Toshiba Mj-1104 User manual

SERVICE MANUAL

FINISHER

MJ-1103/1104

Model: MJ-1103/1104

Publish Date: August 2008

File No. SME070020C0

R070921E5300-TTEC

Ver03_2009-06

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.

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.

General Precautions for Installation/Servicing/Maintenance

for MJ-1103/1104

The installation and service should be done by a qualified service

technician.

1. When installing the MJ-1103/1104, be sure to follow the instructions described in the “Unpacking/

Set-Up Procedure for the MJ-1103/1104”.

2. The MJ-1103/1104 should be installed by an authorized/qualified person.

3. The Finisher is quite heavy; MJ-1103 weighs approximately 40 kg (88.19 lb.) and MJ-1104 weighs

approximately 70 kg (154.32 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. The equipment shall be installed near the socket outlet and shall be accessible.

6. Be sure to fix and plug in the power cable securely after the installation so that no one trips over it.

7. When selecting the installation site, avoid placing the finisher / hole punch unit and equipment on

different levels or inclined floors.

8. The equipment shall be installed near the socket outlet and shall be easily accessible.

9. When the MJ-1103/1104 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 equip-

ment as well.

10.When servicing or maintaining the MJ-1103/1104, be careful about the rotating or operation sections

such as gears, pulleys, sprockets, cams, belts, etc.

11.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.

12.Basically, the machine should not be operated with any parts removed or disassembled.

13.Delicate parts for preventing safety hazard problems (such as switches, sensors, etc. if any) should

be handled/installed/adjusted correctly.

14.Use suitable measuring instruments and tools.

15.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.

16.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.

17.For the recovery and disposal of used MJ-1103/1104, consumable parts and packing materials, fol-

low the relevant local regulations/rules.

18.After completing installation, servicing and maintenance of the MJ-1103/1104, return the MJ-1103/

1104 to its original state, and check operation.

19.When the equipment is used after the option is removed, be sure to install the parts or the covers

which have been taken off so that the inside of the equipment is not exposed.

20.When you move the finisher, do not move it in the direction of the arrow as shown in the figure below

otherwise it might topple over.

21.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.

CONTENTS

MJ-1103/1104

1. SPECIFICATIONS, ACCESSORY AND CONSUMABLES.......................................... 1-1

1.1 Specifications....................................................................................................................... 1-1

1.1.1 Finisher section (Common for MJ-1103/1104) ....................................................... 1-2

1.1.2 Saddle stitch section (MJ-1104) ............................................................................. 1-5

1.2 Accessory ............................................................................................................................ 1-6

1.3 Consumables....................................................................................................................... 1-6

2. GENERAL DESCRIPTION............................................................................................ 2-1

2.1 Main Components................................................................................................................ 2-1

2.2 Sectional View ..................................................................................................................... 2-2

2.3 Electric Parts Layout............................................................................................................ 2-7

2.4 Symbols and Functions of Various Components................................................................. 2-9

2.5 Diagram of Signal Blocks................................................................................................... 2-13

2.6 Description of Interface Signals ......................................................................................... 2-15

3. DESCRIPTION OF OPERATIONS ............................................................................... 3-1

3.1 Basic Operations ................................................................................................................. 3-1

3.1.1 GENERAL DESCRIPTION..................................................................................... 3-1

3.1.2 Junction Box........................................................................................................... 3-3

3.1.3 Simple Stack Mode ................................................................................................ 3-4

3.1.4 Job offset stack mode / Staple stack mode............................................................ 3-9

3.1.5 Operation in the saddle stitch section .................................................................. 3-14

3.2 Flow Chart ......................................................................................................................... 3-20

3.3 Description Of Circuit......................................................................................................... 3-23

3.3.1 Finishier section ................................................................................................... 3-23

3.3.2 Saddle section...................................................................................................... 3-35

4. DISASSEMBLY AND INSTALLATION ........................................................................ 4-1

4.1 Covers ................................................................................................................................ 4-1

4.2 Units (Finisher section) ...................................................................................................... 4-13

4.3 Units (Saddle section: MJ-1104) ....................................................................................... 4-26

4.4 Rollers (Finisher section)...................................................................................................4-38

4.5 Rollers (Saddle section: MJ-1104).................................................................................... 4-58

4.6 Motor (Finisher section).....................................................................................................4-64

4.7 Motor (Saddle section: MJ-1104)...................................................................................... 4-74

4.8 Solenoid............................................................................................................................. 4-79

4.9 Sensors / Switches (Finisher section)................................................................................ 4-91

4.10 Sensors / Switches (Saddle section: MJ-1104) ............................................................... 4-110

4.11 PC Boards / Discharge Brush.......................................................................................... 4-120

4.12 Procedure for lowering the movable tray......................................................................... 4-124

5. ADJUSTMENTS............................................................................................................ 5-1

5.1 Adjusting the Alignment Position ......................................................................................... 5-1

5.2 Adjusting the Stapling Position ............................................................................................ 5-4

5.3 Stapling/folding position adjustment in saddle unit .............................................................. 5-6

5.3.1 Folding position adjustment.................................................................................... 5-8

5.3.2 Stapling position adjustment ................................................................................ 5-10

5.4 Saddle Stitch Skew Adjustment......................................................................................... 5-12

6. TROUBLESHOOTING .................................................................................................. 6-1

6.1 Paper Transport Jam........................................................................................................... 6-1

6.1.1 Paper jam in entrance section................................................................................ 6-1

6.1.2 Paper jam in buffer unit-1 ....................................................................................... 6-3

6.1.3 Paper jam in buffer unit-2 ....................................................................................... 6-5

CONTENTS

6.1.4 Paper jam in finishing tray section.......................................................................... 6-7

6.1.5 Paper jam in movable tray section ....................................................................... 6-12

6.1.6 Cover open jam .................................................................................................... 6-13

6.2 Paper Transport Jam in Saddle Stitch Section (MJ-1104)................................................. 6-15

6.2.1 Paper jam in Saddle Stitch Finisher transport section.......................................... 6-15

6.2.2 Paper jam in side alignment section..................................................................... 6-19

6.2.3 Paper jam in stack transport section .................................................................... 6-19

6.2.4 Paper jam in folding section ................................................................................. 6-21

6.2.5 Paper jam in additional folding section ................................................................. 6-22

6.3 Other Errors....................................................................................................................... 6-23

6.3.1 Stapler related error ............................................................................................. 6-23

6.3.2 Saddle Stitch Finisher stapler related error (MJ-1104)......................................... 6-25

6.3.3 Communication Related Error .............................................................................. 6-26

6.3.4 Memory error........................................................................................................ 6-27

7. PREVENTIVE MAINTENANCE (PM) / FIRMWARE UPDATE ..................................... 7-1

7.1 Maintenance and Inspection Points..................................................................................... 7-1

7.2 Firmware Update ................................................................................................................. 7-6

7.2.1 Update of CNV board ............................................................................................. 7-6

7.2.2 Update of FIN board............................................................................................... 7-8

7.2.3 Update of SDL board............................................................................................ 7-10

8. ELECTRIC CIRCUIT ..................................................................................................... 8-1

8.1 Harness Diagram................................................................................................................. 8-1

8.2 Circuit Diagram.................................................................................................................... 8-5

8.3 PC board ........................................................................................................................... 8-32

SPECIFICATIONS, ACCESSORY AND CONSUMABLES

1 - 1

1. SPECIFICATIONS, ACCESSORY AND CONSUMABLES

1.1 Specifications

• Product Type

MJ-1103: Console Finisher (2 trays)

MJ-1104: Console Saddle Stitch Finisher (3 trays)

• Paper Stacking Device Stationary Tray or Movable Tray, Saddle Tray (MJ-1104)

• Paper Size A3, A4, A4-R, A5, A5-R, A6-R, B4, B5, B5-R, FOLIO, A3 wide,

LD, LG, LT, LT-R, ST, ST-R, COMPUTER, 13”LG, 8.5”SQ,

8K, 16K, 16K-R

• Paper Basis Weight 64 - 300g/m2

• Stacking Mode Simple, Job Offset, Staple and composite, Center-binding (MJ-1104)

• Dimensions with Sub-tray put in: W 617 x D 603 x H 1,085 (mm)

with Sub-tray drawn out: W 750 x D 603 x H 1,085 (mm)

• Gross Weight

MJ-1103: Approximately 40kg (88.19 lb)

MJ-1104: Approximately 70kg (154.32 lb)

• Power Supply DC24V±10% and DC5V±5% supplied from the main equipment.

• Power Consumption DC24V Average 3.7A or less

5V 1.0A or less

SPECIFICATIONS, ACCESSORY AND CONSUMABLES

1 - 2

1.1.1 Finisher section (Common for MJ-1103/1104)

• Stacking Type Facedown

• Stacking Height with

Stationary Tray

The maximum stacking height is 18.4 mm for mixed size paper.

ÅgFullÅh status is defined as when the stationary tray paper-full sensor (S18) detected the full sta-

tus of paper in the size available for feeding.

Movable tray (in the job offset stack mode)

The maximum stacking height is 175 mm for mixed size paper. However, ST-R, A5-R, B5-R, A6-R

and non-standard sizes are not acceptable for mixed size paper.

ÅgFullÅh status is defined as when the number of paper whose maximum stacking height is 350

mm has reached 3,000 or when the number of paper in other sizes has reached 1,500.

The maximum number of sheets acceptable is 1,500 for mixed size paper. However, ST-R, A5-R,

B5-R, A6-R and non-standard sizes are not acceptable for mixed size paper.

Movable tray (in the staple stack mode)

Paper Size Stacking

Height

Number of sheets (reference)

64 - 80g/m2

Paper

81 - 90g/m2

Paper

91 - 105g/m2

Paper

A4, B5, LT, A5-R, ST-R, 8.5”SQ, 16K,

Postcard, A4-TAB, LT-TAB, A6-R

36.75mm 250 225 190

A3, A4-R, B4, FOLIO, LD, LG, LT-R,

COMPUTER, B5-R, 13”LG, 8K, 16K-R,

A3 wide, 12” x 18”, 13” x 19”,

320 x 450mm, 320 x460mm, Universal

18.4mm 125 112 95

Paper Size Stacking

Height

Number of sheets (reference)

80g/m2Paper 90g/m2Paper 105g/m2

Paper

A4, B5, LT, 8.5”SQ, 16K, A4-TAB, LT-TAB 350mm 3,000 2,700 2,300

A3, A4-R, B4, FOLIO, LD, LG, LT-R,

COMPUTER, 13”LG, 8K, 16K-R,

A3 wide,12" x 18"

175mm 1,500 1,350 1,150

ST-R, A5-R, B5-R, A6-R, Postcard,

Universal

- 500 500 500

Paper Size

Stacking Height

64 - 105 g/m2(reference)

Front/Rear Single Position

Stapling

Two-Position Stapling

A4, B5, LT, A4-TAB, LT-TAB A paper-full status is detected

either when the number of

stacks reaches 100 or when

the number of sheets reaches

2,000.

A paper-full status is detected

either when the number of

stacks reaches 150 or when

the number of sheets reaches

2,000.

A3, A4-R, B4, FOLIO, LD, LG, LT-R,

COMPUTER, 13”LG, 8K, 16K, 8.5”SQ

A paper-full status is detected

either when the number of

stacks reaches 50 or when

the number of sheets reaches

1,000.

A paper-full status is detected

either when the number of

stacks reaches 75 or when

the number of sheets reaches

1,000.

SPECIFICATIONS, ACCESSORY AND CONSUMABLES

1 - 3

• Stapling Position

Front single position Rear single position

Two-Position Stapling

• Paper Size for stapling

Stapling is not available for paper in sizes other than the above.

Fig. 1-1 Fig. 1-2

Fig. 1-3

Paper Size A B

A3, A4, A4-TAB 81.0 ±3.5mm 205.0 ±3.5mm

A4-R, FOLIO 37.5 ±3.5mm 161.5 ±3.5mm

B4, B5, COM-

PUTER

61.0 ±3.5mm 185.0 ±3.5mm

LD, LT, LT-TAB 72.0 ±3.5mm 196.0 ±3.5mm

LT-R, LG 40.5 ±3.5mm 164.5 ±3.5mm

Stapling Position Paper Size

Front Single A3, A4, A4-R, B4, B5, FOLIO, LD, LG, LT, LT-R, COMPUTER, 13”LG,

8.5”SQ, 8K, 16K, A4-TAB, LT-TAB

Rear Single A3, A4, A4-R, B4, B5, FOLIO, LD, LG, LT, LT-R, COMPUTER, 13”LG,

8.5”SQ, 8K, 16K, A4-TAB, LT-TAB

Two-Positions A3, A4, A4-R, B4, B5, FOLIO, LD, LG, LT, LT-R, COMPUTER, A4-TAB,

LT-TAB

4.5 ±3.0 mm

6 ±3.5 mm

4.5 ±3.0 mm

6 ±3.5 mm

5 ±3.0 mm

SPECIFICATIONS, ACCESSORY AND CONSUMABLES

1 - 4

• Paper Basis Weight for stapling 64 - 105g/m2

• The number of Stapleable Sheet

Maximum number of sheets acceptable for stapling:

A4, B5, LT, 8.5”SQ, 16K, A4-TAB, LT-TAB - 50 sheets

A3, A4-R, B4, FOLIO, LD, LG, LT-R, COMP, 13”LG, 8K - 30 sheets

* Two sheets of cover sheet (200-256 g/m2) can be included.

• Staple Loading exclusive cartridge (5,000 staples)

• Manual Stapling available

Paper Size 64 - 80g/m2

Paper

81 - 90g/m2

Paper

91 - 105g/m2

Paper

A4, B5, LT, 8.5”SQ, 16K 50 50 30

A3, A4-R, B4, FOLIO, LD, LG, LT-R,

COMPUTER, 13”LG, 8K

30 30 15

SPECIFICATIONS, ACCESSORY AND CONSUMABLES

1 - 5

1.1.2 Saddle stitch section (MJ-1104)

• Binding method Center-binding only

• Paper Size A3, B4, A4-R, LD, LG, LT-R

• Number of sheets available for stapling

* One sheet of cover sheet (200-256 g/m2) can be included.

• Paper Basis Weight for stapling 64 - 105g/m2

• Staple Loading exclusive cartridge (2,000 staples)

• Exiting paper not folded Not available

• Exiting paper not stapled Exited when only one sheet in the stack is unstapled

• Stapling interval 120 mm

• Number of stacks available

No thick paper cover included

Thick paper cover included

A paper-full status is detected when the number of stacks reaches the values shown below.

64 - 80g/m2Paper 81 - 90g/m2Paper 91 - 105g/m2 Paper

15 15 10

Paper Size 64 - 90g/m2Paper 91 - 105g/m2Paper

Under 5 sheets/books 50 40

Under 10 sheets/books 30 25

Under 155 sheets/books 25 -

Paper Size 64 - 90g/m2Paper 91 - 105g/m2Paper

Under 5 sheets/books 50 30

Under 10 sheets/books 15 15

Under 155 sheets/books 10 -

Paper Size No thick paper cover included Thick paper cover included

Under 5 sheets/books 50 50

Under 10 sheets/books 30 15

Under 155 sheets/books 25 10

SPECIFICATIONS, ACCESSORY AND CONSUMABLES

1 - 6

1.2 Accessory

1.3 Consumables

• Staple cartridge for the Finisher section

exclusive cartridge (STAPLE-2400: 5,000staples X 3 cartridges /box)

• Staple cartridge for the saddle stitch section (MJ-1104)

exclusive cartridge (STAPLE-3100: 2,000staples X 4 cartridges /box)

MJ-1103 MJ-1104

Unpacking Instruction 1set 1set

Movable tray 1pc 1pc

Connect rail plate 1pc 1pc

Connect rail 1pc 1pc

Connect plate 1pc 1pc

Joint plate 1pc 1pc

Position plate 1pc 1pc

Connector cover 1pc 1pc

Saddle tray - 1pc

Slide tray - 1pc

Leveling arm - 1pc

Screw: TBID M4x8 6pcs 6pcs

Screw: TBID M4x12 4pcs 4pcs

Screw: M3x8 5pcs 5pcs

Screw: M3x12 - 2pcs

Screw: M3x6 - 2pcs

Harness clamp 1pc 1pc

GENERAL DESCRIPTION

2 - 1

2. GENERAL DESCRIPTION

2.1 Main Components

Fig. 2-1

Front upper cover

Stationary Tray

Movable Tray

Jam access lever

MJ-1103

MJ-1104

Staple bottoms

Rght upper cover

Relay Guide Rear cover

Saddle Tray

Slide Tray

Leveling arm

Grate-shaped guide

Rght cover

PC board access cover

Saddle access cover

Saddle unit

Front cover

Front lower cover

GENERAL DESCRIPTION

2 - 2

2.2 Sectional View

[A] Units

Fig. 2-2

1 Junction box unit

2 Buffer unit

3 Finishing tray unit

4Stapler

5 Movable tray shift motor unit

6 Switchback unit

7 Stacker unit (MJ-1104)

8 Paper holding unit (MJ-1104)

9 Side alignment unit (MJ-1104)

10 Saddle stapler unit (MJ-1104)

11 Folding drive unit (MJ-1104)

12 EFS unit (MJ-1104)

GENERAL DESCRIPTION

2 - 3

[B] Finisher section

[B-1] Front side view

Fig. 2-3

1 Buffer roller

2 Paper pusher plate

3 Buffer tray

4 Finishing tray

5 Stack transport roller-2

6 Stack transport roller-1

7 Gate flap

8 Entrance roller

9Exitroller

M1 Entrance motor

M4 Buffer roller drive motor

M8 Stack transport motor

CLT2 Paper exit guide clutch

SOL2 Gate solenoid

CLT2

SOL2

GENERAL DESCRIPTION

2 - 4

[B-2] Rear side view

Fig. 2-4

1 Stationary tray roller

2 Entrance roller

3 Flapper

4 Feeding roller

5 Junction roller

6 Shutter

7 Paddle

M2 Buffer tray guide motor

M3 Paddle motor

M7 Transport motor

M11 Exit motor

M12 Movable tray shift motor

CLT1 Shutter clutch

SOL5 Transport path switching solenoid

M12

CLT1

SOL5

M11

GENERAL DESCRIPTION

2 - 5

[C] Saddle section

[C-1] Front side view

Fig. 2-5

1Jog

2 Additional folding carrier

3 Folding roller

4 Saddle exit roller

5 Folding blade cam

6 Folding blade

7 Assisting roller

8 Ejecting roller

M15 Side alignment motor

M20 Additional folding motor

SOL6 Assisting roller solenoid

M15

SOL6

M20

GENERAL DESCRIPTION

2 - 6

[C-2] Rear side view

Fig. 2-6

1 Transport roller

2 Paper holding damper

3 Paper holding cam

4 Stacker carrier

M14 Stacker motor

M16 saddle transport motor

M17 Folding motor

CLT3 Folding blade clutch

CLT4 Paper holding clutch

M16

M14

CLT3

M17

CLT4

GENERAL DESCRIPTION

2 - 7

2.3 Electric Parts Layout

Fig. 2-7

S27

S35

S34

S36

SW5

S38

S41

S28

S42

SDL

S31

S39

S32 S29S33 S30

S15 S23S5S13S14 S3

SW2

S18

S25

S26

I/F

SW4

S16

S17

S12

S11

S10

SW3

SW1

S22

FIN

GENERAL DESCRIPTION

2 - 8

Fig. 2-8

SOL2 M10 M2M12

CLT2

SOL1

SOL5

M16

M14 M20 SOL6

CLT4

CLT3

M13

S19

S20

S21

M17

M19

S44

S46

S48

S50

SOL3

CLT1

SOL4

M11

M15

M18

S43

S45

S47

S49

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