Oki MJ-1038 User manual

MC770 / MC770+ / MC780 / MC780+
MPS3537mc / MPS3537mc+
MPS4242mc / MPS4242mc+
MJ-1038 Inner Finisher
Service Manual
060313A

45372301TH Rev.1 ii /
Oki Data CONFIDENTIAL
Document Revision History
Rev.No. Date
Corrected items Person in
charge
No. Page Description of change
1 2013-04-10 ISSUE P2E1 T. Asaba

45372301TH Rev.1 iii /
Oki Data CONFIDENTIAL
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.
© 2013 OKI DATA CORPORATION All rights reserved
Under the copyright laws, this manual cannot be reproduced in any form without prior written
permission of OKI DATA CORPORATION.

45372301TH Rev.1 iv /
Oki Data CONFIDENTIAL
General Precautions for Installation/Servicing/Maintenance for
MJ-1038
The installation and service shall be done by a qualified service
technician.
1. When installing the MJ-1038, be sure to follow the instructions described in the “Unpacking/
Set-Up Procedure for the MJ-1038”.
2. The MJ-1038 should be installed by an authorized/qualified person.
3. The Finisher is quite heavy; MJ-1038 weighs approximately 8.3 kg (18.29 lb.), 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 cable securely after the installation so that no one trips
over it.
6. The equipment shall be installed near the socket outlet and shall be easily accessible.
7. Unplug the power cable and clean the area around the prongs of the plug and socket outlet
once a year or more. A fire may occur when dust lies on this area.
8. When servicing or maintaining the MJ-1038, 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, harnesses to the wrong places.
10.Basically, the machine should not be operated with any parts removed or disassembled.
11. When servicing the equipment with the power turned ON, be sure not to touch live sections
and rotating/operating sections.
12.Delicate parts for preventing safety hazard problems (such as switches, sensors, etc. if any)
should be handled/installed/adjusted correctly.
13.Tools and instruments
- Use designated jigs and tools.
- Use recommended measuring instruments or equivalents.
14.Use the wrist band to avoid static electric shock by touching the ungrounded metallic parts.
The PC board must be stored in antistatic envelope 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 cable 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-1038, consumable parts and packing materials,
follow the relevant local regulations/rules.

45372301TH Rev.1 v /
Oki Data CONFIDENTIAL
[1]
[2]
16.After completing installation, servicing and maintenance of the MJ-1038, return the MJ-1038
to its original state, and check operation.
17. When the MJ-1038 is removed from the equipment due to malfunction or other reasons but
no substitute machine is to be installed, be sure to remove all the installation hardware from
the equipment as well.
18.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.
[1] Identification label
[2] Warning for elevating behavior of tray

45372301TH Rev.1 vi /
Oki Data CONFIDENTIAL
CONTENTS
1. SPECIFICATIONS, ACCESSORY AND CONSUMABLES ...............................1-1
1.1 Specifications............................................................................................... 1-1
1.2 Accessory ....................................................................................................1-3
1.3 Consumables ...............................................................................................1-4
2. GENERAL DESCRIPTION ................................................................................2-1
2.1 Main Components........................................................................................ 2-1
2.2 Sectional View .............................................................................................2-2
2.3 Electric Parts Layout ....................................................................................2-4
2.4 Symbols and Functions of Various Components .........................................2-6
2.5 Diagram of Signal Blocks.............................................................................2-8
3. DESCRIPTION OF OPERATIONS.....................................................................3-1
3.1 Basic Operations..........................................................................................3-1
3.1.1 Specifications............................................................................................................3-1
3.1.2 Transport drive system - General description.......................................................... 3-2
3.1.3 Jam detection .......................................................................................................... 3-9
4. DISASSEMBLY AND INSTALLATION ..............................................................4-1
4.1 Disassembly and Replacement of Covers ...................................................4-1
4.1.1 Upper cover ..............................................................................................................4-1
4.1.2 Front cover................................................................................................................4-1
4.1.3 Rear cover ............................................................................................................... 4-2
4.2 Disassembly and Replacement of Sensors and Switches ...........................4-3
4.2.1 Guide upper ASSY................................................................................................... 4-3
4.2.2 Guide rear ASSY ..................................................................................................... 4-3
4.2.3 Entrance transport sensor (S1)................................................................................ 4-6
4.2.4 Exit transport sensor (S2)........................................................................................ 4-6
4.2.5 Front alignment plate home position sensor (S4).....................................................4-7
4.2.6 Rear alignment plate home position sensor (S5) .....................................................4-7
4.2.7 Ejector home position sensor (S7) .......................................................................... 4-8
4.2.8 Ejector encoder sensor (S8)...................................................................................4-10
4.2.9 Stapler paper sensor (S14).....................................................................................4-13
4.2.10 Stack home position sensor (S9) ...........................................................................4-15
4.2.11 Paper support home position sensor (S6)..............................................................4-17
4.2.12 Door switch (SW2)................................................................................................. 4-20
4.2.13 Stacker tray lower limit switch (SW1)..................................................................... 4-20
4.2.14 Lever path home position sensor (S15) ................................................................. 4-21
4.3 Disassembly and Replacement of motors..................................................4-22
4.3.1 Entrance transport motor (M1)............................................................................... 4-22
4.3.2 Exit transport motor (M2)....................................................................................... 4-22
4.3.3 Front alignment motor (M4) ................................................................................... 4-23
4.3.4 Rear alignment motor (M5).................................................................................... 4-25
4.3.5 Paddle motor (M3) ................................................................................................. 4-27
4.3.6 Paper support motor (M6) ..................................................................................... 4-28
4.3.7 Ejector motor (M7) ................................................................................................. 4-31
4.3.8 Stacker motor (M8) ................................................................................................ 4-34
4.3.9 Lever path motor (M10).......................................................................................... 4-35

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Oki Data CONFIDENTIAL
4.4 Disassembly and Replacement of transport system ..................................4-37
4.4.1 Entrance transport roller ........................................................................................ 4-37
4.4.2 Exit Transport roller................................................................................................ 4-38
4.4.3 Exit roller (PM)....................................................................................................... 4-39
4.4.4 Sub paddle............................................................................................................. 4-41
4.4.5 Main paddle (PM) .................................................................................................. 4-42
4.4.6 SCU paddle............................................................................................................ 4-43
4.5 Disassembly and Replacement of Others................................................. 4-45
4.5.1 Finisher control PC board ASSY............................................................................ 4-45
4.5.2 Finisher control PC board ...................................................................................... 4-45
4.5.3 Stapler ................................................................................................................... 4-46
5. ADJUSTMENT ...................................................................................................5-1
5.1 General description......................................................................................5-1
6. TROUBLESHOOTING .......................................................................................6-1
6.1 Troubleshooting............................................................................................6-1
6.2 Alarm.......................................................................................................... 6-14
7. PREVENTIVE MAINTENANCE (PM) / FIRMWARE UPDATE .......................... 7-1
7.1 PM Parts ...................................................................................................... 7-1
7.2 Consumables and Duration.......................................................................... 7-1
7.2.1 Finisher section.........................................................................................................7-1
7.3 Maintenance by Customers ......................................................................... 7-1
7.4 Maintenance and Inspection Points ............................................................. 7-1
7.5 Grease .........................................................................................................7-2
7.6 Firmware Update..........................................................................................7-2
8. ELECTRIC CIRCUIT ..........................................................................................8-1
8.1 Harness Diagram .........................................................................................8-1
8.2 Circuit Diagram ........................................................................................... 8-4
8.3 PC Boards................................................................................................... 8-9
8.4 Electric Signals .......................................................................................... 8-10
8.4.1 Finisher section.......................................................................................................8-10

45372301TH Rev.1 1-1 /
Oki Data CONFIDENTIAL
1. SPECIFICATIONS, ACCESSORY AND CONSUMABLES
1.1 Specifications
• Product Type Inner Finisher (1 trays)
• Paper Stacking Device Stationary Tray
• Paper Size A4, A5, B5, Executive, Folio, LG13", LG13.5", LG14", LT, Statement,
16K (184 × 260, 195 × 270, 197 × 273)
• Paper Basis Weight 64 - 220 g/m2(17 lb. Bond to 58 lb. Bond)
• Stacking Mode Simple, Offset, Staple and composite
• Dimensions W386.7 × D303.6* × H212 (mm)
  * without stacker tray.
• Gross Weight 8.3 kg (18.29 lb)
• Power Supply DC24V±10% and DC5V±5% supplied from the main equipment.
• Power Consumption DC24V 40W or less
5V 2.6W or less
• Stacking Type Facedown
• Stacking Height with
Operation Mode Sheets loaded Remarks
Non-Sort, Offset Minimum 500 sheets, or 71 mm STACK TRAY movement When using 80 g/m2
Staple STACK TRAY movement 71 mm, up to 20 continuous batches When using 80 g/m2
- Considered full when STACK TRAY reaches lower limit in excess of specifications noted here.
- Exceeding maximum number of continuous batches of staples is not covered by the warranty.
- The Tray movement is a 71 mm motion vertically from the Home position.
Fig. 1-1
71mm

45372301TH Rev.1 1-2 /
Oki Data CONFIDENTIAL
• Stapling Position
(45°)
5 ±2 mm5 ±2 mm
[1]
[1] Transport direction
Fig. 1-2
• Paper Size for stapling
Stapling Position Paper Size
Single A4,B5,Executive,Folio,LG13",LG13.5",LG14",LT,16K(184×260,195×
270, 197 × 273)
Stapling is not available for paper in sizes other than the above.
• Paper Basis Weight for stapling  64 - 220 g/m2
• Number of sheets that can be stapled
Paper Size 64 - 82 g/m2Paper 83 - 104 g/m2Paper 105 - 220 g/m2
Folio,LG13",LG13.5",LG14" 30 15 2 (Cover paper)
A4, B5, Executive, LT, 16K (184 × 260,
195 × 270, 197 × 273)
50 30 2 (Cover paper)
• Staple Loading   exclusive cartridge
• Manual Stapling   Function is not included

45372301TH Rev.1 1-3 /
Oki Data CONFIDENTIAL
1.2 Accessory
Symbol Name Quantity
B BKT MOUNT LEFT 1pc
D BKT MOUNT RIGHT 1pc
EStacker tray 1pc
FFilm 1 sheet
GFilm 2 sheets
aScrew: M3x6 6pc
fScrew: M4x6 2pc
gScrew: M3x10 2pc
Unpacking Instruction 1set
Fig. 1-3

45372301TH Rev.1 1-4 /
Oki Data CONFIDENTIAL
1.3 Consumables
• Staple cartridge exclusive cartridge (45574401)

45372301TH Rev.1 2-1 /
Oki Data CONFIDENTIAL
2. GENERAL DESCRIPTION
2.1 Main Components
[1]
[2] [3]
[6]
[7]
[5]
[4]
Fig. 2-1
1Upper cover 5Stapler
2Front cover 6Side cover
3Rear cover 7 Connector cover
4Stacker tray

45372301TH Rev.1 2-2 /
Oki Data CONFIDENTIAL
2.2 Sectional View
[A] Front sectional view
[3]
[4]
[6][7]
[5]
[8]
[11] [10]
[9]
[15][14][13][12]
[1][2]
Fig. 2-2
1 Stapler motor 9 Paper support home position sensor
2Stapler 10 Stapler paper sensor
3Stacker tray 11 Front alignment motor
4 Lever path motor 12 Stack home position sensor
5Lever path home position sensor 13 Paper support motor
6Paddle home position sensor 14 Ejector encoder sensor
7Front alignment plate home position sensor 15 Ejector motor
8 Stacker motor

45372301TH Rev.1 2-3 /
Oki Data CONFIDENTIAL
[B] Rear sectional view
Fig. 2-3
1Entrance transport sensor 6 Exit transport motor
2Exit transport sensor 7 Stacker tray lower limit switch
3Door switch 8Rear alignment plate home position sensor
4Ejector home position sensor 9 Paddle motor
5 Rear alignment motor 10 Entrance transport motor
[3] [2]
[4]
[1]
[7]
[5]
[6]
[9] [8][10]

45372301TH Rev.1 2-4 /
Oki Data CONFIDENTIAL
2.3 Electric Parts Layout
[A] Sensors and switches
S1
S6
SW1
S2
S7
S5SW2S14S9S3
S4
FIN
S8
S15
Fig. 2-4

45372301TH Rev.1 2-5 /
Oki Data CONFIDENTIAL
[B] Motors and PC boards
M2
M1
M5
M3M9M4
M6
M8
M10
M7
Fig. 2-5

45372301TH Rev.1 2-6 /
Oki Data CONFIDENTIAL
2.4 Symbols and Functions of Various Components
The column <P-I> shows the page and item number in the parts list.
1. Motors
Symbol Name Function P-I Remarks
M1 Entrance transport motor Drives the entrance transport roller
M2 Exit transport motor Drives the exit transport roller
M3 Paddle motor Drives the paddle
M4 Front alignment motor Drives the front alignment plate
M5 Rear alignment motor Drives the rear alignment plate
M6 Paper support motor Drives the paper support
M7 Ejector motor Drives the ejector
M8 Stacker motor Drives the stacker tray
M9 Stapler motor Drives the Stapler
M10 Lever path motor Drives the lever path
2. Sensors and switches
Symbol Name Function P-I Remarks
S1 Entrance transport sensor Detects the paper of the entrance
transport roller.
S2 Exit transport sensor Detects the paper of the exit
transport roller.
S3 Paddle home position sensor Detects the home position of the
paddle.
S4 Front alignment plate home
position sensor
Detects the home position of the
front alignment plate.
S5 Rear alignment plate home
position sensor
Detects the home position of the rear
alignment plate.
S6 Paper support home position
sensor
Detects the home position of the
paper support.
S7 Ejector home position sensor Detects the home position of the
ejector.
S8 Ejector encoder sensor Detects the position of the ejector.
S9 Stack home position sensor Detects the home position of the
stacker tray.
S14 Stapler paper sensor Detects whether there is paper to
staple.
S15 Lever path home position
sensor
Detects the home position of the
lever path.
SW1 Stacker tray lower limit switch Detects the lower limit of the stacker
tray.
SW2 Door switch Detects the opening/closing of the
side cover.

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Oki Data CONFIDENTIAL
3. PC board
Symbol Name Function P-I Remarks
FIN Finisher control PC board Controls the Finisher.

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Oki Data CONFIDENTIAL
2.5 Diagram of Signal Blocks
The operational sequence of the finisher is controlled by the Finisher control PC board (FIN).
The CPU on the PC board controls paper transportation and serial transmissions of the machine.
A block diagram of the finisher is shown below.
Fig. 2-6
MFP Interface
FEED IN PATH SNR
S1
STAPLE PAPER DETECT SNR
S14
FIN PWBA
CN1
DC24V OUT
DC5V OUT
DC24V IN
DC5V IN
DXRataDdneS
POLYSW( R72) COMNO
DOOR I/L SW
S15
STEP MOTOR DRIVER IC STEP
MTR M1
FEED IN MTR
STEP MOTOR DRIVER IC
STEP MOTOR DRIVER IC
STEP MOTOR DRIVER IC
STEP MOTOR DRIVER IC
STEP MOTOR DRIVER IC
DC MOTOR DRIVER IC
DC MOTOR DRIVER IC
DC MOTOR DRIVER
STEP
MTR M2
FEED OUT MTR
POLYSW(R56)
POLYSW(R57)
POLYSW(R71)
POLYSW(R66)
POLYSW(R82)
POLYSW(R67)
POLYSW(R76)
POLYSW(R77)
POLYSW(R145)
STEP
MTR M4
F JOG MTR
STEP
MTR M5
R JOG MTR
STEP
MTR M6
EXT. TRAY MTR
STEP
MTR M3
PADDLE MTR
DC
MTR M7
EJECT MTR
DC
MTRM9
STP MTR
DC
MTR M8
STK MTR
COM NC
STK DN SW
S10
DC24V FOR STK UP
DC24V FOR STK DOWN
CPU
FEED EXIT SNR
S2
F JOG HOME SNR
S4
R JOG HOME SNR
S5
PADDLE HOME SNR
S3
EJECT HOME SNR
S7
EJECT ENCODER SNR
S8
STK TOP SNR
S9
STACKER HOME SNR
S6
STAPLER
STAPLE LOW
S13
STAPLER READY
S12
STAPLER HOME
S11
DOOR OPEN DETECT
STK LOWDETECT
DC5V
DC24V
5V SENSOR
STEP MOTOR DRIVER IC STEP
MTR
LEVER PATH MTR
M10
LEVER PATH HOME SNR
S15
Receive Data TXD
Connect Chk1 GD
POLYSW(R81)

45372301TH Rev.1 3-1 /
Oki Data CONFIDENTIAL
3. DESCRIPTION OF OPERATIONS
3.1 Basic Operations
3.1.1 Specifications
The Finisher exits paper transported from the equipment. Paper exit modes available are; the simple
stack (straight-through paper exit) mode, offset mode and staple stack mode.
The operations noted above are controlled by the Finisher control PC board (FIN) in accordance with
commands from the equipment.