Booklet Finisher SR3020/SR3110

/Finisher SR3030/SR3120
Machine Code: B804/D637/B805/D636
Field Service Manual

September, 2011
Subject to change
Safety and Symbols
Replacement Procedure Safety

• Turn off the main power switch and unplug the machine before beginning any of the replacement
procedures in this manual.

Symbols Used in this Manual

This manual uses the following symbols.

*: See or Refer to
: Screws
: Connector
: Clip ring
: E-ring

1
 TABLE OF CONTENTS
Safety and Symbols............................................................................................................................................1
Replacement Procedure Safety.....................................................................................................................1
Symbols Used in this Manual........................................................................................................................1
1. Replacement and Adjustment
Covers..................................................................................................................................................................5
Exterior Covers...............................................................................................................................................5
Upper Tray, End Fence..................................................................................................................................5
Main Unit.............................................................................................................................................................7
Upper Tray Limit Sensor, Limit Switch...........................................................................................................7
Positioning Roller............................................................................................................................................8
Proof Tray Exit Sensor....................................................................................................................................9
Upper Tray Height Sensors 1, 2...................................................................................................................9
Exit Guide Plate, Upper Tray Exit Sensor...................................................................................................10
Proof Tray Full Sensor..................................................................................................................................11
Finisher Entrance Sensor.............................................................................................................................12
Pre-Stack Tray Exit Sensor...........................................................................................................................12
Stapler Unit.......................................................................................................................................................14
Corner Stapler..............................................................................................................................................14
Positioning Roller..........................................................................................................................................15
Fold Unit............................................................................................................................................................16
Fold Unit........................................................................................................................................................16
Fold Unit Entrance Sensor...........................................................................................................................18
Fold Unit Exit Sensor....................................................................................................................................19
Stack Present Sensor....................................................................................................................................20
Folding Horizontal Skew Adjustment (For B804 only).............................................................................21
Fold Vertical Skew Adjustment (For B804 only).......................................................................................23
Booklet Stapler Unit.........................................................................................................................................25
Booklet Stapler.............................................................................................................................................25
Booklet Stapler Motor.................................................................................................................................25
2. Detailed Section Descriptions
Component Layout...........................................................................................................................................29
General Layout............................................................................................................................................29
Electrical Components.................................................................................................................................31

2
 Summary of Electrical Components............................................................................................................35
Drive Layout..................................................................................................................................................44
Junction Gates..................................................................................................................................................45
Proof Mode..................................................................................................................................................45
Shift Mode....................................................................................................................................................46
Staple Mode................................................................................................................................................46
Pre-Stacking .....................................................................................................................................................47
Tray Movement Mechanism............................................................................................................................49
Upper Tray...................................................................................................................................................49
Lower Tray (B804 Only).............................................................................................................................51
Corner Stapling................................................................................................................................................54
Stacking and Jogging..................................................................................................................................54
Stapler Movement.......................................................................................................................................55
Corner Stapling............................................................................................................................................57
Booklet Stapling (B804 Only)........................................................................................................................58
Booklet Pressure Mechanism......................................................................................................................58
Booklet Stapling and Folding ....................................................................................................................59
Booklet Stapling and Folding Mechanisms...............................................................................................65
Upper Tray Output...........................................................................................................................................68
Feed Out.......................................................................................................................................................68
Feed Out Stacking.......................................................................................................................................69
Punch Unit B702 (For B804/B805)..............................................................................................................70
Overview of Operation...............................................................................................................................70
Punch Mechanisms......................................................................................................................................73
Punch Hopper Mechanism..........................................................................................................................76
Finisher Jam Detection.....................................................................................................................................78

3
4
1. Replacement and Adjustment

Covers 1
Exterior Covers

1. Open the front door [D].

2. Small upper cover [A] ( x1)
3. Upper cover [B] ( x2)
4. Front door bracket [C] ( x1)
5. Front door [D]
6. Front left side cover [E] ( x2)
7. Cover [F]
8. Paper exit cover [G] ( x2)
9. Rear cover [H] ( x2)

Upper Tray, End Fence

1. Remove the rear cover. (* "Exterior Covers")

5
 1. Replacement and Adjustment

1. Support the tray [A] with your right hand.

2. Pull gear [B] toward you ¬ to release.
3. Slowly lower the tray until it stops.

4. Front side cover [C] ( x1)

5. Rear side cover [D] ( x1)
6. Upper tray [E] ( x1)
7. Tray bracket [F] ( x4,  x1 shoulder screw ¬)
8. End Fence [G]( x3)

6
 Main Unit

Main Unit
Upper Tray Limit Sensor, Limit Switch 1

1. Front door, front left side cover, rear cover, upper cover (* "Exterior Cover")
2. End fence (* "Upper Tray, End Fence")
3. Upper tray exit mechanism [A] ( x4,  x3)
4. Upper tray limit sensor [B] ( x1,  x1)
5. Upper tray limit switch [C] ( x2)

7
 1. Replacement and Adjustment

Positioning Roller

1. Open the front door [A].

2. Pull out the stapling unit [B].
3. Positioning roller [C] ( x1, timing belt x1)

8
 Main Unit

Proof Tray Exit Sensor

1. Small upper cover (* "Exterior Cover")

2. Proof tray exit sensor bracket [A] ( x1)
3. Proof tray exit sensor [B] ( x1)

Upper Tray Height Sensors 1, 2

1. Small upper cover, upper cover (* "Exterior Cover")

2. Upper tray paper height sensor bracket [A] ( x1)
3. Upper tray paper height sensor [B] – staple mode (S08) ( x1)

9
 1. Replacement and Adjustment

4. Upper tray paper height sensor [C] – non-staple mode (S09) ( x1)

Exit Guide Plate, Upper Tray Exit Sensor

1

1. Rear cover, Upper covers, Front door, Cover, Paper exit cover (* "Exterior Cover")
2. Inner cover [A] ( x2)

3. Exit guide plate [B] ( x1, Link and spring,  x1,  x1)
4. Upper tray exit sensor [C] (S6) ( x1)

10
 Main Unit

Proof Tray Full Sensor

1. Exit guide plate. (* "Exit Guide Plate, Upper Tray Exit Sensor")
2. Guide plate [A] (hook x 2)
3. Sensor bracket [B] ( x1)
4. Proof tray full sensor [C] (S11) ( x1)

11
 1. Replacement and Adjustment

Finisher Entrance Sensor

1. Disconnect the finisher if it is connected to the copier.

2. Sensor bracket [A] ( x1)
3. Finisher entrance sensor [B] (S1) ( x1)

Pre-Stack Tray Exit Sensor

1. Disconnect the finisher if it is connected to the copier.

12
 Main Unit

2. Sensor bracket [A]

3. Pre-stack tray exit sensor [B] (S2)

13
 1. Replacement and Adjustment

Stapler Unit

1 Corner Stapler

1. Open the front door.

2. Pull out the stapler unit.
3. Inner cover [A] ( x3)
4. Stapler unit holder [B] ( x1)
5. Corner stapler [C] (M20) ( x1)

14
 Stapler Unit

Positioning Roller

1. Open the front door [A].

2. Pull out the stapling unit [B].
3. Positioning roller [C] ( x1, timing belt x1)

15
 1. Replacement and Adjustment

Fold Unit

1 Fold Unit

1. Remove the back cover (* "Exterior Covers").

2. Open the front door.

• The stapler unit is heavy.

3. Ground cable [A] ( x1)
4. Harness [B] ( x6,  x6)
5. Stapler unit [C] ( x4)

16
 Fold Unit

• Support the fold unit with your hand to prevent it from falling.

• The fold unit is heavy.

6. Folding unit [D] ( x4,  x2,  x6)
If you have replaced the folding unit:

1. Read the DIP SW settings on the decal [A] attached to the back of the new folding unit.

17
 1. Replacement and Adjustment

2. Check the DIP SW settings on the main board [B] of the finisher.
3. If these settings are different, change these settings to match the settings printed on the decal attached
to the folding unit.

1
• Set DIP switches 1 to 4 (the switch set on the right). Do not touch the other DIP switches.

Fold Unit Entrance Sensor

1. Pull out the stapler unit (* "Positioning Roller").

2. Fold unit entrance sensor bracket [A] ( x2)
3. Fold unit entrance sensor [B] (S26) ( x1,  x1)

18
 Fold Unit

Fold Unit Exit Sensor

1. Open the front door.

2. Pull out the stapler unit (* "Positioning Roller").
3. Fold unit vertical guide plate [A]
4. Fold unit inner cover [B] ( x2, Spring pin x1)

5. Fold unit upper cover [C] ( x1)

6. Paper clamp mechanism [D] ( x4)
7. Fold unit exit sensor bracket [E] ( x1)
8. Fold unit exit sensor [F] (S31) ( x1)

19
 1. Replacement and Adjustment

Stack Present Sensor

• If you intend to correct the horizontal and vertical skew for the fold unit at the same time, do those
adjustments first, then replace the sensor. (* "Folding Horizontal Skew Adjustment" or "Fold Vertical
Skew Adjustment")
1. Remove the stapler unit (* "Fold Unit")
2. Guide plate [A].
3. Stay [B] ( x4)
4. Left plate [C] ( x4)
5. Sensor bracket [D] ( x1)
6. Stack present sensor [E] (S32) ( x1)

20
 Fold Unit

Folding Horizontal Skew Adjustment (For B804 only)

• The fold unit is adjusted for optimum performance before the finisher is shipped from the factory. Do
this adjustment only if the edges of folded booklets are not even.
1. Switch the copier on and enter the SP mode.
2. Europe, Asia: Use SP6-134-001 (this is for A3 paper). North America: Use SP6-134-005 (this is for
DLT paper).

• If the original setting of SP6-134-001 or -005 is not "0", then you must do the vertical skew
adjustment (* "Fold Vertical Skew Adjustment") after you finish this horizontal skew procedure.
3. Use the 10-key pad to input "-2" (mm) for the SP value. (Press  to enter the minus sign.)
4. Press [#] then exit the SP mode.
5. Open the front door and pull the stapler unit [A] out of the finisher.
6. Open the guide plate [B].
7. Loosen the adjustment screw [C] and then tighten until it stops. (Do not over tighten.)
8. Remove the lock screw [D].
9. Raise the tip [E] of the adjustment screw very slightly and allow it to descend under its own weight.

21
 1. Replacement and Adjustment

10. Push the stapler unit into the finisher and close the front door.
11. Do a folding test.
• Switch the copier on.
• Put one page of A3 or DLT paper in the ARDF.
• On the copier operation panel, select booklet stapling.
• Press [Start]. One sheet is folded.
12. Remove the sheet from the lower tray.
13. Hold the folded sheet with the creased side pointing down and face-up (the same way that it came
out of the finisher).
14. Referring to the diagram, determine if the skew is + [F] or - [G].

22
 Fold Unit

15. Open the front door of the finisher and pull the stapler unit [H] out.
16. Open the guide plate [I].
17. Turn the adjustment screw [J] to correct the amount of skew you measured from the test sheet.
• For + skew [F], turn the adjustment screw (clockwise). 1
• For – skew [G], turn the adjustment screw to the left (counter-clockwise).
• Every click in the +/– direction adjusts the fold position by 0.1 mm by moving the bottom fence
[K].
18. Raise the tip of the adjustment screw [J] and allow it to lower under its own weight.
19. Attach and tighten the lock screw [L].
20. Push the stapler unit into the machine, close the front door, then turn the copier on.
21. Europe, Asia: Do SP6-134-001 (this is for A3 paper). North America: Do SP6-134-005 (this is for
DLT paper).
22. Reset it to "0".
23. Do the test again.
24. If the result is satisfactory, this completes the adjustment. -or- If some skew remains, repeat this ad-
justment.

• After doing this adjustment, adjust for vertical skew, if necessary. (* "Fold Vertical Skew Ad-
justment")

Fold Vertical Skew Adjustment (For B804 only)

• The fold unit is adjusted for optimum performance before the finisher is shipped from the factory. Do
this adjustment only if the edges of folded booklets are not even.
1. Switch the copier on.
2. Do a folding test.
• Switch the copier on.
• Put one page of A3 or DLT paper in the ARDF.
• On the copier operation panel, select booklet stapling.
• Press [Start]. One sheet is folded.
3. Hold the folded sheet with the creased side pointing down, and face-up (the same way that it came
out of the finisher).

23
 1. Replacement and Adjustment

4. Referring to the diagram, determine if the skew is positive [A] or negative [B].
5. Measure the amount of skew.
6. Enter the SP mode
• Europe, Asia: Use SP6-134-001 (this is for A3 paper).
• North America: Use SP6-134-005 (this is for DLT paper).
7. Enter one-half the measured amount of skew. Example: If the measure amount of skew is -1.2 mm,
enter -0.6 mm

• The range for measurement is –3.0 mm to +3.0 mm in 0.2 mm steps for every notch adjustment.
8. Exit the SP mode and do the test again (steps 2 to 5).
9. Repeat this procedure until the skew is corrected.
The illustration below shows the effects of +/- adjustment with SP6113. (The vertical arrows show the
direction of paper feed.)

24
 Booklet Stapler Unit

Booklet Stapler Unit

Booklet Stapler 1

1. Open the front door.

2. Pull out the stapler unit (* "Positioning Roller").
3. Harness cover [A] ( x2)
4. Booklet stapler support stay [B] ( x4,  x2,  x4)
5. Stapler [C] ( x4)

Booklet Stapler Motor

1. Open the front door.

2. Remove the stapler unit. (* "Fold Unit")

25
 1. Replacement and Adjustment

3. Stay [A] ( x4).

4. Left plate [B] ( x4)

5. Harness cover [C] ( x2)

6. Booklet stapler support stay [D] ( x4,  x2,  x4)
7. Booklet stapler [E] ( x4)
8. Booklet stapler motor [F] ( x2,  x1)

26
 Booklet Stapler Unit

To Reattach the Booklet Stapler Motor

1. Reattach the booklet stapler motor.

• Do not tighten the screws.

1

2. Attach the special tool [A] and reattach the booklet stapler stay.

• This tool is included with the stapler spare part.

3. Turn the gear [B] with your finger until it stops.
4. Tighten the screws to attach to the booklet stapler motor.
5. Remove the stay again and remove the special tool.
6. Reattach the booklet stapler stay.
7. Push the stapler unit into the machine.

27
 1. Replacement and Adjustment

28
2. Detailed Section Descriptions

Component Layout
General Layout 2

1. Proof Tray Junction Gate 7. Lower Tray (Booklet)*1

2. Punch Unit 8. Folder Rollers*1
3. Stapler Junction Gate 9. Folder Plate*1
4. Pre-Stack Junction Gate 10. Booklet Stapler*1
5. Pre-Stack Tray 11. Upper Tray (Shift)

29
 2. Detailed Section Descriptions

6. Corner Stapler (M20) 12. Proof Tray

*1: B804 Only

Paper direction

2 The operation of the proof tray and stapler junction gates direct the flow of the paper once it enters the
finisher:

Proof Junction Gate Stapler Junction Gate Paper Feeds

Closed Closed Paper feeds straight through

Open Closed Paper feeds to the proof tray

Closed Open Paper feds to the staple tray

Proof tray
Copies are sent to the proof tray (12) when neither sorting nor stapling are selected for the job.

Upper tray
The upper tray (11) receives copies that are sorted and shifted and also receives copies that have been
corner stapled. Corner stapling is provided on both the B804 and the B805.

Pre-stack tray
The pre-stack tray has a switchback mechanism to increase the productivity of stapling. (* "Pre-Stacking)
Pre-stacking is done for corner stapling in the B804/B805 and for booklet stapling in the B804.

Lower tray
The lower tray (7) receives copies that have been center folded and stapled (booklet stapling). Booklet
stapling is not provided on the B805.

30
 Component Layout

Electrical Components

Upper Area B804/B805

1. Upper/Proof Exit Motor (M4) 10. Upper Tray Limit Switch (SW2)
2. Stapling Tray Junction Gate Solenoid (SOL2) 11. Stacking Roller HP Sensor (S13)
3. Upper Transport Motor (M2) 12. Stacking Sponge Roller Motor (M10)
4. Exit Guide Plate HP Sensor (S7) 13. Upper Tray Exit Sensor (S6)
5. Proof Tray Exit Sensor (S10) 14. Upper Tray Paper Height Sensor (S8) (Staple
6. Proof Tray Full Sensor (S11) Mode)

7. Finisher Entrance Sensor (S1) 15. Shift Roller HP Sensor (S5)

8. Upper Tray Paper Height Sensor (S9) (Non-Sta- 16. Shift Roller Motor (M18)
ple Mode) 17. Exit Guide Plate Motor (M19)
9. Upper Tray Limit Sensor (S12) 18. Proof Junction Gate Solenoid (SOL1)

31
 2. Detailed Section Descriptions

Lower Area B804/B805

1. Upper Tray Lift Motor (M21) 8. Positioning Roller Motor (M14)

2. Lower Transport Motor (M3) 9. Lower Tray Full Sensor – Front (S34)*1
3. Entrance Motor (M1) 10. Lower Tray Full Sensor – Rear (S33)*1
4. Front Door Safety Switch (SW1) 11. Main Board (PCB1)
5. Pre-Stack Tray Exit Sensor (S2) 12. Upper Tray Full Sensor – (S20) *2
6. Stapling Edge Pressure Plate Solenoid 13. Upper Tray Full Sensor – (S19)
(SOL4) 14. Booklet Stapler Board (PCB2)*1
7. Positioning Roller Solenoid (SOL3) 15. Booklet Pressure Roller Solenoid – (SOL5) *1

*1: B804 Only, *2: B805 Only

32
 Component Layout

Punch Unit B702

1. Punch Encoder Sensor (S24) 6. Paper Position Slide HP Sensor (S22)

2. Punch Drive Motor (M24) 7. Paper Position Sensor (S3)
3. Punch HP Sensor (S24) 8. Punch Hopper Full Sensor (S4)
4. Punch Unit Board (PCB3) 9. Punch Movement Motor (M9)
5. Paper position sensor slide motor (M7) 10. Punch Movement HP Sensor (S21)

33
 2. Detailed Section Descriptions

Stacker/Stapler - B804/B805

7. Jogger Fence Motor (M15)

8. Jogger Fence HP Sensor (S15)
1. Stack Present Sensor (S32)*1
9. Corner Stapler Movement Motor (M6)
2. Stack Junction Gate HP Sensor (S27)*1
10. Stapling Tray Paper Sensor (S14)
3. Stack Feed Out Belt HP Sensor (S16)
11. Corner Stapler EH530 (M20)
4. Feed Out Belt Motor (M5)
12. Corner Stapler Rotation Motor (M13)
5. Booklet Stapler EH185R – Rear (M23)*1
13. Corner Stapler HP Sensor (S17)
6. Booklet Stapler EH185R – Front (M22)*1
14. Stapler Rotation HP Sensor (S18)
15. Stack Junction Gate Motor (M17) *1

*1: B804 Only

34
 Component Layout

B804 Fold unit

1. Clamp Roller HP Sensor (S25) 6. Fold Cam HP Sensor (S30)

2. Fold Roller Motor (M12) 7. Fold Bottom Fence HP Sensor (S28)
3. Fold Plate Motor (M11) 8. Fold Unit Entrance Sensor (S26)
4. Fold Plate HP Sensor (S29) 9. Clamp Roller Retraction Motor (M8)
5. Fold Unit Bottom Fence Lift Motor (M16) 10. Fold Unit Exit Sensor (S31)

Summary of Electrical Components

Here is a general summary of all the electrical components of the B804/B805 finishers.

• In the table below a number that appears in bold text (M8, etc.) denotes a component that is on the
2000/3000 Sheet Finisher B804 only.

35
 2. Detailed Section Descriptions

No. Component Function

Boards (PCB)

PCB1 Main Board The main board that controls the finisher

PCB2 Booklet Stapler Board A separate board that controls booklet finishing.
2 PCB3 Punch Unit Board The board that controls the punch unit.

Motors

Drives 1) the finisher entrance rollers, 2) and the punch waste

M1 Finisher Entrance Motor
transport belt of the punch unit.

Drives the paper feed rollers that feed paper 1) to the proof tray,
M2 Upper Transport Motor 2) straight-through to the upper tray, 3) the pre-stack tray entrance
roller.

Drives paper feed rollers forward and reverse in the pre-stack tray
M3 Lower Transport Motor for the switchback, and drives the other rollers in the lower trans-
port area.

Upper/Proof Tray Exit Drives 1) proof tray exit rollers, 2) extension and retraction of the
M4
Motor stacking sponge roller, 3) upper tray exit rollers.

Drives the feed out belt that moves the stapled stacks out of the
M5 Feed Out Belt Motor
stapling tray after stapling.

Moves the corner stapler horizontally on a steel rod to position

Corner Stapler Movement the stapler at the stapling position at 1) the front, 2) the rear
M6
Motor (straight stapling), 3) the rear (diagonal stapling), or 4) the front
and rear for double stapling.

Paper Position Sensor Drives the movement of the paper position slide that holds the
M7
Slide Motor paper position sensor (S3) that detects the position of the paper.

Drives a large cam that alternately clamps and unclamps the

clamp retraction roller, the idle roller of the clamp roller pair.
When these rollers are clamped, they are part of the paper feed
Clamp Roller Retraction path and feed the stack toward the bottom fence of the fold unit.
M8
Motor When the idle roller is retracted, the stacks falls a very short dis-
tance (3 mm) onto the fold unit bottom fence below. These rollers
remain unclamped while the bottom fence positions the stack for
folding and while the stack is folded by the fold rollers.

36
 Component Layout

No. Component Function

Drives the front/back movement of the punch unit to position it

M9 Punch Movement Motor
correctly for stapling the paper below.

Rotates the stacking roller that drags each sheet back against the
Stacking Sponge Roller
M10 end fence to jog the bottom of each sheet after feed out to the
Motor
upper tray. 2
Drives the fold plate that pushes the center of the stack into the nip
M11 Fold Plate Motor
of the fold rollers to start the fold.

Rotates forward and drives the fold rollers that fold the stack and
feed it out of the fold unit, reverses to feed the fold once more into
M12 Fold Roller Motor
the fold unit, and then rotates forward again to feed the fold out
of the fold unit.

Corner Stapler Rotation Swivels the corner stapler and positions it so the staple fires at an
M13
Motor oblique angle at the rear corner of the paper stack.

M14 Positioning Roller Motor Drives the positioning roller in the stapling tray.

Drives the jogger fences in the stapling tray to jog both sides of
M15 Jogger Fence Motor
the stack before stapling.

Raises the bottom fence and stops when the center of the vertical
stack is opposite the edge of the horizontal fold blade. The dis-
Fold Unit Bottom Fence Lift tance for raising the blade is prescribed as one-half the size of the
M16
Motor paper selected for the job. For large paper, (A3, B4) the bottom
fence first lowers the stack 10 mm below the fold position, and
then raises it to the fold position.

Drives the large cam that operates the stack junction gate at the
top of the stapling tray. When this gate is open, it directs the as-
Stack Junction Gate Mo-
M17 cending stack to the upper tray if it has been corner stapled, or if
tor
it is closed the gate turns the booklet stapled stack down so it falls
onto the bottom fence of the folding unit.

Drives the shift roller that operates in shift mode to stagger docu-
M18 Shift Roller Motor ment sets as they feed out to the upper tray (making them easier
to separate).

M19 Exit Guide Plate Motor Drives the mechanism that raises and lowers the exit guide plate.

37
 2. Detailed Section Descriptions

No. Component Function

This is the roving corner stapler, mounted on a steel rail that staples
M20 Corner Stapler EH530 1) at the front, 2) at the rear (straight staple), 3) at the rear (di-
agonal staple), and 4) font and rear (two staples).

Raises and lowers the upper tray during feed out to keep the tray
2 M21 Upper Tray Lift Motor
at the optimum height until it is full.

Booklet Stapler EH185R: Booklet stapler. Staples paper stacks in the center before they are
M22
Front folded.

Booklet Stapler EH185R: Booklet stapler. Staples paper stacks in the center before they are
M23
Rear folded.

M24 Punch Drive Motor Fires the punches that punch the holes in the paper.

Sensors

Provides two functions: (1) Detects paper entering the finisher from
S1 Finisher Entrance Sensor the copier, and (2) Signals a jam if it detects paper at the entrance
when the copier is switched on.

Detects 1) paper fed from the pre-stack tray to the stapling tray,
and detects 2) paper in the pre-stack when the copier is switched
S2 Pre-stack Tray Exit Sensor on. (This sensor performs no timing function. The entire flow of
paper through the pre-stacking mechanism is controlled by motor
pulse counts.)

The photosensor that detects the edge of the paper and sends this
S3 Paper Position Sensor information to the punch unit board where it is used to position the
punch for punching the holes in the paper.

1) A photosensor that detects and signals that the punch hopper

is filled with punch waste and needs emptying, and 2) confirms
S4 Punch Hopper Full Sensor
the presence of the punch hopper and signals an error if it is miss-
ing or not installed completely.

Located near the shift roller motor, controls the front-to-back

S5 Shift Roller HP Sensor movement of the shift roller as shifts paper during straight-through
feed.

A flat, photo sensor located inside the guide plate, detects the
leading edge and trailing edge of the paper as it feeds out to the
S6 Upper Tray Exit Sensor
upper tray during straight-through jobs (with and without stapling).
When paper is fed to the upper tray, at the paper output slot this

38
 Component Layout

No. Component Function

sensor signals an error when it detects (1) paper has failed to
leave the paper exit (lag error), (2) detects paper has failed to
arrive at the paper exit (late error), (3) detects paper is in the exit
slot when the machine is turned on.

S7
Controls the vertical movement of the control exit guide . The guide
Exit Guide Plate HP Sensor plate is in the home position when the guide plate is down and
2
the actuator interrupts the sensor gap.

This is the upper sensor of the upper/lower paper height sensor

Upper Tray Paper Height pair that controls the lift of the upper tray. This sensor detects the
S8
Sensor (Staple Mode) paper height of the stack in the upper tray when the copier is
operating in the staple mode.

This is the lower sensor of the upper/lower paper height sensor

Upper Tray Paper Height
pair that controls the lift of the upper tray. When the machine is
S9 Sensor (Non-Staple
switched on, the upper tray rises until the actuator on the tray
Mode)
triggers this sensor to switch off the upper tray lift motor.

This sensor detects and times the feeding of paper to the proof
S10 Proof Tray Exit Sensor tray. It also detects whether paper is present at the proof tray exit
when the copier is switched on.

The top of the stack in the proof tray increases until it nudges the
feeler of this sensor. The sensor then signals that the proof tray is
S11 Proof Tray Full Sensor
full and the job halts until some paper is removed from the proof
tray.

This sensor controls the position of the upper tray 1) during

straight-through feed out, 2) during shift feed out, 3) when the
machine is turned on. The machine obeys the signal of whichever
sensor is actuated first.
An actuator attached to an arm triggers this sensor. The tip of the
S12 Upper Tray Limit Sensor same arm depresses the upper tray limit switch If the sensor fails,
the tip of the arm will activate the upper tray limit microswitch
(SW2) and stop the lift of the upper tray.
Note: When the machine is turned on, the upper tray position is
controlled by either this sensor or the upper tray paper height
sensor (S9).

Controls the forward and back motion of the stacking roller (a

S13 Stacking Roller HP Sensor
sponge roller) located at the output slot of the upper tray. The

39
 2. Detailed Section Descriptions

No. Component Function

sponge roller drags each ejected sheet back against the end fence
of the upper tray to keep the bottom of the stack aligned.

A photo sensor that detects whether paper is in the stapling tray.

Stapling Tray Paper Sen- When this sensor detects paper, the bottom fence motor raises or
S14
2 sor lowers the bottom fence to position the selected paper size for
booklet stapling.

Detects the home position of the jogger fences. When the actuator
S15 Jogger Fence HP Sensor on the jogger fence interrupts this sensor, the jogger fence is in its
home position and the jogger fence motor (M15) stops.

Controls the position of the stack feed-out pawl on the stack feed-
out belt. Once the actuator on the feed belt nudges the feeler of
Stack Feed-Out Belt HP
S16 this sensor near the top of the stapling unit, the feed out belt motor
Sensor
(M5) remains on for the time prescribed to position the pawl at
the home position to catch the next stack.

Located at the front the stapling tray and mounted above the steel
rod where the corner stapler travels, this sensor detects the home
S17 Corner Stapler HP Sensor position of the corner stapler. The corner stapler is in its home
position when the actuator on the corner stapler unit interrupts this
sensor.

Stapler Rotation HP Sen- Controls the angle of the position of the corner stapler during ob-
S18
sor lique stapling.

B804: When the actuator on the side of the upper fence enters
the gap of this sensor, the sensor signals that the upper tray is at
Upper Tray Full Sensor its lowest position (full) and stops the job.
S19
(B804/B805) B805: One of two upper tray full sensors. This is the higher tray
full sensor for A3 and other heavy paper. The other upper tray full
sensor (20) is for lighter paper.

B804: This sensor is not used on the booklet finisher. There is only
one upper tray full sensor (S18).
Upper Tray Full Sensor
S20 B805: One of two upper tray full sensors. This is the lower tray full
(B805 only)
sensor for A4 and smaller paper. The other upper tray full sensor
(19) is for larger paper.

Switches off the punch movement motor when the punch unit re-
S21 Punch Unit HP Sensor turns to its home position. Pulse counts determine where the punch
unit pauses for punching and reversing.

40
 Component Layout

No. Component Function

Controls the movement of the paper position detection unit.

Paper Position Side HP
S22 Switches on when the horizontal detection unit is at the home po-
Sensor
sition (HP is the reference point).

Detects the home position of the punch unit and controls the ver-
S23 Punch HP Sensor
tical movement of the punches when they fire. 2
When the punch mode is selected for the job (2-hole, 3-hole, etc.),
the machine controls the operation of the punch drive (M24) mo-
S24 Punch Encoder Sensor tor which drives a small encoder shaped like a notched wheel.
This wheel is rotated forward and reverse precisely to select which
punches are moved up and down during the punch stroke.

Controls the movement of the clamp retraction roller (the idle roller
S25 Clamp Roller HP Sensor
of the clamp roller pair).

Detects 1) the leading edge of the stack during booklet stapling,

S26 Fold Unit Entrance Sensor and 2) also used to signal an alarm if a paper is detected at the
entrance of the fold unit when the copier is turned on.

Controls the opening and closing of the stack junction gate.

Stack Junction Gate HP
S27 Switches on when the stack junction gate is open and at the home
Sensor
position.

Controls the movement of the bottom fence in the folding unit using
Fold Bottom Fence HP
S28 pulse counts based on the size of the paper selected for the job
Sensor
to position the stack correctly for feeding.

Along with the fold plate cam HP sensor (S30) this sensor controls
the movement of the fold plate . The fold plate has arrived at the
S29 Fold Plate HP Sensor
home position when the edge of the plate enters the gap of this
sensor.

Along with the fold plate HP sensor (S29), this sensor controls the
movement of the fold plate. The actuator mounted on the end of
the roller that drives the folder plate forward and back makes three
S30 Fold Plate Cam HP Sensor
full rotations, i.e. the actuator passes the sensor gap twice and
stops on the 3rd rotation and reverses. This accounts for the left
and right movement of fold plate.

1) Detects the folded edge of the stack as it feeds out from the nip
S31 Fold Unit Exit Sensor of the fold rollers, stops the rollers, and reverses them so the fold
feeds back into the nip, 2) when the folded booklet finally emerges

41
 2. Detailed Section Descriptions

No. Component Function

from the nip of the fold rollers, detects the leading and trailing
edge of the booklet to make sure that it feeds out correctly.

This sensor determines whether a there is paper at the turn junction

gate when the machine is turned on. If a stack is present, this trig-
2 S32 Stack Present Sensor gers a jam alert. (This sensor performs no dynamic function such
as pulse counting, etc. It only detects whether paper is at the top
of the folding unit when power its turned on.)

This rear sensor is the lower sensor of the lower tray full sensor
pair. Two actuators are attached to the actuator arm that touches
Lower Tray Full Sensor - the top of stapled and folded booklets as they feed out. The on/
S33
Rear off combinations of the two sensors are used to detect when the
tray is full and stop the job. (The lower tray is stationary. At tray
full, the job halts until booklets are removed from the lower tray.)

This front sensor is the higher sensor of the lower tray full sensor
pair. Two actuators are attached to the actuator arm that touches
Lower Tray Full Sensor - the top of stapled and folded booklets as they feed out. The on/
S34
Front off combinations of the two sensors are used to detect when the
tray is full and stop the job. (The lower tray is stationary. At tray
full, the job halts until booklets are removed from the lower tray.)

Solenoids

Opens and closes the proof tray junction gate. When the solenoid
Proof Junction Gate Sole- switches on, it opens the gate and paper is diverted to the proof
SOL1
noid tray. When this gate is closed, the paper goes straight to the upper
tray. I

Directs paper to the stapling tray. When this solenoid is on, paper
Stapling Tray Junction
SOL2 feeds straight through. When this solenoid is off, paper feeds to
Gate Solenoid
the stapler tray below.

Engages the stapler transport motor and the positioning roller of

Positioning Roller Sole- the stapling tray. The positioning roller pushes each sheet down
SOL3
noid against the bottom fence to align the bottom the stack for stapling.
(The jogger fences align the sides.)

Operates the pressure plate of the stapling unit. The pressure plate
Stapling Edge Pressure
SOL4 presses down the edge of stack in the stapling tray so it is tight for
Plate Solenoid
stapling.

42
 Component Layout

No. Component Function

When the paper stack in the stapling tray feeds to the folding unit,
Booklet Pressure Roller
SOL5 this solenoid turns on and operates the roller that pushes on the
Solenoid
surface of the stack to flatten it.

Switches

The safety switch that cuts the dc power when the front door is
2
SW1 Front Door Safety Switch
opened.

A micro-switch that cuts the power to the upper tray lift motor when
the upper tray reaches its upper limit. This switch duplicates the
SW2 Upper Tray Limit SW
function of the upper tray limit sensor (S12) and stops the upper
tray if S12 fails.

43
 2. Detailed Section Descriptions

Drive Layout

1. Upper Transport Motor (M2)

6. Folder Plate Motor*1 (M11)
2. Upper/Proof Exit Motor (M4)
7. Positioning Roller Motor (M14)
3. Upper Tray Lift Motor (M21)
8. Lower Transport Motor (M3)
4. Feed-Out Belt Motor (M5)
9. Entrance Motor (M1)
5. Fold Roller Motor*1 (M12)

*1: B804 Only

44
 Junction Gates

Junction Gates
The positions of the proof tray and staple tray junction gates determine the direction of paper feed after
paper enters the finisher.

Proof Mode 2

Proof tray junction gate [A] opens. Staple tray junction gate [B] remains closed.
The proof tray junction gate directs paper to the proof tray above.

45
 2. Detailed Section Descriptions

Shift Mode

Proof tray junction gate [A] remains closed. Staple tray junction gate [B] remains closed.
With both junction gates closed, the paper goes to the upper tray.

Staple Mode

Proof tray junction gate [A] remains closed. Staple tray junction gate [B] opens
The staple tray junction gate directs the paper to the staple tray below for jogging and stapling.

46
 Pre-Stacking

Pre-Stacking

This example describes what happens to Set 2 during the feed and stapling cycle of sets that contain three
pages.
• [A]: While the Set 1 is being stapled in the staple tray [1], the 1st sheet of Set 2 [2] feeds to the pre-
stack tray, and the 2nd sheet of Set 2 [3] enters the finisher.
• [B]: The pre-stack junction gate opens and the 1st sheet of Set 2 [4] switches back to the top of the
pre-stack tray as the 2nd sheet of Set 2 [5] starts to descend.
• [C]: As the 2nd sheet of Set 2 continues to descend, the 1st sheet of Set 2 is fed from the pre-stack
tray. At this time the leading edges [6] of both sheets are even.
• [D]: The trailing edges of the 1st and 2nd sheets of Set 2 pass the junction gate [7] as the 3rd sheet
of Set 2 [8] enters the finisher.

• [E]: The 1st and 2nd sheets of Set 2 [9] switch back together into the top of the pre-stack and wait for
the 3rd of Set 2 sheet to arrive.
• [F]: The stapling of Set 1 in the staple tray [10] is completed.
• [G]: Set 1 [11] exits the staple tray.

47
 2. Detailed Section Descriptions

• [H]: The three sheets of Set 2 [12] feed together into the stapler tray for stapling.
Pre-stacking is only done for A4, B5, and LT paper.
In one-staple mode, one sheet goes to the pre-stacking tray. Then two sheets go to the stapler tray at the
same time.
In two-staple mode and booklet mode, three sheets go to the pre-stacking tray. Then four sheets go to the
stapler tray at the same time.
2

48
 Tray Movement Mechanism

Tray Movement Mechanism

Upper Tray

[A]: Upper Tray Lift Motor

[B]: Upper Feeler [E]: Lower Feeler

[C]: Upper Tray Paper Height Sensor 1 (Staple [F]: Upper Tray Limit Sensor
Mode) [G]: Upper Tray Limit Switch
[D]: Upper Tray Paper Height Sensor 2 (Non-Sta- [H]: Upper Tray Full Sensors
ple Mode)

• The B804 (shown above) has only one upper tray full sensor (the higher sensor at [H]).
• The B805 has two upper tray full sensors (the upper and lower sensor at [H]). On the B805 the upper
sensor detects tray full for heavier paper (A3, DLT, B4, LG, 12 x 18”), and the lower sensor detects
tray full for lighter paper (A4, LT, etc.).
• The tray full capacity is 2,000 sheets (B804) for A4, LT and 3,000 sheets (B805) for A4, LT.
Five sensors and one switch control the operation of the upper tray lift motor [A].

49
 2. Detailed Section Descriptions

Upper Tray Raising and Lowering

Sensors, Switch Action
Operation Mode
[C] [D] [F] [G]

Stops the lift motor is at the standby position when

the actuator of the upper feeler deactivates sen-
2 Standby (Non-Sta-
OFF OFF
sor [C] (when it is between sensors [C] and [D]).
ple Mode) Note: Sensor [F] and switch [G] are used as
backup if sensor [C] fails or if the upper tray is
not attached.

Straight Through ON Non-staple mode operation: During operation,

tray lift is controlled only by sensor [F]. When the
Shift ON actuator leaves sensor [F], the tray lowers until
the actuator reactivates sensor [F].

Standby: The upper tray stops and waits for the

paper output when the actuator activates sensor
[C]. [D] is not used for staple mode
Staple Mode Operation:

Standby • The upper tray lowers the prescribed dis-

ON tance immediately after the stack exits.
(Staple Mode)
• The upper tray rises until the actuator acti-
vates sensor [C] and stops the tray lift motor
(and the tray) to wait for the next set.
• Sensor [F] and switch [G] are used as back-
up if sensor [C] fails.

Tray Full
When the actuator on the tray activates the upper tray full sensor [H] the tray lift motor [A]
B804 switches off. Operation resumes after some copies are removed from the tray. Upper Tray
Capacity: 2,000 sheets (A4, LT)

The operation of the upper tray full sensor is the same as the B804. Capacity: 1,500 sheets for
A3, B4 or other large paper.
B805
An additional upper tray full sensor (below sensor [H]) allows more sheets to stack on the upper
tray. Capacity: 3,000 sheets (A4, LT)

50
 Tray Movement Mechanism

Lower Tray (B804 Only)

The lower tray sensor actuator arm [A] rests on the top of the stack of stapled booklets as they are output
to the lower tray. A flap depressor [B] keeps the open ends of the booklets down.
The front lower tray full sensor (S34) [C] and rear lower tray full sensor (S33) [D] detect when the lower
tray is full of booklets.

• The front lower tray full sensor is mounted higher than the rear lower tray full sensor.
• The lower tray is stationary. When it becomes full, the stapling and folding job stops until booklets
are removed from the tray.
• If the lower tray is not installed (this is detected if the front and rear sensors remain OFF), the machine
will not operate in the booklet staple and fold mode. When booklet mode is selected, the tray full
message appears on the operation panel.

The combinations of the two actuators and two sensors as the actuator arm rises determines the number of
booklets that the lower tray can hold before the job stops.
The tray full detection depends on the size of the paper and the number of sheets in one stapled and folded
booklet.
In the table below, the conditions (¶ Ready · Full 1, ¸ Full 2 ¹ Full 3: See the illustration on the previous
page) refer to the states of the sensors described on the previous page.

51
 2. Detailed Section Descriptions

Condition Front Sensor Rear Sensor

Ready ON OFF

Full 1 ON ON

Full 2 OFF ON
2 Full 3 (or lower tray not installed) OFF OFF

In the tables below:

• "Sht" denotes "sheets in a stack".
• "Cnt" denotes "Count" (see below for an explanation).
After a booklet is feed out, the fold roller motor stops the exit roller. The machine then monitors the tray full
sensors every 100 ms. The machine checks for a certain condition, based on the size of the paper and the
number of sheets in the booklet.
An example is shown below. Tell the operators that the number of sheets that the lower tray can hold will
vary greatly.
Lower Tray Full Condition Table
A3 (DLT)

1 Sht 2 Sht 3 Sht 4 Sht 5 Sht 6 Sht 7 Sth 8 Sht 9 Sht …

Full 1 3 Cnt — — — — — — — — …

Full 2 — 5 Cnt 15 Cnt — — — — — — …

Full 3 — — — 7 Cnt 13 Cnt 4 Cnt 2 Cnt 2 Cnt 2 Cnt …

A4 (LT)

1 Sht 2 Sht 3 Sht 4 Sht 5 Sht 6 Sht 7 Sth 8 Sht 9 Sht …

Full1 16 Cnt — — — — — — — — …

Full 2 — 10 Cnt 10 Cnt 15 Cnt 20 Cnt 15 Cnt 10 Cnt 8 Cnt 8 Cnt …

Full 3 — — — …

Examples:
After the copier makes a booklet with 1 sheet of A3/DLT paper, the machine checks every 100 ms for the
‘Full 1’ condition. If the Full 1 condition occurs 3 times (shaded block in the table above), the machine
detects that the tray is full.

52
 Tray Movement Mechanism

After the copier makes a booklet with 5 sheets of A4/LT paper, the machine checks every 100 ms for the
‘Full 2’ condition. If the Full 2 condition occurs 20 times (shaded block in the table above), the machine
detects that the tray is full.

53
 2. Detailed Section Descriptions

Corner Stapling
Stacking and Jogging

[A]: Jogger Fence Motor (M15)

[B]: Jogger Fences
[C]: Positioning Roller
[D]: Jogger Fence HP Sensor (S15)
[E]: Stapling Edge Pressure Plate Solenoid (SOL4)
[F]: Pressure Plate
At the beginning of the job, the jogger fence motor (M15) [A] switches on and moves the jogger fences
[B] to the standby position (7.5 mm from the sides of the selected paper size).
When each sheet passes the pre-stack tray exit sensor (S2) and enters the stapling tray:
• The jogger fence motor switches on and moves the jogger fences to within 5.5 mm of the sides of the
selected paper size.
• The positioning roller solenoid (SOL3) switches on for the time prescribed for the paper size. This
pushes the positioning roller [C] onto the sheet and pushes it down onto bottom fence. This aligns the
edge of the stack.
Next, the jogger fence motor:

54
 Corner Stapling

• Switches on again and moves the jogger fences to within 2.6 mm of the sides of the stack to align the
sides of the stack.
• Reverses and moves the fences to the standby position (7.5 mm away for the sides) and waits for the
next sheet.
• The jogger fence HP sensor [D] switches off the jogger motor at the end of the job.
After the last sheet feeds:
• The stapling edge pressure plate solenoid [E] (SOL4) switches on and pushes the pressure plate [F]
2
onto the stack to press down the edge for stapling.
• The corner stapler staples the stack.

Stapler Movement

[A]: Stapler Movement Motor

[B]: Stapler
[C]: Stapler Rotation Motor

The stapler performs horizontal and rotational movement in each of the four staple modes:
• Front 1 staple
• Rear 1 staple
• Rear diagonal staple

55
 2. Detailed Section Descriptions

• Rear/Front 2 staples
The stapler movement motor [A] drives a timing belt that moves stapler [B] left and right on its stainless steel
rail.
The stapler rotation motor [C] rotates the stapler into position for diagonal stapling at the rear.
• The stapler movement motor switches on and moves the stapler the standby stapling position. (This is
the stapling position for the paper size selected for the job.)
2 • The stapler movement motor switches off and the stapler waits for the signal to fire (or swivel and for
diagonal stapling).
If the stack is to be stapled at two positions:
• The stapler movement motor moves the stapler to the front position and staples the front.
• The stapler movement motor moves the stapler to the rear and the stapler staples the rear.
If the stack is stapled at the rear with a diagonal staple, the staple moves to the rear. When it is time for
stapling, the rotation motor rotates the stapler to the correct angle and holds the stapler in that position
while the stapler fires.
The stapling positions can be fine adjusted with SP6-133-001.

56
 Corner Stapling

Corner Stapling

Staple firing is driven by the stapler motor [A] inside the stapler unit. The stapler hammer [B] fires the stapler
[C].
The cartridge set sensor [D] detects the cartridge at the correct position.
The staple end sensor [E] detects the staple end condition.

57
 2. Detailed Section Descriptions

Booklet Stapling (B804 Only)

Booklet Pressure Mechanism

[A]: Booklet Pressure Roller Solenoid (SOL5)

[B]: Booklet Pressure Roller Arm
[C]: Booklet Pressure Roller

As soon as the edges are aligned by the positioning roller and the jogger fences, the stack feed out belt
moves.
In booklet mode, immediately after the edges are aligned by the positioning roller and jogger fences, the
booklet pressure solenoid switches on and the booklet pressure roller presses down on the stack until
booklet stapling is finished. This prevents the stack from shifting during stapling.

58
 Booklet Stapling (B804 Only)

Booklet Stapling and Folding

Overview

1. Leading Edge Pressure Roller 13. Corner Stapler (M20)

2. Stack Present Sensor (S32) 14. Stapling Tray Paper Sensor (S14)
3. Feed Out Belt Pawl 1 15. Feed Out Belt
4. Booklet Staplers x2 (M22, M23) 16. Fold Unit Bottom Fence
5. Stack Feed Out Belt HP Sensor (S16) 17. Fold Bottom Fence HP Sensor (S28)
6. Feed Out Belt Pawl 2 18. Fold Unit Entrance Sensor (S26)
7. Positioning Roller 19. Fold Unit Exit Rollers x2
8. Booklet Pressure Roller (Rear) 20. Fold Unit Exit Sensor (S31)
9. Jogger Fences x2 21. Fold Rollers x2
10. Pre-Stack Exit Roller 22. Clamp Rollers x2

59
 2. Detailed Section Descriptions

11. Pressure Plate 23. Stack Junction Gate

12. Stapling Tray Bottom Fence 24. Stack Transport Roller

1:
The last sheet of the stack [1] enters the stapling tray. The jogger fences [2] jog the last sheet into position
(based on the width of the selected paper size) and then retract and stop 1 mm away from the sides of the
stack.
2:
The pressure plate [3] and booklet pressure roller [4] press down on the sheet. The stack feed out belt
switches on and the pawl [5] on the feed out belt catches the bottom of the stack and raises it. The stapling
tray sensor [6] detects the trailing edge of the paper stack.
3:
The feed out belt [7] raises the stack to the prescribed stapling position and stops. The jogger fences move
to the sides of the stack and the booklet staplers [8] staple the stack.

60
 Booklet Stapling (B804 Only)

4:
The jogger fences remain 1 mm away from the sides of the stack. The feed out belt [1] raises the stack until
the top of the stack is 10 mm past the leading edge pressure roller [2] and stops. The leading edge pressure
roller descends and applies pressure to the top of the stack. The stack junction gate [3] (normally open)
closes. The pressure roller [4] and pressure plate [5] retract.
5:
The feed out belt [6], transport rollers [7], [8], and clamp rollers [9] rotate and feed the stack past the
closed stack junction, over the top and down toward the bottom fence [10]. At the same time, the fold unit
bottom fence descends from its home position and stops 10 mm below the fold position.
6:
The rollers feed the leading edge of the stack to within 3 mm of the stack stopper of the bottom fence [13].
The fold unit entrance sensor [11] detects the stack and opens the clamp rollers [12]. The stack drops 3
mm onto the fold unit bottom fence [13]. At this time, the first sheet [14] of the next stack feeds to the stapling
tray.

61
 2. Detailed Section Descriptions

7:
The bottom fence [1] raises the stack to the prescribed fold position [2].
8:
The fold plate [3] moves to the left and advances 1/3 its maximum horizontal stroke and exerts 20 kg (44
lb.) of pressure at the fold rollers [4].
9:
With the fold plate pushing the stack into nip of the fold rollers [5], the fold rollers begin to rotate and fold
the stack as it feeds out.

62
 Booklet Stapling (B804 Only)

10:
When the fold rollers [1] feed the stack 10 mm past the nip, the fold plate retracts until it no longer touches
the stack. The fold unit exit sensor [2] detects the folded edge of the stack and stops the fold rollers.
11:
The rotation of the fold rollers [4] reverses and feeds the folded edge back until only 3 mm of the fold [5]
remains at the nip.
12:
The fold rollers [6] rotate forward once again feed out. The fold unit exit sensor [7] once again detects the
edge of the fold.

• You can do SP6-136-001 to increase the sharpness of the fold. The number of forward and reverse
feeds can be set in the range of 2 to 30. The machine repeats Steps 11 and 12. For more, please
refer to Section "Service Tables".

63
 2. Detailed Section Descriptions

13:
With the feed of the stack halted, the fold plate [1] retracts. The fold plate HP sensor (not shown) detects
the fold plate and stops it at its home position.
14:
The fold rollers [2] and fold unit exit rollers [3] begin to rotate together and feed out the folded booklet to
the lower tray.
15:
Once the trailing edge of the stack passes the fold unit exit sensor [4], the clamp rollers [5] close to be
ready to feed the next stack. The fold unit bottom fence [6] descends. The bottom fence HP sensor [7] stops
the bottom fence when it detects the actuator on the bottom fence.

64
 Booklet Stapling (B804 Only)

Booklet Stapling and Folding Mechanisms

Booklet Stapler
[A]: Feed Out Belt Pawl. Raises the stack to stapling position.
[B]: Booklet Stapler EH185R – Rear
[C]: Booklet Stapler EH185R – Front
Stack Junction Gate
[D]: Stack Junction Gate Motor. Drives a timing belt and stack junction gate cam.
[E]: Stack Junction Gate Cam. Opens and closes the stack junction gate.
[F]: Stack Junction Gate. The stack junction gate motor and stack junction gate cam close the stack junction
gate. The feed out belt pawl raises the stapled stack and sends it over the top and down to the fold unit.
[G]: Leading Edge Pressure Roller. Presses down on the leading edge of the stack after booklet stapling.

65
 2. Detailed Section Descriptions

Clamp Roller
[A]: Fold Roller Motor. Drives the stationary clamp drive roller ¬ as well as the fold rollers (see next page).
[B]: Clamp Rollers.
¬ Clamp Roller – Drive. Rotated by the fold roller motor, this stationary roller feeds the stack down with
the retracting roller closed.
Clamp Roller – Retracting. Opened and closed by the retraction motor [C].
[C]: Clamp Roller Retraction Motor. Operates the clamp roller cam that retracts the retracting clamp roller.
The clamp rollers feed the stack to within 3 mm of the bottom fence when closed and then open to drop
the stack onto the bottom fence.
[D]: Clamp Roller HP Sensor. Controls the rotation of the clamp roller retraction motor and cam that open
and close the retracting clamp roller.
[E]: Clamp Roller Cam. Forces open the spring loaded retracting clamp roller.
Bottom Fence
[F]: Bottom Fence. Raises the booklet stapled stack to the fold position.
[G]: Bottom Fence HP Sensor. Detects the actuator on the bottom fence and stops it at the home position
after folding.
[H]: Bottom Fence Lift Motor. Raises the bottom fence and stapled stack to the fold position prescribed for
the paper size.

66
 Booklet Stapling (B804 Only)

Fold Plate
[A]: Bottom Fence Stack Stoppers. Catches the stack after it is released by the clamp rollers.
[B]: Fold Plate Motor. Drives the timing belt and gears that move the fold plate.
[C]: Fold Plate Cam. Controls the movement of the fold plate to the left (into the nip of the fold rollers) and
right (toward the fold plate home position).
[D]: Fold Plate HP Sensor. Controls operation of the fold plate motor.
[E]: Fold Plate. Moves left and pushes the stack into the nip of the fold rollers and then moves right to retract.
Fold Rollers
[F]: Fold Roller Motor. Drives forward to feed out the stack at the fold and then reverses to feed the fold in
to sharpen the crease, and then drives forward again to feed out the folded stack. This reverse/forward
cycle is done once.

• This cycle can be repeated by changing the setting of SP6114.

[G]: Fold Rollers. Driven by the fold roller motor, this roller pair feeds out the stack at its fold, reverses to
feed in the stack to, and then feeds forward again (assisted by the fold unit exit rollers – not shown) to feed
out the stack to the lower tray.

67
 2. Detailed Section Descriptions

Upper Tray Output

Feed Out

[A]: Feed Out Belt Motor

[B]: Stack Feed-Out Belt
[C]: Pawl
[D]: Exit Rollers
[E]: Exit Guide Plate Motor
[F]: Exit Guide Plate
[G]: Exit Guide Plate HP Sensor
[H]: Upper Tray

After the stack is stapled, the feed out belt motor [A] switches on and drives the feed out belt [B].
The pawl [C] attached to the feed out belt catches on the stack and lifts the stack toward the feed out slot.
The exit guide plate [F] remains open as the stack emerges at a prescribed distance away from the exit
roller.
Next, the exit guide plate closes and the exit roller feeds the stack out.
The opening and closing of the exit guide plate is controlled by the rising and falling of a link driven by a
rotating cam attached to the shaft of the exit guide plate motor [E].
The feed out belt motor stops 300 ms to prevent the stapled stack from rising too high.

68
 Upper Tray Output

Next, the feed out belt motor switches on again, then the pawl actuates its home position sensor and
switches off the motor.
There are two output pawls on the feed out belt to improve the productivity of the feed out operation.

Feed Out Stacking

2

Upper/proof exit motor [A] drives feed roller [B] and stacking sponge roller [C].
Stacking sponge roller motor [D] moves the sponge roller forward and back with link [E].
The position of the stacking sponge roller [C] is controlled by the stacking sponge roller motor which is
switched on and off by the stacking roller HP sensor [F].

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 2. Detailed Section Descriptions

Punch Unit B702 (For B804/B805)

Overview of Operation

2 Skew Correction before Punching

This punch unit corrects for paper skew and then positions the punch unit to punch holes at the correct
position. Each sheet is punched one at a time.
Paper feeds out of the copier. The finisher entrance sensor [A] detects the leading edge of the sheet.
The finisher entrance roller [B] stops rotating briefly while the copier exit rollers continue to rotate. This
buckles the paper against the finisher entrance roller to correct skew. The finisher entrance roller [C] starts
to rotate again and feeds the sheet into the finisher.
These SP codes adjust the skew operation in the punch unit:
• SP6130. This SP corrects the punch hole alignment. To do this, it corrects the skew of each sheet by
adjusting the amount of time the finisher entrance roller remains off while the exit roller of the machine
remains on. For more, see Section "Service Tables".
• SP6131. This SP determines whether the finisher entrance roller stops to correct skew when paper
enters the finisher. You can use this SP to disable the skew correction. For more, see Section "Service
Tables".

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 Punch Unit B702 (For B804/B805)

Punch Unit Position Correction

These operations (skew correction before punching, and punch unit position correction) increase the ac-
curacy of the punch alignment.
¶:
The trailing edge of the sheet passes the finisher entrance sensor [A].
The paper position slide unit [B] moves the paper position sensor [C] forward to the edge of the paper.
The paper position sensor detects the position of the paper edge and sends this information to the punch
unit board. The machine uses the detected position of the paper edge to calculate the correct position for
punching.
The upper transport motor switches on and rotates the feed rollers [D] the prescribed distance to position
the paper under the punch unit.
·:
Using the result of the position calculation, the punch unit control board moves the punch unit [E] to the
adjusted punch position.
The paper position slide unit and its paper sensor, move back to the paper position slide home position
sensor [F], and the punch unit fires the punches to make the holes.
¸:
The feed rollers [G] feed the punched paper out of the punch unit and into the paper path.

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 2. Detailed Section Descriptions

These SP codes adjust the punch hole alignment:

• SP6-128 Adjusts the punch positions in the direction of paper feed.
• SP6-129 Adjusts the punch position perpendicular to the direction of feed.
For more, see Section "Service Tables".

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 Punch Unit B702 (For B804/B805)

Punch Mechanisms

Paper Position Detection

[A]: Finisher Entrance Motor (M1)

[B]: Finisher Entrance Roller
[C]: Finisher Entrance Sensor (S1)
[D]: Paper Position Sensor Slide Motor (M7)
[E]: Paper Position Sensor (S27)
[F]: Paper Position Sensor Slide HP Sensor (S22)

The finisher entrance motor (M1) [A] drives the finisher entrance rollers [B] that feed paper from the copier
into the finisher. The finisher entrance sensor (S1) [C] detects paper when it enters the finisher, and detects
paper jams.
The paper position slide sensor motor (M7) [D] extends and retracts the paper position slide that holds the
paper position sensor (S27) [E]. The paper position sensor detects the position of the paper edge. The
detected position of the paper is used to calculate and position the punch unit for punching.
The paper position slide HP sensor (S22) [F] detects the paper position slide when it retracts and stops the
paper position slide motor so the slide stops at its home position.

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 2. Detailed Section Descriptions

Punch Unit Movement

[A]: Punch Movement Motor (M9)

[B]: Punch Movement HP Sensor (S21)
[C]: Punch Drive Motor (M24)

The punch movement motor (M9) [A] extends and retracts the punch unit to position it at the correct position
for punching.
The punch movement HP sensor (S21) [B] detects the position when it retracts, switches off the punch
position movement motor, and stops the punch unit at its home position.
The punch drive motor (M24) [C] fires the punches that punch holes in the paper below.

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 Punch Unit B702 (For B804/B805)

Punch Selection and Firing

[A]: Punch Drive Motor (M24)

[B]: Punch Encoder Wheel
[C]: Punch Encoder Sensor (S24)
[D]: Punch HP Sensor (S23)

The punch drive motor (M24) [A] turns the small, notched encoder wheel [B] through the gap in the punch
encoder sensor [C] (S24). The sensor output is used to control the punch timing.

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 2. Detailed Section Descriptions

The timing for 2-hole punching [E] is different from 3-hole punching [F].
When the punch unit is at the punching position, the punch motor turns until the encoder detects the starting
position for 2-hole or 3-hole punching.
• This is the ‘1’ position in the diagrams (the top diagram is for 2-hole punching, and the bottom diagram
is for 3-hole punching).
Then, the punch drive motor turns counter-clockwise to the ‘2’ position. This movement punches the holes
2 in the paper.
Then, the punch drive motor turns clockwise to the ‘1’ position, to be ready for the next sheet of paper.

Punch Hopper Mechanism

[A]: Finisher Entrance Motor (M1)

[B]: Punch Waste Belt
[C]: Punch Waste Hopper
[D]: Punch Hopper Full Sensor (S4)

The finisher entrance motor (M1) [A] drives the timing belt and gears that rotate the punch waste belt [B].
The punchouts fall from the punch unit onto the belt. The belt moves the punchouts to the front and dumps
them in the punch waste hopper [C].
The punch hopper full sensor [D]:
• Signals that the hopper is full when it detects the top of the stack of punchouts that have collected in
the hopper.

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 Punch Unit B702 (For B804/B805)

• It also detects when the punch hopper is set properly.

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 2. Detailed Section Descriptions

Finisher Jam Detection

Display Mode Jam What It Means

After main machine exit sensor goes OFF, finisher en-

Finisher entrance
trance sensor does not go ON even after enough time
Proof sensor late
to feed 450 mm.
R1 to R3 Shift
Staple After finisher entrance sensor goes ON, it does not go
Finisher entrance
OFF after enough time to feed a sheet 1.5 times its length
sensor lag
has elapsed.

After finisher entrance sensor goes ON, proof exit sensor

Proof exit sensor
does not go ON even after enough time to feed 450
late
mm.
R3 Proof
After finisher entrance sensor goes OFF, proof exit sen-
Proof exit sensor
sor does not go OFF even after enough time to feed 450
lag
mm.

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 Finisher Jam Detection

Display Mode Jam What It Means

After finisher entrance sensor goes ON, upper tray exit

Upper tray exit
sensor does not go ON even after enough time to feed
sensor late
485 mm.
R4 Shift
After finisher entrance sensor goes OFF, upper tray exit
Upper tray exit
sensor lag
sensor does not go OFF even after enough time to feed 2
650 mm.

After finisher entrance sensor goes ON, pre-stack tray

Pre-stack tray exit
exit sensor does not go ON even after enough time to
sensor lag
feed 650 mm.
R5 to R7 Staple
After finisher entrance sensor goes ON, pre-stack tray
Pre-stack tray exit
exit sensor does not go OFF even after enough time to
sensor late
feed 1650 mm.

The fold unit entrance sensor goes not go ON after

Fold unit entrance enough time has elapsed to feed 1.5 times the length of
sensor late (S26) the stack after the leading edge of the stack reaches the
Booklet stack present sensor (S32).
Staple
R8 to R12 The fold unit exit sensor does not go ON after enough
(B700 On- Fold unit exit sen-
time has elapsed for the stack to feed 1.5 times its length
ly) sor late (S31)
from the fold position.

Fold unit exit sen- After the fold unit exit sensor goes ON, it does not go
sor lag (S31) OFF after enough time has elapsed to feed 442.9 mm.

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 MEMO

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