Canon K1 Service Manual Download Page 5

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Contents

Safety Precautions 0-1

Points to Note About Turning Off the Main Power Switch

----------0-2

Notes Before it Works Serving ---------------------------------------------0-3

Product Outline

1-1

Features -------------------------------------------------------------------------1-2

Specifications

------------------------------------------------------------------1-3

Names of Parts ----------------------------------------------------------------1-4

External View(Front)

-------------------------------------------------------------- 1-4

External View(Rear)

--------------------------------------------------------------- 1-4

External View(Internal)

----------------------------------------------------------- 1-5

Technology 2-1

Basic Configuration

-----------------------------------------------------------2-2

Functional Configuration

--------------------------------------------------------- 2-2

Overview of Electrical Circuitry

------------------------------------------------- 2-2

Component Configuration

------------------------------------------------------- 2-3

Drive Configuration

---------------------------------------------------------------- 2-4

Basic movement outline ---------------------------------------------------------- 2-4

Various Modes of Control ---------------------------------------------------2-6

Outline of operations -------------------------------------------------------------- 2-6

Jam Detection ---------------------------------------------------------------------2-15

Power Supply

----------------------------------------------------------------------2-17

Work of service --------------------------------------------------------------------2-19

Periodic Servicing 3-1

List of Work for Scheduled Servicing

------------------------------------3-2

Parts Replacement/Cleaning Procedure 4-1

List Of Parts

--------------------------------------------------------------------4-2

External / Internal Covers -------------------------------------------------------- 4-2

Consumale Parts Requiring Periodic Replacement and Cleaning

Points --------------------------------------------------------------------------------- 4-3

Motors/PCBs/Others -------------------------------------------------------------- 4-4

List of Sensors

---------------------------------------------------------------------- 4-5

External/Innernal Covers ----------------------------------------------------4-6

Removing the Rear Upper Cover ---------------------------------------------- 4-6

Removing the Rear Lower Cover

---------------------------------------------- 4-7

Removing the Front Upper Cover --------------------------------------------- 4-7

Removing the Front Inner Cover ----------------------------------------------- 4-8

Removing the Inserter Rear Cover -------------------------------------------- 4-9

Changing the Inserter Top Cover Open/Close Angle --------------------- 4-9

Removing the Inserter Front Cover ------------------------------------------4-10

Changing the Middle Guide Open/Close Angle ---------------------------4-10

Changing the Inserter Open Angle ------------------------------------------- 4-11

Removing the Main Unit --------------------------------------------------- 4-12

Removing the Upper Tray Unit ------------------------------------------------4-12

Removing the Lower Tray Unit

------------------------------------------------4-13

Removing the Inserter Pickup Unit -------------------------------------------4-13

Consumale Parts Requiring Periodic Replacement and Cleaning
Points -------------------------------------------------------------------------- 4-15

Removing the Inserter pickup rollers (upper) ------------------------------4-15

Removing the Inserter pickup roller (lower)

--------------------------------4-16

Removing the Inserter separation roller (upper) --------------------------4-16

Removing the Inserter separation roller (lower)

---------------------------4-17

Removing the Inserter feed roller (upper) ----------------------------------4-17

Removing the Inserter feed roller (lower)

-----------------------------------4-18

Removing the Inserter torque limiter (upper) ------------------------------4-18

Removing the Inserter torque limiter (lower)

-------------------------------4-19

Removing the Inserter electromagnetic clutch (upper) ------------------4-19

Removing the Inserter electromagnetic clutch (lower)

------------------4-20

Removing the Motor -------------------------------------------------------- 4-21

Removing the Tray Pickup Motor (M1) --------------------------------------4-21

Removing the Drive Switchover Motor (M4)

-------------------------------4-22

Removing the Upper Tray Lift Motor (M2)

----------------------------------4-23

Removing the Lower Tray Lift Motor (M3)

----------------------------------4-23

Summary of Contents for K1

Page 1: ...6 5 4 3 2 1 Document Insertion Unit K1 Service Manual May 1 2010 Revision 0 Product Outline Technology Periodic Servicing Parts Replacement Cleaning Procedure Adjustment Installation Appendix ...

Page 2: ...ormation as the need arises In the event of major changes in the contents of this manual over a long or short period Canon will issue a new edition of this manual The following paragraph does not apply to any countries where such provisions are inconsistent with local law Trademarks The product names and company names used in this manual are the registered trademarks of the individual companies Co...

Page 3: ...r switch closing the front door and closing the delivery unit door which results in supplying the machine with power 2 In the digital circuits 1 is used to indicate that the voltage level of a given signal is High while 0 is used to indicate Low The voltage value however differs from circuit to circuit In addition the asterisk as in DRMD indicates that the DRMD signal goes on when 0 In practically...

Page 4: ...0 0 ...

Page 5: ... Upper Cover 4 7 Removing the Front Inner Cover 4 8 Removing the Inserter Rear Cover 4 9 Changing the Inserter Top Cover Open Close Angle 4 9 Removing the Inserter Front Cover 4 10 Changing the Middle Guide Open Close Angle 4 10 Changing the Inserter Open Angle 4 11 Removing the Main Unit 4 12 Removing the Upper Tray Unit 4 12 Removing the Lower Tray Unit 4 13 Removing the Inserter Pickup Unit 4 1...

Page 6: ... 4 32 5 Adjustment 5 1 Adjustment at Time of Parts Replacement 5 2 6 Installation 6 1 Making Pre installation Checks 6 2 Checking the Power Supply 6 2 Checking the Installation Space 6 2 Cautions at the Time of Installation 6 3 Checking Bundled Components 6 4 Unpacking 6 5 Unpacking Procedure 6 5 Installation Procedure 6 7 Preparation for Installation on Upstream Connection Machine Side 6 7 Connec...

Page 7: ...Safety Precautions Points to Note About Turning Off the Main Power Switch Notes Before it Works Serving ...

Page 8: ... Power Switch This machine has two switches related to power supply the Power switch and the breaker Turning on the Power switch powers this machine The breaker detects an excess current and electric leakage to protect you against an electric shock MEMO Explain to the customer that the breaker must be checked once or twice a month and the result must be recorded ...

Page 9: ...Switch Notes Before it Works Serving CAUTION At servicing be sure to turn off the power source according to the specified steps and disconnect the power plug CAUTION Do not turn off the power switch when downloading is under way Turning off the main power switch while downloading is under way can disable the machine ...

Page 10: ...1 1 Product Outline Product Outline Features Specifications Names of Parts ...

Page 11: ...1 1 1 2 1 2 Product Outline Features Product Outline Features Features A free standing inserter with a reversal feature supporting a set of two large tray bins Each tray has a capacity of 200 sheets ...

Page 12: ...er heavy paper coated paper Paper size Uppertray lowtray B5to13 19 2 Feed direction to 139 7to482 6mm Width direction to 98 4to330 2mm Paper weighing 52g m2 to 300g m2 Loading capacity Loading height Up to24mm Defined on the basis of 80g m2 paper Uppertray 200 sheets lowtray 200sheets Reference Center reference Mixed paper loading No Operator console No Display Document loading LED available Size ...

Page 13: ...w Rear Product Outline Names of Parts External View Rear Names of Parts External View Front Upper tray Low tray Upper cover Front upper cover F 1 1 F 1 1 External View Rear Power switch Leakage breaker Rear low cover Rear upper cover Rear cover F 1 2 F 1 2 ...

Page 14: ...duct Outline Names of Parts External View Internal Product Outline Names of Parts External View Internal External View Internal Horizontal feed guide Jam clearing lever through feed unit Jam clearing lever F 1 3 F 1 3 ...

Page 15: ...2 2 Technology Technology Basic Configuration Controls Jam Detection Power Supply Work of service ...

Page 16: ...t and Feed unit 1 tray unit 2 Paper feed unit 3 Feed unit F 2 1 F 2 1 Overview of Electrical Circuitry The machine s sequence of operations is controlled by the DC controller PCB The DC controller PCB is a CPU used to interpret input signals from sensors and host machine and generate signals to drive such loads as motors and clutches at such times as programmed in advance Fin AG1 AG2 DC controller...

Page 17: ...d roller2 4 Registration roller 11 Feed roller3 5 Feed roller lower 12 Inlet roller1 6 Separation roller lower 13 Inlet roller2 7 Pickup roller lower 14 Delivery roller F 2 3 F 2 3 Sensor Layout It describes only all optical sensors on the feed path S20 S21 S3 S16 S17 S9 S12 S7 S8 S18 S3 Upper tray regist sensor S7 Low tray regist sensor S8 Middle feed sensor S9 Upper tray empty sensor S12 Low tra...

Page 18: ...eed motor M2 Upper tray lift motor M3 Low tray lift motor M4 Drive switchover motor M5 Entrance motor 1 M6 Reverse motor CL1 Uppper tray regist clutch CL2 Low tray regist clutch SOL1 Reverse solenoid F 2 4 F 2 4 Basic movement outline Surface insert operation Transfers the paper loaded in the inserter tray to the downstream equipment so the upper surface of the paper will face up Paper is fed from...

Page 19: ...er pickup tray switch operation Back insert operation Transfers the paper loaded in the inserter tray to the downstream equipment so the upper surface of the paper will face down Paper is fed directly to the straight pass F 2 6 F 2 6 Insetrter pickup tray switch operation You can have paper fed from either of the two inserter trays chosen at your option F 2 7 F 2 7 ...

Page 20: ...ation The upper tray lift motor turns in the reverse direction at a speed of 533 pps to move the paper feed tray upward The upper tray pick sensor turns on to stop the upper tray lift motor For plain paper the tray paper feed motor turns in the reverse direction at a speed of 500 mm s to start separating the paper in the tray For thick paper the tray paper feed motor turns in the reverse direction...

Page 21: ...f 533 pps to move the paper feed tray upward The upper tray pick sensor turns on to stop the upper tray lift motor For plain paper the tray paper feed motor turns at a speed of 500 mm s to start separating the paper in the tray For thick paper the motor turns in the reverse direction at a speed of 250 mm s to start separating the paper in the tray For the upper tray the tray paper feed motor stops...

Page 22: ... since the reverse timing sensor was turned off the reverse motor stops 6 Second paper feeding for reversal After the reverse feed motor stops as mentioned above the tray feed motor turns in the normal direction at a speed of 400 mm s and the reverse motor turns in the normal direction to start feeding the paper to the standby position In case of paper feed from the upper tray the tray paper feed ...

Page 23: ...r turned on M6 M6 S16 8 Second paper feeding to horizontal feed block When an Entry signal for the second paper is received the time specified to allocate a the pace between the first and second papers is taken the entrance motor 1 turns in the reverse direction at the same speed as that of the motor in the host machine and the reverse motor turns in the reverse direction at the same speed as that...

Page 24: ... tray For the upper tray the tray paper feed motor stops when the paper has been fed 14 7 mm since the registration sensor turned on For the lower tray the tray paper feed motor stops when the paper has been fed 19 1 mm since the registration sensor turned on The upper tray lift motor turns in the normal direction at a speed of 533 pps to move the paper feed tray 9 pls downward S2 M2 S3 M2 M1 F 2 ...

Page 25: ... S2 S3 M2 M1 F 2 25 F 2 25 F 2 26 F 2 26 4 First paper feeding to horizontal feed block When an Entry signal for the first paper is received the entrance motor 1 turns in the reverse direction at the same speed as that of the motor in the host machine and the reverse motor turns in the reverse direction at the same speed as that of the motor in the host machine thus feeding the paper to the horizo...

Page 26: ...ivery sensor 2 turned on S21 M6 M5 F 2 29 F 2 29 F 2 30 F 2 30 Sequence of inserter pickup tray switch operation This section describes switching of the upper tray to the lower tray that take place when two papers are fed to the upper tray and one paper is fed to the lower tray respectively from the inserter paper feed unit 1 Upper tray paper feeding for separation The upper tray lift motor turns ...

Page 27: ...e the drive switchover motor turns in the normal direction at a speed of 533 pps The drive switchover motor stops when the paper has been fed 32 pls 2mm since the drive switchover HP sensor turned on F 2 32 F 2 32 F 2 33 F 2 33 Drive switchover gear M1 M4 S3 S1 S6 M3 4 Lower tray paper feeding for separation The lower tray motor turns in the reverse direction at a speed of 533 pps to move the pape...

Page 28: ...e In case of reverse side insertion the paper is fed to the standby position following the reverse side insertion sequence 6 Switching between paper feed trays The tray paper feed motor stops when the paper has been fed 10 3 mm since the trailing edge of the paper in the lower tray has turned off the registration sensor At this time the drive switchover motor turns in the reverse direction at a sp...

Page 29: ...ed to detect whether paper is present and whether paper is fed normally S3 Upper tray registration sensor S7 Lower tray registration sensor S8 Middle feed sensor S9 Upper tray empty sensor S12 Lower tray empty sensor S16 Reverse timing sensor S17 Reverse sensor S18 Reverse entrance sensor S20 Entrance sensor S21 Delivery sensor 2 S20 S21 S3 S16 S17 S9 S12 S7 S8 S18 Jam Type F 2 40 F 2 40 ...

Page 30: ...reversal unit standby position started 20E5 Reverse entrance sensor delay jam S18 The reverse entrance sensor does not detect paper even when the specified time has lapsed since the middle feed sensor detected paper 20E6 Reverse sensor delay jam S17 The reverse sensor does not detect paper even when the specified time has lapsed since the reverse entrance sensor detected paper in the reverse inser...

Page 31: ...he load related parts motors solenoids fans and clutches as it is or converted to 5 VDC or 3 3 VDC by the DC DC to be supplied to logic related parts sensors Protection Function The power supply PCB incorporates a primary side secondary side overcurrent and overvoltage protection circuits Each of load related 24V lines has a fuse If overcurrent or overvoltage occurs in a load motor etc due to a tr...

Page 32: ...ller PCB PCB3 LED PCB Solenoid Clutch Motor Motor Motor S1 S2 S3 S4 S5 S6 S7 S8 S9 S11 S12 S14 S15 S16 S17 S18 S19 S20 S21 M2 M3 M4 Motor Motor Motor Fan F1 M5 M1 M6 PCB1 PCB2 SOL1 CL1 CL2 SW1 Remote Signal 24V Remote Signal 3 3V Finisher AG1 AG2 Body SW3 Red Exclusive for AF1 AF2 Remote Signal 3 3V Blue Exclusive for AG1 AG2 SW2 Sensor S10 S13 Option Controller PCB PCB4 SW1 Front upper cover open...

Page 33: ...00 sheets 4 Replace ment separation roller upper lower 100 000 sheets 2 Replace ment feed roller upper lower 100 000 sheets 2 Replace ment torque limiter upper lower 1 000 000 sheets 2 Replace ment electromagnetic clutch upper lower 1 000 000 sheets 2 Replace ment solenoid assembly 1 000 000 sheets 1 Replace ment Periodically serv iced parts pickup roller upper lower 40 000 sheets 4 Cleaning separ...

Page 34: ...3 3 Periodic Servicing P e r i o d i c Servicing Periodic services items ...

Page 35: ... pickup roller lower 4A3 3870 2 CR 100 000sheet No DRBL 2 IS P RL2 9 separation roller lower 4A3 3868 1 CR 100 000sheet No DRBL 2 IS S RL2 10 feed roller lower 4A3 3869 1 CR 100 000sheet No DRBL 2 IS F RL2 11 torque limiter lower 4A3 3888 1 CR 1 000 000sheet No DRBL 2 IS TQLM2 12 electromagnetic clutch lower 4H3 0290 1 CR 1 000 000sheet No DRBL 2 IS CL2 13 Feed unit Reversal solenoid assembl FL2 7...

Page 36: ...rocedure P a r t s Replacement C l e a n i n g Procedure List of Parts External Internal Covers Main Units C o n s u m a b l e P a r t s R e q u i r i n g P e r i o d i c R e p l a c e m e n t a n d Cleaning Points Motors PCBs Sensors ...

Page 37: ...xternal Internal Covers List Of Parts External Internal Covers 6 3 5 3 4 F 4 1 F 4 1 F 4 2 F 4 2 F 4 3 F 4 3 Name Part No Refer to 1 Rear Upper Cover FC9 1851 FC9 1776 4 6 2 Rear Lower Cover FC9 1766 4 7 3 Front Upper Cover FC9 1764 FC9 1767 FC6 5697 4 7 4 Front Inner Cover FC9 1765 4 8 5 Rear Cover FC9 1882 4 9 6 Front Cover FC9 1881 4 10 ...

Page 38: ...let antistatic needle FL3 1472 2 Through pass outlet antistatic needle FL3 1470 3 Inserter pickup roller upper 4A3 3870 4 15 4 Inserter separation roller upper 4A3 3868 4 16 5 Inserter feed roller upper 4A3 3869 4 17 6 Inserter torque limiter upper 4A3 3888 4 18 3 Inserter pickup roller lower 4A3 3870 4 16 4 Inserter separation roller lower 4A3 3868 4 17 5 Inserter feed roller lower 4A3 3869 4 18 ...

Page 39: ...23 M4 Drive switchover motor FH5 1041 4 22 M5 Entrance motor 1 FK2 4582 M6 Reverse motor FK2 4580 SW1 Front upper cover open close switch 4H1 6449 SW2 Upper cover open close switch 4H1 6449 SW3 Power supply switch FK2 1741 CL1 Uppper tray regist clutch 4H3 0290 4 19 CL2 Low tray regist clutch 4H3 0290 4 20 SOL1 Reverse solenoid FH6 5136 F1 Fan FK2 6484 CB1 Breaker FH7 7625 PCB1 Upper tray LED PCB ...

Page 40: ...y lower limit sensor WG8 5696 S6 Low tray pick sensor WG8 5696 S7 Low tray regist sensor WG8 5696 S8 Middle feed sensor WG8 5696 S9 Upper tray empty sensor WG8 5696 4 27 S10 Upper tray width sensor 4H3 0282 4 28 S11 Upper tray last paper sensor WG8 5696 4 29 S12 Low tray empty sensor WG8 5696 4 29 S13 Low tray width sensor 4H3 0282 4 30 S14 Low tray last paper sensor 1 WG8 5696 4 31 S15 Low tray l...

Page 41: ...Innernal Covers Removing the Rear Upper Cover Parts Replacement Cleaning Procedure External Innernal Covers Removing the Rear Upper Cover External Innernal Covers Removing the Rear Upper Cover 1 Remove four screws to remove the rear upper cover x4 F 4 7 F 4 7 ...

Page 42: ...e External Innernal Covers Removing the Front Upper Cover Removing the Rear Lower Cover 1 Remove the rear upper cover Refer to 4 6 2 Remove four screws to remove the rear lower cover x4 Removing the Front Upper Cover 1 Open the front upper cover 2 Remove two resin E rings to remove the upper front cover F 4 8 F 4 8 F 4 9 F 4 9 F 4 10 F 4 10 ...

Page 43: ...External Innernal Covers Removing the Front Inner Cover Removing the Front Inner Cover 1 Open the front upper cover 2 Holding the jam removal lever open the transfer guide 3 Remove two screws to remove the front inner cover small x2 4 Remove five screws to remove the front inner cover x5 F 4 11 F 4 11 F 4 12 F 4 12 F 4 13 F 4 13 F 4 14 F 4 14 ...

Page 44: ... Innernal Covers Changing the Inserter Top Cover Open Close Angle Removing the Inserter Rear Cover 1 Remove two screws to remove the inserter rear cover Changing the Inserter Top Cover Open Close Angle 1 Remove the rear cover Refer to 4 9 2 Remove one screw remove the inserter top cover angle regulating shaft and then open the top cover x1 F 4 15 F 4 15 F 4 16 F 4 16 ...

Page 45: ...emoving the Inserter Front Cover 1 Remove the inserter rear cover Refer to 4 9 2 Increase the inserter top cover open close angle Refer to 4 9 3 Remove two screws to remove the inserter front cover Changing the Middle Guide Open Close Angle 1 Remove the inserter rear cover Refer to 4 9 2 Increase the inserter top cover open close angle Refer to 4 9 3 Remove two screws to open the middle guide x2 F...

Page 46: ...g Procedure External Innernal Covers Changing the Inserter Open Angle Changing the Inserter Open Angle 1 Remove the inserter rear cover Refer to 4 9 2 Remove one screw to remove the support plate 1 x1 3 Remove one screw to remove the cover x2 4 Remove one screw to remove the support plate 2 x1 F 4 19 F 4 19 F 4 20 F 4 20 F 4 21 F 4 21 ...

Page 47: ...edure Removing the Main Unit Removing the Upper Tray Unit Removing the Main Unit Removing the Upper Tray Unit 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove four screws and three connectors to remove the upper tray unit x2 x2 x3 F 4 22 F 4 22 ...

Page 48: ... to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove the upper tray unit Refer to 4 12 5 Remove four screws and one connector to remove the lower tray unit x2 x2 Removing the Inserter Pickup Unit 1 Remove the inserter rear cover Refer to 4 9 2 Increase the inserter open angle Refer to 4 11 3 Remove two screws one clamp and 11 connectors to ...

Page 49: ...nserter Pickup Unit Parts Replacement Cleaning Procedure Removing the Main Unit Removing the Inserter Pickup Unit 4 Remove two screws from the hinge x2 5 Remove two stepped screws and then slide the inserter pickup unit backward and then lift it to remove it x2 F 4 25 F 4 25 F 4 26 F 4 26 ...

Page 50: ... Replacement and Cleaning Points Removing the Inserter pickup rollers upper Consumable Parts Requiring Periodic Replacement and Cleaning Points Removing the Inserter pickup rollers upper 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove two screws to remove the front transfer guide x2 4 Remove two resin E rings to remove two inserter pickup roller...

Page 51: ...ller lower 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Increase the middle guide open close angle Refer to 4 10 4 Remove two resin E rings to remove two inserter pickup rollers lower Removing the Inserter separation roller upper 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove five screws to remov...

Page 52: ... middle guide open close angle Refer to 4 10 4 Remove five screws to remove the transfer guide x5 5 Remove two E rings and one bearing to remove the inserter separation roller lower Removing the Inserter feed roller upper 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove one spring two resin E rings and two bearings to remove the pickup roller uni...

Page 53: ...uide open close angle Refer to 4 10 4 Remove six screws to remove the rear transfer guide x6 5 Remove one spring two resin E rings and two bearings to remove the pickup roller unit 6 Remove three E rings one pickup roller and one lever to remove the inserter feed roller lower Removing the Inserter torque limiter upper 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle R...

Page 54: ...p cover open close angle Refer to 4 9 3 Increase the middle guide open close angle Refer to 4 10 4 Remove five screws to remove the transfer guide x5 5 Remove three E rings one gear one parallel pin two bearings and one separation roller to remove the inserter torque limiter lower Removing the Inserter electromagnetic clutch upper 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open ...

Page 55: ...rts Requiring Periodic Replacement and Cleaning Points Removing the Inserter electromagnetic clutch lower Removing the Inserter electromagnetic clutch lower 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Increase the middle guide open close angle Refer to 4 10 4 Remove one screw and one connector and the remove the inserter electromagnetic clutch lowe...

Page 56: ... M1 Removing the Motor Removing the Tray Pickup Motor M1 1 Remove the rear cover Refer to 4 9 2 Remove one connector and two wire saddles to remove the harness from the harness guide x1 x2 3 Remove four screws one belt and one spring to remove the tray pickup motor unit x4 4 Remove two screws and one connector to remove the tray pickup motor x2 x1 F 4 46 F 4 46 F 4 47 F 4 47 F 4 48 F 4 48 ...

Page 57: ...the Drive Switchover Motor M4 Removing the Drive Switchover Motor M4 1 Remove the rear cover Refer to 4 9 2 Remove four connectors and two clamps 2 Loosen one screw to remove the harness guide x1 4 Remove three screws to remove the drive switchover motor unit x3 5 Remove two screws to remove the drive switchover motor F 4 49 F 4 49 F 4 50 F 4 50 F 4 51 F 4 51 F 4 52 F 4 52 ...

Page 58: ...ing the Lower Tray Lift Motor M3 Removing the Upper Tray Lift Motor M2 1 Remove the rear cover Refer to 4 9 2 Remove two screws and one connector to remove the upper tray lift motor x2 x1 Removing the Lower Tray Lift Motor M3 1 Remove the rear cover Refer to 4 9 2 Remove two screws and one connector to remove the lower tray lift motor x2 x1 F 4 53 F 4 53 F 4 54 F 4 54 ...

Page 59: ...B Parts Replacement Cleaning Procedure Removing the PCB Removing the DC Controller PCB Removing the PCB Removing the DC Controller PCB 1 Remove the rear cover Refer to 4 9 2 Remove one screw three locking supports and all connectors on the PCB and then remove the DC controller PCB x1 F 4 55 F 4 55 ...

Page 60: ...ay unit Refer to 4 12 2 Remove two screws to remove the LED cover x2 3 Remove one screw and one connector to remove the upper tray LED PCB x1 x1 Removing the Lower Tray LED PCB 1 Remove the upper tray unit Refer to 4 12 2 Remove the lower tray unit Refer to 4 13 3 Remove four screws to remove the tray bottom cover large x4 4 Remove four screws to remove the tray lower inner cover x4 F 4 56 F 4 56 ...

Page 61: ... Removing the Lower Tray LED PCB Parts Replacement Cleaning Procedure Removing the PCB Removing the Lower Tray LED PCB 5 Remove two screws to remove the LED cover x2 6 Remove one screw and one connector to remove the lower tray LED PCB x1 x1 F 4 60 F 4 60 F 4 61 F 4 61 ...

Page 62: ...y empty sensor S9 Removing the Sensor Removing the Upper tray empty sensor S9 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove the upper tray unit Refer to 4 12 5 Remove one screw to remove the sensor cover x1 6 Remove one connector to remove the upper tray empty sensor x1 F 4 62 F 4 62 F 4 63 F 4 63 ...

Page 63: ...10 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove the upper tray unit Refer to 4 12 5 Remove two screws to remove the tray lower cover small x2 6 Remove two screws and one connector to remove the upper tray width sensor MEMO After replacing with the upper tray width sensor with a new one adjust the sensor ...

Page 64: ...he upper tray unit Refer to 4 12 5 Remove two screws to remove the tray lower cover small x2 6 Remove one connector to remove the Upper tray last paper sensor x1 Removing the Low tray empty sensor S12 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove the upper tray unit Refer to 4 12 5 Remove the lower tray u...

Page 65: ...tor to remove the Low tray empty sensor x1 Removing the Low tray width sensor S13 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove the upper tray unit Refer to 4 12 5 Remove the lower tray unit Refer to 4 12 6 Remove four screws to remove the tray lower cover large x4 7 Remove four screws to remove the tray ...

Page 66: ...O After replacing with the low tray width sensor with a new one adjust the sensor output value in the service mode x2 Removing the Low tray last paper sensor 1 S14 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove the upper tray unit Refer to 4 12 5 Remove the lower tray unit Refer to 4 12 6 Remove four screw...

Page 67: ...connector to remove the low tray last paper sensor1 x1 Removing the Low tray last paper sensor 2 S15 1 Remove the rear cover Refer to 4 9 2 Increase the top cover open close angle Refer to 4 9 3 Remove the front cover Refer to 4 10 4 Remove the upper tray unit Refer to 4 12 5 Remove the lower tray unit Refer to 4 12 6 Remove four screws to remove the tray lower cover large x4 7 Remove four screws ...

Page 68: ...ts Replacement Cleaning Procedure Removing the Sensor Removing the Low tray last paper sensor 2 S15 8 Remove two screws to remove the tray lower cover small x2 9 Remove two screws to remove the sensor unit x2 z 10 Remove one connector to remove the low tray last paper sensor2 x1 F 4 81 F 4 81 F 4 82 F 4 82 F 4 83 F 4 83 ...

Page 69: ...5 5 Adjustment Adjustment Adjustment at Time of Parts Replacement ...

Page 70: ... the pin enters the frame hole by the inserter s own weight although it does not enter the hole smoothly it is OK 1 2 If the positioning pin does not enter the hole adjust the inserter position by adjustuing the position of the hinge s adjusting plate following the procedure below Adjustment Method 1 Loosen two screws to remove the rear cover 1 F 5 1 F 5 1 F 5 2 F 5 2 2 Remove one screw to remove ...

Page 71: ... with reference to the marks 4 on the front plate Turning the adjusting screw by one scale mark 1 mm moves the front of the inserter 4 6 mm to the left right Turning the adjusting screw clockwise moves the plate forward and moves the inserter to leftward Turning the adjusting screw counterclockwise moves the plate backward and moves the inserter to rightward F 5 6 F 5 6 F 5 7 F 5 7 1 x1 8 Tighten ...

Page 72: ...he right side of the inserter and the finisher is within 1 mm at the front and back A and B If it is not within 1 mm make the height adjustment as the following procedure Adjustment method 1 Remove the rear cover 1 F 5 11 F 5 11 F 5 12 F 5 12 2 Increase the top cover open close angle Remove one screw to remove the upper cover angle restriction shaft 1 Open the top cover x1 1 2 3 Loosen two screws ...

Page 73: ...th adjustment after replacing the document width sensor 1 Remove the rear cover 2 Set the DIP switch as shown below turn on the SW1 push switch and then turn on the inserter Note Keep pressing the SW1 for at least 2 seconds after turning on the power After switching between modes turn off the power and then turn it on again DIPSW ON OFF Test mode 1 2 3 4 5 6 7 8 Tray control adjustment LED1 SW3 ON...

Page 74: ...cover unit adjust the positioning pin following the procedure mentioned below 1 Adjustment method 1 Remove the rear cover 2 Increase the top cover open close angle 3 Loosen two screws 1 and one screw 2 F 5 17 F 5 17 F 5 18 F 5 18 1 1 2 4 Twist the top cover with both hands while twisting it slightly and move the adjusting plate with reference to the marks 3 Next secure the adjusting plate using a ...

Page 75: ...6 Installation Making Pre installation Checks C h e c k i n g B u n d l e d Components Unpacking Installation Procedure ...

Page 76: ...stallation site It is recommended to make a preliminary inspection of the installation site before delivering the equipment to the user Checking the Power Supply The equipment must be connectable to the outlet that can supply the rated voltage 10 15 at the specified ampere or higher 120V 230V 1A Checking the Installation Space The following illustration describes the necessary space for the mainte...

Page 77: ... Turn off the host machine CAUTION Before installing this equipment be sure to perform the following steps in the specified order 1 Turn OFF the main power switch of the host machine 2 Be sure that the control panel display and the main power lamp are both turned OFF and then disconnect the power plug 2 About the Installation This equipment is approx 55 0kg so it should require two or more personn...

Page 78: ...ound plate 1pce 3 Bearing clip 2pcs 4 Positioning pin 1pce 5 Binding head screw M4x10 2pcs 6 Shunt cable 1pce 1 7 Power cord US EUR AUS 120V model 1pce 230V model 3pce 8 Index label 2pcs 2 9 Don ts Form Label 230V model 1pce 10 Wire saddle 1pce 1 Use the correct power cord to match the location area of installation Make sure not to leave unused power cord at the site 2 Only for the 230V model ...

Page 79: ...h tapes and cushioning materials as in structed below before installing the equipment Keep all the shipping fixtures and cushion ing materials in a safe place for later reuse in reshipping the equipment as for relocation and repairs 1 Take out the accessory box from the package CAUTION Leave the four cushioning materials attached to the inserter in position Removing the cushioning materials could ...

Page 80: ...ng its main unit might result in a deformed or damaged cabinet The inserter is so heavy weighing 55 0 kg that it should require a team of two workers at least to handle 3 Remove the pallet and cushioning materials shown in the figure Then put the plastic cover down 4 Elevate the front and rear casters lightly in this order and remove cushioning materials Then remove the plastic cover and packaging...

Page 81: ...ion on Upstream Connection Machine Side Installation Procedure Preparation for Installation on Upstream Connection Machine Side 1 Remove two covers 2 Secure the two bundled clamp plates and positioning pin to the host machine each with two bundled RS tight screws M4 x 8 At this time secure the supplied ground plate along with the rear latch catch x6 F 6 6 F 6 6 F 6 7 F 6 7 ...

Page 82: ...d from the wall outlet 1 Stow the left overturning prevention stay by removing a wing screw and lifting the stay up x1 2 After stowing the overturning prevention stay clamp it with the wing screw removed x1 3 Stow the right overturning prevention stay by removing a wing screw and then clamp it with the wing screw removed 4 Install the inserter in position by inserting the positioning pin into the ...

Page 83: ...Installation Installation Procedure Connecting to Connection Machine 5 With the Upper front cover open remove one screw and press the lock lever to hook on the bearing clip Reinstall the screw removed to secure the lock lever 6 Close the Upper front cover F 6 12 F 6 12 F 6 13 F 6 13 ...

Page 84: ... inclination could result in jams frequently occurring at the paper folding unit inlet 1 Check to see if there is a height difference of 22 3mm between the right upper surface of the inserter and the left upper surface of the connected equipment Inclination Check 1 Check that the difference of clearances at the two positions as shown in the figure The difference should be within 0 2mm F 6 14 F 6 1...

Page 85: ...as shown in the figure The difference should be within 0 2mm Height Adjustment CAUTION I f t h e h e i g h t a n d i n c l i n a t i o n o f t h e i n s e r t e r a n d t h e connected equipment are not within their tolerances adjust them in these steps 1 Open the front upper cover and remove the jam recovery map 2 Remove the wrench from the front upper cover F 6 16 F 6 16 F 6 17 F 6 17 F 6 18 F 6...

Page 86: ...ise to lower and clockwise to heighten After making the adjustment tighten the front and rear nuts 1 on the inserter Inclination Adjustment 1 Turn the nut 1 on the front caster assembly paper ejection side clockwise to loosen it Then turn the nut 2 to adjust the height 1 2 MEMO Turn the nut 2 counterclockwise to lower and clockwise to heighten 2 With the nut 1 on the rear caster assembly paper eje...

Page 87: ...er Connecting the Cables Connecting the Interface cable 1 Connect the installed interface cable to the finisher with two bundled RS tight screws M4x8 Refer to the Staple Finisher A1 Booklet Finisher A1 Installation Procedure Connecting the Power Cord 1 Insert the bundled power cord into the inserter to connect Insert the plug end of the power cord into an external power outlet F 6 23 F 6 23 F 6 24...

Page 88: ...the bundled shunt cable at the rear bottom of the Connection Machine and the connected equipment using the Bundled binding head screw M4x10 and step 1 to the supplied screw x2 Connecting the Wire saddle 1 Attach the bundled wire saddle to the rear lower cover 2 Stow the excess length of the interface cable connected to the downstream finisher into the wire saddle F 6 27 F 6 27 F 6 28 F 6 28 F 6 29...

Page 89: ...g parts which are no longer necessary 1 Cover of the Buffer Pass Unit 2pcs 2 Power cord 2pcs 230Vmodel 3 Binding head screw M4x10 1pce Operation Checks 1 After completion of installation connect the power plug of the host machin and equipment to the power outlet Then open the switch cover and turn ON the main power switch 2 In the operation check mode check for cover sheet insertion operation ...

Page 90: ...7 7 Appendix Appendix Service Tools General Circuit Diagram ...

Page 91: ...vents and Oils No Name Uses Composition Remarks 1 Vic Clean Cleaning e g glass plastic rubber parts external covers Hydrocarbon fluorine family Alcohol Surface activating agent Water Do not bring near fire Procure locally Isopropyl alcohol may be substituted Special Tools None ...

Page 92: ...L S S G N D T Y U K A N S S G N D 5 V 5 V 5 V S G N D C N 3 C N 1 5 C N 1 4 C N 1 C N 5 C N 2 C N 7 C N 9 C N 8 C N 4 C N 1 0 C N 6 C N 1 1 C N 1 3 C N 1 2 S G N D C N 1 S G N D C N 2 C N 3 C N 3 C N 2 C N 1 5 V C N 1 C N 2 C N 3 S G N D S G N D 5 V C N 1 C N 3 5 V 5 V C N 2 S G N D 5 V C N 2 C N 3 C N 1 2 P I C K S 2 L _ S T Y U K A N S 1 L S 2 R E G S S3 S2 S4 C N 9 C N 3 C N 2 C N 5 C N 7 C N 4...

Page 93: ...N 1 C N 8 C N 5 C N 3 C N 4 C N 2 C N 2 C N 1 C N 4 C N 3 C N 1 C N 3 C N 4 C N 2 2UPMOT_ B 1 U P M O T _ A 2 U P M O T _ A 1UPMOT_ B 2UPMOT_ A 2 U P M O T _ B 1 U P M O T _ B 1UPMOT_ A K U M O T _ A KUMOT_ A K U M O T _ B KUMOT_ B C N 6 7 4 C N 3 4 1 C N 1 8 3 1 S G N D C N 2 3 3 2 C N 2 1 4 C N 1 8 4 2 L E D 2 C N 2 3 3 1 C N 1 8 2 1 C N 6 7 2 C N 2 2 6 3 C N 1 8 5 2 2 4 V 2 C N 2 2 7 1 C N 2 2 ...

Page 94: ... N 1 _ B 5 V C N 6 6 5 V P I N 1 _ B C N 6 3 S G N D C N 8 6 2 C N 6 2 H A N T E N _ A S G N D C N 3 1 2 C N 2 1 6 3 C N 3 C N 8 4 3 S G N D C N 2 0 5 1 C N 8 9 1 C N 1 8 0 2 I N S C N 2 1 7 1 2 4 V 1 C N 1 C N 3 1 C N 2 2 0 1 C N 2 0 5 4 C N 8 8 4 O U T 2 S D F O P E N S C N 3 C N 6 9 T X D C N 1 5 3 C N 2 0 5 2 C N 8 5 1 C N 3 1 3 S G N D C N 8 7 4 C N 3 1 7 C N 1 5 1 C N 1 R X D C N 2 0 5 5 P I...

Page 95: ...1 3 C N 8 2 1 C N 8 2 2 C N 8 2 3 C N 8 2 4 C N 8 2 5 C N 8 2 6 C N 8 2 7 C N 8 2 8 C N 8 2 9 C N 8 2 1 0 C N 8 2 1 1 C N 8 2 1 2 C N 8 2 1 3 C N 2 3 5 1 C N 2 3 6 2 C N 2 3 5 2 C N 2 3 6 1 S G N D C N 8 0 8 C N 8 0 7 S G N D M O D E C O N E C T T X D P O W E R O N E N T R Y A C K E N T R Y R E S E T E X I T S G N D S G N D S G N D R X D S G N D E X I T A C K S G N D C N 2 2 3 1 C N 4 2 G N D S G ...

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