ejection roller (lower)
Shutter home position

sensor (PI45)
Shutter
Shutter clutch (CL31)
F02-208-01
2-46
2.9 Detecting Jams

The following sensors are used to detect the presence of paper and to determine that paper is
delivered properly.
Inlet sensor (PI33)
A jam is identified by checking whether paper is present at each sensor at the timing programmed in the memory of the microcomputer (CPU) on the finisher controller PCB.
When the CPU identifies a jam, it suspends the finishers delivery operation and informs the
host machine DC controller of the presence of a jam. When all doors are closed after the paper
jam is removed, the finisher checks whether paper is detected by the above two 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.
PI34
PI33
PI33:Inlet sensor
PI34:Feed path sensor
F02-209-01
2-47
Jam type
Delay at inlet
sensor
Sensor
PI33
Stationary at inlet
sensor
PI33
Delay at feed
path sensor
PI34
Stationary at feed
path sensor
PI34
Delivery delay*
LED, PTR5
Stationary
delivery*
LED, PTR5
Timing
PI33
Staple
PI50
Power-on
PI33
PI34
PI31
PI32
MS31
PI63
Door open
Punch*
Punch power-on*
LED1 to 4
PTR1 to 4
Jam Condition
When the inlet sensor (PI33) does not detect paper after a
prescribed time (distance) has elapsed since receiving a delivery
signal from the host machine.
If the optional puncher unit is installed, when the inlet sensor
(PI33) does not detect paper after delivering for a prescribed time
(distance) after the rear end sensor (LED, PTR5) detected paper.
When paper does not exit the inlet sensor (PI33) after delivering
for a prescribed time (distance) after the inlet sensor (PI33)
detected paper.
When the feed path sensor (PI34) does not detect paper after
prescribed time (distance) has elapsed since the inlet sensor
(PI33) detected paper.
When paper does not exit the feed path sensor (PI34) after
delivering for a prescribed time (distance) after the feed path
sensor (PI34) has detected paper.
When the rear end sensor (LED, PTR5) does not detect paper
after a prescribed time (distance) has elapsed since receiving a
delivery signal from the host machine.
When paper does not exit the rear end sensor (LED, PTR5) after
delivering for a prescribed time (distance) after the rear end
sensor (LED, PTR5) has detected paper.
When the inlet sensor (PI33) detects paper before receiving a
delivery signal from the host machine.
When the staple motor (M41) is rotated forward and the staple
home position sensor (PI50) does not turn on within prescribed
time after it is turned off and the staple motor (M41) is rotated
backward and the staple home position sensor (PI50) turns on
within prescribed time.
When paper is detected by the inlet sensor (PI33) or the feed path
sensor (PI34) during power on.
When the upper cover sensor (PI31), front cover sensor (PI32), or
the front cover switch (MS31) detects that the cover is opened.
When the punch home position sensor (PI63) does not turn on
after a prescribe time has elapsed since it is turned off.
When paper is detected by the horizontal registration sensors
(LED1 to 4, PTR1 to 4) during power on.
* When the optional puncher unit is installed
T02-209-01
2-48
3 Power Supply System

3.1 Outline
When the host machine power is turned on, a 24VDC and a 5VDC power are supplied to the
finisher controller PCB from the host machine. The 24VDC power is used to drive the solenoid.
The 5VDC power is used to drive the sensors and is converted to 3.3VDC by the regulator IC
(IC108) on the finisher controller PCB and used to drive the ICs inside the PCB. Each power
supply is also supplied from the finisher controller PCB to the saddle stitcher controller PCB.
If an optional puncher unit is installed, the power is also supplied to the punch controller PCB.
A part of the motor drive 24VDC is cut off when the front cover switch (MS31) is opened.
The power supply block diagram is shown below.
Saddle stitcher
controller PCB
(Saddle Finisher)
Front cover
switch (MS31)
24V
24V
Motor
Motor
24V
24V
Solenoid

Host
machine
5V
Sensors
(IC108)
5V
Regulator IC
3.3V
Logic
Punch controller PCB

(Puncher Unit (option))
F02-301-01
3.2 Protection Function

The motor solenoid drive 24 VDC line has a fuse which melts when there is an over current.
2-49
CHAPTER 3
SADDLE STITCHER UNIT
OUTLINE OF OPERATION
#ChapterCover_b.p65
03/05/13, 20:48
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION
1 Basic Operations
1.1 Outline
The unit stitches (2 points) a stack of sheets delivered by the finisher unit and folds it in two
for delivery. All these operations are controlled by the saddle stitcher controller PCB in response
to commands from the host machine via the finisher unit.
Finisher unit control system
Guide plate drive system

Paper positioning plate
drive system
Control system
Alignment drive system

Stitcher drive system
Delivery drive system
Feed drive system
Paper pushing plate
drive system
Paper folding roller
drive system
F03-101-01
3-1
1.2 Electrical Circuitry

The sequence of operations used for the saddle stitcher is controlled by the saddle stitcher controller PCB. The saddle stitcher controller PCB has a microprocessor. This microprocessor is
used to control the sequence of operations and to handle serial communications with the finisher
controller PCB, driving solenoids and motors in response to the various commands from the finisher controller PCB.
The saddle stitcher controller PCB is also used to communicate the state of various sensors and
switches to the finisher controller PCB in serial.
The functions of the major ICs mounted on the saddle stitcher controller PCB are as follows:
IC7 (CPU)
Controls the sequence of operations.
Contains the sequence program.
IC8 (communications IC)
Communicates with the finisher unit.
IC10 (regulator IC)
Generates 3.3V.
Electrical circuitry block diagram
Sensor
Saddle stitcher
controller PCB
Motor
IC7 CPU
Solenoid
Switch
IC10
Regulator IC
IC8
Communications IC
Finisher controller
PCB
F03-102-01
3-2
Host machine
1.3 Inputs to and Outputs from the Saddle Stitcher Controller PCB
1.3.1 Inputs to the Saddle Stitcher Controller PCB (1/3)
Saddle stitcher controller PCB
J107-1
-2
-3
PI3
J103-3
-1
-2
PI4
J102-1
-2
-3
PI5
J101-3
-1
-2
PI6
J100-3 -1
-1 -3
-2 -2
PI7
J134-3
-1
-2
Delivery cover
sensor
Paper folding
motor clock
sensor
Alignment
plate home
position sensor
Tray paper
sensor
Paper
positioning
plate home
position sensor
J11-15 +5V
-14 LUNGECLK When the paper pushing plate
motor is rotating, alternately
-13
between 1 and 0.
J303-1
-3
-2
J203-3
-1
-2
J11-7 +5V
-9 EJCVR
-8
J11-6 +5V
-5 FLDCLK
-4
J309-1
-3
-2
J209-3
-1
-2
-3 -4
-1 -6
-2 -5
-1
-3
-2
J302
J202
J202
PI1
J502
J402
J402
Paper pushing
plate motor
clock sensor
J11-1 +5V
-3 JOGHP
-2
-3
-1
-2
J6-7 +5V
-9 TRYPAR
-8
-6
-4
-5
J6-4 +5V
-6 PAPPOS
-5
When the delivery cover is

open, 0.
When the paper folding motor

is rotating, alternately between
1 and 0.
When the alignment plate is
at home position, 1.
When paper is present on the

tray, 1.
When the paper positioning

plate is at the home position
sensor, 1.
F03-103-01
3-3
Paper positioning
plate paper sensor
Inlet cover sensor
PI8
J105-3
-1
-2
PI9
J124-3
-1
-2
-1
-3
-2
J301
J301A
J201
J6-1 +5V
-3 PPOSPAR When paper is present at the
paper positioning plate, 1.
-2
-3
-1
-2
J10-6 +5V
-8 INLTCVR When the inlet cover is
closed, 1.
-7
Crescent roller
phase sensor
PI12 J126-3
-1
-2
J9-4 +5V
-6 FDRLHP
-5
When the flag of the crescent

roller is at the sensor, 1.
Guide home
position sensor
PI13 J127-3
-1
-2
J9-7 +5V
-9 GIDHP
-8
When the guide is at home

position, 1.
-2
-4
-3
-3
-1
-2
-2
-4
-3
J225
J225
J125
PI11 J525-3
-1
-2
J425
J425
J325
Delivery sensor
-3 J9-1 +5V
-1 -3 DELV
-2 -2
When paper is present in

the delivery sensor unit, 1.
J9-10 +5V
-12 LUNGEHP When the paper pushing plate
is at home position, 1.
-11
PI15 J129-3
-1
-2
J9-13 +5V
-15 LUNGETOP When the paper pushing plate
is at the leading edge, 1.
-14
Stitcher unit IN
sensor
PI16 J131-3
-1
-2
J13-1 +5V
-3 STPLHP* When the stitcher unit is
housed, 0.
-2
Vertical path
paper sensor
PI17 J132-3
-1
-2
Paper folding
home position
sensor
PI21 J130-3
-1
-2
Paper pushing
plate top position
sensor
-1
-3
-2
J308
J308A
J208
PI14 J128-3
-1
-2
Paper pushing
plate home
position sensor
-4
-2
-3
When paper is present in the

vertical path, 1.
J18-1 +5V
-3 PAFLDHP* When the paper folding roller
is at home position, 0.
-2
F03-103-02
3-4
J13-4 +5V
-6 VPJM
-5

Paper sensor PCB
PI18
PI19
No.2 paper sensor
PI20
J123-5
-4
-3
-2
-1
-1
-2
-3
-4
-5
J304
J304A
J204
No.1 paper sensor

J10-1
-2
-3
-4
-5
-5
-4
-3
-2
-1
+5V
1STPA
2NDPA
3RDPA
When paper is present at

the No.1 paper sensor, 1.
Saddle inlet
sensor
J137-3
-1
-2
-1
-3
-2
-3 -3
-1 -5
-2 -4
-10 J21-1 +5V

-3 INLET-ROLL When paper is in the
-8
saddle inlet unit, 1.
-2
-9
J138
PI22
J136
J133
No.3 paper sensor
Stitcher unit (front)
-1
-2
J316-5
-3
-7
-6
-1
-2
Stitcher unit (rear)
Staple
switch (rear)
SW5
SW4
Inlet door switch

N.O.
J109-3
SW1
-2
Delivery door switch
N.O.
J111-3
SW3
-2
-7
-6
-5
JD2B
Stitcher
home
position
switch (rear)
JD1A
-7
-6
-5
JD1B
SW6
-3
JD2A
Staple
switch (front)
J315-5
J8-3
STCHHP1*
-1
-2 HKEMP1
When the stitcher unit is

at the home position for
stitching, 0.
When no staple is present,
0.
JD2
JD1
SW7
-7
-6
J8-10
STCHHP2*
-8 HKEMP2
-9
When the stitcher unit is

at the home position for
stitching, 0.
When no staple is present,
0.
+24V
J4-1
-2
-1
-2
J305
J205
Stitcher
home
position
switch (front)
-1
J4-5
-2
-6
When the inlet door is

INLTCVRMS closed, 1.
DELVMS
When the delivery door

is closed, 1.
F03-103-03
3-5
1.3.4 Outputs from the Saddle Stitcher Controller PCB (1/2)

+24V
No.1 flapper solenoid

-1
J118
SL1
-2
-2
-1
J117
-2
-2
-4 FLPSL2*
J116
-2
J15-5
-1
-6 RLNIPSL* When 0, the solenoid turns ON.

+24V
-2
J135
J135
SL5
-1 -2
J138
-2 -1
-1
-12
J19-1
-11
-2
SDLINSL* When 0, the solenoid turns ON.
J5-1 A
-1
-4
-2
-3
-2 A*
-2
-3 B
-4 B*
-3
-4
J115
M1
When 0, the solenoid turns ON.
+24V
-2
Saddle inlet solenoid
Feed motor
When 0, the solenoid turns ON.
J15-3
-1
Feed plate contact solenoid

-1
SL4
-2 FLPSL1*
+24V

-1
SL2
J15-1
-1
The pulse signals change according

to the rotation of the motor.
Paper folding motor

J112-2
J4-8
-1
-7
J119-5
J12-1
-4
-3
-2
-1
-2
-3
-4
-5
J114-5
J7-6
-4
-3
-2
-1
-7
-8
-9
-10
J113-5
J7-1
-4
-3
-2
-1
-2
-3
-4
-5
The states (+ and -) change according

M2
+24V
Guide motor
M3
M4
Alignment motor
M5
F03-103-04
3-6
B*
A*
B
A
B*
A*
B
A
B*
A*
B
A

+24V

+24V

1.3.5 Outputs from the Saddle Stitcher Controller PCB (2/2)

-7
-6
-5
-4
J316-4
-3
-2
-1
-4
-5
-6
-7
JD1A
M7
J315-1
-2
-3
-4
JD2A

-1
-2
-3
-4
J8-7
-6
-5
-4
The states (+ and -) change

according to the rotation
of the motor.
-4
-3
-2
-1
J8-11
-12
-13
-14

of the motor.
M6
JD2B
JD1B
JD2
JD1
Stitcher motor
(front)
Stitcher motor
(rear)
Paper pushing plate motor
J108-1
J4-9
-2
-10
M8

of the motor.

J703-6 J138L-6
-8
-4
-10
-2
-7
-5
-9
-3
-11
-1
J138D-7
-5
-3
-6
-4
-2
J2-1
-3
-5
-2
-4
-6
+5V
Communication line
+24V
J704-1
J139L-1
J139D-1
J1-1
-2
-2
-2
-2
Saddle driver PCB

Saddle inlet motor
M9
J806-1
J803-4 B*
-3
-3 B
-4
-2 A
-1 A*
-6

F03-103-05
3-7
2 Feeding/Drive System
2.1 Outline
The stitcher unit aligns the sheets coming from the finisher unit and stitches the resulting stack
for delivery to the delivery tray according to the commands coming from the finisher controller
PCB.
The machines operation consists of the following:
1. Receive sheets
2. Aligns the sheets
3. Stitches the stack
4. Feeds the stack
5. Folds and delivers the stack
1) Receive sheets
3) Stitches the stack

2) Aligns the sheets
5) Folds and
delivers the
stack
4) Feeds the stack
F03-201-01
3-8
2.1.1 Receiving Sheets

The stitcher unit receives sheets from the finisher unit and outputs them inside the vertical
path in vertical orientation.
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 80 g/m2 + 1 sheet of 256 g/m2)
Direction of
delivery
Second sheet
First sheet
F03-201-02
3-9
2.1.2 Aligning the Sheets

The alignment plates operate to put the sheets in order each time a sheet of paper is output to
the vertical path assembly. The alignment plates are mounted at the edge of the vertical path assembly.
The alignment plates also operate after stapling to prepare the stack for delivery.
Sheets
Alignment plate
Alignment plate
F03-201-03
3-10
2.1.3 Stitching
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 to the next operation (stack feeding).
Stitcher
Staple
F03-201-04
3-11
2.1.4 Feeding the Stack

The unit folds the stitched stack of sheets, and then feeds it to the point of delivery. This point
is where 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.
Paper pushing guide

Guide plate
F03-201-05
3-12
2.1.5 Folding/Delivering the Stack

The paper pushing plate pushes against the center of the stack to move it in 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
Delivery roller
F03-201-06
3-13
3 Paper Output Mechanism

3.1 Outline
The paper output mechanism serves to keep a stack of sheets coming from the finisher in place
for the next steps (stapling, folding).
The paper inlet is equipped with the No.1 flapper and the No.2 flapper, which operate to configure the paper path to suit the size of paper. The paper positioning plate is kept in wait at a predetermined location to suit the size of paper. The paper positioning plate is driven by the paper
positioning plate motor (M4), and the position of the plate is identified in reference to the number of motor pulses coming from the paper positioning plate home position sensor (PI7). A sheet
moved by the inlet roller is handled by the feed rollers and 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 position sensor (PI5).
To prevent interference between paper and the paper folding rollers when the paper is being
output, the folding rollers are designed to be covered by a guide plate. The guide plate moves
down before paper is folded so as to expose the paper folding rollers.
The inlet is equipped with the No.1, No.2 and No.3 paper sensors (PI18, PI19 and PI20) each
suited to a specific paper size, and the paper positioning plate is equipped with a paper positioning plate paper sensor (PI8).
3-14
SL2
M6/
M7
M3
PI4
M4
No.2 flapper
solenoid drive signal FLPSL2
Feed plate contact solenoid drive signal RLNIPSL
SL1
Paper pushing plate motor clock signal LUNGECLK
SL5
No.1 flapper
solenoid drive signal FLPSL1
M9
Paper folding motor clock signal FLDCLK

drive signal
Saddle inlet
solenoid drive
signal
SDLINSL
Saddle inlet
motor drive
signal
Finisher controller
PCB
Paper folding motor drive signal
Paper pushing plate motor drive signal
Alignment motor drive signal
Stitcher motor drive signal

(front/rear)
Guide motor drive signal
Feed motor drive signal
Saddle stitcher controller PCB (1/2)
M5
M1
SL4
M8
PI1
M2
F03-301-01
3-15
3-16
PI7
F03-301-02

PI13
PI8
Saddle inlet paper detection signal INLET-ROLL
No.1 paper detection signal 1STPA
No.2 paper detection signal 2NDPA
PI12
No.3 paper detection signal 3RDPA
Paper pushing plate home

position detection signal LUNGEHP
Paper pushing plate top

position detection signal LUNGETOP
PI6
Vertical path paper detection signal VPJM
Paper folding home position detection signal PAFLDHP
Delivery detection signal DEIV
Crescent roller position detection signal FDRLHP
Guide home position detection signal GIDHP
Tray paper detection signal TRYPAR
Paper positioning plate paper detection signal PPOSPAR
Paper positioning plate home position detection signal PAPPOS
PI22
PI18
PI19
PI20
PI11
PI17
PI21
PI15
PI14
3.2 Controlling the Inlet Flappers

3.2.1 Outline
The two flappers mounted at the paper inlet are operated to configure the feed path according
to the size of paper. The flappers are used to enable the following:
1. To detect the 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,
Table T03-302-01 shows the relationship between sensors and paper sizes.
SENSOR
A3/LD
B4
A4-R/LT-R
No.1 paper sensor (PI18)

Used
Not used
Not used
Used
Used
Not used
Used
Used
Used
T03-302-01
Each flapper is driven by its own solenoid.
T03-302-02 shows the relationship between solenoids and paper sizes.
Solenoid
A3/LD
B4
A4-R/LT-R
No.1 flapper solenoid (SL1)

No.2 flapper solenoid (SL2)
OFF
OFF
ON
OFF
ON
ON
T03-302-02
3-17
3.2.2 A3/LD Paper Path (3 sheets)
No.1 paper sensor PI8

Passage of paper
OFF
SL1
Non-passage of paper
OFF
SL2
Top edge
PI18
PI19
PI20
PI18
PI19
PI20
Entry of First sheet
Entry of Second sheet
Entry of Third sheet
F03-302-01
3-18
3.2.3 B4 Paper Path (3 sheets)
No.1 paper sensor

PI18
No.2 paper sensor
PI19
No.3 paper sensor
PI20
SL1
Passage of paper
ON
Passage of paper
SL2
OFF
PI18
PI19
Top edge
PI20
PI18
PI19
PI20
F03-302-02
3-19
3.2.4 A4-R/LT-R Paper Path (3 sheets)
No.1 paper sensor

PI18
No.2 paper sensor
PI19
No.3 paper sensor
PI20
Passage of paper
SL1
ON
Passage of paper
SL2
ON
Passage of paper
PI18
PI19
PI20
Top edge
PI18
PI19
PI20
F03-302-03
3-20
3.3 Controlling the Movement of Sheets

3.3.1 Outline
When the leading edge of a sheet has moved past the inlet flapper, the intermediate feed roller
and the crescent roller start to move the sheet forward.
The intermediate feed roller is normally not in contact with the path bed. When the leading
edge of a sheet reaches the intermediate feed roller contact section, the feed plate contact solenoid (SL4) causes the roller to come into contact with the 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 since the first sheet will still be over the sensor.
The crescent roller keeps rotating while sheets are being output, butting the leading edge of
each sheet against the paper positioning plate, and ultimately, keeping the leading edge of the
stack in order.
The alignment motor (M5) drives the alignment plates for each 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.
Intermediate feed roller

Feed motor
M1
ON
SL4
Feed plate contact
solenoid
F03-303-01
3-21
2) The solenoid turns OFF when the paper butts against the paper positioning plate. The feed
motor continues to rotate.
M1
OFF
SL4
F03-303-02
3) The solenoid turns ON when the next sheet arrives, and the feed plate comes into contact.
M1
ON
F03-303-03
3-22
SL4
3.4 Controlling the Aligning the Sheets

The alignment motor (M5) drives the alignment plates each time a sheet is output, putting both
left and right edges of the sheet in order. The alignment motor is a 4-phase stepping motor. The
position of the alignment plate is identified in reference to the number of motor pulses from the
alignment plate home position sensor (PI5).
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.
Sheets
Alignment
plate
Paper positioning
plate
Alignment
plate
Alignment plate home

position sensor
(PI5)
F03-304-01
2) The alignment plates move away from the edges of the stack over a short distance and then
butt against the edges once again (Second alignment).
F03-304-02
3-23
3) The alignment plates escape to points 10 mm from the edge of the stack.
F03-304-03
4) When the following stack arrives, steps 1 through 3 above are repeated.
5) The alignment plates butt against the stack once again, during which stitching takes place.
F03-304-04
6) The alignment plates escape to points 10 mm from the edges of the stack, after which folding
and delivery take place.
F03-304-05
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.
F03-304-06
3-24
In case of 2 sheets:
Entry of Entry of 1st sheet of follow1st sheet 2nd sheet ing stack entry
[2] [3] [4]
Alignment plate home [1]
position sensor (PI5)
Alignment motor (M5)
motor (M4)
: Alignment
: Escape
[1]: Move to wait position
[2]: Stapling period
[3]: Paper folding/delivery period
[4]: Move to following stack size wait position
F03-304-07
Alignment plate
Alignment motor
M5
Alignment plate
Stack
Alignment plate
home position
sensor (PI5)
F03-304-08
3-25
3.5 Controlling the Phase of the Crescent Roller

3.5.1 Outline
If alignment was executed with the crescent roller in contact with the stack of sheets, the resulting friction against the roller causes the stack to move inappropriately (Figure F03-305-01). To
prevent this problem, the phase of the roller is identified and used to determine the timing of
alignment.
The phase of the crescent roller is identified by the crescent roller phase sensor (PI12). The flag
for the crescent roller phase sensor is mounted to the crescent roller shaft. The flag will 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 (Figure F03-305-03). The alignment plates are operated to correspond with this change in the state of the sensor.
Crescent roller
phase sensor (PI12)
Alignment plates
Flag
Crescent roller
M1
Feed motor
Stack
F03-305-01
3-26
Alignment plates
Crescent roller
phase sensor (PI12)
Sensor flag
Crescent roller
If the crescent roller was in

contact with the stack,
alignment operation could
be obstructed.
Alignment operation is
started when the flag
has covered the sensor
and the crescent roller
is away from the stack.
F03-305-02
F03-305-03
First sheet
Crescent roller phase
sensor (PI12)
Second sheet Feed motor

stops
Alignment operation
Feed motor (M1)
F03-305-04
3-27
4 Stitching System
4.1 Outline
The stitching system stitches the center of an output stack with staples.
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 switch
(SW7, SW5) for detection of position and a staple switch (SW6, SW4) for detection of the presence/absence of staples.
The stitcher base is designed so that it may be drawn out to the front from the saddle 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.
Stitcher (rear)
Stitcher (front)
Stack
F03-401-01
3-28
4.2 Stitcher Unit Operation

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 units are operated with a time delay so as to prevent wrinkling of paper and to limit
the load applied to the power supply. (A time delay for initiating the stitcher motor startup current helps decrease the load on the power supply.)
The stitcher home position switch (SW7, SW5) is used to monitor the movement of the rotary
cam, enabling identification of individual stitcher operations. The presence/absence of staples inside the staple cartridge fitted to the stitcher is detected by the staple switch (SW6, SW4).
The alignment plates keep both edges of the stack in place while stitching takes place.
F03-402-01
Stitcher home position switch

(front) (SW7)
Stitcher motor (front) (M7)
Stitcher home position
switch (rear) (SW5)
Stitcher motor (rear) (M6)
Alignment
Escape
F03-402-02
3-29
Cam
Mount
F03-402-03
3-30
5 Folding/Delivery System
5.1 Outline
The paper folding mechanism consists of a guide plate, paper folding rollers, paper pushing
plate, and paper positioning plate.
The guide plate is used to cover the folding rollers while sheets are output so as to prevent
sheets from coming into contact with the folding rollers during output. Before the stack is folded,
the guide plate moves down to enable the folding rollers to operate.
The folding rollers are driven by the paper folding motor (M2), and the drive of the motor is
monitored by the paper folding motor clock sensor (PI4). The mechanism is also equipped with a
paper folding home position sensor (PI21) for detecting the position of the paper folding rollers.
The paper pushing plate is driven by the paper pushing plate motor (M8), and the drive of the
paper pushing plate motor is monitored by the paper pushing plate motor clock sensor (PI1). The
paper pushing plate home position sensor (PI14) and the paper pushing plate top position sensor
(PI15) are used to detect the position of the paper pushing plate.
After being folded into two by the paper folding rollers, a stack is moved ahead by the delivery
roller for delivery. The delivery roller is driven by the paper folding motor. The delivery sensor
(PI11) is mounted to the delivery assembly to detect delivery of paper. The tray paper sensor
(PI6) is used to detect the presence/absence of paper on the tray, but does not detect jams. The
vertical path paper sensor (PI17) serves to detect the presence of paper after jam removal.
3-31
5.2 Controlling the Movement of Stacks

When a stack has been stitched (2 points), the paper positioning plate lowers so that the stack
will move to where the paper folding rollers come into contact with the stack and where the paper pushing plate is located. The position of the paper positioning plate is controlled in reference
to the number of motor pulses coming from the paper positioning home position sensor (PI7).
At the same time as the paper positioning plate operates, the guide plate lowers so that folding
may take place.
Stitching
ends
motor (M4)
Guide motor (M3)
Guide home position
sensor (PI13)
F03-502-01
3-32
Equivalent of specific
number of pulses
5.3 Folding a Stack

A stack is folded by the action of the paper folding rollers and the paper pushing plate.
The paper pushing plate pushes against the center of a stack toward the roller contact section.
The paper pushing plate starts at its home position and waits at the leading edge position until 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 position. The
stack gripped in this way by the paper folding roller is drawn further by the paper folding roller
and then is moved by the delivery roller to the paper tray.
Half of the peripheral area of the paper folding rollers excluding the center part is punched out.
This punched out area only feeds the paper as the paper feeding roller (lower) contacts the paper
feeding roller (upper) only at the center of the roller to prevent the paper from wrinkling. As the
paper feeding roller (lower) contacts the paper feeding roller (upper) at their entire surfaces on
the remaining half of the peripheral area, paper folding starts from this half of the peripheral area,
and paper is fed while it is being folded. The stop position of the paper folding rollers is in this
half of the peripheral area.
The paper folding start and stop positions on the paper folding rollers is controlled according to
the motor clock signals from the paper folding home position sensor (PI21).


Paper folding roller (upper)

Sensor flag
Paper folding home
Paper pushing plate
Paper folding
roller (lower)
M8
M2 Paper pushing plate motor
Stack of sheets
Paper folding motor
F03-503-01
3-33
Paper pushing plate top position sensor

(PI15)

Sensor flag
Paper folding home
Paper pushing plate
M2
M8
Paper folding motor
F03-503-02
[Paper folding start position]
Stack of sheets
Paper pushing plate

Paper feed inlet
Delivery outlet
Sensor flag
Paper folding home
Paper folding/feeding is performed.
Paper feeding is performed.
F03-503-03
3-34
[Paper folding roller stop position]
Delivery outlet
Paper feed inlet
Sensor flag
Paper folding home
Paper folding/feeding is performed.
Paper feeding is performed.
F03-503-04
Paper folding motor (M2)

Paper pushing plate
motor (M8)
Equivalent of 10mm by paper folding motor
Delivery sensor (PI11)

Tray paper sensor (PI6)
Paper folding home
: Motor CW
: Motor CCW
F03-503-05
3-35
5.4 Double Folding a Stack

To fold a stack consisting of 10 or more A4-R or LT-R sheets, folding is executed twice for the
same sheet.
The paper folding rollers rotate in reverse for an equivalent of 20 mm after gripping the stack
for a length of 20 mm, enabling the paper folding rollers to apply an increased degree of pressure
along the crease on the stack. Then, the paper folding rollers rotate normally, 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.
Paper pushing plate
M2
M8
Paper folding motor

F03-504-01
2) The paper folding rollers grip the stack for a length of about 20 mm.
20 mm
(appro
x.)
M2
Paper folding motor
F03-504-02
3-36
3) The paper folding rollers rotate in reverse, pushing back the stack for a length of about 20 mm
(reverse feeding).
20 m
m
(appr
ox.)
M2
Paper folding motor
F03-504-03
4) The paper folding rollers rotate again, feeding out the stack. The paper pushing plate returns
to its home position.
M2
M8
Paper folding motor
F03-504-04
Gripping of paper stack
Equivalent of 20 mm
Paper pushing plate
motor (M8)
Equivalent of 20 mm (reverse feeding)
Delivery sensor (PI11)

Paper folding home
: Motor CW
: Motor CCW
F03-504-05
3-37
6 Checking For a Jam

6.1 Outline
The saddle stitcher unit identifies any of the following conditions as a jam, and sends the jam
signal to the host machine. In response, the host machine may stop printing operation and indicate the presence of a jam on its control panel.
When all doors are closed after the user has removed the jam, the saddle stitcher unit checks
whether 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.
PI22
PI18
PI19
PI20
PI11
PI17
PI15
PI8
F03-601-01
No.
PI11
PI17
PI18
PI19
PI20
PI22
Sensor
Delivery sensor
Vertical path paper sensor
No.1 paper sensor
No.2 paper sensor
No.3 paper sensor
Saddle inlet sensor
T03-601-01
3-38
PI14
Jam Type
Delay at inlet
sensor
Sensor
PI22
Stationary at inlet PI22

sensor
Delay at delivery PI18
sensor
Stationary at
delivery sensor
PI18
PI19
PI20
Delivery delay
PI11
Stationary
delivery
PI11
PI17
Stitcher staple
SW7
SW5
Power-on
PI8
PI11
PI17
PI18
PI19
PI20
PI22
PI3
PI9
PI32
Door open
Jam Condition
When the saddle inlet sensor (PI22) does not detect paper after a prescribed time (distance) has elapsed since receiving a saddle delivery
request from the Finisher.
When paper does not exit the saddle inlet sensor (PI22) after delivering
for a prescribed amount with the feed motor (M1) after the saddle inlet
sensor (PI22) detected the leading edge of the paper.
When the 1st paper sensor (PI18) does not detect paper after prescribed time (distance) has elapsed since the saddle inlet sensor (PI22)
detected the leading edge of the paper.
When paper does not exit the 1st paper sensor (PI18), 2nd paper sensor
(PI19), and 3rd paper sensor (PI20) after delivering for a prescribed
amount with the feed motor (M1) after the 1st paper sensor (PI18) has
detected the leading edge of the paper.
When delivery sensor (PI11) cannot detect the paper after delivering
the stack for a prescribed amount with the paper folding motor (M2)
after completing paper pushing motion with the paper pushing plate.
When stack does not exit the delivery sensor (PI11) after delivering the
stack for a prescribed amount with the paper folding motor (M2) after
detecting the leading edge of the paper with the delivery sensor (PI11).
When stack does not exit the vertical path paper sensor (PI17) after delivering the stack for a prescribed amount with the paper folding motor
(M2) after detecting the stack with the delivery sensor (PI11).
When stitcher motors (M7/M6) are rotated forward and the stitch
home position switches (SW7/SW5) do not turn ON within 0.5 seconds after they are turned OFF and the motors are rotated backward
and the sensors turn ON within 0.5 seconds.
When paper is detected by one of the sensor on the paper sensor PCB
(1st paper sensor (PI18), 2nd paper sensor (PI19), 3rd paper sensor
(PI20)), vertical path paper sensor (PI17), delivery sensor (PI11), paper
positioning plate paper sensor (PI8), or saddle inlet sensor (PI22) during power ON.
When the delivery cover sensor (PI3) or inlet cover sensor (PI9) detects that the cover is opened during operation.
When the front cover sensor (PI32) detects cover open with paper
present on the processing tray while the device is not operating.
T03-601-02
3-39
7 Power Supply
7.1 Outline
When the host machine power switch is turned ON, 24V and 5V power lines are supplied by
the finisher controller PCB.
The 24V power is used to drive solenoids. The 24V power from the finisher controller PCB to
solenoids does not pass through any protective mechanisms (microswitches, or the like).
The 24V power to motors, on the other hand, will not be supplied if any of the two door
switches is open. The 5 VDC power is used to drive the sensor. It is also converted to 3.3 VDC by
the regulator IC (IC10) on the saddle stitch controller PCB to drive the ICs on the PCB.
Inlet door
switch
(SW1)
Front cover
switch
(MS31)
Delivery
door switch
(SW3)
24V
24V
24V
Circuit
breaker
(CB1)
Finisher
controller
PCB
24V
Saddle stitcher
controller PCB
5V
Motor systems
Solenoids
Sensors
(IC10)
5V
Regulator IC
3.3V
Logic
F03-701-01

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 equipped with a fuse designed to blow when an
overcurrent flows.
3-40
CHAPTER 4
PUNCHER UNIT (OPTION)
OUTLINE OF OPERATION
#ChapterCover_b.p65
03/05/13, 20:48
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION
1 Basic Operation
1.1 Outline
The puncher unit is optionally installed in the delivery path between the host machine and the
finisher.
When the paper delivered from the host machine reaches the puncher unit, it is fed by the
punch feed roller. Then when the trailing edge of the paper is detected, the paper is temporarily
stopped and the punch axis rotates to punch holes in the trailing edge of the paper. These operations are controlled by the finisher controller PCB and the punch controller PCB drives each
puncher component.
Feed
drive
system
Punch
drive
system
Horizontal
registration
drive
system
Punch
controller
PCB
Finisher unit
control system
F04-101-01
4-1
1.2 Inputs to and Outputs from Punch Driver PCB

1.2.1 Inputs to Punch Driver PCB (1/1)
PI61
Horizontal
registration home
position sensor
PI62
Punch motor
clock sensor
PI63
Punch home
position sensor
J611-3
-2
-1
J605A-7
+5V
-9
-8 SREGHP
J612-1
-2
-3
J605A-6
+5V
-5
-4 PUNCHCLK
J613-3
-2
-1
J605A-3
+5V
-2
-1 PUNCHHP*
When the punch slide

unit is at the home
position, 1.
When the punch motor

is rotating, alternately
between 1 and 0.
When the hole puncher is

at the home position, 0.
+24V
Upper door
switch
N.O.
J621-2
J602-6
-1
-4
J622-2
J602-3
-1
-1
MSW61
UDROPN
When the upper door is

closed, 1.
+24V
Front door
switch
N.O.
MSW62
FDROPN
When the front door is

closed, 1.
Photosensor PCB
+5V
+5V
PTR1
PTR2
PTR3
PTR4
PTR5
J615-2
-3
-4
-5
-6
-7
J605B-6
-5
-4
-3
-2
-1
-1
-7
F04-102-01
4-2
SREG1*
SREG2*
SREG3*
SREG4*
PAEND*
When a paper is detected,

0.
1.2.2 Outputs from Punch Driver PCB (1/2)

LED PCB
LED5
LED4
LED3
LED2
LED1
J614-6
-5
-4
-3
-2
J605B-8
-9
-10
-11
-12
-1
-13
LEDON5
LEDON4
LEDON3
LEDON2
LEDON1
Scrap full detector PCB

LED6
When 1, LED is ON.
+5V
J618-3
J606-2
-4
-1
-2
-1
-3
DFULL
-4
PTR6
LEDON*
When light is blocked, 0.
Punch motor
J603-1
J620-1
According to direction of
motor rotation, changes
between + and -.
M61
-2
-2
Horizontal registration
motor
J610L-4
J610D-1
J605A-13
-3
-2
-12
-2
-3
-11
-1
-4
-10
M62
B*
B
A*
The pulse signal is switched

according to motor rotation.
Punch feed motor
M63
J619-6
J604-1
-4
-2
-3
-3
-1
-4
A*
A
B
The pulse signal is switched

according to motor rotation.
B*
F04-102-02
4-3
1.2.3 Outputs from Punch Driver PCB (2/2)


J705B-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
J607B-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
J705A-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
J607A-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
+24V
J706-1
-2
J601-1
-2
F04-102-03
4-4
2 Punch Operation
2.1 Outline
The puncher unit is located on the feed path between the host machine and the finisher, and
successively punches holes when the paper stops temporarily.
The paper delivered from the host machine is fed by the punch feed roller. The punch feed
roller is driven by the punch feed motor (M63). When the trailing edge of the paper reaches the
puncher unit, the inlet roller of the finisher unit temporarily stops the paper and holes are
punched on the trailing edge of the paper.
The puncher unit consists of a die and hole puncher (punch blade).
The hole puncher is driven by the punch motor (M61). The hole puncher is attached to the eccentric cam of the punch shaft, and rotary action of the punch shaft is converted to reciprocal motion to perform punching.
Punch motor (M61) is a DC motor. The home position of the punch shaft is detected by punch
home position sensor (PI63). To stop the DC punch motor accurately at its home position, the
punch motor clock sensor (PI62) counts a predetermined number of clock pulses to stop the
punch motor. A single punch operation is performed by rotating the punch shaft 180 from its
home position.
Five light sensors (photosensor PCB) are located at the upper side of the inlet paper feed path
of the puncher unit and a set of five LEDs (LED PCB) are located at the lower side. These sensors and LEDs function as five sensors. The frontmost sensor (LED5, PTR5) are the trailing edge
sensor and are used for detecting the trailing edge of the paper. The remaining sensors (LED1 to
LED4, PTR1 to PTR4) are horizontal registration sensors, and are used for detecting the inner
position of the paper for determining the hole punching position.
The punch motor, puncher unit and above sensors comprise the punch slide unit. This unit
moves backwards and forwards according to the size of the paper. Backward and forward movement is driven by the horizontal registration motor (M62). The home position of the punch slide
unit is detected by the horizontal registration home position sensor (PI61). The horizontal registration motor (M62) is a 2-phase stepping motor.
The punch motor and horizontal registration motor is driven by the punch controller PCB according to control signals from the finisher controller PCB.
Punch scraps caused by punching are stored in the punched scrap container. Scrap full detection is performed by a reflective sensor (LED6 and PTR6 on the scrap full detector PCB unit).
4-5
4
2
Punch controller PCB (2/2)
F04-201-01
4-6
Horizontal registration motor (M62) drive signal
Punch feed motor (M63) drive signal
Horizontal registration home position (PI61) detection signal SREGHP
Scrap full detection signal

(LED6,PTR6) DFULL
Punch home position (PI63)

detection signal PUNCHHP
Punch motor clock (PI62)

detection signal PUNCHCLK
Punch motor (M61) drive signal
Horizontal registration detection signal

(LED1 to 4, PTR1 to 4) SREG1 to 4
Trailing edge detection signal

(LED5, PTR5) PAEND
Punch controller PCB (1/2)
3
PTR1
3
LED1
2.2 Punch Operation

The hole puncher is driven by the punch motor (M61). The hole puncher home position is detected by the punch home position sensor (PI63).
In all, there are four types of puncher units depending on the destination: 2-hole type (MJ6004E), 2-/3-hole Dual Use (MJ-6004N), and two 4-hole types (MJ-6004F and MJ-6004S). With
the 2-hole and 4-hole types, the hole puncher is moved reciprocally and punching is performed
by the punch shaft rotating 180 from its home position. With the 2-/3-hole dual use type, too,
the hole puncher is moved reciprocally and punching is performed by the punch shaft rotating
180 from its home position. However, half of the peripheral area of the punch shaft can be used
as a 2-hole type while the other half can be as a 3-hole type. Whether the punch shaft is used as a
2-hole punch or a 3-hole punch depends on the instructions from the host machine.
4-7
2.2.1 2-/4-hole Type

At the home position, the punch home position sensor is ON. Punching of the first sheet ends
when the punch shaft has rotated in the forward direction 180, and the state of the punch home
position sensor has changed from OFF to ON. Punching of the second sheet ends when the
punch shaft has rotated in the reverse direction 180, and the state of the punch home position
sensor has changed from OFF to ON.
The following illustrates punching when two sheets are punched.
1) A hole is punched in the trailing edge of the first sheet.
Sensor flag
Punch home
position sensor
(PI63)
Punch shaft
Eccentric
cam
Die
Hole
puncher
Sheet
Die
[punch shaft stopped/
home position]
Punched scrap
[punch shaft rotated 90
in the forward direction /
hole punched]

in the forward direction /
punch operation completed]
F04-202-01
2) A hole is punched in the trailing edge of the second sheet.

home position]

in the reverse direction/
hole punched]
F04-202-02
4-8

2.2.2 2-/3-hole Dual Use Type

At the home position, the punch home position sensor is ON. To punch two holes, punching of
the first sheet ends when the punch shaft half peripheral area has rotated in the forward direction
180, and the state of the punch home position sensor has changed from OFF to ON. At this time,
the 3-hole puncher is moved reciprocally in the escape direction (hole puncher rise direction) on
the remaining half peripheral area on the punch shaft. Punching of the second sheet ends when
the punch shaft half peripheral area has rotated in the reverse direction 180, and the state of the
punch home position sensor has changed from OFF to ON. Also at this time, the 3-hole puncher
is moved reciprocally in the escape direction (hole puncher rise direction) on the remaining half
peripheral area on the punch shaft. To punch three holes, the 2-hole puncher is moved reciprocally in the escape direction (hole puncher rise direction).
The following illustrates punching when two sheets are punched with two holes.
1) A hole is punched in the trailing edge of the first sheet.
Punch home
position
sensor (PI63)
Sensor flag
Punch shaft
Eccentric
cam
Die
Hole
puncher
Sheet
Die
home position]
Punched scrap
[punch shaft is rotated 90
in the forward direction/
hole punched]

F04-202-03
4-9
When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction
(hole puncher rise direction) as shown below.
[punch shaft stopped/ [punch shaft is rotated 90

home position]
hole puncher rises to
topmost position]

hole puncher returns to
original position]
F04-202-04
2) A hole is punched in the trailing edge of the second sheet.

home position]

hole punched]
F04-202-05
4-10

When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction
(hole puncher rise direction) as shown below.

home position]

hole puncher rises to
topmost position]

hole puncher returns to
original position]
F04-202-06
4-11
2.3 Horizontal Registration Operation

Horizontal registration drive of the punch slide unit is performed by the horizontal registration
motor (M62). The home position of the punch slide unit is detected by the horizontal registration
home position sensor (PI61). The punch slide unit detects the trailing edge of the paper by the
trailing edge sensor (LED5, PTR5) and horizontal registration sensors (LED1 to 4, PTR1 to 4)
and is moved to the trailing edge position matched to the paper size.
The following shows horizontal registration operation.
1) When the leading edge of the paper from the host machine is detected by the trailing edge
sensor (LED5, PTR5) on the puncher unit, the horizontal registration motor (M62) starts to
move the punch slide unit towards the front.
Punch slide unit

Horizontal registration motor (M62)
Trailing edge detection sensor

(LED5,PTR5)
Sheet delivery direction
Sheet
F04-203-01
4-12
2) After the horizontal registration sensors (LED1 to 4, PTR1 to 4) detect the edge of the paper
at its inner side in keeping with the paper size signals arriving from the host machine, the
horizontal registration motor (M62) drives the punch slide unit to a predetermined position
further towards the front, and stops the unit at this position.
Horizontal registration sensor 1(LED1,PTR1)

: detects the edge of A3, A4, LT and LD paper
Horizontal registration sensor 2 (LED2,PTR2)
detects the edge of B4, B5, LT-R and LG paper
: detects the edge of A4-R paper
: detects the edge of B5-R paper
F04-203-02
3) When the trailing edge sensor (LED5, PTR5) detects the trailing edge of the paper, drive of
the punch feed motor (M63) is stopped to stop paper feed. Next, the punch motor (M61) is
driven to punch holes in the paper.
Punch
F04-203-03
4-13
4) When punching ends, drive of the punch feed motor (M63) is started, the horizontal registration motor (M62) is operated in the reverse direction, and the punch slide unit is returned to its
home position where it comes to a stop.
5) Even if paper to be punched continues to arrive, the punch slide unit returns to its home position for each arriving sheet, and steps 1 to 4 are repeated.
Trailing edge detection
sensor (LED5, PTR5)
Horizontal registration sensor
(LED1 to 4, PTR1 to 4)
Punch home position
sensor (PI63)
Horizontal registration home
motor (M62)
Punch motor (M61)
First feed motor (M63)
: Motor CW
F04-203-04
4-14
: Motor CCW
3 Power Supply System

3.1 Outline
24V power and 5V power are supplied from the finisher controller PCB when the power switch
on the host machine is turned ON.
24V power is used for driving motors, while 5V power is used for driving sensors and the ICs
on the punch controller PCB.
24V power to the motors is not supplied when either of the two door switches on the puncher
unit is open.
Upper door
switch
(MSW61)
Front door
switch
(MSW62)
24V
Finisher
controller
PCB
24V
Motor system

5V
5V
5V
Sensors
Logic
F04-301-01

The 24V power supplies are equipped with a fuse designed to blow when an overcurrent flows.
4-15
CHAPTER 5
BRIDGE KIT (OPTION)
BASIC OPERATION
CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION
1 Basic Operation
1.1 Outline
This unit transports paper from the exit section of the equipment to the finisher. The transport
rollers which comprise the bridge unit are rotated by the drive from the host machine.
This unit has a switching gate on its entrance section which decides whether the transported paper from the exit roller of the host machine is transported to the finisher or to the receiving tray.
The gate operates with ON/OFF of the gate solenoid.
The sensor which detects the paper full on the receiving tray is also equipped.
KN-3511: For e-STUDIO3511/4511/281c/351c/451c
KN-3520: For e-STUDIO350/450/352/452 (e-STUDIO200L/230/280/202L/232/282)
5-1
06/04
1.2 Construction
1.2.1 Front side sectional view
The figure below is that of KN-3511.
Transport roller
Transport sensor 2
Transport sensor 1
Paper full detection sensor

Gate
F05-102-01
1.2.2 Rear side view
The figure below is that of KN-3511.
Timing belt
Drive pulley/gear
(G27/P18)
Drive pulley/gear
(P20/G25)
Drive pulley/gear
(G24/P18)
F05-102-02
5-2
Drive pulley (P18)
1.3 Arrangement of Electrical Parts
[3]
[2]
[1]
[4]
[5]
F05-103-01
Name
Photointerrupter
Notation
1
2
3
Microswitch
Solenoid
Function
Bridge unit transport sensor 1
- Detecting paper on transport path (Bridge unit entrance side)
Bridge unit transport sensor 2
- Detecting paper on transport path (Bridge unit exit side)
Paper full detection sensor
- Detecting paper full on receiving tray
Cover open/close detection switch
- Detecting open/close of bridge unit jam access cover
Gate solenoid
- Switching paper transport path
T05-103-01
5-3
2 Disassembly and
Adjustment
2.1 Electrical Parts
[1]
1. Bridge unit transport sensors 1 and 2,

cover open/close detection switch
1) Take off the bridge unit.
2) Disconnect each connector for transport
sensor [1], release the corresponding
latches and take off the bridge unit
transport sensor [2].
3) Disconnect 1 connector [3], release the
latches and take off the cover open/close
detection switch [4].
[2]
[3]
[4]
F05-201-01
2. Paper full detection sensor
[KN-3511]
2) Remove 1 screw [1] and take off the cover
[2].
[1]
[2]
F05-201-02
5-4
3) Disconnect 1 connector [3] and take off

the paper full detection sensor [4].
[3]
[4]
F05-201-03
[KN-3520]
2) Remove 4 screws [5] and take off the
guide [6].
[5]
[5]
[6]
F05-201-04
3) Disconnect 1 connector [7] and take off
the paper full detection sensor [8].
[8]
[7]
F05-201-05
5-5
3. Gate solenoid
2) Disconnect 1 connector [1]. Remove 1
screw [2] and take off the gate solenoid
[3].
[2]
[3]
[1]
F05-201-06
5-6
3 Maintenance
3.1 Periodically Replaced Parts
The bridge unit does not have the parts that must be replaced on a periodical basis.
3.2 Scheduled Maintenance

Clean the transport rollers and transport guide at the finisher maintenance.
5-7
CHAPTER 6
MECHANICAL SYSTEMS
1 Finisher Unit
1.1 Externals and Controls
[1] Tray 1
[2] Tray 2
[3] Front cover
[4] Front door
[5] Front lower cover
[6] Upper cover
[7] Left upper cover
[8] Rear cover
[9] Grate-shaped upper guide
[10] Grate-shaped lower guide
F06-101-01
F06-101-02
6-1
1.1.1 Removing the Front Cover

1) Remove screw [1] and remove the front
lower cover [2].
F06-101-03
2) Open the front door [3] and remove three
screws [4].
3) Remove the front cover [5].
F06-101-04
6-2

1) Remove three screws [1] and remove the
rear cover [2].
F06-101-05
1.1.3 Removing the Left Upper Cover
1) Remove the front cover (see 1.1.1).
2) Remove the rear cover (see 1.1.2).
3) Remove the front inside upper cover
(Only on model with saddle unit) (see
2.1.3).
4) Remove two screws [1].
5) With the upper cover [2] open, remove the
left upper cover [3] by tilting to the right.
F06-101-06
6-3
Note:
When replacing, hook the two claws [4] of the
left upper cover to the steel plate.
F06-101-07

2.1.3).
4) Remove the left upper cover (see 1.1.3).
5) Open the upper cover [1] and unhook the
two hooks [2].
6) Remove screw [3] and remove the upper
cover [1].
F06-101-08
6-4
1.1.5 Removing Tray 1

2.1.3).
5) Remove screw [1] and remove the steel
plate [2] and slide guide [3]. However, if
the grate-shaped upper guide is removed,
this step is not necessary.
F06-101-09
6) Remove screw [4] and remove the stopper
[5].
F06-101-10
7) Remove two screws [6], open two harness
retainers [7] and disconnect two connectors [8].
F06-101-11
6-5
8) Insert your finger in the hole at the rear

side of tray 1 [9], push the tray lift motor
gear [10] to the front to release the clutch
and lift tray 1 [9].
Note:
When the tray lift motor gear clutch is released,
the tray drops by its own weight. Therefore, hold
the tray with your hand when releasing the clutch.
Also, be careful not to twist the tray cable when
installing.
F06-101-12
1.1.6 Removing Tray 2
2.1.3).
5) Remove tray 1 (see 1.1.5).
6) Remove screw [1] and remove the stopper
[2].
F06-101-13
6-6
7) Remove two screws [3] and disconnect

one connector [4].
8) Insert your finger in the hole at the rear
side of tray 2 [5], push the tray lift motor
gear [6] to the front to release the clutch
and lift tray 2 [5].
F06-101-14
Note:
When the tray lift motor gear clutch is released
the tray drops by its own weight. Therefore, hold
the tray with your hand when releasing the clutch.
Also, be careful not to twist the tray cable when
installing.
6-7
1.1.7 Removing the Grate-shaped Upper Guide

2.1.3).
5) Lower the tray 1 [1] below the grateshaped upper guide [2] (see 1.1.5 step 8).
6) Remove five screws [3] and remove the
grate-shaped upper guide [2].
F06-101-15
1.1.8 Removing the Grate-shaped Lower Guide
2.1.3).
5) Remove the grate-shaped upper guide (see
1.1.7).
8) Remove ten screws [1] and remove the
grate-shaped lower guide [2].
Note:
When replacing, be careful not to hook the grateshaped lower guide to the sensor flag arm on the
delivery side.
F06-101-16
6-8
1.2 Delivery System

1.2.1 Removing the Stapler
2.1.3).
3) Pull out the stapler, remove screw [1], and
remove the PCB cover [2].
F06-102-01
4) Release the claw [3] and remove the PCB
[4].
5) Disconnect three connectors [5].
6) Remove screw [6] and remove the stapler
together with the stapler base [7].
Note:
When removing, be careful not to damage the
flag [8].
F06-102-02
6-9
7) Turn the stapler over, disconnect two connectors [9], remove two screws [10], and
remove the stapler from the stapler base.
F06-102-03
1.2.2 Removing the Processing Tray
2.1.3).
1.1.7).
8) Remove the grate-shaped lower guide (see
1.1.8).
9) Unfasten four snap fasteners [1] and remove the sensor flag [3] from the stack
ejection roller [2].
F06-102-04
6-10
Note:
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.
10) Remove the stack delivery roller front side

E-ring [4], gear [5], parallel pin [6], Ering [7], and bushing [8].
Note:
The parallel pin [6] drops when the gear [5] is removed. Be careful not to loose it.
F06-102-05
11) Remove all finisher controller PCB connectors [9].
12) Remove four screws [10]. Remove the
screw [11] securing the ground wire and
remove the finisher controller PCB [12].
F06-102-06
6-11
13) Release the claw [13] of the stack delivery

roller rear side clutch [12] and remove the
clutch [12].
14) Remove the E-ring [14] and bushing [15]
and remove the stack delivery roller.
F06-102-07
15) Disconnect the connector [16] and remove
harness from the clamp and edge saddles
[17].
16) Remove two screws [18] and pull out the
processing tray [19] to the paper delivery
direction.
F06-102-08
Note:
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.
6-12
1.2.3 Removing the Buffer Roller

2.1.3).
5) Remove the upper cover (see 1.1.4).
6) Remove the buffer roller axis [2] from two
arms [1].
7) Remove two clips [3] and remove two
buffer rollers [4].
F06-102-09
1.2.4 Removing the Return Roller
2.1.3).
1.1.7).
1.1.8).
9) Remove the processing tray (see 1.2.2).
10) Remove two clips [1] of the return roller
axis.
11) Pull out the return roller axis and remove
two return rollers [2] together with collar.
12) Separate the return roller and collar.
Note:
Note the direction when installing the return
roller.
Front side : Black
Rear side : White
The paper will not stack properly if it is installed
in the wrong direction.
F06-102-10
6-13
1.2.5 Removing the Swing Unit

2.1.3).
1.1.7).
1.1.8).
10) Remove screw [1] and pull up the swing
pressure guide [2].
F06-102-11
11) Remove two E-rings [3] at the joint between the swing unit and the return roller
unit and then slide the two return roller
unit collars [4] inside.
12) Unhook the swing pressure rack [5] from
the swing unit center hook.
13) Remove the belt on the gear [6] at the rear
side of the swing unit and then pull out
the swing unit [7] to the delivery direction.
F06-102-12
Note:
The parallel pin [8] drops when the gear [6] is removed. Be careful not to loose it.
6-14
1.2.6 Removing the Return Roller Unit

2.1.3).
1.1.7).
1.1.8).
9) Remove the stapler (see 1.2.1).
11) Remove the swing unit (see 1.2.5).
12) Remove the return roller unit front side
connector [1] and remove the harness
from the clamps [2].
13) Remove two screws [3] and pull out the
return roller unit [4] to the front side.
F06-102-13
1.2.7 Removing the Swing Unit Static Charge Eliminator
2.1.3).
1.1.7).
1.1.8).
9) Remove the stapler (see 1.2.1).
6-15
11) Remove the screw [1] securing the static

charge eliminator at the center of the
swing unit.
12) Remove two screws [2] securing the
ground of the delivery side static charge
eliminator.
F06-102-14
13) Pull out the static charge eliminator at the
center of the swing unit from the bottom.
14) Remove the four claws [4] securing the
delivery side static charge eliminator and
remove the two static charge eliminators
[5].
F06-102-15
6-16
1.2.8 Removing the Inlet Static Charge Eliminator

1) Open the upper cover and unhook the
hook linking the upper cover and inlet upper guide (see 1.1.4).
2) Remove two screws [1] and remove the
right side section [2] of the inlet upper
guide (Only on model with saddle unit).
F06-102-16
inlet static charge eliminator [4].
F06-102-17
6-17
1.3 PCB
1.3.1 Removing the Finisher Controller PCB
2) Disconnect all connectors [1] on the finisher controller PCB.
3) Remove four screws [2] and remove the
finisher controller PCB [3].
F06-103-01
6-18
2. Saddle Stitcher Unit

2.1 Exterior Control Components
[1]
[2]
[3]
[4]
[5]
Front cover
Saddle delivery tray
Rear cover
Inlet delivery unit
PCB cover
F06-201-01
F06-201-02
6-19
2.1.1 Removing the Front Cover

1) Open the front cover [1] and remove the
clip [2].
2) Lift the front cover [1] to remove.
F06-201-03
1) Shift the tray cable cover [1] toward the
tray side to remove.
2) Remove six screws [2] and remove the
rear cover [3].
3) Pull out the power supply cable from the
hole [4].
6-20
F06-201-04
2.1.3 Removing the Front Inside Upper Cover

front inside upper cover [2].
F06-201-05
2.1.4 Removing the Front Inside Lower Cover
2) Remove the front inside upper cover (see
2.1.3).
3) Remove screw [1] and then remove the
roller knob [2].
front inside lower cover [4].
F06-201-06
6-21
2.1.5 Removing the Saddle Delivery Tray Unit

1) Lift the saddle delivery tray unit open/
close lever [2] and open the saddle delivery tray unit [1] .
F06-201-07
2) Remove the door axis [3] in the direction
of the arrow and pull out the saddle delivery tray unit [4] toward the delivery side.
[4]
[3]
F06-201-08
6-22
3) Remove the harness wire from the clamps

[5].
4) Remove two connectors [6] and remove
the saddle delivery tray unit [7].
F06-201-09
2.1.6 Removing the Upper Delivery Guide
2.1.3).
1.1.7).
1.1.8).
9) Remove two screws [1] and ground wire
[2] and remove the upper delivery guide
[3].
F06-201-10
6-23
2.1.7 Removing the PCB Cover

1) Remove seven screws [1] and remove the
PCB cover [2].
F06-201-11
2.1.8 Removing the Inlet Delivery Unit
2.1.3).
4) Disconnect four connectors [1] and remove the harness from clamp [2].
F06-201-12
6-24
5) Remove four screws [3].

6) Open the upper cover [4] and remove the
inlet delivery unit [5].
F06-201-13
6-25
2.2 Saddle Unit

2.2.1 Removing the Saddle Unit
2.1.3).
5) Remove the grated-shaped upper guide
(see 1.1.7).
1.1.8).
9) Remove the saddle delivery tray unit (see
2.1.5).
10) Remove the PCB cover (see 2.1.7).
11) Remove the inlet delivery unit (see 2.1.8).
12) Disconnect two connectors [1] and remove the harness from three clamps [2].
13) Remove the harness from two clamps [3]
at the bottom of the delivery side.
F06-202-01
14) Remove two screws [4].
F06-202-02
6-26
15) Remove three screws [5].

16) Remove the saddle unit [6] to the paper
feeding side.
F06-202-03
Note:
When installing the saddle unit, install so that the
Mylar [1] at the front upper side of the saddle
unit is on the outside of the delivery guide plate
[2] as shown in the figure.
Delivery fault will occur if it goes inside.
[2]
[1]
F06-202-04
6-27
2.2.2 Removing the Paper Folding Roller

2.1.3).
5) Remove the grated-shaped upper guide
(see 1.1.7).
8) Remove the upper delivery guide (see
2.1.6).
9) Disconnect two connectors [1] and remove the harness from edge saddle [2]
and clamp [3].
F06-202-05
10) Disconnect two connectors [4] and remove the harness from four edge saddles
[5].
paper folding/paper pushing motor base
[7].
F06-202-06
6-28
12) Unhook the upper side of the front tension

spring [8] and rear tension spring [9].
[8]
F06-202-07
[9]
F06-202-08
6-29
13) Remove the two C-rings [10] at the rear,

and remove the sensor flag [11] and two
bearings [12].
[12]
[10]
[11]
F06-202-09
14) Remove the two C-rings [13] at the front
and remove the two gears [14].
[14]
[13]
F06-202-10
6-30
15) Remove the two bearings [15].
[15]
F06-202-11
16) Open the saddle delivery tray [16].
two aligning plates [18].
18) Slide the two paper folding rollers [19] to
the front, and then pull it out in the delivery direction.
[19]
[17]
[17]
[18]
[16]
F06-202-12
6-31
Note:
When installing, attach the gear [2] so that the
grooves [1] of the paper folding rollers face each
other and align the phase.
[2]
[1]
F06-202-13
6-32
2.2.3 Removing the Stitcher Mount Unit

2.1.3).
3) Remove the front inside lower cover (see
2.1.4).
4) Remove the E-ring [1], shaft [2], and
roller [3].
[3] [1]
[2]
F06-202-14
5) Pull out the stitcher mount unit [4] to the
front.
[4]
F06-202-15
2.2.4 Adjusting the Stitcher Unit
2) Pull out the stitcher mount unit to the
front, then pull out the stitcher towards
yourself and then pull up the stitcher.
stitcher cover [3].
[2]
[1]
[3]
F06-202-16
6-33
4) Remove the stitcher positioning tool [4]

from the back of the cover.
[4]
F06-202-17
5) To adjust the front stitcher, remove the
front guide plate [5] 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)
[7]
[6]
[5]
F06-202-18
6) To adjust the front stitcher, loosen the two
screws [9] on the stitcher mount [8]. To
adjust the rear stitcher, loosen the two
screws [10] on the stitcher mount [8].
[10]
[9]
[8]
6-34
F06-202-19
7) Insert the tool [12] into the staple slot of

the stitcher [11].
[11]
[12]
F06-202-20
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.
[13]
[14]
[15]
F06-202-21
6-35
2.2.5 Removing the Positioning Plate Unit

2.1.3).
4) Remove the front inside lower cover (see
2.1.4).
6) Remove the saddle stitcher controller
PCB (see 2.3.1).
stay [2]. The clamped harness of edge
saddle of the stay need not be removed.
F06-202-22
8) Disconnect two connectors [3], remove
three clamps [4] and remove the harness
[5] from two clamps [6].
9) Remove two screws [7], shift the positioning plate unit [8] forward once, and then
pull it out from the paper feeding side.
F06-202-23
6-36
2.2.6 Removing the No.1 and No.2 Flappers

2.1.3).
4) Remove the inlet delivery unit (see 2.1.8).
5) Remove the claw [1] of the No.1 flapper
bushing, and pull out the No.1 flapper
shaft [2] toward the rear. (The procedure
is the same for the No.2 flapper.)
F06-202-24
6) After detaching the front shaft of the No.1
flapper [3] from the front side plate, remove the No.1 flapper.
F06-202-25
6-37
2.3 PCBs
2.3.1 Removing the Saddle Stitcher Controller PCB
2) Remove the four screws [1] and 16 connectors [2], and remove the saddle stitcher
controller PCB [3].
F06-203-01
6-38
3. Puncher Unit (Option)

3.1 Externals and Controls
[1] Upper cover
[2] Upper cover 2
[3] Front door
[4] Right guide assembly
[5] Rear cover
F06-301-01
rear cover [2].
F06-301-02
6-39
3.1.2 Removing the Right Guide Unit

1) Remove four screws [1], and remove the
right guide assembly [2].
F06-301-03
2) Open the front door [1], remove three
screws [2], and remove the upper cover
[3].
F06-301-04
6-40
3.2 Puncher Driver System

3.2.1 Removing the Punch Motor
3) Disconnect the connector [1].
punch motor [3].
F06-302-01
3.2.2 Removing the Horizontal Registration Motor
2) Remove the right guide assembly (see
3.1.2).
3) Disconnect the connector [1].
4) Remove two screws [2] and slide the horizontal registration motor [3] in the direction of the arrow to remove.
F06-302-02
6-41
3.2.3 Removing the Puncher Unit

Note:
When removing the punch unit, the punch unit
section sometimes opens. If necessary, perform
work with the punch unit section in an open state.

3.1.2).
4) Remove E-ring [1], washer [2], and
puncher spring [3].
F06-302-03
5) Turn the gear [4] in the direction of the arrow, and move the punch unit section [5]
to the front side.
F06-302-04
6-42
6) Remove the three screws [6], and remove

the sensor mount (upper) [7]. Then, remove the connector [8] on the LED PCB.
F06-302-05
7) Disconnect the connector [9] and remove
the screw [10], and remove the horizontal
registration home position sensor [11].
[11]
[10]
[9]
F06-302-06
6-43
8) Turn the gear [12] in the direction of the

arrow, and move the punch unit section
[13] to the rear side.
F06-302-07
9) Remove the binding band [14] while holding its claw between your fingers.
(The binding band must be removed without being cut.)
10) Disconnect the three connectors [15] and
remove the screw [16], and remove the
harness guide [17].
[15]
[15]
[14]
[16]
[17]
F06-302-08
6-44
11) Lift up the front side of the punch unit

section [18] first, then move in the direction of the arrow to remove the punch unit
section [18].
F06-302-09
12) Disconnect the connector [19] on LED
PCB.
[19]
F06-302-10
13) Remove the slide shaft support [20], the
sensor mount (lower) [21] and the
puncher knob [22] from the punch unit
section.
Note:
The slide shaft support [20] is not attached to
punch unit section that are currently set as consumable parts.
When replacing the punch unit section, be sure to
attach the slide shaft support that was in use beforehand.
If you forget to attach the slide shaft support, the
machine may malfunction.
[20]
[22]
[21]
F06-302-11
6-45
3.2.4 Removing the Punch Unit Harness

Note:
When removing the punch unit, the punch unit
section sometimes opens. If necessary, perform
work with the punch unit section in an open state.

3.1.2).
4) Disconnect the two connectors [2] on the
punch controller PCB [1] and remove the
harness from the edge saddle [3].
[2]
[1]
F06-302-12
5) Remove the two binding band [4] while
holding its claw between your fingers.
(The binding band must be removed without being cut.)
6) Disconnect the three connectors [5].
7) Remove the harness [7] from the three
harness clamps [6].
[5]
[5]
[6]
[4]
[6]
[4]
[7]
[6]
F06-302-13
6-46
8) Turn the gear [8] in the direction of the arrow, and move the punch unit section [9]
to the front side.
F06-302-14
9) Remove the three screws [10] and sensor
mount (upper) [10].
10) Disconnect the connector [12] on the
photosensor PCB and the connector [13]
on the LED PCB and remove the harness
from the edge saddle [14].
F06-302-15
6-47
11) Remove the harness [16] from the four

harness clamps [15].
F06-302-16
12) Disconnect the connector [16] of the horizontal registration motor and the connector [17] of the horizontal registration
home position sensor, and remove the
punch unit harness.
F06-302-17
6-48
3.2.5 Installing the Punch Unit Harness

Note:
Offset punch unit harnesses can cause malfunction. The punch unit harnesses must be firmly installed at the positions described below.
1) Fasten the punch unit harnesses so that the

two binding bands [1] of the punch unit
harnesses are on the outside of the two
harness clamps [2].
F06-302-18
PI62
PI63
M61
LED PCB
Photosensor
PCB
[1]
PI61
M62
[1]
Punch Controller
PCB
F06-302-19
6-49
3.3 PCBs
3.3.1 Removing the LED PCB
3) Remove the screw [1].
4) Disconnect the connector [2] and the remove the LED PCB [3].
F06-303-01
3.3.2 Removing the Photosensor PCB
3.1.2).
4) Remove the punch unit (see 3.2.3).
5) Remove the screw [1], and remove the
photosensor PCB [2].
F06-303-02
6-50
3.3.3 Removing the Scrap Full Detector PCB Unit

3.1.2).
2) Remove the screw [1], disconnect the connector [2], and remove the scrap full detector PCB unit [3].
F06-303-03
3.3.4 Removing the Punch Controller PCB
1) Remove the puncher unit from the finisher.
3) Remove the two screws [1], two lock supports, disconnect seven connectors [2],
and remove the punch controller PCB [3].
F06-303-04
6-51
CHAPTER 7
MAINTENANCE AND INSPECTION
1 Periodically Replaced Parts

1.1 Finisher Unit
The Finisher unit does not have parts that must be replaced on a periodical basis.
1.2 Saddle Stitcher Unit

The Saddle stitcher unit does not have parts that must be replaced on a periodical basis.
1.3 Puncher Unit (option)

The Puncher unit does not have parts that must be replaced on a periodical basis.
7-1
2 Consumables and Durables

Some of the parts of the machine may need to be replaced one or more times because of wear
or tear during the machines warranty period. Replace them as necessary.
2.1 Finisher Unit

No. Name
Quantity Approx. life
Stapler
500,000 times
Delivery side static charge

eliminator (R)
Delivery side static charge
eliminator (F)
Inlet static charge eliminator
Swing unit center static
charge eliminator
Buffer roller
Return roller
1,000,000 times
1,000,000 times
1
1
1,000,000 times
1,000,000 times
1
2
1,000,000 times
1,000,000 times
3
4
5
6
7
Remark
1 cartridge lasts approximately
5,000 times
T07-201-01

No. Name
1
Stitcher
100,000 times
Remark
1 cartridge lasts approximately
2000 times
T07-202-01

No. Name
1
2
3
4
5
Puncher unit
Puncher unit
Puncher unit
Puncher unit
Punch unit harness
1
1
1
1
1
1,000,000 times
1,000,000 times
1,000,000 times
1,000,000 times
1,000,000 times
Remark
2 hole model
2/3 hole model
4 hole model
4 hole model
(E)
(N)
(F)
(S)
T07-203-01
3 Periodic Maintenance
Item
Interval
Description Remark
Transmittance sensor (puncher unit (option))
25 million sheets
Cleaning
T07-300-01
7-2
Wipe with dry cloth
3. Updating Finisher ROM

There are two types of finisher ROMs: the ROM with finisher firmware and the ROM with
saddle stitcher firmware each written on. These two types of firmware can be updated individually by installing the download jig (K-PWA-DLM-320) to the finisher control PC board.
(1) Install the ROM to the download jig.
Make sure the applicable model, the direction and the type of ROM are correct.
Connector
Mark for ROM

installation direction
LED
ROM
[Jig board:K-PWA-DLM-320]
(2) Turn OFF the power of the equipment.

(3) Remove the finisher rear cover.
Finisher rear cover
Finisher rear cover
[MJ-1023]
[MJ-1024/1030]
* Connect the finisher interface cable with the equipment after removing the finisher rear
cover.
7-3
06/04
(4) Connect the download jig with the jig connector on the finisher control PC board.
Connector
(5) Change the setting of the DIP switch on the finisher contorol PC board.
Change the setting of the DIP switch as follows according to the firmware to be updated.
Note:
Record the current settings of the DIP switch before changing them. After the updating is completed,
return the DIP switch to the status as record.
<Updating Finisher Firmware>

Change all the setting of the DIP switch (1 to 8) to OFF.
<Updating Saddle Stitcher Firmware>
Change the setting of the DIP switch (1 to 6) to OFF and (7 to 8) to ON.
7-4
(6) Turn ON the power while [0] and [8] button are pressed simultaneously.
Updating starts automatically and the LED on the download jig lights.
Tip:
The processing status can be confirmed by the lighting of the LED (LED 101 to 103) on the finisher
control board.
Processing status
0% or above
15% or above
30% or above
45% or above
60% or above
75% or above
90% or above
LED103
OFF
OFF
OFF
ON
ON
ON
ON
LED
LED102
OFF
ON
ON
OFF
OFF
ON
ON
LED101
ON
OFF
ON
OFF
ON
OFF
ON
(7) After the update is completed properly, the LED on the download jig blinks slowly (at interval of 0.8 sec). The LED starts blinking in approx. 30 sec. (finisher section) or 2 min. 30
sec. (saddle stitcher section) since the update starts. It is assumed that the update is failed if
it does not start blinking even though 1 min. has passed (finisher section) or 3 min. (saddle
stitcher section), or LED blinks fast (at interval of 0.1 sec.). In this case, turn OFF the
power and check the following items. Then, clear the problem and restart updating from the
beginning.
Is the download jig connected properly?
Is the ROM installed to the download jig properly?
Is the updating data written on the ROM of the download jig properly?
Do the download jig and the copier operate properly?
Is the DIP switch on the finisher control PC board set properly according to the download
section (finisher or saddle stitcher)?
(8) Turn OFF the power, remove the download jig and return the DIP switch to the status before
updating.
(9) Install the finisher rear cover.
7-5
CHAPTER 8
TROUBLESHOOTING
1 Adjustments
Note
Before performing each adjustment, make sure that all covers (incl. those of the finisher and
host machine) are closed. Otherwise, the power is not supplied to the finisher and the adjustment may not be performed properly.
1.1 Electrical System (finisher unit)
1.1.1 Adjusting the Alignment Position

Perform this adjustment after replacing the finisher controller PCB or when the alignment position must be changed for some reason.
1) Remove the rear cover of the finisher unit.
2) Check that the power of the host machine is off and set SW104 on the finisher controller
PCB as follows according to the paper used for adjustment.
ON
ON
4 5
A4 paper
4 5
LT paper
F08-101-01
3) Turn on the power of the host machine while [0] button and [8] button are pressed simultaneously.
4) Press SW103 on the finisher controller PCB.
When SW103 is pressed, the swing guide opens and the alignment plate moves to prescribed position.
5) Place ten sheets of A4/LT paper between the alignment plates and push them against the
stopper.
6) Press SW101 or SW102 on the finisher controller PCB and push the alignment plate against
the paper.
When SW101 is pressed, alignment plate moves 0.42 mm forward.
When SW102 is pressed, alignment plate moves 0.42 mm backward.
7) When adjustment is complete, remove paper and press SW103 on the finisher controller PCB
once to store the adjustment in memory.
8) Turn off all bits of finisher controller PCB SW104.
9) Turn off the power of the host machine and install the rear cover of the finisher unit.
8-
07/09
1.1.2 Adjusting the Staple Position

Perform this adjustment after replacing the finisher controller PCB or when the staple position
must be changed for some reason. This adjustment adjusts the front/rear stitches with A4/A4-R
when the paper used for adjustment is AB type and with LT/LT-R when the paper is INCH type.
1) Remove the rear cover of the finisher unit.
2) Check that the host machine power is off and set SW104 on the finisher controller PCB as
follows according to paper/stitch position used for adjustment.

ON
ON
4 5
A4/front stitch
4 5
4 5
A4-R/rear stitch
ON
ON
4 5
LT/front stitch
LT/rear stitch
ON
ON
ON
A4-R/front stitch
4 5
A4/rear stitch
ON
4 5
LT-R/front stitch
4 5
LT-R/rear stitch
F08-101-02
4) Press SW103 on the finisher controller PCB.
When SW103 is pressed, the swing guide opens and the alignment plate moves to prescribed position.
5) Place a sheet of paper between the alignment plates. Push it against the stopper and push the
rear edge of the paper against the rear alignment plate. If the gap between the front alignment
plate and front edge of the paper is 1 mm or greater, stop the staple position adjustment and
repeat the staple position adjustment after completing alignment plate adjustment.
8-
07/09
6) Press SW103 on the finisher controller PCB once to staple. However, remove the stapled paper manually because the paper is not ejected. Press SW103 on the finisher controller PCB
once again.
7) Verify the staple position. If any adjustment is needed, proceed to the step 8). If no adjustment is needed, proceed to the step 9).
8) Press SW101 or SW102 on the finisher controller PCB to adjust the staple position.
When SW101 is pressed, the staple position shifts 0.49 mm to the front side.
When SW102 is pressed, the staple position shifts 0.49 mm to the rear side.
Repeat the steps 5) to 7).
9) After confirming that the staple position is adjusted correctly, place a sheet of paper between
the alignment plates and push it against the stopper and push the rear edge of the paper
against the rear alignment plate. Then press SW103 once. (Stapling is performed and the adjustment value is stored in memory.)
The staple position adjustment is completed.
10) Turn off all bits of SW104 on the finisher controller PCB.
11) Turn off the power of the host machine and install the rear cover of the finisher unit.
8-
1.2 Electrical System (Saddle stitcher unit)
1.2.1 Adjusting the Folding Position

The folding position is adjusted by changing setting of bits 6 through 8 of SW504 on the saddle
stitcher controller PCB to match the stitching position (adjusting the distance over which the
paper positioning plate is moved to the folding position from the stitching position).
If you have replaced the saddle stitcher controller PCB, be sure to set the new SW504 so that
the settings will be the same as those on the old SW504. Perform this adjustment if, for any
reason, you must change the folding position.
1) Check that the power of the host machine is off and separate the finisher from the host
machine. If the optional puncher unit is installed, remove it from the finisher.
2) Remove the PCB cover and set bits 1 through 4 of SW504 on the saddle stitcher controller
PCB as follows:
ON
4 5
Do not change bits 5 through 8.
F08-102-01
3) Remove the rear cover, open the inlet cover of the saddle stitcher unit and tape the actuator
of inlet cover sensor (PI9) and inlet door switch (SW1).
4) Before inserting the paper, mark the top of the paper. You will be using two sheets of A3 or
LD paper.
Mark
A3/LD paper
Insert direction
F08-102-02
8-
5) Turn on the power of the host machine while [0] button and [8] button are pressed
simultaneously.
6) Press SW1 on the saddle stitcher controller PCB so that the feed motor (M1) starts to rotate.
(Press SW1 three seconds or more if LD paper is used.)
7) Open the inlet cover and insert two sheets of paper. Push them in by hand until the front edge
of the sheets push against the paper positioning plate.
8) Close the inlet cover.
9) Press SW1 on the saddle stitcher controller PCB.
The saddle stitcher unit will stitch the sheets, and fold and deliver the stack automatically.
10) Measure the distance (L) between the stitching position and the folding position. Then
perform positive width adjustment or negative width adjustment to suit the relationship
between the stitching 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.
Positive Width Adjustment
Mark
Negative Width Adjustment
Folding position
Stitching position
Unit: mm
Example: If L is 1 mm, provide +1 mm.
Mark
Stitching position
Folding position
Unit: mm
Example: If L is 0.5 mm, provide -0.5 mm.
F08-102-03
8-
07/09
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, requiring no change.
If for positive width adjustment
Set SW504 so that the difference resulting from subtraction of the interval from the
appropriate setting in T08-102-01 is provided.
Example: If SW504 is currently set to +2 and the interval is +1 mm, set SW504 to reflect
-2.
If for negative width adjustment
Set SW504 so that the sum resulting from addition of the interval from the appropriate
setting in T08-102-01 is provided.
Example: If SW504 is currently set to -1 and the interval is -0.5mm, set SW504 to reflect
+1.

DIPSW1 bit settings

Bit 6
Bit 7
OFF
ON
OFF
ON
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
ON
ON
Bit 8
ON
OFF
ON
OFF
ON
OFF
ON
Setting
(in units of 0.5 mm)
+3
+2
+1
0
-1
-2
-3
Do not use the following setting

Bit 6
Bit 7
Bit 8
ON
OFF
OFF
T08-102-01
12) Set SW504 bits 1 to 4 to OFF.
1.2.2 Adjusting the Stitching Position (adjusting center stitching)
Use the host machine adjustment mode to perform this adjustment.
8-
1.3 Electrical System (Puncher unit(option))
1.3.1 Sensor Output Adjustment

Perform this adjustment when replacing the punch controller PCB, transmittance sensor
(photosensor PCB/LED PCB), or deflection sensor (scrap full detector PCB unit).
1) Check that the power of the host machine is off and then remove the rear cover of the
puncher.
2) Set SW601 on the punch controller PCB as shown below.
ON
F08-103-01
3) Turn on the power of the host machine while [0] button and [8] button are pressed
simultaneously.
4) Press SW602 on the punch controller PCB. Sensor output is adjusted automatically when the
switch is pressed.
Adjustment is complete if LED601 and LED602 on the punch controller PCB blinks alternately.
5) Press SW602 or SW603 on the punch controller PCB to end the adjustment mode and set all
bits of SW601 to OFF.
6) Turn off the power of the host machine.
8-
07/09
1.3.2 Registering the Number of Punch Holes

This operation registers which puncher unit is attached to the IC on the punch driver PCB so
that the puncher unit can be identified by the finisher. For this reason, this operation must be
performed when the punch driver PCB has been replaced.
1) Check that the power of the host machine is off and then remove the rear cover of the puncher.
2) Set SW601 on the punch controller PCB as shown below.
ON
F08-103-02
4) Press SW602 on the punch controller PCB to select the number of punch holes.
The items in the following table are displayed repeatedly from top to bottom each time
SW602 is pressed.

Number of punch holes

2 hole (E)
2/3 hole (N)
4 hole (F)
4 hole (S)
LED601/LED602
Blinks 1 times per cycle

T08-103-01
5) Press SW603 on the punch controller PCB. The number of punch holes is registered to the
punch controller PCB each time the switch is pressed.
Registration is complete if LED601 and LED602 on the punch controller PCB blinks alternately.
6) Press SW602 or SW603 on the punch controller PCB to end the adjustment mode and set all
bits of SW601 to OFF.
7) Turn off the power of the host machine.
8-
07/09
2 Arrangement of Electric Components

2.1 Finisher Unit
2.1.1 Sensors
PI35
PI31
PI42
PI37
PI38
PI39
PI36
PI34
PI41
PI48
PI32
PI49
PI33
PI45
PI46
PI40
PI43
F08-201-01
8-
Name
Photo interrupter

Notation Function
PI31
PI32
PI33
PI34
PI35
PI36
PI37
PI38
PI39
PI40
PI41
PI42
PI43
PI45
PI46
PI48
PI49
Detects upper cover open/close

Detects front cover open/close
Detects paper in inlet
Detects paper in vertical path
Detects swing guide home position
Detects front aligning plate home position
Detects rear aligning plate home position
Detects paper in processing tray
Detects rear end assist home position
Detects stapler home position
Detects paper surface
Detects paper on tray 1
Detects paper on tray 2
Detects shutter home position
Detects stapler alignment interference
Detects paper surface on tray 2
Detects gear change home position
T08-201-01
8-10
2.1.2 Microswitches
MS34
MS32
MS33
MS31
F08-201-02
Name
Micro-switch

Notation Function
MS31
MS32
MS33
MS34
Detects front cover close

Detects swing guide open
Detects tray 1
Detects swing guide open
T08-201-02
8-11
2.1.3 Solenoids
SL32
SL33
SL31
SL34
F08-201-03
Name
Solenoid

Notation Function
SL31
SL32
SL33
SL34
Inlet roller separation solenoid

Buffer roller separation solenoid
1st delivery roller separation solenoid
Buffer rear end holding solenoid
T08-201-03
8-12
2.1.4 Motors
M36
M37
M32
M31
M40
M34
M39
M33
M38
M35
M41
F08-201-04
8-13
Name
Motor

Notation Function
M31
M32
M33
M34
M35
M36
M37
M38
M39
M40
M41
Inlet motor
Stapler shift motor
Swing motor
Tray 1 shift motor
Tray 2 shift motor
Rear end assist motor
Gear change motor
Staple motor
T08-201-04
8-14
2.1.5 Clutches
CL32
CL31
F08-201-05
Name
Clutch

Notation Function
CL31
CL32
Shutter clutch
Stack ejection lower roller clutch
T08-201-05
8-15
2.1.6 PCBs
[6]
[1]
[4]
[2]
[7]
[5]
[3]
F08-201-06
Reference
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Name

Stapler PCB1
Stapler PCB2
Tray1 driver PCB
Tray2 driver PCB
Tray1 shift area sensor PCB
Tray2 shift area sensor PCB
T08-201-06
8-16

2.2.1 Sensors
PI18
PI19
PI20
PI22
PI16
PI9
PI21
PI11
PI17
PI6
PI12
PI14
PI15
PI13
PI5
PI8
PI3
PI7
PI4
PI1
F08-202-01
8-17
Name
Photo interrupter

Notation Function
PI1
PI3
PI4
PI5
PI6
PI7
PI8
PI9
PI11
PI12
PI13
PI14
PI15
PI16
PI17
PI18
PI19
PI20
PI21
PI22
Detects paper pushing plate motor clock

Detects delivery cover open
Detects paper folding motor clock
Detects alignment plate home position
Detects paper on tray
Detects paper positioning plate home position
Detects paper on paper positioning plate
Detects inlet cover open
Detects paper delivery
Detects crescent roller phase
Detects guide home position
Detects paper pushing plate home position
Detects paper pushing plate top position
Detects stitcher unit storage
Detects paper in vertical path
Detects paper (No. 1; on paper sensor PCB)
Detects paper folding home position
Detects saddle inlet paper
T08-202-01
8-18
2.2.2 Microswitches
SW1
SW4,5
SW6,7
SW3
F08-202-02
Name
Micro-switch

Notation Function
SW1
SW3
SW4
SW5
SW6
SW7
Detects inlet door open

Detects delivery door open
Detects presence of staples (rear)
Detects stitcher home position (rear)
Detects presence of staples (front)
Detects stitcher home position (front)
T08-202-02
8-19
2.2.3 Motors
M9
M6
M7
M4
M3
M1
M5
M2
M8
F08-202-03
Name
Motor

Notation Function
M1
M2
M3
M4
M5
M6
M7
M8
M9
Feed motor
Paper folding motor
Guide motor
Alignment motor
Stitcher motor (rear)
Stitcher motor (front)
Saddle inlet motor
T08-202-03
8-20
2.2.4 Solenoids
SL5
SL1
SL2
SL4
F08-202-04
Name
Solenoid

Notation Function
SL1
SL2
SL4
SL5

T08-202-04
8-21
2.2.5 PCBs
[3]
[2]
[1]
F08-202-05
Reference
[1]
[2]
[3]
Name

Paper sensor PCB
Saddle driver PCB
T08-202-05
8-22
2.3 Punch Unit (option)

2.3.1 Sensors
PI62
PI61
PI63
F08-203-01
Name
Photo interrupter

Notation Function
PI61
PI62
PI63
Detects horizontal registration home position

Detects punch motor clock
Detects punch home position
T08-203-01
8-23
2.3.2 Microswitches
MSW61
MSW62
F08-203-02
Name
Micro-switch

Notation Function
MSW61
MSW62
Detects upper door open

Detects front door open
T08-203-02
8-24
2.3.3 Motors
M61
M62
M63
F08-203-03
Name
Motor

Notation Function
M61
M62
M63
Punch motor
Horizontal registration motor
Punch feed motor
T08-203-03
8-25
2.3.4 PCBs
[2]
[3]
[1]
[4]
F08-203-04
Reference
[1]
[2]
[3]
[4]
Name

Photosensor PCB
LED PCB
T08-203-04
8-26
3 LEDs and Check Pins by PCB

Of the LEDs and check pins used in the machine, those needed during servicing in the field are
discussed.
Do not touch the check pins not found in the list herein. They are exclusively for factory
use, and require special tools and a high degree of accuracy.
3.1 Finisher Controller PCB

1
13 4
J708
1 5
J718
1 1
J709
9 1
J707
7 1
J710
5 1
4 1
J727
J715
J714
2
J719
SW103
J724
2
J713
1
SW104
1
4
SW102
J712
SW101
A1
J702 J726
J711
J705
A10
A10
A1
J716
A1
2
A10
J701
J704
J722
J703
J721
J717
J706
1 A12
A1
A8
A1
15
F08-301-01
Switch
Function
SW101
SW102
SW103
SW104
Adjust the alignment plate position/staple position, etc.

T08-301-01
8-27
J11
15
J18
J13
J2
SW1
J21
SW504
J10
1
J7
10
8
J9
1
J4
10
15
J6
1
12
CB1
J1
9
J19
J8
J15
J12
J5
1
14
F08-302-01
Switch
Function
SW504 (bits 1-2)
Starts correction of discrepancy between stitching position and

folding position.
Stores corrected settings for stitching position and folding
position.
Starts correction of discrepancy between stitching position and
folding position.
SW504 (bits 6-8)

SW1
T08-302-01
8-28
3.3 Punch Controller PCB
J603
2
J602
J604
J601
1
J605
A13
J607
A1
A1
J606
4
J608
A11
SW602
SW603
SW601
F08-303-01
Switch
Function
SW601
SW602
SW603
Punch hole count registration/sensor output adjustment etc.

T08-303-01
8-29
4 Troubleshooting
4.1 Troubleshooting (finisher unit)
4.1.1 Saddle stitcher controller PCB communication error
Finisher controller PCB/Saddle stitcher controller PCB
1) Does it improve when the host machine power switch is turned OFF/ON?
YES : End
NO : Next
Wiring
2) Is the wiring between the finisher controller PCB and saddle stitcher controller
PCB normal?
YES : Next
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
T08-401-01
4.1.2 Puncher unit (option) communication error
Finisher controller PCB/Punch controller PCB
YES : End
NO : Next
Wiring
2) Is the wiring between the finisher controller PCB and punch controller PCB
normal?
YES : Next
Finisher controller PCB/Punch driver PCB

3) Does it improve when the finisher controller PCB and punch controller PCB
are replaced?
YES : End
T08-401-02
8-30
4.1.3 Backup RAM error

Finisher controller PCB/Punch controller PCB
YES : End
NO : Next
2) Does it improve when the finisher controller PCB and punch controller PCB
are replaced?
YES : End
T08-401-03
4.1.4 Front aligning plate motor error
Front aligning plate home position sensor (PI36)
1) Check the front aligning plate home position sensor. Does the sensor operate
normally?
YES : Next
NO : Replace the sensor.
Wiring
2) Is the wiring between the finisher controller PCB and front aligning plate motor normal?
YES : Next

3) Is there any mechanical trapping in the path of the aligning plate?
YES : Repair the mechanism.
NO : Next
Front aligning plate motor (M33)/Finisher controller PCB

4) Does it improve when the front aligning plate motor is replaced?
YES : End
NO : Replace the finisher controller PCB.
T08-401-04
8-31
4.1.5 Rear aligning plate motor error

Rear aligning plate home position sensor (PI37)
1) Check the rear aligning plate home position sensor. Does the sensor operate
normally?
YES : Next
Wiring
2) Is the wiring between the finisher controller PCB and rear aligning plate motor
normal?
YES : Next
Rear aligning plate

3) Is there mechanical trapping in the path of the aligning plate?
NO : Next
Rear aligning plate motor (M34)/Finisher controller PCB

4) Does it improve when the rear aligning plate motor is replaced?
YES : End
T08-401-05
4.1.6 Staple motor error
Wiring
1) Is the wiring between the finisher controller PCB and stapler normal?
YES : Next
Stapler/Finisher controller PCB

2) Does it improve when the stapler is replaced?
YES : End
T08-401-06
8-32
4.1.7 Stapler shift motor error

Stapler drive home position sensor (PI40)
1) Check the stapler drive home position sensor. Does it operate normally?
YES : Next
Wiring
2) Is the wiring between the finisher controller PCB and stapler shift motor normal?
YES : Next
Stapler shift base

3) Is there mechanical trapping in the path of the stapler shift base?
NO : Next
Stapler shift motor (M35)/Finisher controller PCB

4) Does it improve when the stapler shift motor is replaced?
YES : End
T08-401-07
4.1.8 Swing motor error
1) Check the swing home position sensor. Does the sensor operate normally?
YES : Next
Wiring
2) Is the wiring between the finisher controller PCB and swing motor normal?
YES : Next
Swing mechanism
3) Is there any abnormality in the swing machanism?
YES : Repair the swing mechanism.
NO : Next
Swing motor (M36)/Finisher controller PCB

4) Does it improve when the swing motor is replaced?
YES : End
T08-401-08
8-33
4.1.9 Tray 1 shift motor error

1) Check the tray 1 shift area sensors 1 to 3. Do the sensors operate normally?
YES : Next
NO : Replace the tray 1 shift area sensor PCB.
Wiring
2) Is the wiring between the finisher controller PCB and tray 1 shift motor normal?
YES : Next
Tray up/down mechanism

3) Is there any abnormality in the tray up/down mechanism?
YES : Repair the tray up/down mechanism.
NO : Next
Tray 1 shift motor (M37)/Finisher controller PCB

4) Does it improve when the tray 1 shift motor is replaced?
YES : End
T08-401-09
4.1.10 Tray 2 shift motor error
1) Check the tray 2 shift area sensors 1 to 3. Do the sensors operate normally?
YES : Next
NO : Replace the tray 2 shift area sensor PCB
Wiring
2) Is the wiring between the finisher controller PCB and tray 2 shift motor normal?
YES : Next
Tray up/down mechanism

3) Is there any abnormality in the tray up/down mechanism?
YES : Repair the tray up/down mechanism.
NO : Next
Tray 2 shift motor (M38)/Finisher controller PCB

4) Does it improve when the tray 2 shift motor is replaced?
YES : End
T08-401-10
8-34
4.1.11 Stack ejection motor error

Shutter home position sensor (PI45)
1) Check the shutter home position sensor. Does the sensor operate normally?
YES : Next
Wiring
2) Is the wiring between the finisher controller PCB and stack ejection motor, and
between the finisher controller PCB and shutter clutch normal?
YES : Next
Shutter mechanism
3) Is there any abnormality in the shutter mechanism?
YES : Repair the shutter mechanism.
NO : Next
Stack ejection motor (M32)/Shutter clutch (CL31)/Finisher controller PCB

4) Does it improve when the stack ejection motor and shutter clutch are replaced?
YES : End
T08-401-11
4.1.12 Rear end assist motor error
Rear end assist guide home position sensor (PI39)
1) Check the rear end assist guide home position sensor. Does the sensor operate
normally?
YES : Next
Wiring
2) Is the wiring between the finisher controller PCB and rear end assist motor
normal?
YES : Next
Rear end assist mechanism

3) Is there any abnormality in the rear end assist mechanism?
YES : Repair the rear end assist mechanism.
NO : Next
Rear end assist motor (M39)/Finisher controller PCB

4) Does it improve when the rear end assist motor is replaced?
YES : End
T08-401-12
8-35
4.1.13 Gear change motor error

Gear change home position sensor (PI49)
1) Check the gear change home position sensor. Does the sensor operate normally?
YES : Next
Wiring
2) Is the wiring between the finisher controller PCB and Gear change motor normal?
YES : Next
Gear change mechanism

3) Is there any abnormality in the gear change mechanism?
YES : Repair the gear change mechanism.
NO : Next
Gear change motor (M40)/Finisher controller PCB

4) Does it improve when the gear change motor is replaced?
YES : End
T08-401-13
8-36
4.2 Troubleshooting Procedure (Saddle Stitcher Unit)

4.2.1 Paper positioning plate motor error
Paper positioning plate home position sensor (PI7)
1) Check the paper positioning plate home position sensor. Is the sensor normal?
YES : Next
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.
NO : Next
Paper positioning plate motor (M4)/Saddle stitcher controller PCB

3) Is the problem solved by replacing the paper positioning plate motor?
YES : END
NO : Replace saddle stitcher controller PCB.
T08-402-01
4.2.2 Paper folding motor error
Paper folding motor clock sensor (PI4)/Paper folding home position sensor (PI21)
1) Check the paper folding motor clock sensor and paper folding home position
sensor. Are the sensors normal?
YES : Next
NO : Replace sensor.
Paper folding roller drive mechanism

2) Is there a problem with the paper folding roller drive mechanism?
YES : Repair the paper folding roller drive mechanism.
NO : Next
Paper folding motor (M2)/Saddle stitcher controller PCB

3) Is the problem solved by replacing the paper folding motor?
YES : Complete.
NO : Replace saddle stitcher controller PCB.
T08-402-02
8-37
4.2.3 Guide motor error

Guide home position sensor (PI13)
1) Check the guide home position sensor. Does the sensor operate normally?
YES : Next
Guide plate drive mechanism

2) Is there any abnormality in the guide plate drive machanism?
YES : Repair the guide plate drive mechanism.
NO : Next
Guide Motor (M3)/Saddle stitcher controller PCB

3) Does it improve when the guide motor is replaced?
YES : End
NO : Replace the saddle stitcher controller PCB.
T08-402-03
4.2.4 Aligning motor error
Aligning plate home position sensor (PI5)
1) Check the aligning plate home position sensor. Does the sensor operate normally?
YES : Next
Aligning plate drive mechanism

2) Is there any abnormality in the aligning plate drive mechanism?
YES : Repair the aligning plate drive mechanism.
NO : Next
Alignment motor (M5)/Saddle stitcher controller PCB

3) Does it improve when the aligning motor is replaced?
YES : End
T08-402-04
8-38
4.2.5 Stitcher (rear) error

Installing the stitcher (rear)
1) Are the stitcher (rear) and mount installed properly?
YES : Next
NO : Install them properly.
Stitcher home position sensor (rear) (SW5)

2) Check the stitcher home position switch. Does the switch operate normally?
YES : Next
NO : Replace the stitcher.
Stitcher motor (rear) (M6) / Saddle stitcher controller PCB

3) Does it improve when the stitcher is replaced?
YES : End
T08-402-05
4.2.6 Stitcher (front) error
Installing the stitcher (front)
1) Are the stitcher (front) and mount installed properly?
YES : Next
NO : Install them properly.
Stitcher home position sensor (front) (SW7)

2) Check the stitcher home position switch. Does the switch operate normally?
YES : Next
NO : Replace the stitcher.
Stitcher motor (front) (M7) / Saddle stitcher controller PCB

3) Does it improve when the stitcher is replaced?
YES : End
T08-402-06
8-39
4.2.7 Paper pushing plate motor error

Paper pushing plate home position sensor (PI14)/Paper pushing plate top position sensor (PI15)/
Paper pushing plate motor clock sensor
1) Check the sensors. Do the sensors operate normally?
YES : Next
NO : Replace the sensors.
Paper pushing plate drive mechanism

2) Is there any abnormality in the paper pushing plate drive mechanism?
YES : Repair the paper pushing plate drive mechanism.
NO : Next
Paper pushing plate motor (M8)/Saddle stitcher controller PCB

3) Does it improve when the paper pushing plate motor is replaced?
YES : End
T08-402-07
4.2.8 Sensor connector error
Disconnection of the connectors of guide home position sensor (PI13)/paper pushing plate home
position sensor (PI14)/paper pushing plate top position sensor (PI15)
1) Are the sensors connectors and the saddle stitcher controller PCB connector
connected properly?
YES : Next
NO : Connect them properly.
Wiring
2) Is the wiring between the sensors and saddle stitcher broken?
YES : Repair the wiring.
NO : Next
Power supply
3) Is 5VDC supplied from J9-7, J9-10, J9-13 of the saddle stitcher controller
PCB?
YES : Next
Ground
4) Is a ground for J9-8, J9-11, J9-14 of the saddle stitcher controller PC established properly?
T08-402-08
8-40
4.2.9 Micro switch error

Front cover switch (MS31)/Inlet door switch (SW1)/Delivery door switch (SW3)
1) Check the switches. Do the switches operate normally?
YES : Next
NO : Replace the switches.
Power supply and wiring

2) Measure the voltage between J704-1 (+) and J704-2 (-) of the finisher controller
PCB. Is the voltage 24V?
YES : Next
3) Is the wiring between J704 of the finisher controller PCB and J1 of the saddle
stitcher controller normal?
YES : Replace the saddle stitcher controller PCB.
T08-402-09
8-41
4.3 Troubleshooting Procedure (Puncher unit (option))

4.3.1 Puncher unit backup RAM error
NO : Replace the punch controller PCB.
T08-403-01
4.3.2 Punch motor error
Punch home position sensor (PI63)
1) Check the punch home position sensor. Does the sensor operate normally?
YES : Next
Punch motor clock sensor (PI62)

2) Check the punch motor clock sensor. Does the sensor operate normally?
YES : Next
Wiring
3) Is the wiring between the punch controller PCB and sensors normal?
YES : Next
Punch mechanism/Punch motor (M61)

4) Is there any abnormality in the punch mechanism?
YES : Repair the punch mechanism.
NO : Replace the punch motor.
Punch controller PCB/Finisher controller PCB

5) Does it improve when the punch controller PCB is replaced?
YES : End
T08-403-02
8-42
4.3.3 Horizontal registration motor error

Horizontal registration home position sensor (PI61)
1) Check the horizontal registration home position sensor. Does the sensor operate
normally?
YES : Next
Wiring
2) Is the wiring between the punch controller PCB and the sensor normal?
YES : Next
Horizontal registration mechanism/ Horizontal registration motor (M62)

3) Is there any abnormality in the horizontal registration mechanism?
YES : Repair the horizontal registration mechanism.
Punch controller PCB/Finisher controller PCB

4) Does it improve when the punch controller PCB is replaced?
YES : End
T08-403-03
8-43
5 Self Diagnosis
5.1 Outline
The CPU on the machines finisher controller PCB is equipped 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.
5.2 Errors
5.2.1 Finisher Unit
Error Description
Detection timing
Communication error
The communication with the saddle stitcher is interrupted.

The communication with the puncher unit (option) is interrupted.
The checksum for the finisher controller PCB has an error when
the power is turned on.
The checksum for the punch controller PCB has an error when the
power is turned on.
The aligning plate does not leave the aligning plate front home position sensor when the alignment plate front motor has been driven
for 4 seconds.
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.
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.
The aligning plate does not return to aligning plate rear home position sensor when the alignment plate rear motor has been driven for
4 seconds.
Backup RAM error

(M33) error
Front aligning plate home
position sensor (PI36) error

(M34) error
Rear aligning plate home
T08-502-01
8-44
Error Description
Detection timing
Staple motor error

Staple home position detect
switch error
The stapler does not leave the staple home position when the staple
motor has been driven for 0.4 sec.
The stapler does not return to the staple home position when the
staple motor has been driven for 0.4 sec.
The stapler does not leave the stapler shift home position when the
stapler shift motor has been driven for 5 seconds.
The stapler does not return to the stapler shift home position when
the stapler shift motor has been driven for 20 seconds.
The stapler does not leave the swing home position when the swing
motor has been driven for 3 seconds.
The stapler does not return to the swing home position when the
swing motor has been driven for 3 seconds.
If the tray does not move to other area when tray 1 shift motor is
driven for 4 seconds.
If the tray does not return to home position when the tray 1 shift
motor is driven for 20 seconds.
If the tray does not move to other area when tray 2 shift motor is
driven for 4 seconds.
If the tray does not return to home position when the tray 2 shift
motor is driven for 20 seconds.
The stapler does not leave the shutter home position when the stack
ejection motor has been driven for 3 seconds.

error
Stapler shift home position
sensor (P140) error
Swing motor (M36) error
Swing guide home
Tray 1 shift motor (M37)

error
error
error
error
error
Shutter open/close clutch
(CL31) error
The stapler does not return to the shutter home position when the
Shutter home position sensor
stack ejection motor has been driven for 3 seconds.
(PI45) error
Rear end assist motor (M39) The stapler does not leave the rear end assist home position when
error
the rear end assist motor has been driven for 3 seconds.
Rear end assist home position The stapler does not return to the rear end assist home position
sensor (PI39) error
when the rear end assist motor has been driven for 3 seconds.
T08-502-02
8-45
Error Description
Detection timing
Gear change motor (M40)

error
Gear change home position
sensor (PI49) error
The stapler does not leave the gear change home position when the
gear change motor has been drive for 387 pulses.
The stapler does not return to the gear change home position when
the gear change motor has been drive for 387 pulses.
T08-502-03
8-46

Error Description
Detection timing
Paper positioning plate motor The paper positioning plate home position sensor does not turn ON
(M4) error
when the paper positioning plate motor has been driven for 300
Paper positioning plate home
pulses.
The paper positioning plate home position sensor does not turn
OFF when the paper positioning plate motor has been driven for
1500 pulses.
Paper fold motor (M2) error
The number of pulses detected by the paper fold motor clock sen Paper fold motor clock sensor
sor is less than standard value.
(PI4) error
The status of the paper fold home position sensor does not change
Paper fold home position
when the paper fold motor has been driven for 3 seconds.
sensor (PI21) error
Guide motor (M3) error
The guide home position sensor does not turn ON when the guide
Guide home position sensor
motor has been driven for 50 pulses.
(PI3) error
The guide home position sensor does not turn OFF when the guide
motor has been driven for 700 pulses.
Aligning motor (M5) error
The aligning plate home position sensor does not turn ON when
the aligning plate motor has been driven for 50 pulses.
Aligning plate home position
sensor (PI5) error
The aligning plate home position sensor does not turn OFF when
the aligning plate motor has been driven for 500 pulses.
Stitch motor (rear) (M6) error The stitching home position sensor does not turn OFF when the
Stitching home position
stitch motor (rear) has been driven forward for 0.5 sec.
sensor (rear) (SW5) error
The stitching home position sensor does not turn ON when the
stitch motor (rear) has been driven backward for 0.5 sec.
Stitch motor (front) (M7)
The stitching home position sensor does not turn OFF when the
error
stitch motor (front) has been driven forward for 0.5 sec.
Stitching home position
The stitching home position sensor does not turn ON when the
sensor (front) (SW7) error
stitch motor (front) has been driven backward for 0.5 sec.
T08-502-04
8-47

Error Description
Detection timing

(M8) error
Paper pushing plate leading
edge position sensor (PI15)
error
clock sensor (PI1) error
The paper pushing plate home position sensor does not turn ON
when the paper pushing plate motor has been driven for 0.3 sec.
The paper pushing plate home position sensor does not turn OFF
when the paper pushing plate motor has been driven for 80 ms.
The paper pushing plate leading edge position sensor does not turn
OFF when the paper pushing plate motor has been driven for 80
ms.
The number of pulses detected by the paper pushing plate motor
clock sensor is less than standard value.
The paper pushing plate leading edge position sensor does not turn
ON when the paper pushing plate motor has been driven for 0.3
sec.
Loose guide home position sensor connector is detected.
(PI13) connector error
Loose paper pushing plate home position sensor connector is dePaper pushing plate home
tected.
position sensor (PI14) connec- Loose paper pushing plate leading edge position sensor connector
tor error
is detected.
Paper pushing plate leading
edge position sensor (PI15)
connector error
Inlet door switch (SW1) error The inlet door switch is in open state when all covers are closed.
Ejection door switch (SW3)
The ejection door switch is in open state when all covers are
error
closed.
Front cover close detect
The front cover close detect door switch is in open state when all
switch (MS31) error
covers are closed.
T08-502-05
8-48
5.2.4 Puncher Unit (option)

Error Description
Detection timing
Backup RAM error
The checksum for the punch controller PCB has an error when the
power is turned on.
The puncher does not leave the puncher home position sensor when
the punch motor has been driven for 200 ms.
The puncher does not return to the puncher home position sensor
when the punch motor has been driven for 200 ms.
The punch motor clock sensor could not detect target clock count
when starting operation.
No clock is detected by the punch motor clock sensor for 100 ms
when the punch motor has been driven.
The puncher does not leave the horizontal registration home position sensor when the horizontal registration motor has been driven
for 1000 msec.
The puncher does not return to the horizontal registration home position sensor when the horizontal registration motor has been
driven for 1000 msec.
Punch motor (M61) error

Punch motor clock sensor
(PI62) error
Punch home position sensor
(PI63) error
Horizontal registration motor

(M62) error
T08-502-06
8-49
5.3 Alarm
5.3.1 Finisher Unit
Alarm Description
Condition
Detection timing Machine operation
Stapler is absent
The stapler is
not set.
Always monitored
Staple is absent
The staple cartridge has run

out of staples.
Always monitored
Stapler safety
Stapler safety
When starting
protection func- protection func- staple operation.
tion activated
tion was activated.
Stack tray
overstacking
Stapler staple
jam
The number of
sheets on the
ejection tray has
exceeded the
stackable sheet
or set count.
Staple could not
be positioned
correctly.
The staple motor

(M41) and stapler
shift motor (M35)
operation prohibited.
Normal operation
can be continued.
However, whether to
operate or not depends on the instruction from the host
machine.
Stop staple motor
(M41).
After ejecting the

Normal operation
sheet/set exceeding will continue.
the limit.
When positioning
staple.
Replace the staple cartridge; or, set it correctly.
Check stapler mechanism and move the stapler to where the staple
alignment interference
sensor (PI46) goes off.
Remove paper from
ejection tray.
Normal operation
Check staple cartridge
can be continued.
and repeat staple posiHowever, whether to tioning.
operate or not depends on the instruction from the host
machine.
T08-503-01
8-50
Resetting
Set the stapler.

Alarm Description
Staple is absent
Occurs when
Detection timing
The staple cartridge has run

out of staples.
Always monitored
Machine operation
Normal operation
will continue. However, operation is
subject to instruction
from host machine.
Mixed paper
Sheets of differ- When the sheet that Stitching is prohibsizes
ited.
ent sizes are out- causes the fault is
put in the hold- output to the hold- Alignment is prohibing area.
ing area.
ited.
Stack exceeded The stack of
When output of the Normal operation is
sheets on the out- sheet that cause an continued.
put tray exceeds excess is output on
the maximum
the output tray.
number of sheets
that can be
stacked.
Stitching capac- The number of When the sheet that Stitching is prohibity
sheets in the
causes an excess is ited.
holding area has output to the holdexceeded 15.
ing area.
Reset
Replace the staple cartridge; or, set it correctly.
Remove the sheets from

the holding area.
Remove the stack of

sheets from the tray.
Remove the sheets from

the holding area.
T08-503-02
5.3.3 Puncher Unit (option)
Alarm Description
Occurs when
Punch scrap full The amount of

punch scraps
has reached the
scrap container
capacity.
Punch scrap
The amount of
overflow
punch scraps
has exceeded
the scrap container capacity.
Detection timing
Machine operation
Reset
During punching
Normal operation
will continue.
Empty the scrap container.
During punching
Punching will be
disabled.
Empty the scrap container.
T08-503-03
8-51
APPENDIX
1 General Timing Chart

1.1 Finisher Unit
Stapling : A4 size paper, 2-sheet document, rear1-point stapling
Operation start signal

Host machine eject signal
Operation
1
Inlet sensor (PI33)
Inlet motor (M31)
1st delivery roller separation

solenoid (SL33)

(CL32)
Swing motor (M36)
Swing guide home position

sensor (PI35)
10
Front aligning plate home position

sensor (PI36)
up
Alignment
down
Retract
up
up
down
Alignment
Retract
Retract
11 Rear aligning plate motor (M34)

12
Retract
Rear aligning plate home position

sensor (PI37)
13 Stapler shift motor (M35)

14
Stapler shift home position

sensor (PI40)
15 Staple motor (M41)

16 Rear end assist motor (M39)
17
Rear end assist guide home

18 Tray 1 shift motor (M37)

19 Paper surface sensor (PI41)
down
up
up
down
up
CW
CCW
A-1

Stitching : A4-R size paper, 3-sheet document, 1 set
Copying starts
Operation
Initialization
Delivery signal
Loading the first sheet
Loading the second sheet
Loading the third sheet
Stitching
Feeding
a bundle
Folding, delivery
1 Saddle inlet motor (M9)

2
Saddle inlet solenoid (SL5)
3 Feed motor (M1)

4 No.1 paper sensor (PI18)
5
7 No.1 flapper solenoid (SL1)

8 No.2 flapper solenoid (SL2)
9

(SL4)
10
Alignment plate home position

sensor (PI5)
11 Alignment motor (M5)

12
Crescent roller phase sensor

(PI12)
13 Stitcher motor (front) (M7)

14

(front) (SW7)
15 Stitcher motor (rear) (M6)

16

(rear) (SW5)
17 Guide home position sensor

(PI13)
18 Guide motor (M3)
19 Paper positioning plate paper
sensor (PI8)
20 Paper positioning plate home
21 Paper positioning plate motor
(M4)
22

23
Paper pushing plate top position

sensor (PI15)
24 Paper pushing plate motor (M8)

25 Paper folding motor (M2)
26 Delivery sensor (PI11)
27 Tray paper sensor (PI6)
28 Paper folding home position
sensor (PI21)
A-2
CW
CCW

Punching : A4 size paper, 2-sheet document, job offset
Operation start signal
Host machine eject signal
Operation
1
Rear end detect sensor

(LED5, PTR5)
Inlet sensor (PI33)
4 Punch feed motor (M63)

5
Inlet motor (M31)
7 Inlet roller separation solenoid

(SL31)
8 1st delivery roller separation
solenoid (SL33)
9
Stack ejection lower roller

clutch (CL32)
10 Swing motor (M36)

up
11 Swing guide home position

sensor (PI35)
down
up
up down
12 Front aligning plate motor

(M33)
13
Front aligning plate home

Alignment Retract
Alignment
Retract
Retract
14 Rear aligning plate motor (M34)

Retract
15 Rear aligning plate home

16 Rear end assist motor (M39)
17 Rear end assist guide home
18 Tray 1 shift motor (M37)
19 Paper surface sensor (PI41)
down
up
up
down
up
20 Horizontal registration sensor

(LED1 to 4, PTR1 to 4)
21 Horizontal registration motor
(M62)
22

23 Punch motor (M61)

24

(PI63)
25 Punch motor clock sensor (PI62)
CW
CCW
A-3
A-4
APPENDIX
2 List of Signal Names/Abbreviations

The following presents the abbreviations of signals used in this manual and in drawings, and
the meaning of each signal.
Reference: Signals enclosed by brackets [ ] are electrical signals, However, the state 1 or 0
of these analog signals cannot be indicated. Otherwise, the state of digital signals 1 or 0 can
be indicated.
2.1 Finisher Unit

ASSIST-HP
BIND-CL
BUFF-P-SL
BUFF-ROL-SL
DELIV-ROL-SL
F-COVER
F-COVER-SW
FJOG-HP
G-CHANGE-HP
INLET
INLET-ROL-SL
JOGTRY-P
RJOG-HP
SHUT-CL
SHUT-HP
STP-HP
STP-INFERE
STP-LS
STP-READY
STPSFT-HP
STP-SW
SWG-HP
SWG-SW
TIMMING
TRY1-AREA1
TRY1-AREA2
TRY1-AREA3
TRY1-P
TRY2-AREA1
TRY2-AREA2
TRY2-AREA3
TRY2-P
TRYSFT2-P
UP-COVER
UPPER-P
UPPER-TRY
REAR END ASSIST GUIDE HP DETECT Signal

STACK EJECTION LOWER ROLLER CLUTCH DRIVE Signal
BUFFER REAR END HOLDING SOLENOID DRIVE Signal
BUFFER ROLLER ALIENATE SOLENOID DRIVE Signal
1ST DELIVERY ROLLER ALIENATE SOLENOID DRIVE Signal
FRONTCOVER OPEN/CLOSE DETECT Signal
FRONT DOOR CLOSED DETECT SWITCH Signal
FRONT ALIGNMNT PLATE HP DETECT Signal
GEAR CHANGE HP DETECT Signal
INLET PAPER DETECT Signal
INLET ROLLER ALIENATE SOLENOID DRIVE Signal
PROCESSING TRAY PAPER DETECT Signal
REAR ALIGNMNT PLATE HP DETECT Signal
SHUYYER OPEN/CLOSE CLUTCH DRIVE Signal
SHUTTER HP DETECT Signal
STAPLER HP DETECT Signal
STAPLER ALIGNMENT INTERFERENCE DETECT Signal
HOOK EMPTY DETECT Signal
HOOK TOP POSITION DETECT Signal
STAPLER SHIFT HP DETECT Signal
CARTRIDGE DETECT SWITCH Signal
SWING GUIDE HP DETECT Signal
SWING GUIDE CLOSED DETECT SWITCH Signal
FEED PLATE PASS PAPER DETECT Signal
TRAY 1 AREA DETECT Signal 1
TRAY 1 PAPER DETECT Signal
TRAY 2 PAPER DETECT Signal
TRAY 2 PAPER SURFACE DETECT Signal
UPPER COVER OPEN/CLOSE DETECT Signal
PAPER SURFACE DETECT Signal
TRAY 1 CLOSED DETECT SWITCH Signal
A-5
APPENDIX

1STPA
2NDPA
3RDPA
DELV
DELVMS
EJCVR
FDRLHP
FLDCLK
FLPSL1
FLPSL2
GIDHP
HKEMP1
HKEMP2
INLET-ROLL
INLTCVR
INLTCVRMS
LUNGECLK
LUNGEHP
LUNGETOP
PAFLDHP
PAPPOS
PPOSPAR
RLNIPSL
SDLINSL
STCHHP1
STCHHP2
STPLHP
TRYPAR
VPJM
A-6
No.1 PAPER SENSOR DETECT Signal

DELIVERY DETECT Signal
DELIVERY DOOR OPEN DETECT SWITCH Signal
DELIVERY COVER OPEN DETECT Signal
CRESCENT ROLLER PHASE DETECT Signal
FOLD MOTOR CLOCK Signal
FLAPPER DRIVE Signal 1
FLAPPER DRIVE Signal 2
PAPER GUIDE HP DETECT Signal
HOOK EMPTY DETECT Signal 1
HOOK EMPTY DETECT Signal 2
SADDLE INLET PAPER DETECT Signal
INLET COVER OPEN DETECT Signal
INLET COVER OPEN SWITCH Signal
LUNGE MOTOR CLOCK Signal
LUNGE HP DETECT Signal
LUNGE TOP POSITION DETECT Signal
PAPER FOLD HP DETECT Signal
PAPER POSITION PLATE HP DETECT Signal
PAPER POSITIONING GUIDE PAPER DETECT Signal
FEED PLATE CONTACT SOLENOID DRIVE Signal
SADDLE INLET SOLENOID DRIVE Signal
STITCHING HP DETECT Signal 1
STITCHING HP DETECT Signal 2
STITCHER IN DETECT Signal
TRAY PAPER DETECT Signal
VERTICAL PATH PAPER DETECT Signal
APPENDIX

DFULL
FDROPN
LEDON
LEDON1
LEDON2
LEDON3
LEDON4
LEDON5
PAEND
PUNCHCLK
PUNCHHP
SREGHP
SRGE1
SRGE2
SRGE3
SRGE4
UDROPN
DUST FULL DETECT Signal

FRONT DOOR OPEN DETECT SWICH Signal
LED ON Signal
LED1 ON Signal
LED2 ON Signal
LED3 ON Signal
LED4 ON Signal
LED5 ON Signal
PAPER END DETECT Signal
PUNCH MOTOR CLOCK DETECT Signal
PUNCH HOME POSITION DETECT Signal
SIDE REGISTRATION HOMEPOSITION DETECT Signal
SIDE REGISTRATION DETECT Signal 1
UPPER DOOR OPEN DETECT SWICH Signal
A-7
APPENDIX
A-8
3 Finisher Unit General Circuit Diagram

Swing guide home
position sensor
PI35
Feed path
sensor
Front cover
sensor
PI34
PI32
Gear change
motor
M40
Gear change
home position
sensor
Upper cover
sensor
Inlet sensor
PI49
PI31
PI33
Swing motor
Inlet motor
Stack ejection
motor
M36
M31
M32
J1001
J1002
J1003
J1004
Buffer rear end

holding solenoid
1st delivery roller

separation solenoid
Buffer roller separation

solenoid
SL34
SL33
SL32
SL
2
J1005
J1006
2
2
1
1
J1008
J1009
J1010
J1011
SL31
SL
SL
1
J1012
SL
Inlet roller separation

solenoid
J1007
J1012
J1013
J1013
J1014
J1014
J1016
J1016
J1007
10
11
12
13
J718
2
1
J1015
J1015
+24V
INLET-ROL-SL
BUFF-ROL-SL
J713
+24V
+24V
+24V
DELIV-ROL-SL
BUFF-P-SL
B*
A*
B*
A*
B*
B
3
J709
J708
J707
A*
S-GND
INLET
S-GND
9
+5VR
+5V
UP-COVER
S-GND
6
G-CHANGE-HP
+5VR
B*
A*
S-GND
F-COVER
S-GND
5
+5VR
TIMMING
+5VR
S-GND
SWG-HP
+5VR
J710

2
11
10
J711A
5
10
10
P-GND
11
+24V
+24V
P-GND
+5VR
S-GND
TRY1-CLK
TRY1-I
TRY1-CW
TRY1-EN
S-GND
TRY1-AREA-1
TRY1-AREA-2
TRY1-AREA-3
+5VR
+5VR
S-GND
J711B
J714
J715
TRT1-P
+24V
J712
UPPER-TRY-SW
+24V
+24V
STP-SW
SWG-SW
J701
3
BIND-CL
+24V
+24V
COPY-RXD
J951
Tray 1 driver PCB
J1021
NO
CL
MS32
Swing guide
switch
COM
MS34
Staple safety
switch
COM
Stack ejection lower

roller clutch
COM
CL32
J981
B*
J1020
A*
NO
J1018
+24V
NO
J952
J1019
1
+24V
S-GND
N.C
P-GND
J702
3
S-GND
+5V
S-GND
COPY-TXD
J724
7
PI42
MS33
Tray 1 paper
sensor
Tray 1 switch
Tray 1 shift area

sensor PCB
J1024
M
M37
Tray 1 shift
motor
1
10
11
12
J1017
TO HOST MACHINE
A-9
Stapler shift motor
Staple motor
Stapler alignment
interference
sensor
M41
PI46
M35
Tray 2 shift motor

M38
1
6
3
3
4
2
J1027
J1028
J1029
J1030
M
6
Tray 2 paper
sensor
J1025
J993
J1981
1
2
B*
A*
+24V
+24V
J1026
Tray 2 shift area sensor

PCB
PI43
10
12
14
11
16
13
18
15
17
19
J995
J1953
J994
Stapler PCB 2
J992
11
13
10
15
12
14
+5VR
S-GND
STP-INFERE
+5V
STP-HP
STP-READY
STP-LS
10
S-GND
A*
B*
STP-M-CW
STP-M-CW
STP-M-CW
STP-M-CCW
STP-M-CCW
J1951
STP-M-CCW
Tray 2 driver PCB
17
19
16
18
SMCD-19X875-C-P1.25-S(3)+(3)-M-N UL20624
+5VR
TRY2-AREA-3
10
11
12
13
14
15
J717
10
11
12
13
14
15
1
10
J706
J705B
J705A
STP-M-CCW
STP-M-CCW
STP-M-CW
+5VR
10
J704
J703
J716B
J716A
TO SADDLE DRIVER PCB

OR PUNCH CONTROLLER PCB
TO SADDLE STITCHER CONTROLER PCB
10
STP-M-CW
B*
TRY2-AREA-2
TRY2-AREA-1
S-GND
TRY2-P
S-GND
+5VR
A*
STP-LS
TRY2-EN
TRY2-CW
TRY2-CLK
STP-READY
STP-HP
TRY2-I
S-GND
+5VR
P-GND
7
+5V
STP-INFERE
J991
S-GND
10
P-GND
+24V
+24V
Stapler PCB 1
10
11
12
10
11
12
12
11
10
12
11
10
J727
3
J719
2
+24VU
+5VR
+5VR
S-GND
UPPER-P-2
+5VR
J1040
J1041
J1041
J1040
J1032
J1046
J1046
1
2
J1044
J1043
J1042
COM
1
1
2
2
3
3
J1038
1
1
2
2
3
3
J1037
1
1
2
2
3
3
J1036
1
1
2
2
3
3
1
1
4
4
A-10
PI38
PI36
PI37
Processing Tray
sensor

home position
sensor
Rear aligning plate

home position
sensor
PI39
M33
Rear end
Front aligning
assist guide
plate motor
home position
sensor
J1035
1
1
J1034
3
1
4
2
5
3
6
4
J1033
CL
CL31
M34
M39
Shutter
clutch
Rear aligning
plate motor
Rear end assist

motor
PI40
Stapler shift
home position
sensor
PI45
Shutter
home position
sensor
J1031
J1045
J1039
F-COVER-SW
J721A
3
S-GND
+5VR
J1032
J1040
J1032
SHUT-HP
J1040
J1032
S-GND
+24V
SHUT-CL
STPSFT-HP
A*
S-GND
J721B
5
A*
B*
B*
10
A*
11
12
B*
+5VR
S-GND
ASSIST-HP
+5VR
S-GND
TRYSFT2-P
J722A
RJOG-HP
+5VR
S-GND
FJOG-HP
10
+5VR
S-GND
JOGTRY-P
11
J722B
12
NO
PI41
PI48
MS31
Paper surface
sensor
Tray 2 paper
surface
sensor
Front cover
switch

C143
X101
IC104
R131
R134
1
+3.3V
C113
+5V
2
J724
C137
R133
1
+5V
VDD
2 XOUT
7
REFOUT/RS0
3 REF_OFF
6
MODOUT/RS1
4 LF
5
VSS
R130
1 XIN
C142
R123
C138
C139
IC117
+5V
Q201
1
R490
R505
PCH-UNIT-ON
R491
+3.3V
C307
Q175
10
IC117
11
R601
PCH-M-STB
TRY1-M-CLK
PCH-M-I1
PCH-M-I0
TRY2-M-CLK
PCH-M-B
PCH-M-B
PCH-M-A
PCH-M-A
R418
R142
D129
R493
R1412
RESET
R132
R401
RD
R400
WR
SWG-M-A
SWG-M-B
SWG-M-I0
FWE-WR-LED
PCH-TXD
PCH-RXD
Q202
PCH-OUT
Q195
3
IC117
R124
1
+3.3V
C501
Q196
2
1
2
1
R127
65
R504
66
P60/_DREQ0/_CS4
68
69
67
VSS10
VSS11
P61/_TEND0/_CS5
70
72
71
P63/_TEND1
P62/_DREQ1
P27/PO7/TIOCB5/TMO1
74
75
73
P26/PO6/TIOCA5/TMO0
P25/PO5/TIOCB4/TMCI1
P24/PO4/TIOCA4/TMRI1
76
P23/PO3/TIOCD3/TMCI0
P22/PO2/TIOCC3/TMRI0
77
79
78
P21/PO1/TIOCB3
P20/PO0/TIOCA3
80
81
RES
WDTOVF[_FWE]
83
82
NMI
STBY
VCC4
84
85
XTAL
86
87
88
PF7/
VSS12
EXTAL
89
VCC5
PF6/_AS
90
92
91
PF5/_RD
PF3/_LWR
PF4/_HWR
93
94
95
PF1/_BACK
96
PF0/_BREQ
P50/TXD2/_IRQ4
97
98
P51/RXD2/_IRQ5
100
101
99
VSS13
P52/SCK2/_IRQ6
VSS9
R499
54
DBUS4
IC117
13
12
DBUS3
DBUS2
DBUS1
DBUS0
3
4
J5P
J5P
48
TRY2-M-I1
J5P
47
TRY2-M-I0
46
J5P
TRY2-M-EN
45
TRY2-M-CW
C133
51
52
49
J5P
Q203
RA102
50
R498
DL-MODE
3
1
DBUS5
DBUS6
PE2/D2
TRY1-M-EN
40
TRY1-M-CW
+3.3V
+5V
R416
3
Q186
P64/_IRQ0
C135
Q187
P65/_IRQ1
R429
RESET
38
37
VSS6
VSS5
VCC2
36
P66/_CS6/_IRQ2
TRY1-M-I0
41
39
35
34
VSS4
P67/_CS7/_IRQ3
33
32
31
30
29
28
PA2/A18
PA1/A17
PA0/A16
PA3/A19
27
26
25
24
PB7/A15
TRY1-M-I1
42
PB6/A14
43
1 PG3/_CS1
PG2/_CS2
PA7/A23/_IRQ7
PE0/D0
PA6/A22/_IRQ6
PG1/_CS3
PA5/A21/_IRQ5
PE1/D1
PA4/A20/_IRQ4
PG0/_CAS
PE3/D3
MD2
R471
MD1
23
128
VSS7
22
J726
44
PB5/A13
127
EXIO-CS
PE4/D4
MD0
PB4/A12
IPC-CS
R4701
2
PE5/D5
P10/PO8/TIOCA0/_DACK0
VSS3
126
P11/PO9/TIOCB0/_DACK1
21
125
PE6/D6
20
124
INLET-ROL-SL-ON
PE7/D7
P12/PO10/TIOCC0/TCLKA
PB3/A11
123
P13/PO11/TIOCD0/TCLKB
19
122
55
PD0/D8
18
121
56
PD1/D9
PB2/A10
INLET-M-B
INLET-M-A
DBUS7
PD2/D10
P14/PO12/TIOCA1
PB1/A9
120
IC101
P15/PO13/TIOCB1/TCLKC
PB0/A8
INLET-M-A
PD3/D11
P16/PO14/TIOCA2
17
119
VSS8
P17/PO15/TIOCB2/TCLKD
16
118
INLET-M-B
RA101
57
53
15
117
INLET-M-I0
PD4/D12
VSS15
PC7/A7
INLET-M-I1
PD5/D13
AVSS
PC6/A6
116
P47/AN7/DA1
14
115
M-STB
PD6/D14
13
BUFF-ROL-SL-ON
PD7/D15
P46/AN6/DA0
PC5/A5
114
58
PC4/A4
113
+3.3V
TXD0
VCC3
P45/AN5
VSS2
112
RXD0
61
P44/AN4
12
111
TRY2-AREA-SEN3
62
P33/RXD1
59
11
TRY2-AREA-SEN2
PF2/_LCAS/_WAIT/_BREQO
110
P34/SCK0
P30/TXD0
9 PC3/A3
109
TRY2-AREA-SEN1
63
60
8 PC2/A2
G-CHAN-HP-SEN
P43/AN3
+3.3V
64
P35/SCK1
P32/RXD0
10
108
P31/TXD1
7 PC1/A1
F-COVER-SEN
P42/AN2
6 PC0/A0
107
P41/AN1
5 VCC1
UP-COVER-SEN
P40/AN0
4 NC
106
VSS14
102
105
VREF
P53/_ADTRG/_IRQ7/_WAIT/_BREQO
SUDDLE-UNIT-ON
SWG-HP-SEN
AVCC
3 VSS
104
2 PG4/_CS0
103
+3.3V
Q197
IC117
6
C290
1
+3.3V
IC105
C136
C291
DBUS[7:0]
VCC
M/R
SUB
4
2
+3.3V
VOUT
GND
1
2
3
C140
INLET-SEN
R469
C141
TRAIL-EDGE-SEN
PCH-IN
BIND-M-A
ROM-PCB-ON
RA203
TRYSFT2-P-SEN
TRY2-P-SEN
5
4
6
3
5
4
7
2
RA202
RA201
5
4
6
3
5
4
6
3
7
2
RA108 1
5
4
7
2
8
1
RA107
TIMMING-SEN
ROM-CS
C502
RESET2
ABUS18
+3.3V
IC106
EEPROM-DATA-IN
CS
VCC
SK
NC2
DI
NC1
DO
GND
C144
6
5
EEPROM-DATA-CLK
EEPROM-DATA-OUT
8
2
RA105
EEPROM-DATA-CS
ABUS17
ABUS16
ABUS15
ABUS14
ABUS13
ABUS12
ABUS11
ABUS10
ABUS9
ABUS8
ABUS7
ABUS6
ABUS5
ABUS4
ABUS3
ABUS2
ABUS1
ABUS0
ABUS[18:0]
Q192
R140
A-11
ABUS[7:0]
(A507)
(A510)
(A507)
(A507)
(A501,A507)
(A507)
(A507)
(A507)
(A510)
(A506)
(A510)
(A506)
(A501,A502)
JOGTRY-P-SEN
22
ASSIST-HP-SEN
23
DL-MODE
24
P11
P51
P12
P50
P13
P47
P14
P46
P15
P45
VDD1
VDD2
(A509)
(A509)
17
18
ABUS5
ABUS6
51
ABUS7
ABUS4
52
A5
ABUS3
53
A4
ABUS2
54
A3
ABUS1
55
A2
ABUS0
56
DBUS7
57
A1
A0
DBUS6
59
58
VCC
DBUS5
60
DQ7
DBUS4
61
DQ6
DBUS3
62
DQ5
DBUS2
63
DQ4
A6
45
(5V-DETECT)
44
24V-DETECT
(A503)
43
DOOR-24V-DETECT
42
FAN-ERR
41
FAN-ON
40
LED1
R145
+3.3V
(A503)
(A505)
LED101
1
(A505)
LED102
LED2
R146
38
LED3
R147
37
POWER-ON
(A503)
ROLLET-SL-ON
(A505)
LED103
1
33
(A509)
P01
P02
32
(A509)
(A509)
(A509)
(A506)
(A506)
(A506)
X102
(A506)
54
SW104
DIPSW0
DIPSW1
10
RESET2
DIPSW2
11
(A501,A502)
DIPSW3
12
DIPSW4
13
DIPSW5
14
DIPSW6
15
DIPSW7
16
53
52
51
C292
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
[ENTER]
[+]
[-]
26
SW103
34
P03
TRY1-AREA-SEN1
P00
31
55
PB7
P12
30
TRY1-AREA-SEN2
P13/CLK
P04
56
35
29
TRY1-AREA-SEN3
36
P05
57
PB6
P06
TRY1-P-SEN
PB5
P14/_CTS1
P07
58
PB4
P15/_CTS2
28
STPSFT-M-A
P16
27
STPSFT-M-B
59
PB3
26
60
PB2
TXD1
VSS
STP-M-CW
RXD1
R602
(A505)
2
STP-M-CCW
61
16
(A506)
63
62
15
C146
(A509)
SW102
PUSHSW3
39
25
TRY1-IAS-SEN
14
PB1
XOUT
UPPER-TRY-MSW-ON
64
13
(A510)
PB0
TXD2
XIN
STP-HP-SEN
65
(A509)
SW101
PA7
RXD2
P10
66
12
P11/INT
STP-READY
11
CNVSS
STP-LS
67
10
SADDLE-TXD
68
(A509)
SADDLE-RXD
STPSFT-HP-SEN
(A512)
24
P52
STP-INFERE-SEN
69
(A512)
(A509)
PA6
IC102
LVL
23
P10
70
PUL
(A505)
PA5
22
P53
STPSFT-M-I0
INTR
PUSHSW2
47
46
21
GND2
P07
STPSFT-M-I1
71
PA4
RESET
76
77
P74
78
P75
79
P76
P77
80
81
P80/D15
83
82
P81/D14
P82/D13
P83/D12
84
85
GND3
86
P84/D11
P85/D10
87
89
88
P86/D9
P87/D8
90
GND4
91
D7
D6
92
94
93
D5
D4
95
GND5
D3
96
97
D2
99
98
D1
D0
P54
GND0
25
P55
P06
72
(A505)
PA3
VBUS
PUSHSW1
48
21
P56
P05
DELIV-ROL-SL-ON
C147
RJOG-HP-SEN
P04
BUFF-P-SL-ON
73
PA2
49
20
P57
74
FJOG-HP-SEN
P60
P03
R143
75
PA1
C148
19
EEPROM-DATA-IN
PA0
20
18
IPC-CS
A7
DQ0
19
EEPROM-DATA-CLK
RD
50
DQ1
17
GND1
16
EEPROM-DATA-CS
IC103
P02
P44
EEPROM-DATA-OUT
P61
P43
(A501)
15
P01
P42
(A510)
14
P62
P41
(A510)
13
CHANGE-M-I1
STPSFT-STB
P63
P00
P40
(A510)
CHANGE-M-I0
A3
P37
(A510)
12
P64
P36
(A502)
11
P65
A2
P35
(A502)
10
A1
P34
(A502)
ABUS3
CHANGE-M-A
CHANGE-M-B
P66
P33
(A509)
(A502)
P67
A0
P32
(A504)
(A504)
ABUS2
WRB
P31
(A504)
ABUS1
P70
P30
(A501,A502)
(A504)
P71
RDB
P27
ABUS[7:0]
ABUS0
P72
CSB
P26
WR
RESETB
P25
P24
(A501,A502)
P23
(A501,A502)
EXIO-CS
RD
P73
P22
(A501)
DBS
P21
(A501,A502)
P20
(A501)
VDD3
P17
C311
RESET2
(A501,A502)
WR
VDD0
P16
GND6
100
(A501,A502)
64
DQ2
+3.3V
DQ3
DBUS0
DBUS1
BIND-CL-ON
SHUT-CL-ON
BIND-M-I1
BIND-M-I0
BIND-M-A
BIND-M-B
BIND-M-A
BIND-M-B
UPPER-P-SEN2
STP-MSW-ON
+3.3V
DBUS7
DBUS6
DBUS5
DBUS4
DBUS3
DBUS2
DBUS0
DBUS1
DBUS[7:0]
(A501,A502)
SHUT-HP-SEN
SWG-MSW-ON
DBUS[7:0]
(A501,A502)
ASSIST-M-STB
ASSIST-M-I1
ASSIST-M-I0
ASSIST-M-B
ASSIST-M-A
FJOG-M-I0
FJOG-M-B
FJOG-M-A
SL-ON
RJOG-M-I0
RJOG-M-A
RJOG-M-B
J702
(NC)
J702
(COPY-RXD)
J702
(COPY-TXD)
R152
1
J702
(GND-L)
R150
D106
R153
(A511)
C149
1
(A511)
(A511)
(A511)
(A511)
(A511)
(A511)
(A511)
(A505)
(A511)
(A511)
IC206
+5V
+5V
IC206
(A511)
OP-TRY-SET
ENGINE I/F
(A506)
R151
2
IC117
8
Q106
1
R148
(A506)
OP-TRY-P-SEN
C145
+5V
J702
(GND-L)
R149
J702
(+5V)
J702
(GND-L)
[A503]
A-12
+3.3V
+24U
+24V
2
1
R474
FU119
DOOR-24V-DETECT
J719
ZD106
R475
2
Q193
(A502)
Q151
R431
Front cover
switch
(MS31)
R158
2
R159
2
Q178
1
R496
Q194
3
R430
1
+24R CP117
1
R473
POWER-ON
Q172
2
(IC102-37P)
(A502)
JP101
1
R472
2
+3.3V
Q179
J701
(+24V-P)
+3.3V
2
J701
(GND-P)
R154
(A502)
(IC102-44P)
24V-DETECT
2
R477
2
Q128
ZD101
C117
+5R
CP106
[A502]
+5V
CP103
1
JNT101
J
+3.3V
CP102
D107
2
2
C114
CP105
1
FU118
C154
ETH104
1
1
1
C153
3
2
IN OUT
GND
IC108
C115
1
2
A-13
J4P
(INLET-B)
J4P
(INLET-B*)
J4P
R179
R166
1
2
C158
I1 15
IN3 14
IN4 13
10 NC3
11 OUT4
12 VCC1
CCPA
9 CCPB
2
FU106
1
C156
C119
2
2
R172
IC110
C157
C120
INLET-M-I0
C118
Q109
I0
Gear change motor (M40)
R167
R173
1
R177
Q108
I1
22
(A501)
(IC101-117P)
INLET-M-I1
R168
(GEAR-CHANGE-MOTOR)
+24V
(A501)
(IC101-118P)
C155
+3.3V
R164
0.1
R165 2
1
0.8
C159
+24V
10
8 CCPC
7 VM
GND1
6 RSB
21
5 RSA
+5V
4 VREFB
+5V
3 VREFA
1.0
2 VDD
1.0
1 CR
VSB 17
STB 16
(IC101-116P)
+5V
R180
8 RSB
9 VMMB
M-STB
IC109
R102
(IC103-13P)
11
12
13
14
15
22
16
17
18
19
(IC103-14P)
CHANGE-M-I0
STANDBY
OUTA-
PHASEA
PHASEB
OUTA
GND2
OUTB
ENABLEA
ENABLEB
I1
OUTB-
TORQUE
20
(A501)
(IC103-11P)
GND2 25
CR 18
(A502)
CHANGE-M-A
CHANGE-M-I1
26 GND1
7 OUT3
(A502)
I0
Q181
VSA 20
VR 19
(A502)
(INLET-MOTOR)
IN2 22
I0 21
(IC101-119P)
+5V
(IC101-120P)
INLET-M-B
CP121
(IC101-121P)
INLET-M-A
Inlet motor
(M31)
5 RSA
6 OUT2
(A501)
INLET-M-B
(IC103-12P)
CHANGE-M-B
3 NC2
4 VMMA
(A501)
(IC101-122P)
(A502)
VCC2 24
IN1 23
(A501)
INLET-M-A
Q180
1 NC1
2 OUT1
(A501)
(IC101-116P)
(A501)
M-STB
R101
1
CP118
J4P
(INLET-A)
J718
(INLET-A*)
R433
+3.3V
R434
+3.3V
R178
0.2
0.15
0.06
(CHANGE-A)
J708
(CHANGE-A*)
J708
(CHANGE-B)
J708
(CHANGE-B*)
J708
+3.3V
R175
C162
(A501)
(IC101-109P)
J5P
(SWG-A)
J5P
C160
(SWG-B)
J5P
(SWG-B*)
J5P
(A501)
SWG-M-B
(IC101-94P)
J5P
J708
R196
1
Swing motor
(M36)
R207
(A501)
(IC101-107P)
R210
UP-COVER-SEN
Upper cover sensor (PI31)
10
J708
(IC101-93P)
J708
(IC101-116P)
SWG-M-A
M-STB
(A501)
+5R
+3.3V
(A501)
J708
R171
CP119
C161
(SWG-A*)
J709
R170
G-CHAN-HP-SEN
Gear change home position sensor (PI49)
R169
CP107
C174
C173
+5V
J708
+5R
R209
1
(SWING-MOTOR)
R204
Inlet sensor (PI33)
R185
R188
C121
2
1
2
1
C122
R194
1
1
A-14
CP108
CCPA
CCPB
2
10
CCPC
8
RSB
GND1
VM
7
21
RSA
VREFB
VREFA
CR
VDD
2
1
R191
2
R189
C166
+24V
C165
J708
12
J708
11
J708
R205
R192
C171
Q110
C164
1
3
13
+5R
C163
SWG-M-I0
J708
INLET-SEN
2
(A501)
(IC101-38P)
STANDBY
R206
IC111
C172
+5V +5V
+3.3V
(A501)
(IC101-95P)
1
11
12
OUTA-
13
PHASEA
PHASEB
14
22
15
OUTA
OUTB
GND2
16
17
ENABLEA
0.2A
ENABLEB
0.1
TORQUE
1.0A
18
0.8
19
20
I
OUTB-
I0
+3.3V
CP120
+3.3V
R201
C176
C175
J727
+24V
J727
J727
J727
J727
+3.3V
5
2
+5V
R211
FAN-ERR
2
(A502)
(IC102-42P)
Q129
+24V
+3.3V
CLR
FU115
IC132
R435
PR
12
11
Q185
C312
D126
2
(A501,A502)
R458
RESET2
10
2
1
C104
FAN-ON
D102
R112
(A502)
(IC102-41P)
PR
2
C261
R114
Q101 3
IC132
2
1
R200
SL-ON
R111
IC125
(A501)
(IC103-36P)
+5V
R457
R113
R110
+5V
K
8
13
CLR
ROLLET-SL-ON
2
(A502)
(IC102-34P)
R459
Inlet roller separation solenoid (SL31)

J710
J710
D110
R214
2
J707
J707
INLET-ROL-SL-ON
R181
11
13
Q156
Buffer roller separation solenoid (SL32)
C178
1
C177
+5R R213
J707
+3.3V
R203
BUFF-ROL-SL-ON
R183
8
10
J707
1st delivery roller separation solenoid (SL33)
+24V
FU114
C170
J707
+5R R208
J707
J710
J710
J710
Q159
D111
J707
J707
IC131
+5R R198
2
(A502)
(IC103-74P)
BUFF-P-SL-ON
R182
3
C168
Q157
1
C167
1
R199
Buffer rear end holding solenoid (SL34)
J707
TRY1-IAS-SEN
(A502)
(IC103-64P)
R184
6
DELIV-ROL-SL-ON
2
2
SWG-HP-SEN
IC131
(A502)
(IC103-73P)
+3.3V
(A501)
(IC101-106P)
J710
D113
4
1
C169
R197
J710
Q158
R202
1
IC131
(A501)
(IC101-115P)
TIMMING-SEN
2
(A501)
(IC102-2P)
J710
D112
6
1
12
(A501)
(IC101-126P)
F-COVER-SEN
(A501)
(IC101-108P)
IC131
Front cover sensor (PI32)
R212
+3.3V
C266
A-15
+24V
+3.3V
2
J715
FU109
Staple safety switch

(MS34)
(A502)
R117
R115
1
ZD107
R479
3
Q191
+5V
+5V
+3.3V
2
STP-MSW-ON
(A502)
(IC103-87P)
R466
IC125
OP-TRY-SET
R340
(IC103-28P)
5
2
R116
C240
1
STP-M+24V
(A509)
+3.3V
R344
3
+3.3V
2
Q138
Swing guide switch

(MS32)
ZD105
R481
(A502)
J711
R392
1
SWG-MSW-ON
(A502)
(IC103-89P)
R390
OP-TRY-P-SEN
B11
(IC103-27P)
C270
C271
B10
+3.3V
2
+5R
J714
R391
R329
1
UPPER-TRY-MSW-ON
2
J714
Tray 1 switch
(MS33)
+3.3V
1
1
DA102
1
B7
5
+5R
J711
R334
4
1
(+24V)
A11
(+24V)
A10
(GND)
A9
(GND)
A8
+5R
B5
(TRAY1-MOTOR)
2.0
(A502)
(IC103-57P)
1.3
0.3
TRY1-AREA-SEN3
R389
1
A7
C268
1.6
+3.3V
Tray 1 area sensor 2

(PS982)
B3
A6
2
(GND)
B4
C269
R338
IC120
4
R339
3
2
2
A5
TRY1-AREA-SEN2
(TRY1-M-I)
(A502)
(IC103-56P)
R342
R341
(+5R)
H
CP115
22
Q123
1
3
R343
TRY1-M-I1
Q122
(A501)
(IC101-43P)
3
2
TRY1-M-I0

(PS981)
1
IC120
+5R
I1
R388
I0
B6
Tray 1 shift motor

(M37)
+3.3V
+3.3V
B8
C235
C236
TRY2+24V
2
2
R333
TRY1-P-SEN
2
(A502)
(IC103-58P)
FU110
(A507)
Tray 1 paper sensor

(PI42)
R335
R701
(A501)
(IC101-42P)
B9
Q137
ZD104
R483
(A502)
(IC103-65P)
C238
C239
+3.3V
R336
5
C234
1
(TRY1-M-CW)
(A501)
(IC101-41P)
TRY1-M-EN
C295
A2
(TRY1-M-EN)
C296
Q136
A1
A-16
Q135
B1
DA103
A3
TRY1-M-CW
B2
C237
(A501)
(IC101-40P)

(PS983)
2
2
C294
R337
Q134
TRY1-AREA-SEN1
TRY1-M-CLK
(A502)
(IC103-55P)
(A501)
(IC101-72P)
IC120
A4
(TRY1-M-CLK)

+24V

(CL32)
FU116
2
J712
J712
(BIND-A*)
J713
(BIND-A)
J713
(BIND-B)
J713
(BIND-B*)
J713
D115
BIND-CL-ON
Q161
R301
(A502)
(IC103-77P)
R302
CP122
(A501)
(A501,A502)
(A502)
(A502)
(A502)
M-STB
(IC101-116P)
BIND-M-A
(IC103-81P)
BIND-M-B
(IC103-82P)
BIND-M-A
(IC103-83P)
BIND-M-B
(IC103-84P)
R290
1

(M32)
12
13
11
STANDBY
CCPA
10
OUTA-
PHASEA
CCPC
CCPB
9
14
15
1
2
R294 2
PHASEB
VM
22
GND2
OUTA
RSB
GND1
16
2
R295
1
C211
C131
2
1
2
1
C212
C213
+24V
C132
2
2 2
R292
Q120
IC116
R291
C214
R293
1
BIND-M-I1
R298
(A502)
(IC103-79P)
Q121
BIND-M-I0
(A502)
(IC103-80P)
1
1
R296
21
TORQUE
+5V
CR
+5V
+3.3V
17
0.1
OUTB
RSA
0.8
18
ENABLEA
ENABLEB
1.15
VREFB
VREFA
1.15
20
OUTB-
VDD
I1
I0
19
(BIND-MOTOR)
CP113
A-17
A8
J716
(GND)
A7
J716
IC120
1.6
1.3
0.3
R394
1
(+5R)
A6
J716
+3.3V
(GND)
A5
J716
IC120
(A501)
(IC101-26P)
TRY2-AREA-SEN2
10
C249
+3.3V
J716

(PS982)
B6
J716

(PS983)
B5
J716
B4
J716
J716
IC120
TRY2-AREA-SEN1
12
R357
R358
1
13
2
2
C250
J716
C299
Q140
A3
C251
(TRY2-M-CLK)
(A501)
(IC101-73P)
B7
C248
A4
(TRY2-M-I)
(A501)
(IC101-25P)
TRY2-M-CLK
J716
C273
R352
R353
1
11
R349
B8

(PS981)
C272
+5R
TRY2-AREA-SEN3
R393
2.0
J716
+5R
+3.3V
(A501)
(IC101-27P)
J716
B9
(GND)
CP116
R350
J716
B10
1
2
2
A9
R351
Q124
TRY2-M-I1
I1
22
(A502)
(IC101-48P)
Q125
(+24V)
I0
TRY2-M-I0
J716
(TRAY2-MOTOR)
+3.3V
(A502)
(IC101-47P)
A10
TRY2+24V
(+24V)
(A506)
FU111
J716
Q139
C297
1
TRY2-M-EN
A1
J716
R356
B3
J716
B2
J716
B1
J716
C252
+5R
DA104
1
R355
2
3
(A502)
(IC101-46P)
(TRY2-M-EN)
R354
1
C253
1
TRY2-P-SEN
(A501)
(IC101-29P)
C298
Q141
A2
TRY2-M-CW
(A502)
(IC101-45P)
+3.3V
(TRY2-M-CW)
Tray 2 paper sensor

(PI43)
A-18
(IC103-65P)
(IC103-66P)
(IC103-67P)
(A502)
(A502)
(A502)
10
12
R288
R287
11
13
R310
J717
R311
IC128
(+5R)
(STP-HP-SEN)
(STP-READY)
(STP-LS)
R309
+5R
Staple home position sensor (PI50)

Staple edging sensor (PI51)
Staple sensor (PI52)
6
7
J717
CP123
4
DA101
STPSFT-STB
STPSFT-M-A
STPSFT-M-B
(A502)
(A502)
(A502)
(IC103-15P)
(IC103-59P)
(IC103-60P)
(A502)
(IC103-72P)
STPSFT-M-I1
12
(STP-M-CCW)
14
Q119
3
13
Staple motor (M41)
11
13
12
OUTA-
STANDBY
10 CCPA
14
PHASEA
9 CCPB
8 CCPC
2
2
R276
2
1
22
15
OUTA
PHASEB
7 VM
16
GND2
6 RSB
21 GND1
17
18
ENABLEA
2 VDD
1 CR
R282
OUTB
2
CP101
C210
+24V
C130
2
R286
1
C215
R279
(STP-M-CW)
5 RSA
TORQUE
C207
STPSFT-M-I0
C129
(A502)
(IC103-71P)
Q155
Q131
R314
Q118
1
R322
Q154
10
9
IC121
IC122
+3.3V
0.1
ENABLEB
0.6
4 VREFB
R321
2
R316
R319
1
L
H
R315
2
C221
C208
C220
0.8
+3.3V
0.9
R280
IC115
4
6
L
H
+5V +5V
IC122
I1
I0
R285
STP-M+24V
(A506)
Q163
Q162
22
IC122
1
(STAPLER-SHIFT-MOTOR)
Q155
19
1
20
3 VREFA
R218
1
(STAPLER-MOTOR)
Q154
Stapler alignment
interference sensor (PI46)
C182
+5R
CCW
11
OUTB-
(STP-INTERFERENCE-SENSOR)
C181
CW
10
(STPSFT-B*)
+5V
R226
R219
1
(STPSFT-B)
R300
+3.3V
STP-INFERE-SEN
(STPSFT-A)
C218
2
1
C229
C228
2
1
C219
2
1
C227
2
1
C226
(A502)
(IC103-70P)
(STPSFT-A*)
IC128
IC128
STP-HP-SEN
STP-READY
STP-LS
R308
+5R
R283
C209
1
Q163
Q162
+3.3V
R500
2
(A502)
(IC103-61P)
STP-M-CW
R289
15
IC121
1
CP112
R305
1
IC121
R304
12
11
13
Q132
10
12
C216
1
+3.3V
R503
C309
2
1
14
15
C/R
2
C
Q
13
IC133
+3.3V
3
1
CLR
Q199
+3.3V
C308
CP114
+5V
C
C223
R327
2
2
R317
R324
R323
ETH105
R326
1
C222
1
Q184
1
R325
+5V
IC133
R318
IC129
+3.3V
CLR
R320
12
Q200
R445
D116
IC129
10
+5V
C/R
C224
R502
2
11
(A502)
(IC103-62P)
9
13
STP-M-CCW
IC121
IC122
11
R313
2
R501
A-19
J721
+24V
FU117
B8
Processing Tray
sensor (PI38)
(A502)
(IC103-22P)
Q160
1
R215
R396
JOGTRY-P-SEN
R397
C275
1
C274
1
SHUT-CL-ON
2
(A502)
(IC103-78P)
+3.3V
Shutter clutch
(CL31)
B12
J722
B11
J722
B10
J722
B7
D114
+3.3V
+5R
1
R452
+5R
(IC103-20P)
R446
1
Stapler shift home

position sensor
(A502)
(PI40)
R269
FJOG-HP-SEN
R267
C202
C201
B4
B9
J722
B8
J722
B7
J722
B5
C286
C287

B6
R395
+3.3V
R448
(A502)
(IC103-69P)
R447
STPSFT-HP-SEN
+5R
+3.3V
+3.3V
Rear aligning plate

B3
RJOG-HP-SEN
R230
C184
C183
B1
B6
J722
B5
J722
B4
J722
(A502)
(IC103-21P)
R220
B2
+5R R222
Shutter home
position sensor
(PI45)
C185
C186
SHUT-HP-SEN
R228
(A502)
(IC103-88P)
R223
R268
+5R
1
R221
+3.3V
2

2
2
A6
C289
A5
C288
+5R R450
1
Paper surface sensor

(PI41)
A4
+3.3V
A3
C204
1
R270
TRYSFT2-P-SEN
R272
(A501)
(IC101-30P)
C203
A2
+5R R271
1
A-20
A1
J722
B2
J722
B1
J722
2
1
R451
C188
R224
R449
1
B3
+5R
+3.3V
UPPER-P-SEN2
C187
A7
(A502)
(IC103-86P)
R225
1
ASSIST-HP-SEN
1
A8
(A502)
(IC103-23P)
J721
R229
Tray 2 paper surface sensor

(PI48)

(RJOG-A)
A5
J722
(RJOG-A*)
A6
J722
A7
J722
A8
J722
(RJOG-B)
CP124
(RJOG-B*)
(FJOG-A)
R255
(IC101-116P)
M-STB
RJOG-M-A (IC103-29P)
RJOG-M-B (IC103-30P)
CP126
1
(A501)
(A502)
(A502)
(A501)
(A502)
(A502)
+5V
(IC101-116P)
M-STB
FJOG-M-A (IC103-37P)
FJOG-M-B (IC103-38P)
A9
J722
(FJOG-A*)
A10
J722
(FJOG-B)
A11
J722
(FJOG-B*)
A12
J722
R243
11
12
13
14
15
22
16
11
STANDBY
CCPA
10
OUTACCPB
PHASEA
CCPC
8
PHASEB
VM
7
OUTA
GND2
GND1
RSB
26
17
OUTB
RSA
25
19
18
21
ENABLEA
VREFB
ENABLEB
VREFA
3
VDD
C195
2
1
1
R253
R252
2
1
C126
C194
C125
+24U
R250
R251
C196
Q114
FJOG-M-I0
CP111
C193
A1
J722
(ASSIST-A)
A2
J722
(ASSIST-B)
A3
J722
(ASSIST-B*)
A4
J722
(ASSIST-A*)
CP125
R247
(A502)
(A502)
(A502)
IC112
2
1
C197
2 9
+3.3V
(A502)
(IC103-39P)
R259
ASSIST-M-STB
ASSIST-M-A
ASSIST-M-B
OUTB-
20
C127
CR
+5V +5V
1
0.5
0.06
R254
R265 1
R264 1
2
1
C128
2
1
L
H
R263
1
2
C198
R262
+24U
RJOG-M-I0
(A502)
(IC103-31P)
Q116 3
C200
C199
I0
TORQUE
(FRONT-JOG-MOTOR)
12
STANDBY
IC113
10
CCPA
13
OUTACCPB
2 9
15
14
PHASEA
CCPC
8
PHASEB
22
OUTA
RSB
+5V
VM
7
17
16
GND2
GND1
21
2 6
OUTB
2 5
RSA
18
3
CR
VDD
2
ENABLEA
TORQUE
+3.3V
R266
+5V +5V
VREFB
0.06
ENABLEB
0.5
VREFA
20
OUTB-
I0
19
(REAR-JOG-MOTOR)
CP110
R242
(IC103-49P)
(IC103-45P)
(IC103-46P)
+5V
STANDBY 11
CCPA
IC114
10
12
OUTACCPB
2 9
13
PHASEA
CCPC
8
VM
RSB
OUTA 15
PHASEB 14
7
CR
VDD
2
R237
+3.3V
GND1
0.06
21
26
+5V +5V
OUTB 16
GND2 22
0.2
RSA
1.0
2 5
17
ENABLEA
1.0
VREFB
18
ENABLEB
I1
VREFA
I0
TORQUE 20
OUTB- 19
(ASSIST-MOTOR)
2
1
R235 1
2
1
R236 1
2
1
C123
C191
C124
Q113
2
22
Q112
R233
R239
2
C192
1
R234
ASSIST-M-I1
+24U
(A502)
(IC103-48P)
ASSIST-M-I0
(A502)
(IC103-47P)
R238
C190
C189
CP109
A-21
SADDLE I/F
+24V
J704
(+24V)
(GND)
(GND)
J703
J703
J703
+5V
(+5V)
+3.3V
2
(GND)
+5R
(+5R)
(TXD0)
(RXD0)
(GND)
SADDLE-RXD
R364
(SADDLE-RXD)
+3.3V
4
J703
2
R347
2
(A502)
(IC102-10P)
TXD0
R363
2
D117
R365
(A501)
(IC101-59P)
+3.3V
R345
+3.3V
J723
C255
R346
(A501)
(IC101-61P)
RXD0
R348
2
+3.3V
R360
R359
SADDLE-UNIT-ON
(SADDLE-UNIT-ON)
J703
J703
(A501)
(IC101-105P)
C107
R455
2
SADDLE-TXD
R454
A-22
Q188
(A502)
(IC102-11P)
R453
IC128
(SADDLE-TXD)
[SADDLE DRIVER PCB or PUNCH CONTROLLER PCB]

+24R
(GND)
(GND)
PCH-OUT
Q150
J705
(PCH-OUT)
B2
J705
(PCH-RXD)
B3
J705
(PCH-TXD)
B4
J705
(PCH-IN)
B5
J705
(GND)
B6
J705
(PCH-UNIT-ON)
B7
J705
(TRAIL-EDGE-SEN)
B8
J705
B9
J705
B10
J705
C306
(A501)
(IC101-101P)
(+24V)
B1
J706
+3.3V
J705
+3.3V
2
D119
J705
(A501)
(IC101-98P)
PCH-RXD
2
1
A2
R372
R373
1
C260
(+5R)
IC128
R374
+5R
A1
(GND)
A3
J705
C302
A4
J705
(A501)
(IC101-77P)
PCH-M-B
(PCH-M-B)
A5
J705
(PCH-M-B*)
A6
J705
(PCH-M-A*)
Q165
C301
PCH-M-A
PCH-TXD
C300
Q147
1
(A501)
(IC101-78P)
(A501)
(IC101-97P)
Q105
+3.3V
2
3
C303
Q146
PCH-M-I0
2
1
Q149
(A501)
(IC101-66P)
Q148
R366
PCH-UNIT-ON
C256
A9
J705
+3.3V
C305
1
Q144
(A501)
(IC101-37P)
TRAIL-EDGE-SEN
IC128
4
R369
R368
J705
C257
C258
1
A10
(GND)
PCH-M-STB
R367
J705
2
A8
PCH-M-I1
(PCH-M-STB*)
(A501)
(IC101-71P)
2
1
+3.3V
(PCH-M-I1)
(A501)
(IC101-74P)
J705
(A501)
(IC101-75P)
1
2
A7
C276
R413
C278
(PCH-M-I0)
C277
C304
Q145
PCH-M-B
PCH-IN
(A501)
(IC101-76P)
(A501)
(IC101-34P)
R371
3
Q166
(A501)
(IC101-79P)
(PCH-M-A)
PCH-M-A
(GND)
A-23

[TRAY1-AREA-SENSOR]
[TRAY2-AREA-SENSOR]
+3.3V
26
VCCA
VCCB1
VCCB2
22
DIR
GND1
GND2
GND3
+3.3V
VCCB2
11
GND1
12
13
17
16
15
14
B1
A1
B2
A2
B3
A3
B4
A4
B5
A5
B6
A6
B7
A7
B8
A8
10
27
11
28
12
29
13
10
30
14
J801
IC206
14
VCC
7
GND
31
J801
15
J801
IC204
RD
IC206
IC206
J801
10
11
11
10
22
J801
A7
A8
18
19
20
10
21
DIR
22
13
+3.3V
12
34
J801
+5V
12
R605
R606
1
32
J801
33
J801
J801
J801
+5V
IC206
8
13
IC204
ROM-PCB-ON
9
16
17
A-24
B7
A6
A5
B6
IC205
FWE-WR-LED
A4
B5
B4
A3
B8
A2
B3
14
15
A1
B2
16
B1
17
18
19
12
RA302
4
20
RA301
IC203
21
R604
11
IC206
+5V
DBUS0
DBUS1
DBUS2
DBUS3
DBUS4
DBUS5
DBUS6
DBUS7
IC205
10
DBUS[7:0]
R603
1
IC205
IC204
ROM-CS
C409
IC205
2
C407
+3.3V
IC205
IC204
ABUS18
14
VCC
7
GND
IC205
2
IC204
ABUS17
VCCB1
11
VCCB2
12
13
J801
J801
J801
J801
J801
J801
J801
J801
13
R607
2
14
VCC
7
GND
GND1
C404
GND2
GND3
+5V
IC204
VCCA
24
IC205
22
+3.3V
C403
+3.3V
DIR
IC204
ABUS16
J801
J801
J801
J801
J801
J801
J801
J801
18
GND3
23
+5V
IC203
C401
19
GND2
C402
20
VCCB1
24
21
VCCA
23
+5V
IC202
IC202
ABUS8
ABUS9
ABUS10
ABUS11
ABUS12
ABUS13
ABUS14
ABUS15
+5V
IC201
C408
1
23
+3.3V
24
11
12
13
C405
25
C310
A7 9
A8 10
24
16
VCC
GND
A5 7
A6 8
J801
J801
J801
J801
J801
J801
J801
J801
23
A3 5
A4 6
15 B7
14
B8
A1 3
A2 4
B6
C246
B5
B4
14
16
B3
17
B2
18
B1
VCC
GND
19
C242
IC133
1
20
14
IC128
+3.3V
IC201
21
+3.3V
IC117
VCC
GND
ABUS[18:0]
ABUS0
ABUS1
ABUS2
ABUS3
ABUS4
ABUS5
ABUS6
ABUS7
C111
14
VCC
GND
C110
C245
VCC
GND
14
14
VCC
GND
IC122
IC121
IC120
C109
VCC
GND
C247
14
14
VCC
GND
[PUNCH I/F]
+5V
+3.3V
IC132
IC131
[SADDLE I/F]
[FLASH I/F]
+5V
+3.3V
+3.3V
[STAPLER-MOTOR]
[STAPLER-MOTOR]
[SOLENOID]
C406
APPENDIX
3.15 Stapler PCB1

J991
J992
(+5R)
19
(GND)
18
(STP-INFERE-SEN)
17
(+5V)
16
(STP-HP-SEN)
15
(STP-READY)
14
(STP-LS)
13
12
(STPSFT-M-A*)
11
(STPSFT-M-A)
10
10
(STPSFT-M-B)
11
(STPSFT-M-B*)
12
(STP-M-CW)
13
14
15
(STP-M-CCW)
A-25
APPENDIX
3.16 Stapler PCB2

J993
J994
19
(+5R)
18
(GND)
17
(STP-INFERE-SEN)
16
(+5V)
15
(STP-HP-SEN)
14
(STP-READY)
13
(STP-LS)
12
(GND)
(STPSFT-M-A*)
10
(STPSFT-M-A)
STAPLE EDGING
SENSOR (PI51)
STAPLE SENSOR
(PI52)
STAPLE SHIFT MOTOR

(M35)
(STPSFT-M-B)
(STPSFT-M-B*)
(GND)
(STP-M-CW)
STAPLE
HOME POSITION
SENSOR (PI50)
11
STAPLER ALIGNMENT
INTERFERENCE SENSOR
(PI46)
5
7
STAPLE MOTOR
(M41)
3
(STP-M-CCW)
2
1
J995
A-26
APPENDIX
3.17 Tray1/Tray2 Shift Area Sensor PCB
[AREA SENSOR3]
PS981
[AREA SENSOR2]
PS982
[AREA SENSOR1]
R981
R982
PS983
R983
1
+5V
AREA-SEN3
AREA-SEN2
J981
AREA-SEN1
J981
J981
GND
J981
J981
A-27
APPENDIX
A-28
3.18 Tray1/Tray2 Driver PCB
+24V
J951/J1951
(+24V)
(GND)
(GND)
+5R
+5R
1
J951/J1951
(+24V)
D951
J951/J1951
J951/J1951
R951
R952
1
+5R
5
(+5V)
(GND)
JP951
1
+5R
JP952
+5R
JP954
JP953
J951/J1951
J951/J1951
R953
J951/J1951
+5R
+24V
R956
(TRY-M-I)
+5R
J952/J1953
J952/J1953
J952/J1953
J952/J1953
J952/J1953
(TRY-M-CW)
Q952
R961
(TRY-A)
R957
2
1
+5R
3
(TRY-A*)
Q951
(TRY-B*)
R958
(TRY-B)
+5R
R962
(TRY-M-EN)
2
1
2
1
C967
C966
2
1
2
1
C965
C964
2
1
C968
2
1
C951
2
1
C963
2
1
C953
2
1
C962
2
1
C961
2
1
C957
2
1
C956
2
1
C955
2
1
C952
2
1
R955
1
C954
R959
GND
BB
AB
VDD
VREF
MODE
CLOCK
CWB
RESETB
ENABLE
10
11
12
10
C958
J951/J1951
C959
J952/J1953
(+24V)
C960
J951/J1951
R960
(TRY-M-CLK)
(+24V)
J951/J1951
Q953
Tray 1 shift motor / Tray 2 shift motor

(M37/M38)
IC951
A-29
4 Saddle Stitcher Unit Circuit Diagram

Vertical path
paper sensor
PI17
J138
J138
TXD
6
5
PAFLDHP*
4
3
2
PI22
Saddle inlet sensor
J137
To FINISHER CONTROLLER PCB
J13
J19
J21
10 11 12 13 14 15
2
1
5
3
4
2
1
5
4
3
2
3
6
5
4
2
1
2
3
2
1
3
2
1
3
2
1
4
3
PI14
Paper pushing plate home position sensor
PI15
Paper pushing plate top position sensor

3
2
1
TRYPAR
S-GND
3
2
1
2
+5V
PAPPOS
PI8
Paper positioning
plate paper sensor
S-GND
PPOSPAR
+5V
J129
S-GND
J201 J301
+5V
1
3
4
3
2
1
1
3
10
9
8
7
2
1
2
PI13
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
2
3
PI12
2
LUNGEHP
Delivery sensor
PI11
1
2
3
J525
3
J425
J325
S-GND
LUNGEHP
+5V
S-GND
J128
J17
7
J15
J5
3
J12
2
7
6
5
4
1
2
4
3
SL
SL
SL4
JD2A
JD1A
Guide motor
J115
J116
J315
J118
M7
Stitcher motor (front)
NO
COM
J117
Feed plate
contact
solenoid
SL2
No.2 flapper
solenoid
SL
SL1
No.1 flapper
solenoid
M
M1
Feed motor
3
2
6
5
4
3
2
A*
B*
+24V
FLPSL1*
+24V
+24V
FLPSL2*
RLNTPSL*
S-GND
HKEMP1
STCHHP1*
SDL-FRONT-STP-CW
SDL-FRONT-STP-CCW
SDL-FRONT-STP-CCW
S-GND
HKEMP2
SDL-FRONT-STP-CW
STCHHP2*
SDL-REAR-STP-CCW
SDL-REAR-STP-CW
SDL-REAR-STP-CW
2
1
4
SW7
Stitcher
1
home position
switch (front)
NO
COM
Staple switch (front)
NO
SW6
M3
home position sensor
JD1B
PI7 Paper positioning plate
JD2B
COM
COM
Stitcher motor (rear)
M
2
M6
NO
J202 J302
J316
1
J119
1
SW4
Staple switch (rear)
J134
A*
B*
1
To FINISHER CONTROLLER PCB
J139D
SDL-REAR-STP-CCW
+24V
J139L
GIDHP
J127
J126
+24V
J704
Stitcher SW5
home position
switch (rear)
J225
J125
+5V
14 13 12 11 10
COM
S-GND
INLTCVRMS
Inlet door switch
+5V
10 11 12 13 14 15
J8
NC
FDRLHP
NO
SW1
A-30
S-GND
J6
J1
+24V
J305 J205
J109
DELV
+5V
COM
P-GND
J105
NC
Delivery door switch
S-GND
J111
NO
SW3
+5V
Paper folding motor M2
S-GND
J9
J4
J112
+5V
INLTCVR
DELVMS
PI9
M8
No.2 paper sensor

3
Inlet cover sensor
2
3
J113
Paper pushing
plate motor
PI19
No.3 paper sensor
J7
J108
PI20
B*
+24V
S-GND
A*
3 RDPA
Alignment motor M5
2 NDPA
+24V
1 STPA
No.1 paper sensor

3
B*
+5V
PI18
J123
J124
J10
A*
J304
J204
+5V
Paper sensor PCB

PCB10
S-GND
J703
J20
J114
Paper positioning M4
plate motor
J2
J18
S-GND
JOGHP
10 11
J209
10 11 12 13 14
J14
3
2
1
FLDCLK
J11
+5V
+5V
S-GND
J309
EJCVR
J101
LUNGECLK
J102
Alignment plate
PI5
+5V
S-GND
Paper folding motor

PI4
clock sensor
J16
Delivery cover sensor PI3
J203
J303
J103
VPJM
S-GND
+5V
STPLHP
+5V
S-GND
S-GND
+5V
1
2
10 11 12
J136
+5V
L-GND
S-GND
J107
Paper pushing plate

motor clock sensor PI1
RXD
J133
S-GND
INLET-ROLL
J208
SL5
J135
S-GND
+5V
J308
J131
1
1
SL
2
2
3
3
J130
J135
1
SDLINSL*
+24V
J132
PI16
Stitcher unit
IN sensor
PI21
10 11 12
Paper folding
home position
sensor
J502
J402
J100
PI6
Tray paper sensor
ABUS[7:0]
(A508)
(A508)
PD4/D12
VSS8
P17/PO15/TIOCB2/TCLKD
PD3/D11
IC7
PD2/D10
P15/PO13/TIOCB1/TCLKC
PD1/D9
P14/PO12/TIOCA1
PD0/D8
P13/PO11/TIOCD0/TCLKB
PE7/D7
P12/PO10/TIOCC0/TCLKA
PE6/D6
P11/PO9/TIOCB0/_DACK1
PE5/D5
P10/PO8/TIOCA0/_DACK0
PE4/D4
MD0
VSS7
MD1
PE3/D3
MD2
PE2/D2
PG0/_CAS
PE1/D1
PE0/D0
VCC2
RA1 1
8
56
2
7
55
3
6
54
4
5
52
RA2 1
8
51
2
7
50
3
6
49
4
48
47
46
45
43
42
41
40
(A502)
S-EDOOR-SW
S-JOG-HP
EDOOR-SEN
FDOOR-SEN
FOLD-HP-SEN
PUSH-RV
PUSH-FWD
PUSH-EN
DBUS3
DBUS2
DBUS1
DBUS0
(A507)
(A508)
(A508)
(A508)
(A509)
(A505)
(A505)
(A505)
DBUS7
DBUS6
DBUS5
DBUS4
R278
2
+3.3V
1
RESET
S-JOG-A
S-JOG-B
S-JOG-I0
P-POS-I0
P-POS-A
P-POS-B
SL-TIME
FOLD-PWM
FOLD-RV
FOLD-FWD
S-INLET-SW
S-FDOOR-SW
R263
S-INRET-SEN
WR
RD
(A507)
(A507)
(A504)
(A504)
(A504)
(A504)
(A504)
(A506)
(A506)
(A505)
(A505)
(A505)
(A501)
C17
(A509)
C18
(A506)
(A507)
(A506)
(A506)
(A506)
(A506)
(A502)
(A502)
(A504)
(A506)
D101
(A502)
53
C144
12
IC501
5
+3.3V
R280
Q63
(CPU) RESET
(IPC)
Q66
R273
DBUS[7:0]
3
2
C15
R272
1
R286
(A502)
C14
C13
1
+5V
R274
2
13
[FWE]
R275
2
[TXD]
R276
2
44
VCC
VOUT
M/R
SUB
GND
14
VCC
GND 7
PD5/D13
AVSS
57
P47/AN7/DA1
PD6/D14
(A502)
11
P46/AN6/DA0
IC501
VCC3
59
PD7/D15
60
P45/AN5
61
IC501
VSS15
Q68
P30/TXD0
62
(A502)
(A502)
R501
65
66
67
68
69
70
71
72
73
S-NDLF-SEN
S-NDLR-SEN
INRET-FLAP-SL
S-FLAP1-ON
S-FLAP2-ON
S-PICK-ON
S-FEED-STBY
S-STPF-CCW
10
P31/TXD1
63
TRM-JOIN
TRM-OUT
FLASH-RXD
TRM-RXD
FLASH-TXD
TRM-TXD
VSS9
P60/_DREQ0/_CS4
VSS10
VSS11
P61/_TEND0/_CS5
P62/_DREQ1
P63/_TEND1
P27/PO7/TIOCB5/TMO1
P26/PO6/TIOCA5/TMO0
P25/PO5/TIOCB4/TMCI1 74
P32/RXD0
64
76
77
P24/PO4/TIOCA4/TMRI1 75
P23/PO3/TIOCD3/TMCI0
78
79
+3.3V
C12
P21/PO1/TIOCB3
P20/PO0/TIOCA3
80
81
82
83
84
R259
R260
R15
RES
NMI
STBY
VCC4
XTAL 85
P22/PO2/TIOCC3/TMRI0
P33/RXD1
87
88
89
90
91
92
93
EXTAL 86
VSS12
PF7/
VCC5
PF6/_AS
PF5/_RD
WDTOVF[_FWE]
P34/SCK0
PF3/_LWR
PF4/_HWR
P35/SCK1
C11
38 P64/_IRQ0
37 P65/_IRQ1
95
96
97
98
99
100
101
102
PF2/_LCAS/_WAIT/_BREQO 94
PF1/_BACK
PF0/_BREQ
P50/TXD2/_IRQ4
P51/RXD2/_IRQ5
VSS13
VSS14
P52/SCK2/_IRQ6
P53/_ADTRG/_IRQ7/_WAIT/_BREQO
+3.3V
PUSH-CLK
FOLD-CLK
36 VSS6
35 VSS5
34 P66/_CS6/_IRQ2
33 P67/_CS7/_IRQ3
32 PA7/A23/_IRQ7
31 PA6/A22/_IRQ6
30 PA5/A21/_IRQ5
29 PA4/A20/_IRQ4
28 VSS4
27 PA3/A19
26 PA2/A18
25 PA1/A17
24 PA0/A16
23 PB7/A15
22 PB6/A14
21 PB5/A13
20 PB4/A12
19 VSS3
PG2/_CS2
PUSH-HP-SEN
PUSH-TOP-SEN
TRM-IN
S-FEED-A
S-STPF-HP
S-STPR-HP
S-REDGE-SEN1
S-REDGE-SEN2
S-REDGE-SEN3
S-PASS-SEN
S-POS-SEN
S-GUIDE-SEN
INRET-COVER-SEN
S-STP-SEN
18 PB3/A11
17 PB2/A10
16 PB1/A9
15 PB0/A8
14 PC7/A7
13 PC6/A6
12 PC5/A5
PG1/_CS3
(A508)
(A508)
(A502)
(A504)
(A506)
(A507)
(A509)
(A509)
(A509)
(A508)
(A509)
(A508)
(A509)
(A508)
(A509)
(A509)
(A508)
(A508)
S-TRY-SEN
S-PAPER-SEN
S-HALF-SEN
S-EXIT-SEN
P16/PO14/TIOCA2
(A501)
(A502)
2
128
11 PC4/A4
127
10 VSS2
126
125
RA4
S-STPR-CW
S-STPR-CCW
S-STPF-CW
124
ABUS4
ABUS5
ABUS6
ABUS7
123
9 PC3/A3
122
8 PC2/A2
121
120
119
118
117
7 PC1/A1
116
6 PC0/A0
115
S-FEED-B
S-FEED-A
S-FEED-B
S-FEED-A
S-FEED-I0
GUIDE-I0
GUIDE-B
GUIDE-A
114
113
112
P44/AN4
5 VCC1
111
P43/AN3
4 NC
110
P42/AN2
RA3
109
P41/AN1
3 VSS
108
P40/AN0
2 PG4/_CS0
1 PG3/_CS1
107
VREF
ABUS0
ABUS1
ABUS2
ABUS3
106
C201
R282
105
S-FSTP-AN
S-RSTP-AN
S-EDOOR-CONNECT
S-FDOOR-CONNECT
PUSH-HP-CONNECT
S-GUIDE-CONNECT
S-STP-CONNECT
PUSH-TOP-CONNECT
FOLD-HP-CONNECT
104
AVCC
R271
CS0
103
1
R402
(A502)
(A509)
C10
1
+3.3V
X1
(A507)
(A507)
(A506)
+3.3V
2
(A501)
(A504)
(A504)
(A504)
(A504)
(A504)
(A506)
(A504)
(A504)
(A504)
C9
+3.3V
(A506)
(A507)
(A508)
(A508)
(A508)
(A508)
(A508)
(A508)
4.1 Saddle Stitcher Controller PCB (A501)
+3.3V
IC501
8
+5V
R277
[+5V]
J22
1
[RESET]
2
Q67
[MD2]
3
C141
IC501
4
R401
5
Q65
+5V
[RXD]
6
[GND]
7
+3.3V
IC501
58
+5V
R279
1
C142
C202
39
+3.3V
+3.3V
IC1
1
2
C16
+3.3V
IC501
C61
A-31
Q2
(A501)
J20
J20
J20
J20
R18
2
+3.3V
J2
J2
R24
R38
2
(A501)
Q23
TRM-TXD
C22
R37
C28
D3
1
IC502
R19
2
J20
R17
+3.3V
CP1
TRM-RXD
R35
D1
R34
J2
CP3
IC502
+3.3V
R36
CP6
CP2
+3.3V
C27
+3.3V
J2
1
CP4
PB1 40
13 TXD1
14 P16
PB3 38
15 P15/_CTS2
16 P14/_CTS1
PB5 36
17 P13/CLK
18 P12
PB7 34
PB2 39
P01
2
1
11
J20
R26
LED1
(A501)
TRM-JOIN
R23
2
2
1
R21
R22
J20
J20
J20
C20
R27
R28
LED3
LED2
SW504
C26
J20
+3.3V
D2
+3.3V
X2
+3.3V
POW-ON (A503)
10
2
1
(A503)
(A503)
(A510)
(A510)
(A510)
(A510)
(A510)
(A510)
(A510)
+5V
32
P03
P02
31
30
P05
P04
29
28
P06
27
P07
26
XOUT
XIN
VSS
25
24
23
P10
22
19
P11/INT
P00 33
C25
5V-DETECT
24V-DETECT
S-TRY-POS3-SEN
S-TRY-POS2-SEN
S-TRY-HP-SEN
TRY-MTR-A
TRY-MTR-B
TRY-MTR-I0
LED
PB4 37
PB6 35
J20
11 TXD2
12 RXD1
PB0 41
C23
PA7 42
PA6 43
Q22
PA5 44
RESET
(A501)
A-32
C21
R25
7 INTR
8 PUL
PA4 45
C19
PA3 46
IC8
CP5
A6 51
A5 52
A4 53
A3 54
A2 55
5 S
6 VBUS
(A501)
TRM-OUT
SW1
PA2 47
CNVSS
R33
PA1 48
9 LVL
10 RXD2
TRM-IN
50
3 W
4 R
21
(A501)
PA0 49
RESET
R32
1
A7
20
WR
RD
CS0
ABUS7
ABUS0
ABUS1
ABUS2
ABUS3
ABUS4
ABUS5
ABUS6
A1 56
A0 57
VCC 58
DQ7 59
DQ6 60
DQ5 61
1 DQ1
2 DQ0
+3.3V
(A501)
(A501)
(A501)
DQ4 62
DBUS2
DBUS3
DBUS4
DBUS5
DBUS6
DBUS7
DQ2 64
C24
DQ3 63
DBUS1
DBUS0
+3.3V
Q6
2
(A501)
R20
ABUS[7:0]
(A501)
DBUS[7:0]
16
15
14
13
12
11
10
+3.3V
R287
1
R299
1
2
3
Q71
2
R298
2
Q76
5V-DETECT
(A502)
POW-ON
(A502)
Q24
R47
CB1
2
J1 (+24V)
J1 (P-GND)
+3.3V
2
+24V
R48
24V-DETECT
(A502)
Q72
R289
ZD1
+5R
CP11
J2 (+5V)
J2 (L-GND)
C4
+5V
CP9
JNT1
1
D4
1
ETH1
+3.3V
CP8
IC10
FU14
1
2
2
IN OUT
GND
C1
C30
C2
1
C31
ETH2
A-33

CP19
OUTB
TDB
GB
REFB
J7
INB
J7
10
12
14
2
1
2
1
C155
C158
OUT/B
J7
VS
RSB
J7
2
1
C147
0.4
RSA
C44
R51 1
R52 1
15
R74
R68
ETH10
0.1
0.51
0.1
13
OUT/A
S-JOG-B
I0
C36
R54
C43
GA
INA
CP20
10 CCPA
1
2
R14
(A501)
C37
C33
C5
R71
C35
I0
9
11
TDA
REFA
C157
R67
R66
CP18
OUTA- 12
J7
C34
2
1
R53
9 CCPB
8 CCPC
7 VM
6 RSB
21 GND1
5 RSA
4 VREFB
1 CR
CP17
1
STANDBY 11
PHASEA 13
OUTA 15
PHASEB 14
GND2 22
OUTB 16
ENABLEA 17
19
OUTB-
R49
C42
+24V
Q7
3 VREFA
2 VDD
S-FEED-I0
(A501)
ENABLEB 18
TORQUE 20
+5V +5V
IC2
R70
OUTA
C156
R69
IC4
1
Q9
C45
R73
R72
S-JOG-I0
+3.3V
+3.3V
+3.3V
2
1
C206
2
1
C205
C204
(A501)
FU5
1
S-JOG-A
(A501)
S-FEED-STBY
S-FEED-A
S-FEED-B
S-FEED-A
S-FEED-B
C203
(A501)
(A501)
(A501)
(A501)
(A501)
+5R
R50
+24R
+5R
J5
J5
J5
J5
CP13
CP12
CP24
CP25
Feed motor (M1)
CP22
Paper positioning plate motor (M4)
+24R
+5R
+5R
VS
RSB
OUTB
TDB
GB
REFB
INB
10
14
0.1
0.51
C151
1
E
J12
0.1
0.51
R82
J7
J7
VS
RSB
OUTB
TDB
GB
REFB
INB
8
10
14
2
1
C159
1
E
OUT/B
J7
10
J7
12
C162
R83
ETH9
I0
RSA
C148
OUT/B
J12
12
C40
C48
P-POS-B
C146
(A501)
2
RSA
CP23
R62
1
2
OUT/A
C154
15
J12
J12
R60
R63
13
CP15
C39
2
R59
C153
GA
INA
11
TDA
REFA
J12
C152
ETH8
A-34
R64
R65
CP16
GUIDE-B
I0
C38
(A501)
R58
OUTA
IC3
1
15
C41
R57
Q8
GUIDE-I0
(A501)
+3.3V
R61
+3.3V
(A501)
GUIDE-A
OUT/A
13
GA
INA
C161
11
C47
TDA
REFA
R77
J7
C160
R80 1
OUTA
2
2
R76
C46
R79
FU4
1
R78
IC5
1
C49
R75
+24V
CP21
CP14
Guide motor (M3)
+5R
Q10
+3.3V
R81
+3.3V
(A501) P-POS-I0
+5R
P-POS-A
(A501)
FU6
ETH3

+24R
FU7
+24R
1
Paper pushing plate motor (M8)
J4
10
J4
IC504
4
IC517
R113
2
Q54
IC517
9
8
+3.3V
C7
2
R1
C/R
12
Q31
C/R
R2
15
C8
+3.3V
14
10
13
R88
CLR
1
R92
+3.3V
IC516
IC516
1
R93
A
CLR
11
+3.3V
2
1
1
C53
2
2
ETH4
1
CW
CCW
EN
(CW)
(CW)
(F.H)
(F.H)
(CCW)
(CCW)
(F.H)
(F.H)
L
L
Q542
Q543
+5V
+5V
IC516
IC504
14
VCC
GND
16
C62
VCC
GND
Q535
C6
Q534
PWM
CCW
Q536
Q537
Q544
Q545
+5V
IC517
14
VCC
GND
IC517
CW
C3
12
11
C52
Q53
R89
R91
1
10
R90
4
2
R114
R95
IC517
+5V
Q46
IC509
C54
R94
D7
IC509
Q11
D8
10
+5V
R10
Q29
PUSH-RV
(A501)
S-GUIDE-SEN
(A501)
(A508)
R101
2
IC504
10
CP26
1
+5V
R9
CP33
Q45
Q30
PUSH-EN
(A501)
FOLD-RV
(A501)
+3.3V
IC508
CP30
11
13
Q52
R303
Q51
R97
+3.3V
12
PUSH-FWD
(A501)
CP32
R100
IC504
R306
2
R305
J4
R304
C59
J4
CP31
R96
2
C58
2
Q44
IC504
3
R98
FOLD-PWM
(A501)
Q43
CP29
R117
+3.3V
Q28
FOLD-FWD
(A501)
R301
2
R307
R302
R300
C51
FU11
CP28
C50
13
A-35

CW
CCW
Q541
Q548
Q549
(CW)
(CCW)
+24V
2
Q540
Q47
J8
J8
J8
S-FLAP2-ON
Q58
R143
Q33
R99
R145
R140
R128
1
2
D12
D15
C67
C71
R134
R135
D13
1
2
D14
R126
J8 sensor (front) (SW7)
J8
J8 Staple sensor (front) (SW6)
VCC
GND
IC508
C63
VCC
GND
14
14
C66
VCC
GND
IC507
14
C60
7
1
C65
IC506
14
VCC
GND
IC505
+3.3V
+5R
+3.3V
+5R
14
VCC
GND
+5R
ETH6
R139
+5V
Q59
IC503
D19
2
1
D18
(A501)
13
1
R124
C70
R123
1
R146
11
IC506
12
INRET-FLAP-SL
R125
CP39
1
+5R
Saddle inlet
solenoid (SL5)
C139
IC503
R136
IC511
+24V
+3.3V
R119
IC503
FU9
11
CP36
1
R11
2
Q60
10
+5V
D11
S-FSTP-AN
(A501)
(A501)
S-PICK-ON
IC514
+3.3V
IC514
R148
11
13
CLR
IC506
12
S-FEED-I0
(A501)
13
+3.3V
CLR
12
IC508
R147
C/R
15
C/R
R3
R4
10
C29
14
+3.3V
C32
Feed plate contact

solenoid (SL4)
CP40
R133
12
1
13
+3.3V
A-36
D17
R144
11
2
C73
(A501)
IC505
IC506
R138
6
R132
S-NDLF-SEN
No.2 paper deflecting

solenoid (SL2)
Q55
(A501)
CP38
S-STPF-HP
IC507
4
3
2
(A501)
Q57
IC507
1
R137
Q56
S-STPF-CCW
(A501)
R142
3
IC507
9
11
+3.3V
D16
J8
R141
IC507
12
R118
IC506
1
Q48
C72
10
SL-TIME
S-FLAP1-ON
(A501)
(A501)
R310
Q32
13
CP34
10
R131
2
1
IC505
8
CP35
R311
R130
+3.3V
S-STPF-CW
(A501)
R309
R308
R129
C69
No.1 paper deflecting

solenoid (SL1)
FU12
Stitcher motor (front) (M7)

1
C68
CP37
FU8
+24U
C74

CW
CCW
Q540
Q541
Q548
+24V
Q549
(CCW)
R163
Stitcher motor (rear) (M6)
C82
C81
1
(A501)
S-INRET-SW
13
Q61
R159
9
8
ZD3
2
14
J4
J8
13
J8
12
J8
11
J8
+3.3V
Q62
2
11
R161
IC513
12
R293
Q50
Q49
Q37
IC513
CP42
10
R165
1
S-STPR-CW
(A501)
IC505
R155
J4
R315
R313
C75
2
1
+3.3V
R314
Q73
R312
R167
J4
Inlet door switch (SW1)
+24U
+3.3V
+24U
FU13
(CW)
+3.3V
IC513
(A501)
R158
ZD5
2
J4
IC505
R157
5
S-STPR-CCW
(A501)
J4
Q38
R156
C76
R162
R294
1
CP41
Q75
IC513
S-FDOOR-SW
+3.3V
2
Delivery door switch (SW3)
15
C/R
C
Q
12
(A501)
S-EDOOR-SW
R296
ZD4
Q74
3
C
13
J4
+3.3V
11
CLR
+3.3V
CLR
10
C/R
C77
R5
R6
+24R
R164
+3.3V
C78
14
+3.3V
IC515
IC515
+5V
C83
CP43
+3.3V
D24
R169
IC511
2
R12
S-RSTP-AN
(A501)
IC515
8
16
C79
VCC
GND
IC513
C140
VCC
GND
14
VCC
GND
ETH7
IC514
16
R174
+5R
2
2
R173
C84
R172
+3.3V
+3.3V
R160
C163
C138
E
2
+5R
R149
R154
R151
J8
J8

sensor (rear) (SW5)
J8
Staple sensor (rear) (SW4)
D20
10
D21
1
2
R150
2
1
2
D23
R153
1
C80
IC503
8
D22
R152
5
S-NDLR-SEN
IC503
6
(A501)
S-STPR-HP
C85
(A501)
+5R
A-37

+5R
2
CP44
+3.3V
IC502
C90
J11
J11
CP45
Delivery sensor
(PI11)
R183
C87
J9
J9
J9
C86
1
2
C91
+5R
+3.3V
R184
S-EXIT-SEN
(A501)
R188
S-JOG-HP
(A501)
R185
R186
Alignment plate
J11 (PI5)
2
2
IC502
R182
1
+5R
+3.3V
CP46
+5R
R197
C96
C97
J9
J9
J9
+3.3V
+5R
CP47

(PI12)
R196
S-HALF-SEN
(A501)
J11
2
1
IC508
J11
R195
C88
+3.3V
C89
FOLD-CLK
(A501)
CP48
Paper folding motor

J11 clock sensor
(PI4)
R187
R189
R190
J11
C95
J11
J11
+5R
CP49
+3.3V
S-GUIDE-SEN
(A501)
(A505)
C99
Q18
+3.3V
R201
PUSH-HP-SEN
(A501)
C100
1
C101
1
J11
R203
J11
R202
J9
10
J9
CP51
+3.3V
J11
13
+5R
R180
R175
IC502
R205
13
R204
2
12
PUSH-TOP-SEN
(A501)
C102
R210
J13
J13
+3.3V
+5R
R178
IC502
J13
J13
J13
J13
R211
1
R213
C107
1
C106
14
VCC
GND
R209
C64
+3.3V
CP53
Vertical path paper sensor

(PI17)
IC508
4
6
5
15
J9
14
J9
13
J9
R179
1
S-STP-CONNECT
(A501)
J13
R266
Q15
+3.3V
R269
3
C109
C108
Q16
PUSH-TOP-CONNECT
(A501)
R208
Stitcher unit IN sensor

(PI16)
R212
+3.3V
+5R
+3.3V
C103
CP54

C105
Paper pushing plate

motor clock sensor
(PI1)
J11
C104
J11
14
15
PUSH-HP-CONNECT
(A501)
R207
2
R268
Q17
R206
A-38
J9
11
+5R
R177
+3.3V
CP55
S-PASS-SEN
(A501)
12
+3.3V
S-FDOOR-CONNECT
(A501)
S-STP-SEN
(A501)
Paper pushing plate

J11
R265
3
+5R
R267
1
1
11
10
Q14
J9
R181
C93
+3.3V
J9
12
C92
PUSH-CLK
(A501)
+3.3V
CP50
R193
1
S-GUIDE-CONNECT
(A501)
R214
FDOOR-SEN
(A501)
J9
+5R
R191
R176
CP52
C98
+3.3V
S-EDOOR-CONNECT
(A501)

(PI13)
R199
R200
R264
Q13
R198
+3.3V
C94
Delivery cover sensor

(PI3)
R194
R192
EDOOR-SEN
(A501)

+5R
CP60
J6
S-REDGE-SEN1
C113
J10
C114
2
2
(A501)
J6
J10
C115
C112
R218
R219
1
2
11
+3.3V
R222
R225
10
+5R
CP57
1
R226
IC502
S-PAPER-SEN
(A501)

paper sensor (PI8)
+3.3V
J6
CP58
+3.3V
J6
J6
2
1
CP59
+3.3V
C123
R223
2
J10
+5R
+3.3V
CP63
R235
1
R233
IC503
R234
1
J6
J6
J6
Inlet cover sensor (PI9)
13
2
12
J6
J10
C119
C118
4
4
2
R224
S-REDGE-SEN3
2
C122
(A501)
S-TRY-SEN
(A501)
J10
C117
C116
R232
11

IC503
10
R231
R236
S-POS-SEN
(A501)
(A501)
R220
R221
S-REDGE-SEN2
CP62
+5R
+3.3V
C124
+3.3V
CP61
+5R
2
C125
R229
R227
INRET-COVER-SEN
J18
J18
J18
J10
J10
J10
C121
C120
2
1
Paper folding
R217
R215
C110
C111
+3.3V
FOLD-HP-SEN
(A501)
(A501)
+3.3V
R216
R228
CP56
+5R
R270
Q19
FOLD-HP-CONNECT
(A501)
+3.3V
R230
+5R
2
CP64
R239
Saddle inlet sensor (PI22)
R237
3
J21
C126
C127
1
(A501)
R238
S-INRET-SEN
J21
J21
A-39
+3.3V
R247
IC8-41
TRY-MTR-A
TRY-MTR-I0
TRY-MTR-B
(A502)
R246
IC8-39
(A502)
R245
IC8-40
(A502)
IC8-42
R255
S-TRY-HP-SEN
S-TRY-POS2-SEN
(A502)
R257
IC8-43
(A502)
R241
IC8-44
S-TRY-POS3-SEN
(A502)
R254
IC8-38
(A502)
A-40
LED
4.11 Saddle Driver PCB

J801
A1
A10
J804
J801
A2
STBY
A9
J804
J801
A3
I1
A8
J804
A4
I0
A7
J801
J804
A5
B*
A6
J804
A6
A5
J804
A7
A*
A4
J801
A8
A3
J804
J801
A9
A2
J804
J801
A10
A1
J804
J801
J801
J801
+5V
+5V
+5V
J804
+5V
3
Q1
R2
A11
J801
2
1
R7
2
1
R8
R9
1
R10
R1
C2
+24V
R3
J802
J802
R4
R5
R6
2
1
J803
J803
J803
+5V
4
STANDBY 11
13
14
OUTA- 12
PHASEA
OUTA 15
GND2 22
OUTB 16
ENABLEA 17
20
ENABLEB 18
PHASEB
J805
J805
9 CCPB
10 CCPA
8 CCPC
7 VM
6 RSB
5 RSA
21 GND1
4 VREFB
3 VREFA
2 VDD
+24V
C3
1
C5
J804
R14
R17
B10
R16
J801
B1
1 CR
+24V
R12
+5V
+5V
Q2
R18
+5V
+5V
J803
Q3
R11
1
+5V
TORQUE
IC1
+5V
+5V
OUTB- 19
C4
J801
B4
B7
J804
J801
B5
B6
J804
C7
C6
1
C1
B6
B5
J804
J801
B7
B4
J804
J801
B8
B3
J804
J801
B9
B2
J804
J801
B10
B1
J804
J801
B11
R13
1
ETH1
1
J801
J804
R15
1
B8
J804
1
B3
B9
R19
J801
B2
J801
J802
A-41
A-42
APPENDIX
R1
4.12 Paper Sensor PCB
No.1 paper
sensor
PI18
J123
J123
J123
J123
R2
No.2 paper
sensor
PI19
J123
R3
No.3 paper
PI20
sensor
A-43
APPENDIX
A-44
5 Puncher Unit General Circuit Diagram

motor
M62
Punch feed
motor
home position
sensor
M
2
Punch motor clock

sensor
PI61
M63
Punch home position

sensor
PI62
LED PCB
Photosensor PCB
PI63
Punch motor
M61
J611
J610
J610
4
1
3
2
2
3
1
1
2
2
3
3
1
1
J612
2
2
3
3
J614
1 2 3
1 2 3
J613
J615
5
2
2
1
1
J619
13 12 11 10 9
13 12 11 10 9
J605A
A*
A
2
J604
J603
J605B
B*
PAEND*
SREG4*
SREG3*
SREG2*
+5R
6
SREG1*
GND
LEDON5
LEDON4
LEDON3
LEDON2
LEDON1
GND
GND
PUNCHHP*
+5R
GND
PUNCHCLK
+5R
+5R
GND
SREGHP
A*
B*
J620
J601
9 10 11
J622
NO
TO FINISHER CONTROLLER PCB
10 9
10 9
J705A
OR SADDLE DRIVER PCB
J804A
J804B
3
NC
NO
J805
J621
4
COM
NC
J706
1
J705B
J606
J602
3
GND
DFULL
LEDON*
+5R
+24V
9 10 11
J607A
8
+24V
UDROPN
FDROPN
+24V
P-GND
J607B
1
COM
MSW62
MSW61
Front door
switch
Upper door
switch
J618
PCB13
A-45
5.1 Punch Controller PCB (A501)

[Down load]
+5V
+5V
J608
[+5V]
J608
[RESET*]
J608
[MD2]
J608
[FWE] [P85]
J608
[TxD]
J608
[RxD]
J608
[GND]
R721
1
Q620
RESET
+5V
8
R723
C678
C615
+5V
2
RA606
R726
IC607
32
31
[A504]
13
PCH-IN
4
6
IC604
3
43
5
4
+5V
42
41
36
R603
LED602
35
34
33
[A503]
[A503]
R618
37
R742
2
REG-M-B
REG-M-A
38
+5V
LED601
R602
[A504]
R720
FRONT-COVER-SW
39
40
TP10
TP11
+5V
TP8
TP9
SW602
LED-PWM
REG-M-I
[A502]
[A502]
SW603
PCH-M-CW
PCH-M-CCW
[A503]
[A503]
R724
2
1
R606
2
1
R605
SW601
8
[A503]
[A502]
CS
VCC
SK
NC2
DI
NC1
DO
GND
8
7
C611
+5V
14
7
VCC
GND
IC603
R607
+5V
R620
44
IC604
A-46
RA606
R747
2
1
R622
45
REG-M-STB
REG-HP-SEN
R611
R608
R609
R610
RA606
RA606
[FIN-X4 SCI]
IC604
R604
[A504]
+5V
17
1
1
46
TP12
TP13
[A504]
PCH-TXD
NC8
NC9
NC7
NC10
NC4
P76 TMOV
NC3
R746
P14 51
P15 52
NC14 50
IRQ0
IRQ1
IRQ2
P16 53
P17 54
PB4/AN4 55
PB5/AN5 56
PB6/AN6 57
PB7/AN7 58
PB3/AN3 59
PB2/AN2 60
NMIN
47
PCH-RXD
+5V
48
[A504]
R619
P81
P51
TP6
TP7
NC13 49
P82
P80
P75
16
FTIOA
P50
P74
15
VCC
30
FTIOB
29
TP4
TP5
OSC1
NC5
C662
P83
OSC2
P57
14
P84
28
13
P85
IC601
VSS
27
12
TEST
P56
11
P86
26
10
X601
P87
RESN
P12
VCL
25
P20
X1
P11
P21
24
P22
RxD
P10
TxD
X2
23
AVCC
P55
C612 1
P54
NC11
P53
NC12
NC2
22
TP3
NC1
21
20
P52
TP16
TP17
+5V
PCH-OUT
TP1
TP2
PB1/AN1 61
NC15 63
C610
+5V
C609
PB0/AN0 62
NC16 64
NC6
VOUT
18
GND
11
IC604
1
1
1
1
TP14
TP15
SUB
19
VCC
12
C674
M/R
IC604
R601
IC602
+5V
UP-COVER-SW
DUST-AN
A3-REG-AN
B4-REG-AN
A4R-REG-AN
B5R-REG-AN
TAIL-EDGE-AN
10
[A504]
[A502]
[A502]
[A502]
[A502]
[A502]
[A502]
R743
14
PCH-HP-SEN [A502]
PCH-CLK-SEN [A502]
TAIL-EDGE-SEN1 [A502]
C637

[LED PCB]
B13
[PHOTOSENSOR PCB]
J605
+5R
1
R626
+5R
1
[A4R LED]
J605
C624
[A501]
[AN3]
B4-REG-AN
C625
R629
C626
1
3
B4
J605
[B4 PTR]
B9
J605
B3
J605
[A4R PTR]
B2
J605
[B5R PTR]
RA603
J605
[A3 PTR]
B5
RA602
+5R
Q607
J605
[5V]
B10
1
3
[B4 LED]
R628
+5R
Q605
J605
Q604
1
2
1
2
C623
RA601
C618
B11
+5R
A3-REG-AN
R627
D601
2
1
R632
LED-PWM
[A501]
[AN7]
[A501]
[TMOV]
C622
B6
RA602
[A3 LED]
RA603
J605
[GND]
Q603
J605
+5R
IC608
B12
+24V
B7
+5R
Q602
[B5R LED]
RA602
[A501]
[AN2]
R638
A4R-REG-AN
[TAIL EDGE LED]
C627
1
C628
1
J605
RA603
B8
R639
[SCRAP FULL DETECTION PCB]

RA602
+5R
2
1
[DUST LED]
R654
[A501]
[AN0]
J606
1
1
+5V
[DUST SENS]
J605
[TAIL EDGE PTR]
R653
C632
C631
R624
B1
J606
R727
1
C616
C617
TAIL-EDGE-AN
J606
R625
DUST-AN
C629
[A501]
[AN6]
C630
J606
R631
Q606
1
RA603
R630
1
B5R-REG-AN
[A501]
[AN1]
TAIL-EDGE-SEN1
2
[A501]
[IRQ1]
+24V
Q623
3
+5R
2
1
A2
J605
A3
J605
+5R
2
+5R
J605
2
1
A5
J605
A6
J605
A7
J605
A8
J605
A9
J605
R636
R669
PCH-CLK-SEN
R635
R634
2
A4
R668
2
+5R
2
[A501]
[IRQ2]

(PI63)
C644
1
C643
+24V
PCH-HP-SEN
J605
[A501]
[P17]
A1
R667
TAIL-EDGE-SEN2
R666
IC608
[A504]
C645
C646
Punch motor clock sensor

(PI62)
+5R R659
+5R
R662
2
(PI61)
REG-HP-SEN
C641
C642
1
[A501]
[P54]
R661
A-47

CP603
REG-M-STB
REG-M-A
REG-M-B
+5R
+5R
+5R
[A504]
OUTA 15
R676
14
8 CCPC
PHASEA
13
9 CCPB
OUTA-
12
10 CCPA
C647
2
1
R692
2
1
R688
A11
ENABLEA
17
OUTB 16
GND2 22
6 RSB
OUTA 15
PHASEB
14
8 CCPC
PHASEA
13
OUTA-
12
10 CCPA
STANDBY 11
7 VM
9 CCPB
C655
R690
J605
18
R682
19
5 RSA
+24V
A10
OUTBENABLEB
21 GND1
J605
STANDBY 11
R677
1
4 VREFB
PHASEB
3 VREFA
J605
2
GND2 22
6 RSB
2 VDD
A12
Punch feed motor (M63)

TORQUE 20
21 GND1
R689
17
OUTB 16
C670
ENABLEA
IC611
4 VREFB
CP605
1 CR
18
J605
ENABLEB
A13
3 VREFA
19
C669
OUTB-
5 RSA
TORQUE 20
2 VDD
COVER+24V
FEED-M-I1
Horizontal registration motor (M62)
R672
R675
CP604
1 CR
R674
R673
Q610
[A504]
IC610
7 VM
[A501]
+5R
R687
REG-M-I
FEED-M-I0
Q609
Q608
[A501]
[P75]
FEED-M-STB
FEED-M-A
FEED-M-B
FEED-M-A
FEED-M-B
R693
[A501]
[FTIOA]
[A501]
[FTIOB]
[A504]
[A504]
[A504]
[A504]
[A504]
[A501]
[P55]
CP602
R722
2
2
ETH4
C654
2
1
C673
2
1
C653
C605
ETH3
1
C648
2
1
C672
2
1
C649
2
1
C601
R691
1
6
7
IO
628m A
I1
I0
97m A
L
L
H
H
L
H
L
H
721m A
573m A
345m A
99m A
COVER+24V
+5V
IC606
02
2
14
C640
C652
C651
VCC
GND
+5V
R683
IC606
5 02
L
2
1
1
Q618
Q617
R685
1
IC606
2 02
R695
1
R694
+5V
R681
R680
IC606
R729
2
10
8 02
14
11
10
3
1
IC607
C657
IC606
R686
11 02
13
2
R696
A-48
Q613
[A501]
[P56]
PCH-M-CCW
R697
12
J603
Punch motor (M61)
C656
Q616
Q612
IC607
Q615
PCH-M-CW PCH-M-CCW Q615 Q616 Q617 Q618

3
12
13
R728
14
PCH-M-CW
[A501]
[P57]
R679
R678
C650
R684
J603
J604
J604
J604
J604
14
J607
B9
[SGND]
+24V
J607
C658
[PCH-OUT]
B8
J607
[PCH-RxD]
B7
J607
[PCH-TxD]
C675
+5V
IC607
2
R714
R713
14
R715
C676
C659
+24V
R730
CP609
1
2
2
B6
C677
B5
J607
B4
J607
[SGND]
R731
R732
[TAIL-EDGE-SEN]
J602
J602
J602
Front door switch

(MSW62)
J607
[5V]
B1
J607
[SGND]
UP-COVER-SW
+5V
ZD603
R741
[A501]
R739
B2
J602
Upper door switch

(MSW61)
FU601
1
CP601
Q627
+5V
+5V +5R
C608
ZD602
R745
Q611
ETH2
J602
J607
J602
Q625
2
B3
[PCH-IN]
PCH-IN
Q614 3
J607
[PCH-UNIT-ON]
[A502]
[24V]
PCH-RXD
TAIL-EDGE-SEN2
J601
Q601
CB601
CP608
[A501]
[P20]
PCH-TXD
[PGND]
R711
C666
[A501]
[RXD]
J601
FU602
1
C665
CP607
[A501]
[TXD]
J601
3
1
14
PCH-OUT
[A501]
[IRQ0]
Q621
IC607
J607
B10
R710
CP606
IC607
B11
ETH1
+5V
Q626
C680
J607
[5V]
A8
J607
[FEED-M-A]
A7
J607
[FEED-M-A*]
A6
J607
[FEED-M-B]
FEED-M-A
RA604
1
+5V
R738
3
Q622
ZD601
2
C668
COVER+24V
[A503]
FRONT-COVER-SW
RA605
[A501]
A9
[SGND]
J607
+5V
R736
J607
A10
A11
RA605
2
+5V
6
[A503]
RA604
FEED-M-A
RA605
3
+5V
14
[A503]
[A503]
FEED-M-I0
A5
J607
[FEED-M-B*]
A4
J607
[FEED-M-I0]
A3
J607
[FEED-M-I1]
A2
J607
[FEED-M-STB]
A1
J607
[SGND]
R734
FEED-M-I1
+5V
R708
2
2
FEED-M-STB
C639
R733
Q619
[A503]
[A503]
VCC
GND 7
RA605
RA604
FEED-M-B
+5V
IC607
2
FEED-M-B
[A503]
RA604
C679
C664
1
A-49
A-50
APPENDIX
5.5 Scrap Full Detector PCB
+5V
J671
J671
C673
1
R674
1
R673
C672
2
R672
+5V
+5V
1
3
J671
Q671
D671
1
J671
+5V
8
7
4
Q671
2
C671
1
PTR671
LED671
R671
A-51
APPENDIX
5.6 LED PCB
J10
LED1
1
J10
LED2
1
J10
LED3
1
J10
LED4
1
J10
LED5
1
A-52
J10
5.7 Photosensor PCB
C1
C7
1
R1
R13
1
+5V
+5V
+5V
5
4
Q2
J11
PTR1
1
3
C14
JP4
JP3
7
C9
1
C3
2
R17
1
1
3
1
+5V
J11
PTR2
1
3
5
4
Q1
J11
C13
Q3
JP1
7
R8
R20
+5V
D2
1
D5
JP6
C5
1
R9
1
2
1
+5V
+5V
J11
C15
5
4
Q3
PTR3
1
3
1
3
JP5
Q2
J11
+5V
2
J11
R20
+5V
D3
1
R5
2
+5V
2
+5V
PTR5
J11
Q1
D1
D4
1
3
JP2
PTR4
R16
R4
+5V
A-53
A-54
APPENDIX
6 Solvents and Oils

No.
Name
Cleaner
Lubricant
Description
Composition
Cleaning:
e.g., glass,
plastic,
rubber parts,
external
covers
Sliding units
Hydrocarbon
(fluorine family)
Alcohol
Surface activating
agent
Water
Silicone oil
Remarks
Do not bring near fire.
Procure locally.
Isopropyl alcohol may be substituted.
TA-600-01
A-55
1-1, KANDA NISHIKI-CHO, CHIYODA-KU, TOKYO, 101-8442, JAPAN

mj1023 SM v03

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FINISHER

File No. SME030019C0

c 2003 TOSHIBA TEC CORPORATION All rights reserved

General Precautions for Installation/Servicing/Maintenance for the Finisher MJ-1023/1024/

Indicates an item requiring care to avoid electric shocks.

Indicates an item requiring care to avoid combustion (fire).

Indicates an item prohibiting disassembly to avoid electric shocks or problems.

2 Outline of the Manual

General Description: features, specifications

The descriptions in this Service Manual are based on he following rules:

3 Names of Parts....................................... 1-9

CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION

Saddle Stitcher Delivery

2.8 Shutter Operation ....................... 2-46

3 Power Supply System .......................... 2-49

CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF

A3/LD Paper Path (3 sheets)

CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF

2 Punch Operation .................................... 4-5

CHAPTER 5 BRIDGE KIT (OPTION)BASIC OPERATION

2 Disassembly and Adjustment ................ 5-4

CHAPTER 6 MECHANICAL SYSTEMS

1.2 Delivery System ........................... 6-9

Removing the Inlet Static

Removing the No.1 and No.2

CHAPTER 7 MAINTENANCE AND INSPECTION

2.1 Finisher Unit ................................. 7-2

2.2.3 Motors .................................. 8-20

4.1.12 Rear end assist motor error .. 8-35

Puncher unit backup RAM

3.16 Stapler PCB2 ............................. A-26

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

Trays 1 and 2: by lifting tray

Small size: 30 sheets, Large size: 15 sheets

Equivalent of 80 g/m2 (21.3

Whichever the stack reaches first.

Equivalent of 80 g/m2 (21.3

CHAPTER 1 GENERAL DESCRIPTION

Special staple cartridge (5000 staples)

Stacking capacity is equivalent of 80 g/m2 (21.3 lb. Bond) paper.

CHAPTER 1 GENERAL DESCRIPTION

Stapling Positions (Finisher Unit)

Front 1-point stapling (45deg.)

A4-R, LG, LT-R and FOLIO

A3, B4, A4, B5,

Rear 1-point stapling (45deg.)

A4-R, LG, LT-R and FOLIO

Rear 1-point stapling (30deg.)

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

2.1.2 Saddle Stitcher Unit

Center binding (double folding)

Including 1 cover page.

CHAPTER 1 GENERAL DESCRIPTION

Staple and Folding Position (Saddle Finisher Unit)

CHAPTER 1 GENERAL DESCRIPTION

2.1.3 Puncher Unit (Option)

Reciprocating punching (Sequential punching)

CHAPTER 1 GENERAL DESCRIPTION

Hole position (Puncher Unit)

CHAPTER 1 GENERAL DESCRIPTION

[1] Delivery tray