Document Insertion Unit-J1 SERVICE MANUAL September 17, 2009 Rev. 0 COPYRIGHT 2009 CANON INC. CANON Document Insertion Unit-J1 Rev. 0 PRINTED IN U.S.A.
Application This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair of products. This manual covers all localities where the products are sold. For this reason, there may be information in this manual that does not apply to your locality. Corrections This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When changes occur in applicable products or in the contents of this manual, Canon will release technical information 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. Copyright This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc. COPYRIGHT 2001 CANON INC. Printed in Japan Caution Use of this manual should be strictly supervised to avoid disclosure of confidential information.
Introduction Symbols Used This documentation uses the following symbols to indicate special information: Symbol Description Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning. Indicates an item requiring care to avoid electric shocks. Indicates an item requiring care to avoid combustion (fire). Indicates an item prohibiting disassembly to avoid electric shocks or problems. Indicates an item requiring disconnection of the power plug from the electric outlet. Memo Indicates an item intended to provide notes assisting the understanding of the topic in question. REF. Indicates an item of reference assisting the understanding of the topic in question. Provides a description of a service mode. Provides a description of the nature of an error indication.
Introduction The following rules apply throughout this Service Manual: 1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with reference to the timing of operation. In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol, the arrow indicates the direction of the electric signal. The expression "turn on the power" means flipping on the power 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 all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessors used in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads. The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins. All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and be able to identify and isolate faults in the machine."
Contents Contents Chapter 1 Specifications 1.1 Product Specifications...1-1 1.1.1 Specifications...1-1 1.2 Names of Parts...1-2 1.2.1 External view...1-2 1.2.2 Cross Section...1-3 Chapter 2 Installation 2.1 Making Pre-Checks...2-1 2.1.1 Checking the Contents...2-1 2.1.2 Installation Precautions...2-3 2.1.3 Selecting the Site of Installation...2-3 2.2 Preparation Before Installation...2-4 2.2.1 Unpacking...2-4 2.2.2 Preparing the Host Machine for Installation...2-7 2.3 Installation Procedure...2-7 2.3.1 Connecting to the Host Machine...2-7 2.3.2 Connecting the Power Cord...2-14 2.3.3 Attaching the Labels... 2-14 2.3.4 Checking Operation...2-14 Chapter 3 Functions 3.1 Insertion Unit...3-1 3.1.1 Basic Construction... 3-1 3.1.1.1 Electric Circuit Overview... 3-1 3.1.2 Basic Operation...3-1 3.1.2.1 Basic Operation... 3-1 3.1.2.2 Drive Train/Sensor Layout... 3-2 3.1.3 Pickup/Feed System... 3-4 3.1.3.1 Overview... 3-4 3.1.3.2 Inserter's Straight Paper Feed Sequence... 3-4 3.1.3.3 Inserter's Reverse Paper Feed Sequence... 3-7 3.1.3.4 Through Feed Sequence... 3-10 3.1.4 Document Detection... 3-11 3.1.4.1 Detection of Presence/Absence of Document... 3-11 3.1.5 Detecting Jams...3-11 3.1.5.1 Overview... 3-11 3.1.6 Power Supply...3-13 3.1.6.1 Overview... 3-13 3.1.6.2 Protection Function... 3-13 Chapter 4 Parts Replacement Procedure 4.1 External Covers...4-1 4.1.1 External Covers...4-1 4.1.1.1 Removing the Rear Upper Cover... 4-1 4.1.1.2 Removing the Rear Lower Cover... 4-1 4.1.1.3 Removing the Front Upper Cover... 4-1 4.1.1.4 Removing the Front Lower Cover... 4-1 4.1.1.5 Removing the Right Cover... 4-2
Contents 4.1.1.6 Removing the Left Cover... 4-2 4.1.1.7 Removing the Rear Inner Cover... 4-2 4.1.1.8 Removing the Front Inner Cover... 4-3 4.1.1.9 Removing the Right Inner Cover... 4-3 4.1.1.10 Removing the Inserter Rear Cover... 4-3 4.1.1.11 Removing the Inserter Front Left cover... 4-4 4.1.1.12 Removing the Inserter Front Right cover... 4-4 4.1.1.13 Changing the Inserter Pickup Unit Open/Close Angle... 4-4 4.1.1.14 Removing the Inserter Paper Feed Unit... 4-4 4.2 Insertion Unit... 4-5 4.2.1 Drive System...4-5 4.2.1.1 Removing the Inserter Pickup Motor (M1)... 4-5 4.2.1.2 Removing the Tray Lift Motor (M2)... 4-6 4.2.1.3 Removing the Reverse Unit Motor (M3)... 4-6 4.2.1.4 Removing the Reverse Solenoid (SL1)... 4-6 4.2.2 Document Feeding System...4-6 4.2.2.1 Removing the Inserter Pickup Roller... 4-6 4.2.2.2 Removing the Inserter Feed Roller... 4-7 4.2.2.3 Removing the Inserter Separation Roller... 4-8 4.2.2.4 Removing the Torque Limiter... 4-8 4.2.2.5 Removing the Feed Collar (Straight Pass Assembly)... 4-9 4.2.2.6 Removing the Tray Unit... 4-9 4.2.3 Electrical System...4-9 4.2.3.1 Removing the Inserter Controller PCB... 4-9 4.2.3.2 Removing the Power Supply PCB... 4-10 4.2.3.3 Removing the Tray LED PCB... 4-10 4.2.3.4 Removing the Inserter Open/Close Sensor (S1)... 4-11 4.2.3.5 Remoeing the Top Cover Open/Close Sensor (S2)... 4-11 4.2.3.6 Removing the Pickup Sensor (S3)... 4-11 4.2.3.7 Removing the Registration Sensor (S4)... 4-11 4.2.3.8 Removing the Paper Set Sensor (S6)... 4-13 4.2.3.9 Removing the Tray Paper Sensor 1 (S7)... 4-13 4.2.3.10 Removing the Tray Paper Sensor 2 (S8)... 4-13 4.2.3.11 Removing the Tray Paper Width Senor (S9)... 4-14 4.2.3.12 Removing the Reverse Sensor (S10)... 4-15 4.2.3.13 Removing the Reverse Timing Sensor (S11)... 4-15 4.2.3.14 Removing the Reverse Entrance Sensor (S12)... 4-15 4.2.3.15 Removing the Front Upper Cover Open/Close Switch (SW1)... 4-15 Chapter 5 Maintenance 5.1 Maintenance and Inspection... 5-1 5.1.1 Periodically Replaced Parts...5-1 5.1.1.1 Periodically Replaced Parts... 5-1 5.1.2 Durables...5-1 5.1.2.1 Consumables and Durables... 5-1 5.1.3 Periodical Servicing...5-2 5.1.3.1 Periodical Servicing... 5-2 5.2 Adjustment... 5-3 5.2.1 Basic Adjustment...5-3 5.2.1.1 Overview... 5-3 5.2.1.2 Adjusting the inserter open/close... 5-3 5.2.1.3 Adjusting the Height... 5-3 5.2.2 Adjustment at Time of Parts Replacement...5-5 5.2.2.1 Adjustment when replacing the Reverse Solenoid (SL1)... 5-5 5.3 Outline of Electrical Components... 5-5 5.3.1 Sensors...5-5 5.3.2 Motor/ Solenoid/ PCB...5-7 5.4 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB... 5-8 5.4.1 Inserter Controller PCB...5-8
Contents 5.5 Upgrading...5-10 5.5.1 Upgrading...5-10 Chapter 6 Error Code 6.1 Overview...6-1 6.1.1 Overview...6-1 6.2 Service Error Code...6-1 6.2.1 Service Error Code List...6-1
Contents
Chapter 1 Specifications
Contents Contents 1.1 Product Specifications...1-1 1.1.1 Specifications... 1-1 1.2 Names of Parts...1-2 1.2.1 External view... 1-2 1.2.2 Cross Section... 1-3
Chapter 1 1.1 Product Specifications 1.1.1 Specifications 0023-9169 Item Description Remarks Original pickup method auto pickup/delivery top separation using separation roller Original placement Original transport mode Original type Original size Stacking capacity Original weight Placement reference Original mix control panel Display Original size detection Outside dimensions (size WXDXH) Weight face-up single-sided thin paper, plain paper, recycled paper, colored paper, thick paper, coated paper B5 to 13"x19.2" (width: 330.2 to 487.7 mm) 12mm less than (100 sheets (80 g/m2)) 64 g/m2 to 256 g/m2 center no no LED (indicating placement of original) yes length: photo sensor (2pcs.) width: slide volume (1pc.) 662 mm X 679 mm X 1242 mm Not included a ground rail approx. 40kg Power source yes Consent type Maximum power consumption in operation: 87 W or less 1-1
Chapter 1 1.2 Names of Parts 1.2.1 External view 0023-9171 [3] F-1-1 T-1-1 Tray Top cover [3] Front upper cover 1-2
Chapter 1 1.2.2 Cross Section 0023-9173 [3] [4] [12] [5] [6] [7] [11] [8] [9] [10] F-1-2 Pickup roller [7] Feed roller 2 Feed roller [8] Feed roller 3 [3] Separation roller [9] Inlet roller [4] Registration roller [10] Delivery roller [5] Feed roller 1 [11] Inserter mount unit [6] Reverse roller [12] Inserter pickup unit 1-3
Chapter 2 Installation
Contents Contents 2.1 Making Pre-Checks...2-1 2.1.1 Checking the Contents... 2-1 2.1.2 Installation Precautions... 2-3 2.1.3 Selecting the Site of Installation... 2-3 2.2 Preparation Before Installation...2-4 2.2.1 Unpacking... 2-4 2.2.2 Preparing the Host Machine for Installation... 2-7 2.3 Installation Procedure...2-7 2.3.1 Connecting to the Host Machine... 2-7 2.3.2 Connecting the Power Cord... 2-14 2.3.3 Attaching the Labels... 2-14 2.3.4 Checking Operation... 2-14
Chapter 2 2.1 Making Pre-Checks 2.1.1 Checking the Contents - Document InsertionUnit-J1 - Document Insertion/Folding Unit-G1 0023-7011 *1 [5] [3] [6] *2 [7] [4] [5] [6] [9] [17]*6 [8] [16]*5 [6] [6] [11] [9] [10] [12]*3 [13] [14] [15] *4 F-2-1 2-1
Chapter 2 Relay connector 1pc.*1 [10] Fixing plate(front) 1pc. Screw(binding;M3x6) 1pc.*1 [11] Ground plate unit 1pc. [3] Relay connector(for puncher unit) 1pc.*2 [12] Power cord 1pc.*3 [4] Edge saddle 1pc.*2 [13] Document setting label 1pc. [5] Wire saddle 2pcs.*1, *2 [14] Document prohibition label 1pc. [6] Screw(binding;M4x7) 7pcs.*2 [15] Jam removal label 1pc.*4 [7] Document insertion/folding unit 1pc. [16] Rail extension plate 1pc.*5 [8] Fixing plate(rear) 1pc. [17] Spacer 1pc.*6 [9] Stepped screw(m4x5) 2pcs. *1: Use the parts, and [5](1pc.) when connecting this machine and the finisher. (Refer to finisher/puncher unit installation procedure.) *2: Use the parts [3], [4], [5](1pc.) and [6](1pc.) only when installing the puncher unit. (Refer to puncher unit installation procedure.) *3: The package may contain several power cords intended for use in Europe. Use the correct power cord to match the location/area of installation. Make sure not to leave unused power cords at the site. *4: The part [15] is supplied with the Document Insertion/Folding Unit only. *5: The part [16] is supplied with the finisher. *6: The part [17] is supplied with the finisher or the puncher unit. 2-2
Chapter 2 2.1.2 Installation Precautions 0023-8576 MEMO: -This document provides information mainly through the use of the illustrations of the document insertion/folding unit. -In some paragraphs in this document, Document Insertion Unit-J1 and Document Insertion/Folding Unit-G1 are generically called the document insertion/folding unit. 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. 2.1.3 Selecting the Site of Installation The following illustration describes the necessary space for the maintenance. - Document Insertion Unit-J1 0023-7016 100 mm or more 905 mm - Document Insertion/Folding Unit-G1 F-2-2 100 mm or more 1170 mm F-2-3 MEMO: Be sure to install the host machine and the document insertion/folding unit/finisher on a level surface without any step or gap. Otherwise, faults associated with paper movement can occur. 2-3
Chapter 2 2.2 Preparation Before Installation 4) Tuck the vinyl cover wrapping this unit down to the position shown. 5) Slightly lift the front and rear casters, and remove the cushioning material (Styrofoam). Then, remove the vinyl cover. 2.2.1 Unpacking 0023-7018 MEMO: The machine is packed using tape and cushioning materials to be protected against vibration and shock during transit.be sure to remove them before starting to install the machine. (It is a good idea to store away the removed tape and cushioning material for possible relocation of the machine, e.g., to a new site or for repairs.) 1) Take out the accessory box from the shipping box. CAUTION: At this point, do not remove the four cushioning materials (Styrofoam) from the document insertion/folding unit. Otherwise, you would likely deform some areas of the machine. F-2-6 6) Remove the tape affixed to the exterior of this unit. 7) Open the upper-front cover. 8) While holding the jam removal lever, raise the transfer guide [3]. 9) Draw out the folder assembly [4]. (not required for the document insertion unit) [3] F-2-4 2) Lift the document insertion/folding unit together with its cushioning base (Styrofoam). Be sure to work in a group of two persons. CAUTION: - If you shift up the document insertion/folding unit on its side, you would likely deform or damage the machine. Do not hold the tray of the inserter. - The document insertion/folding unit is rather heavy. (Weight: 76.0 kg/ document insertion unit: 40 kg) Be sure to work in a group of two persons. Particularly when moving it over a step on the floor, be sure to take full care not to let it tumble over. [4] F-2-7 10) Remove the packing tape securing the folder assembly. (not required for the document insertion unit) F-2-5 3) Remove the cushioning materials (Styrofoam) protecting the bottom lid and top cover. 2-4
Chapter 2 11) Open the folder guide plate (right) fully (two levels). (not required for the document insertion unit) 12) Remove the one fixing part and two fixing parts [3] at the front of the folder guide plate (right). (not required for the document insertion unit) CAUTION: The fixing part will not be removed until the folder guide plate is opened fully. Never pull them out forcibly. 14) Secure the two plates for connection to the host machine (supplied with the finisher) to the bottom plate of the folder assembly using the screw (binding; M4x8) (supplied with the finisher). MEMO: Use the connection plate when connecting the finisher/puncher unit to the host machine directly when a unit such as the document insertion/folding unit gets out of order. 15) Return the folder guide plate (right) to the original position, then return the folder assembly [3] to the original position. (not required for the document insertion unit) 16) While holding the jam removal lever [4], lower the transfer guide [5]. 17) Close the front-upper cover [6]. [3] [6] [4] [5] F-2-8 CAUTION: The two screws (pointed to by screwdrivers) at the front and rear are used to adjust the folding roller pressure. Never loosen these screws. Right side view [3] F-2-10 18) Remove the screw from the supplied ground plate unit, and then remove the ground plate. F-2-9 13) Remove the three fixing parts at the back of the folder guide plate (right) in the same manner as above. (not required for the document insertion unit) F-2-11 MEMO: Removed screw and ground plate are reused for later steps. 2-5
Chapter 2 19) Mount the metal plate removed step 18 with supplied two screws (binding, M4x7). 21) Mount the ground plate removed step 18 with the screw (binding, M4x7) removed step 18. F-2-12 20) Mount the rail extension plate supplied with the finisher with the screw (binding, M4x8) supplied with the finisher. F-2-14 22) Affix the spacer (supplied with the finisher or the puncher unit) to the document insertion/folding unit with it aligned with the line for affixing. F-2-15 F-2-13 2-6
Chapter 2 2.2.2 Preparing the Host Machine for Installation 0023-7025 1) Using two screws [3] (binding, M4 x 7), mount the fixing plate (front) supplied with the document insertion/folding unit and the fixing plate (rear). 2) Open the front upper cover. 3) While holding the jam removal lever, raise the transfer guide [3]. 4) Draw out the folder assembly [4]. (not required for the document insertion unit) [3] [3] [3] F-2-16 2.3 Installation Procedure 2.3.1 Connecting to the Host Machine 1.3.1.1 Checking the Height/Tilt 1.3.1.1.1 Checking Check the height/tilt of the document insertion/folding unit. MEMO: - Check to make sure that the host machine is off and its power plug is not connected to the power outlet. - Depending on the condition of the floor of the site of installation, you may need to adjust the height or the tilt of the document insertion/folding unit. A discrepancy in the height or tilt of the document insertion/folding unit can well lead to frequency jams. Check the height/tilt as follows, and make adjustments as necessary. 0023-7027 [4] F-2-18 [Checking the Height/Tilt at the Front] 1-A) For the document insertion/folding unit, check whether the screw hole [3] is between the upper marking-off line and the lower markingoff line on the connection plate. 1) Fit the pin of the fixing plate (front) on the host machine in the slot on the document insertion/folding unit. MEMO: Connect the document insertion/folding unit to the host machine with no spaceout any clearance between them. [3] F-2-19 F-2-17 2-7
Chapter 2 1-B-1) For the document insertion unit, open the inserter pickup unit and the front upper cover, and remove the front upper cover by detaching the resin E-ring. Then detach the front-lower cover [3] by removing the screw [4]. MEMO: After checking or adjusting the height/tilt, connect the Document Insertion Unit to the host machine. When mounting the front-lower cover, be sure to fit the bottom hooks of the front-lower cover in place. F-2-20 [4] F-2-21 1-B-2) Check whether the screw hole [3] is between the upper marking-off line and the lower marking-off line on the connection plate. [3] F-2-23 [Checking the Height/Tilt at the Rear] 1) Check whether the screw hole [3] is between the upper marking-off line and the lower markingoff line on the connection plate. [3] F-2-22 [3] F-2-24 2-8
Chapter 2 MEMO: If the screw holes at the front and rear are between the upper and lower marking-off lines, refer to "1.3.1.3 Connecting the Document Insertion/ Folding Unit to the Host Machine" and follow the procedure. 2-9
Chapter 2 1.3.1.2 Making Adjustments 1.3.1.2.1 Adjusting the Height/Tilt MEMO: After the cheking the height/tilt, if the screw holes at the front and rear between the upper and lower marking-off lines, go through the following steps to make appropriate adjustments. Be sure to adjust the height first, and then adjust the tilt. 1) Detach the wrench from the backside of the front cover of the finisher. <When installing the finisher (without saddle unit) together with the document insertion/folding unit > A) Open the upper-front cover, remove the screw, and open the lowerfront cover [3]. [3] F-2-25 B) By removing a screw, take out a wrench from the bottom of the frontlower leg cover. F-2-26 <When installing the saddle finisher together with the document insertion/ folding unit > A) Open the front cover, then from the back of the front cover, remove the fixing screw and detach the pliers. F-2-27 2-10
Chapter 2 Adjusting the Height-1 1) Loosen the nut on the front caster (on the host machine side) of the document insertion/folding unit. 2) Turn the nut on the caster (on the host machine side) to adjust the height. MEMO: Turning the nut counterclockwise [3 reduces the height, and turning the nut clockwise [4] increases the height. Adjusting the Tilt 1) Loosen the nut on the front caster (paper delivery side) of the document insertion/folding unit. 2) Turn the nut on the caster (paper delivery side) to adjust the tilt. MEMO: Turning the nut counterclockwise [3 reduces the height, and turning the nut clockwise [4] increases the height. [3] [3] [4] [4] F-2-28 3) Loosen the nut on the rear caster (on the host machine side) of the document insertion/folding unit. 4) Turn the nut on the caster (on the host machine side) to adjust the height. F-2-30 3) Loosen the nut on the rear caster (paper delivery side) of the document insertion/folding unit. 4) Turn the nut on the caster (paper delivery side) to adjust the tilt. F-2-29 F-2-31 Making Checks after Making Adjustments 1) Check whether the screw hole is between the upper and lower markingoff lines on the connection plate which is used to connect the document insertion/folding unit to the host machine. If the screw hole is not between these marking-off lines, make adjustments again. 2-11
Chapter 2 2) After making the adjustments, tighten the front and rear nuts on the document insertion/folding unit. Adjusting the Height-2 (Not required for the Document Insertion Unit) MEMO: If the height of the Paper Folding Unit or Document Insertion/Folding Unit has been changed at the installation, adjust the caster roller height of the folding unit according to the following procedure. 1) Remove the two screws and then remove the folder front cover. F-2-33 2) Return the folder assembly to the original position. 3) Loosen the two screws. Adjust the height of the caster roller by turning the nut [3] so that the space between the caster roller and the floor becomes about 1 mm. MEMO: Turning the nut in the direction of A reduces the height, and turning the nut in the direction of B increases the height. [3] B A Approx. 1mm F-2-32 3) Attach the wrench in place to the backside of the front cover. F-2-34 4) Tighten the two screws loosened in Step 3). 5) Attach the folder front cover. 2-12
Chapter 2 1.3.1.3 Connecting the Document Insertion/Folding Unit to the Host Machine 1.3.1.3.1 Connecting to the Host Machine 1) Using the two supplied stepped screws (M4 x 5), secure the front and rear of the document insertion/folding unit to the host machine. 2-A) For the document insertion/folding unit, return the folder assembly to the original position. 2-B-1) For the document insertion unit, mount the front-lower cover using two screws. 2-B-2) For the document insertion unit, mount the front upper cover using resin E-ring. 3) While holding the jam removal lever [3], lower the transfer guide [4]. 4) Close the front-upper cover [5]. <Rear side> <Front side> F-2-35 [3] [4] [5] F-2-36 2-13
Chapter 2 2.3.2 Connecting the Power Cord 0023-8569 1) Connect the AC cable of the document insertion/folding unit to the power receptacle. 2) Turn on the circuit breaker. 3) Open the front upper cover. (not required for the document insertion unit) 4) While holding the jam removal lever, raise the transfer guide. (not required for the document insertion unit) 5) Draw out the folder assembly. (not required for the document insertion unit) 6) Open the transfer guide (right), and then affix the jam removal label. (not required for the document insertion unit) F-2-39 2.3.4 Checking Operation 0023-8572 After installation, turn on the host machine and check the surface insert, Z- folding, C-folding operation. F-2-37 2.3.3 Attaching the Labels 1) Affix the document setting label to the inserter. 2) Affix the prohibited paper label to the inserter. 0023-8570 F-2-38 2-14
Chapter 3 Functions
Contents Contents 3.1 Insertion Unit...3-1 3.1.1 Basic Construction... 3-1 3.1.1.1 Electric Circuit Overview...3-1 3.1.2 Basic Operation... 3-1 3.1.2.1 Basic Operation...3-1 3.1.2.2 Drive Train/Sensor Layout...3-2 3.1.3 Pickup/Feed System... 3-4 3.1.3.1 Overview...3-4 3.1.3.2 Inserter's Straight Paper Feed Sequence...3-4 3.1.3.3 Inserter's Reverse Paper Feed Sequence...3-7 3.1.3.4 Through Feed Sequence...3-10 3.1.4 Document Detection... 3-11 3.1.4.1 Detection of Presence/Absence of Document...3-11 3.1.5 Detecting Jams... 3-11 3.1.5.1 Overview...3-11 3.1.6 Power Supply... 3-13 3.1.6.1 Overview...3-13 3.1.6.2 Protection Function...3-13
Chapter 3 3.1 Insertion Unit 3.1.1 Basic Construction 3.1.1.1 Electric Circuit Overview 0023-9174 The operation sequence of this unit is controlled by the inserter controller PCB. The inserter controller PCB incorporates a CPU. The CPU interprets the signals from sensors and the signals from the host machine to output the signals for driving DC loads such as motors and solenoids at the predetermined timings. The inserter controller PCB reports the information about various sensors to the host machine through serial communication. Host machine Inserter controller PCB CPU Motor Solenoid Sensor F-3-1 3.1.2 Basic Operation 3.1.2.1 Basic Operation This unit supports the following two functions. 0023-9203 1. Insertion Function This function is used to feed paper from the inserter tray to the finisher to add the front cover, back cover, and interleaving paper to the sheets delivered from to the host machine. When the sheets are saddle-stitched for face-up delivery, the sheets are reversed in the reversing unit. F-3-2 3-1
Chapter 3 2. Through Path Feed Function This function allows the paper from the host machine to be handed over to the finisher directly. 3.1.2.2 Drive Train/Sensor Layout F-3-3 0023-9204 M2 M1 S6 S3 S4 S7 S8 S5 S12 SL1 S11 S10 M3 M11 S13 F-3-4 Symbol Name Symbol Name S3 Paper feed sensor M1 Paper feed motor S4 Paper registration sensor M2 Tray lift motor S5 Tray lower limit sensor M3 Reverse unit motor S6 Paper set sensor M11 Straight path feed motor S7 Tray paper sensor 1 SL1 Reverse solenoid S8 Tray paper sensor 2 S10 Reverse sensor 3-2
Chapter 3 Symbol Name Symbol Name S11 Reverse timing sensor S12 Reverse entrance sensor S13 Delivery sensor 3-3
Chapter 3 3.1.3 Pickup/Feed System 3.1.3.1 Overview When a paper feed signal is received from the host machine after completion of paper setting on the tray, the following three sequences are executed: 1. Inserter's straight paper feed sequence 2. Inserter's reverse paper feed sequence 3. Through path feed sequence 3.1.3.2 Inserter's Straight Paper Feed Sequence This section explains the operation performed when two document sheets are fed from the inserter paper feed unit. a. Separate Feed - The tray lift motor (M2) turns in the reverse direction to raise the paper feed tray. - When turning on of the paper feed sensor (S3) is detected, the tray lift motor stops. - The paper feed motor (M1) turns in the reverse direction to start separating the document sheets on the tray. - When the sheet has been fed by the specified distance since detection of turning on of the paper registration sensor (S4), the paper feed motor stops. - The tray lift motor turns in the normal direction to lower the paper feed tray. 0023-9205 0023-9206 M2 M2 M1 S3 S3 S4 F-3-5 b. Feeding the First Sheet to the Standby Position - The feed motor (M1) turns in the normal direction and the reverse unit motor (M3) turns in the reverse direction to feed the document sheet to the standby position. - When the sheet has been fed by the specified distance since detection of turning off of the paper registration sensor (S4), the paper feed motor stops. - When the sheet has been fed by the specified distance since detection of turning on of the reverse timing sensor (S11), the reverse unit motor stops. M1 S4 S11 M3 M3 F-3-6 3-4
Chapter 3 c. Feeding the First Sheet to the Horizontal Feed Section - The straight path feed motor (M11) turns in the reverse direction and the reverse unit motor (M3) also turns in the reverse direction to feed the document sheet to the horizontal feed section. - When the sheet has been fed by the specified distance since detection of turning off of the reverse timing sensor (S11), the reverse unit motor stops. d. Separate Feed of the Second Sheet - The tray lift motor (M2) turns in the reverse direction to raise the paper feed tray. - When turning on of the paper feed sensor (S3) is detected, the tray lift motor stops. - The paper feed motor (M1) turns in the reverse direction to separate the sheets on the tray. - When the sheet has been fed by the specified distance since detection of turning on of the paper registration sensor (S4), the paper feed motor stops. M2 M1 S3 S4 S11 M3 M11 M11 S13 S13 F-3-7 e. Feeding the Second Sheet to the Standby Position - The paper feed motor (M1) turns in the normal direction and the reverse unit motor (M3) turns in the reverse direction to feed the document sheet to the standby position. - When turning off of the paper set sensor (S6) is detected, the tray lift motor (M2) turns in the normal direction to lower the paper feed tray. - When turning on of the tray lower limit sensor (S5) is detected, the tray lift motor stops. - When the sheet has been fed by the specified distance since detection of turning off of the paper registration sensor (S4), the paper feed motor stops. - When the sheet has been fed by the specified distance since detection of turning on of the reverse timing sensor (S11), the reverse unit motor stops. M2 M1 S6 S4 S5 S11 M3 F-3-8 3-5
Chapter 3 f. Feeding the Second Sheet to the Horizontal Feed Section - The straight path feed motor (M11) turns in the reverse direction and the reverse unit motor (M3) also turns in the reverse direction to feed the document sheet to the horizontal feed section. - When the sheet has been fed by the specified distance since detection of turning off of the reverse timing sensor (S11), the reverse unit motor stops. - When the sheet has been fed by the specified distance since detection of turning off of the delivery sensor (S13), the straight path feed motor (M11) stops. S11 M3 M11 S13 F-3-9 3-6
Chapter 3 3.1.3.3 Inserter's Reverse Paper Feed Sequence This section explains the operation performed when two document sheets are fed from the inserter paper feed unit. a. Separate Feed - The tray lift motor (M2) turns in the reverse direction to raise the paper feed tray. - When turning on of the paper feed sensor (S3) is detected, the tray lift motor stops. - The paper feed motor (M1) turns in the reverse direction to start separating the document sheets on the tray. - When the sheet has been fed by the specified distance since detection of turning on of the paper registration sensor (S4), the paper feed motor stops. - The tray lift motor turns in the normal direction to lower the paper feed tray. 0023-9207 M2 M2 M1 S3 S3 S4 F-3-10 b. Feeding the First Sheet with It Reversed - The feed motor (M1) turns in the normal direction and the reverse unit motor (M3) turns in the reverse direction to feed the document sheet to the standby position. - When the sheet has been fed by the specified distance since detection of turning on of the paper registration (S4), the reverse solenoid (SL1) turns on. - When the sheet has been fed by the specified distance since detection of turning off of the paper registration sensor, the paper feed motor stops. - When turning off of the reverse sensor (S10) is detected, the reverse solenoid turns off. - When the sheet has been fed by the specified distance since detection of turning off of the reverse sensor, the reverse unit motor stops. M1 S4 SL1 M3 M3 S10 F-3-11 3-7
Chapter 3 c. Feeding the First Sheet to the Standby Position - The reverse unit motor (M3) turns in the reverse direction to feed the document sheet to the standby position. - When the sheet has been fed by the specified distance since detection of turning on of the reverse timing sensor (S11), the reverse unit motor stops. S11 M3 F-3-12 d. Feeding the First Sheet to the Horizontal Feed Section - The straight path feed motor (M11) turns in the reverse direction and the reverse unit motor (M3) turns in the reverse direction to feed the document sheet to the horizontal feed section. - When the sheet has been fed by the specified distance since detection of turning off of the reverse timing sensor (S11), the reverse unit motor stops. e. Separate Feed of the Second Sheet - The tray lift motor (M2) turns in the reverse direction to raise the paper feed tray. - When turning on of the paper feed sensor (S3) is detected, the tray lift motor stops. - The paper feed motor (M1) turns in the reverse direction to separate the sheets on the tray. - When the sheet has been fed by the specified distance since detection of turning on of the paper registration sensor (S4), the paper feed motor stops. At the same time, the tray lift motor (M2) turns in the normal direction to lower the paper feed tray. M2 M1 S3 S4 S11 M3 M11 M11 S13 F-3-13 S13 3-8
Chapter 3 f. Feeding the Second Sheet with it Reversed - The paper feed motor (M1) turns in the normal direction and the reverse unit motor (M3) also turns in the normal direction to feed the document sheet to the standby position. - When turning off of the paper set sensor (S6) is detected, the tray lift motor (M2) turns in the normal direction to lower the paper feed tray. - When turning on of the tray lower limit sensor (S5) is detected, the tray lift motor stops. - When the sheet has been fed by the specified distance since detection of turning on of the registration sensor (S4), the reverse solenoid (SL1) turns on. - When the sheet has been fed by the specified distance since detection of turning off of the registration sensor (S4), the paper feed motor stops. - When turning off of the reverse sensor (S10) is detected, the reverse solenoid turns off. - When the sheet has been fed by the specified distance since detection of turning off of the reverse sensor, the reverse unit motor stops. M2 M1 S6 S4 S5 SL1 M3 S10 F-3-14 g. Feeding the Second Sheet to the Standby Position - The reverse unit motor (M3) turns in the reverse direction to feed the original sheet to the standby position. - When the sheet has been fed by the specified distance since detection of turning on of the reverse timing sensor (S11), the reverse unit motor stops. S11 M3 F-3-15 h. Feeding the Second Sheet to the Horizontal Feed Section - The straight path feed motor (M11) turns in the reverse direction and the reverse unit motor (M3) also turns in the reverse direction to feed the document sheet to the horizontal feed section. - When the sheet has been fed by the specified distance since detection of turning off of the reverse timing sensor (S11), the reverse unit motor stops. - When the sheet has been fed by the specified distance since detection of turning off of the delivery sensor (S13), the straight path feed motor (M11) stops. S11 M3 M11 S13 F-3-16 3-9
Chapter 3 3.1.3.4 Through Feed Sequence This section explains the operation performed when a single document sheet is fed from the host machine. a. Feed Operation - The straight path feed motor (M11) turns in the reverse direction to feed the document sheet to the horizontal feed section. - When the sheet has been fed by the specified distance since detection of turning on of the delivery sensor (S13), the straight path feed motor stops. 0023-9208 M11 S13 F-3-17 3-10
Chapter 3 3.1.4 Document Detection 3.1.4.1 Detection of Presence/Absence of Document 0023-9209 The paper set sensor (S6) is used to detect presence/absence of paper on the tray. When paper is placed on the tray, the detection lever interlocked with the light shielding plate moves to allow the light blocked by the photo interrupter to pass through. Thus, the paper set sensor (S6) generates a paper detection signal (EMPS). Upon detection of the paper detection signal (EMPS), the inserter controller PCB turns on the paper set indicator. Inserter controller PCB Paper EMPS S6 F-3-18 3.1.5 Detecting Jams 3.1.5.1 Overview This unit is provided with the following paper sensors to detect presence/absence of paper and check whether paper is fed normally. Paper feed sensor (S3) Paper registration sensor (S4) Paper set sensor (S6) Tray paper sensor 1 (S7) Tray paper sensor 2 (S8) Reverse sensor (S10) Reverse timing sensor (S11) Reverse entrance sensor (S12) Delivery sensor (S13) 0023-9211 Occurrence of a jam is judged according to whether paper exists at the sensors at the check timings memorized in the micro computer (CPU) on the inserter controller PCB. When the CPU judges that a jam has occurred, all operations of this unit stop and occurrence of the jam is reported to the DC controller of the host machine. When all doors and covers have been closed after removal of the jam, the inserter controller PCB checks whether the above nine sensors detect paper. If any sensor detects paper, the PCB judges that the jam has not been removed completely and sends a jam removal signal to the host machine again. 3-11
Chapter 3 S6 S3 S4 S7 S8 S12 S10 S11 S13 F-3-19 3-12
Chapter 3 3.1.6 Power Supply 3.1.6.1 Overview This unit is supplied with DC power by the power supply unit. Functions of the power supply unit and others are summarized in the table below. 0023-9212 Name Function Power supply unit Generates DC power (5 V line and 24 V line). Supplies DC power to the inserter controller PCB. Front upper cover switch (SW1) Leak current breaker Turns on/off the 24 VDC. Turns the power off when a failure occurs. Front upper cover switch (SW1) Consent AC Leak current breaker Power supply PCB +24V +5V Inserter controller PCB +24V +5V Solenoid motor Sensor F-3-20 3.1.6.2 Protection Function 0023-9213 The inserter controller PCB incorporates a fuse or a motor driver with an overcurrent protection function so that a current exceeding 24 VDC does not flow to motors and solenoids. The power supply PCB is provided with an overcurrent/overvoltage protection function to shut off the output voltage automatically when a short circuit or trouble occurs on the load side or an overcurrent or overvoltage is generated, thus preventing the power supply circuit from malfunctioning. When the overcurrent/overvoltage protection function has been activated, turn off the Power switch, fix the load-side trouble, and turn on the Power switch again to reset the overcurrent/overvoltage protection function. The fuse (F1) provided in the circuit blows out to shut off the power when an excessive current flows to the AC line. 3-13
Chapter 3 3-14
Chapter 4 Parts Replacement Procedure
Contents Contents 4.1 External Covers...4-1 4.1.1 External Covers... 4-1 4.1.1.1 Removing the Rear Upper Cover...4-1 4.1.1.2 Removing the Rear Lower Cover...4-1 4.1.1.3 Removing the Front Upper Cover...4-1 4.1.1.4 Removing the Front Lower Cover...4-1 4.1.1.5 Removing the Right Cover...4-2 4.1.1.6 Removing the Left Cover...4-2 4.1.1.7 Removing the Rear Inner Cover...4-2 4.1.1.8 Removing the Front Inner Cover...4-3 4.1.1.9 Removing the Right Inner Cover...4-3 4.1.1.10 Removing the Inserter Rear Cover...4-3 4.1.1.11 Removing the Inserter Front Left cover...4-4 4.1.1.12 Removing the Inserter Front Right cover...4-4 4.1.1.13 Changing the Inserter Pickup Unit Open/Close Angle...4-4 4.1.1.14 Removing the Inserter Paper Feed Unit...4-4 4.2 Insertion Unit...4-5 4.2.1 Drive System... 4-5 4.2.1.1 Removing the Inserter Pickup Motor (M1)...4-5 4.2.1.2 Removing the Tray Lift Motor (M2)...4-6 4.2.1.3 Removing the Reverse Unit Motor (M3)...4-6 4.2.1.4 Removing the Reverse Solenoid (SL1)...4-6 4.2.2 Document Feeding System... 4-6 4.2.2.1 Removing the Inserter Pickup Roller...4-6 4.2.2.2 Removing the Inserter Feed Roller...4-7 4.2.2.3 Removing the Inserter Separation Roller...4-8 4.2.2.4 Removing the Torque Limiter...4-8 4.2.2.5 Removing the Feed Collar (Straight Pass Assembly)...4-9 4.2.2.6 Removing the Tray Unit...4-9 4.2.3 Electrical System... 4-9 4.2.3.1 Removing the Inserter Controller PCB...4-9 4.2.3.2 Removing the Power Supply PCB...4-10 4.2.3.3 Removing the Tray LED PCB...4-10 4.2.3.4 Removing the Inserter Open/Close Sensor (S1)...4-11 4.2.3.5 Remoeing the Top Cover Open/Close Sensor (S2)...4-11 4.2.3.6 Removing the Pickup Sensor (S3)...4-11 4.2.3.7 Removing the Registration Sensor (S4)...4-11 4.2.3.8 Removing the Paper Set Sensor (S6)...4-13 4.2.3.9 Removing the Tray Paper Sensor 1 (S7)...4-13 4.2.3.10 Removing the Tray Paper Sensor 2 (S8)...4-13 4.2.3.11 Removing the Tray Paper Width Senor (S9)...4-14 4.2.3.12 Removing the Reverse Sensor (S10)...4-15 4.2.3.13 Removing the Reverse Timing Sensor (S11)...4-15 4.2.3.14 Removing the Reverse Entrance Sensor (S12)...4-15 4.2.3.15 Removing the Front Upper Cover Open/Close Switch (SW1)...4-15
Chapter 4 4.1 External Covers 4.1.1 External Covers 4.1.1.1 Removing the Rear Upper Cover 1) Remove the rear upper cover. - Screw 4 pcs. 0023-9424 4.1.1.3 Removing the Front Upper Cover 1) Open the inserter pickup unit. 2) Open the front upper cover. 3) Remove the front upper cover. - Resin E-ring 1 pc. 0023-9426 F-4-3 4.1.1.4 Removing the Front Lower Cover F-4-1 4.1.1.2 Removing the Rear Lower Cover 1) Remove the rear upper cover. 2) Remove the rear lower cover. - Screw 4 pcs. 0023-9425 1) Pull out the folder unit until it stops. 2) Detach the front lower cover toward the upper. - Screw 2 pcs. 0023-9427 F-4-4 F-4-2 4-1
Chapter 4 MEMO: When attaching the front lower cover, hang the right/left plates located lower of the front cover on the hook of folder unit. 4.1.1.6 Removing the Left Cover 1) Remove the left cover. - Screw 5 pcs. 0023-9429 F-4-7 4.1.1.7 Removing the Rear Inner Cover 1) Open the front upper cover and the upper feed guide. 0023-9430 F-4-5 4.1.1.5 Removing the Right Cover 1) Remove the right cover. - Screw 4 pcs. 0023-9428 2) Remove the rear upper cover. 3) Remove the rear lower cover. 4) Remove the two screws. F-4-8 F-4-6 F-4-9 4-2
Chapter 4 5) Push the folder unit forward about 20 cm, and detach the rear inner cover toward the upper while shifting the cable. 4.1.1.8 Removing the Front Inner Cover 1) Remove the front upper cover. 2) Remove the lever. - Screw 1 pc. 3) Turn jam removal lever [3] in the direction of the arrow. 4) Remove the front inner cover [4]. - Screw [5] 4 pcs. 0023-9431 [4] F-4-10 [5] MEMO: When attaching the rear inner cover, insert the hook of rear inner cover into the hole of folder unit. [3] F-4-13 4.1.1.9 Removing the Right Inner Cover 1) Pull out the folder unit until it stops. 2) Open the right feed guide unit fully. 0023-9432 F-4-11 F-4-14 3) Remove the right inner cover. - Screw 2 pcs. F-4-12 F-4-15 4-3
Chapter 4 4.1.1.10 Removing the Inserter Rear Cover 4.1.1.12 Removing the Inserter Front Right cover 1) Open the top cover. 2) Remove the inserter rear cover. - Screw 3 pcs. 0023-9433 1) Remove the inserter front left cover. 2) Remove the inserter front right cover. - Screw 5 pcs. 0023-9436 F-4-16 4.1.1.11 Removing the Inserter Front Left cover 1) Open the inserter pickup unit. 2) Remove the inserter front left cover. - Screw 1 pc. 0023-9434 F-4-18 4.1.1.13 Changing the Inserter Pickup Unit Open/Close Angle 1) Remove the inserter rear cover. 2) Remove the fixing plate. - Screw 1 pc. 3) Remove the cover angle regulating plate [3]. 0023-9437 F-4-17 [3] F-4-19 4-4
4.1.1.14 Removing the Inserter Paper Feed Unit 1) Remove the inserter rear cover. 2) Open the inserter more. 3) Disconnect the interface cable. - Connector 7 pcs. - Screw [3] 2 pcs. - Clamp [4] 1 pc. 0023-9438 Chapter 4 1. Checking the Open/Closed State of the Inserter Paper Supply Unit Close the inserter paper supply unit and check whether the positioning pin fits in the bottom frame hole. (If the pin fits in the hole finally owing to the weight of the inserter paper supply unit although it has stopped in the middle of the hole, it's OK.) If the positioning pin has not fitted in the bottom hole finally, adjust the inerter position by adjusting the hinge adjusting plate position following the specified procedure. [4] [3] F-4-20 4) Slide the inserter paper supply unit rearward, and remove it by lifting. - Stepped screw 2 pcs. F-4-22 2. Checking the Height of the Inserter Supply Unit Close the inserter paper supply unit, and then check whether the difference between the front gap (A) and rear gap (B) between the right-side bottom edge of the inserter paper supply unit and the right-side upper edge of the inserter base falls within ±1 mm. If the difference does not fall within ±1 mm, adjust the height of the inserter paper supply unit following the specified procedure. A B F-4-23 F-4-21 CAUTION: After reinstalling the inserter paper supply unit, check its open/closed state and height. If they are out of spec, make adjustments. 4-5
Chapter 4 4.2 Insertion Unit 4.2.1.3 Removing the Reverse Unit Motor (M3) 4.2.1 Drive System 4.2.1.1 Removing the Inserter Pickup Motor (M1) 1) Remove the rear upper cover. 2) Remove the reverse unit motor. - Connector 1 pc. - Screw [3] 2 pcs. 0023-9442 1) Remove the inserter rear cover. 2) Remove the pickup motor. - Connector 1 pc. - Screw [3] 2 pcs. - Belt [4] 1 pc. 0023-9440 [4] [4] [3] F-4-26 [3] 4.2.1.4 Removing the Reverse Solenoid (SL1) 1) Remove the rear upper cover. 2) Open the inserter controller PCB. - Screw 4 pcs. - Connector [3] 8 pcs. (Connectors CN1,2,3,6,7,8,10,27 on the controller) 0023-9443 [3] [3] F-4-24 [3] 4.2.1.2 Removing the Tray Lift Motor (M2) 1) Remove the inserter rear cover. 2) Remove the tray lift motor. - Connector 1pc. - Clamp [3] 2pcs. 0023-9441 [3] F-4-27 3) If the reverse solenoid needs to be detached, secure the solenoid position by applying markings before detaching it so that the solenoid can be located to its original position. When reinstalling the reverse solenoid, install it to its previous position. 4) Remove the reverse solenoid. - Screw [3] 1pc. - Connector [4] 1pc. F-4-25 [3] [4] F-4-28 4-6
Chapter 4 4.2.2 Document Feeding System 4.2.2.1 Removing the Inserter Pickup Roller 0023-9444 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the two top cover angle regulating plate (front/rear). - Screw 2 pcs. 4.2.2.2 Removing the Inserter Feed Roller 0023-9446 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the two top cover angle regulating plate (front/rear). - Screw 2 pcs. F-4-29 3) Open the inserter pickup unit, and remove the front feed guide. - Screw 2 pcs. F-4-32 3) Open the inserter pickup unit, and remove the front feed guide. - Screw 2 pcs. F-4-30 4) Remove the two pickup rollers. - Resin E-ring 2 pcs. F-4-33 4) Remove the pickup roller unit. - Spring 1 pc. - Resign E-ring [3] 2 pcs. - Bearing [4] 2 pcs. [4] F-4-31 [3] F-4-34 4-7
Chapter 4 5) Remove the feed roller. - E-ring 3 pcs. - Pickup roller [3] 1 pc. - Lever [4] 1 pc. 4) Remove the pin. - Screw 1 pc. 5) Remove the feed guide [3]. - Screw [4] 5 pcs. [4] [4] [3] F-4-35 4.2.2.3 Removing the Inserter Separation Roller 0023-9447 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the two top cover angle regulating plate (front/rear). - Screw 2 pcs. [3] F-4-38 6) Remove the separation roller unit. - E-ring 1 pc. - Bushing [3] 1 pc. [3] F-4-39 7) Remove the separation roller. - E-ring 1 pc. 3) Remove the gear cover. - Screw 2 pcs. F-4-36 F-4-40 4.2.2.4 Removing the Torque Limiter 1) Remove the separation roller unit. 2) Remove the separation roller. - E-ring 1 pc. 3) Remove the torque limiter [3]. 0023-9448 [3] F-4-37 F-4-41 4-8
Chapter 4 4.2.2.5 Removing the Feed Collar (Straight Pass Assembly) 1) Remove the front upper cover. 2) Remove the eight feed collars. - Spring 4 pcs. 0023-9449 3) Remove the gear cover. - Screw 2 pcs. F-4-42 F-4-44 4) Remove the two connectors, and then remove the cable from the guide. 5) Remove the tray unit [3]. - Screw [4] 4 pcs. 4.2.2.6 Removing the Tray Unit 0023-9450 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the two top cover angle regulating plate (front/rear). - Screw 2 pcs. [4] F-4-45 [4] [3] F-4-43 4-9
Chapter 4 4.2.3 Electrical System 4.2.3.1 Removing the Inserter Controller PCB 1) Remove the rear upper cover. 2) Disconnect all connectors from the PCB. 3) Remove the inserter controller PCB. - Screw 1 pc. - Locking support [3] 3 pcs. 0023-9451 2) Remove the power supply PCB. - Screw 5 pcs. [3] F-4-48 4.2.3.3 Removing the Tray LED PCB 0023-9453 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the tray unit. 3) Remove the reverse lower cover. - Screw 4 pcs. F-4-46 4.2.3.2 Removing the Power Supply PCB 1) Remove the rear lower cover. 2) Remove the power supply PCB unit. - Connector 2 pcs. - Screw [3] 4 pcs. 0023-9452 [3] F-4-49 4) Remove the reverse upper cover. - Screw 4 pcs. F-4-47 5) Remove the LED cover. - Screw 2 pcs. F-4-50 F-4-51 4-10
Chapter 4 6) Remove the tray LED PCB. - Screw 1 pc. 4.2.3.6 Removing the Pickup Sensor (S3) 0023-9456 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the two top cover angle regulating plate (front/rear). - Screw 2 pcs. [3] F-4-52 4.2.3.4 Removing the Inserter Open/Close Sensor (S1) 1) Remove the inserter rear cover. 2) Remove the inserter open/close sensor. - connector 1 pc. 0023-9454 F-4-55 3) Open the inserter pickup unit, and remove the front feed guide. - Screw 2 pcs. F-4-53 4.2.3.5 Remoeing the Top Cover Open/Close Sensor (S2) 0023-9455 1) Remove the inserter rear cover. 2) Remove the top cover open/close sensor. - Connector 1 pc. 4) Remove the pickup sensor. - Connector 1 pc. F-4-56 F-4-54 F-4-57 4-11
Chapter 4 4.2.3.7 Removing the Registration Sensor (S4) 0023-9458 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Increase the inserter pickup unit open/close angle. 3) Remove the two top cover angle regulating plate (front/rear). - Screw 2 pcs. 6) Remove the right plate. - Screw 4 pcs. 7) Remove the right cover. - Screw 2 pcs. F-4-61 F-4-58 4) Open the inserter pickup unit, and remove the front feed guide. - Screw 2 pcs. F-4-62 8) Close the inserter pickup unit, remove the rear feed guide. - Spring 1 pc. - Screw [3] 4 pcs. [3] F-4-59 5) Remove the rear cable of the top cover from the guide. [3] F-4-63 F-4-60 4-12
9) Remove the registration sensor. - Connector 1 pc. Chapter 4 4.2.3.9 Removing the Tray Paper Sensor 1 (S7) 0023-9460 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the tray unit. 3) Remove the reverse lower cover. - Screw 4 pcs. F-4-64 4.2.3.8 Removing the Paper Set Sensor (S6) 0023-9459 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the tray unit. 3) Remove the sensor cover. - Screw 1 pc. F-4-67 4) Remove the reverse upper cover. - Screw 4 pcs. F-4-65 4) Remove the paper set sensor. - Connector 1 pc. F-4-68 5) Remove the tray paper sensor 1. - Connector 1 pc. F-4-66 F-4-69 4-13
Chapter 4 4.2.3.10 Removing the Tray Paper Sensor 2 (S8) 0023-9461 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the tray unit. 3) Remove the reverse lower cover. - Screw 4 pcs. 6) Remove the tray paper sensor 2. - Connector 1 pc. F-4-70 4) Remove the reverse upper cover. - Screw 4 pcs. F-4-73 4.2.3.11 Removing the Tray Paper Width Senor (S9) 0023-9462 1) Remove the inserter rear cover, the inserter front left cover and the inserter front right cover. 2) Remove the tray unit. 3) Remove the reverse lower cover. - Screw 4 pcs. 5) Remove the sensor unit. - Screw 2 pcs. F-4-71 F-4-74 4) Remove the reverse upper cover. - Screw 4 pcs. F-4-72 F-4-75 4-14
Chapter 4 5) Remove the sensor unit. - Screw 2 pcs. 5) Remove the reverse sensor. - Connector 1pc F-4-79 F-4-76 6) Remove the tray paper width senor. - Screw 2 pcs. - Cable [3] 1 pc. [3] 4.2.3.13 Removing the Reverse Timing Sensor (S11) 1) Remove the front upper cover and the front inner cover. 2) Remove the reverse timing sensor. - Connector 1 pc. - Screw [3] 1 pc. 0023-9465 F-4-77 [3] 4.2.3.12 Removing the Reverse Sensor (S10) 1) Remove the inserter rear cover. 2) Increase the inserter pickup unit open/close angle. 3) Remove the right cover and the left cover. 4) Remove the inserter mount upper cover. - Screw 6 pcs. 0023-9464 F-4-80 4.2.3.14 Removing the Reverse Entrance Sensor (S12) 1) Remove the front upper cover and the front inner cover. 2) Remove the reverse entrance sensor. - Connector 1 pc. - Screw [3] 1 pc. 0023-9466 [3] F-4-78 F-4-81 4-15
Chapter 4 4.2.3.15 Removing the Front Upper Cover Open/Close Switch (SW1) 1) Remove the front upper cover and the front inner cover. 2) Remove the front upper cover open/close switch assembly. - Screw 1 pc. 0023-9468 F-4-82 3) Remove the front upper cover open/close switch. - Screw 1 pc. - Fixing mount [3] 1 pc. - Faston 1 pc. [4] [3] F-4-83 4-16
Chapter 5 Maintenance
Contents Contents 5.1 Maintenance and Inspection...5-1 5.1.1 Periodically Replaced Parts... 5-1 5.1.1.1 Periodically Replaced Parts...5-1 5.1.2 Durables... 5-1 5.1.2.1 Consumables and Durables...5-1 5.1.3 Periodical Servicing... 5-2 5.1.3.1 Periodical Servicing...5-2 5.2 Adjustment...5-3 5.2.1 Basic Adjustment... 5-3 5.2.1.1 Overview...5-3 5.2.1.2 Adjusting the inserter open/close...5-3 5.2.1.3 Adjusting the Height...5-3 5.2.2 Adjustment at Time of Parts Replacement... 5-5 5.2.2.1 Adjustment when replacing the Reverse Solenoid (SL1)...5-5 5.3 Outline of Electrical Components...5-5 5.3.1 Sensors... 5-5 5.3.2 Motor/ Solenoid/ PCB... 5-7 5.4 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB...5-8 5.4.1 Inserter Controller PCB... 5-8 5.5 Upgrading...5-10 5.5.1 Upgrading... 5-10
Chapter 5 5.1 Maintenance and Inspection 5.1.1 Periodically Replaced Parts 5.1.1.1 Periodically Replaced Parts The machine does not have parts that require periodical replacement. 5.1.2 Durables 0023-9596 5.1.2.1 Consumables and Durables 0023-9598 Some parts of the machine may require replacement once or more during the period of machine warranty because of deterioration or damage. Replace them when they fail. T-5-1 As of Aug. 2009 No. Parts name Parts number Q'ty Actual number Remarks 1 Pickup roller 4A3-3870 2 100,000 2 Feed roller 4A3-3869 1 100,000 3 Separation roller 4A3-3868 1 100,000 4 Torque limitter 4A3-3888 1 1,000,000 5 Horizontal feed collar FC5-3670 8 2,000,000 The host machine feed number of sheets [3] [4] [5] F-5-1 5-1
Chapter 5 MEMO: These values are estimates only, and are subject to change based on future data. 5.1.3 Periodical Servicing 5.1.3.1 Periodical Servicing T-5-2 0023-9606 No Parts name Scheduled service remarks 40,000 100,000 1,000,000 2,000,000 1 2 Pickup roller Feed roller Clean Clean Replace Replace Clean it with a cloth dampened with water or neutral detergent and squeezed hard, and then wipe it with a dry soft 3 Separation roller Clean Replace cloth. 4 Torque limitter Replace 5 Horizontal feed collar Replace MEMO: The foregoing values are estimates only, and are subject to change based on future data. 5-2
Chapter 5 5.2 Adjustment 5.2.1 Basic Adjustment 5.2.1.1 Overview 0023-9612 Adjustment items of this machine are as follows: 1. Inserter open/close adjustment (when the inserter pickup unit is installed) 2. Inserter height adjustment (when the inserter pickup unit is installed) 5.2.1.2 Adjusting the inserter open/close 0023-9614 Close the inserter pickup unit and check whether the positioning pin on the finisher fits in the hole on the bottom of the inserter. (The check result is OK when he inserter closes by its own weight even if the positioning pin does not enter the hole smoothly.) [4] [3] [5] F-5-2 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 Procedure> 1. Open the inserter pickup unit and loosen the two screws (M4). 2. Remove the protection nut. 3. Loosen the hex nut [3] and turn the adjusting screw [4] using a hex wrench. Adjust the inserter position with reference to the marks [5] on the front plate. Moving the plate by one gradation (1 mm) moves the front side of the inserter 4.6 mm to the left/right. -Turning the adjusting screw clockwise moves the plate forward and moves the inserter pickup unit to the left. -Turning the adjusting screw counterclockwise moves the plate backward and moves the inserter pickup unit to the right. 4. Tighten the two screws (M4) to secure the hinge. 5. Repeat steps 1-4 until the positioning pin fits in the hole. F-5-3 5.2.1.3 Adjusting the Height 0023-9617 1. Pre-check Check whether the difference in clearance (between the right side of the inserter pickup unit and the inserter mount unit) between the front end (A) and rear end (B) is within 1 mm. If it is not within 1 mm, adjust the eight following the procedure below. A B F-5-4 <Adjustment Procedure> 1) Remove the inserter front cover and the inserter front right cover. 2) Loosen the screw and hex nut on the right-side height adjusting mechanism. 3) Using a hex wrench, turn the adjusting screw [3] to adjust the difference in clearance (between the right side of the inserter pickup unit and the inserter mount unit) between the front end and rear end to within 1 mm. Turning the adjusting screw by one gradation (1 mm) moves the inserter 1 mm. - Turning the adjusting screw clockwise moves the inserter up. - Turning the adjusting screw counterclockwise moves the inserter down. 4) Tighten the screw and hex nut. 5-3
Chapter 5 [3] F-5-5 5) Adjust the height of the left-side height adjusting mechanism to the same mark as that of the right-side height adjusting mechanism. Follow the same procedure. 6) After completion of adjustment, reinstall the removed parts. 5-4
Chapter 5 5.2.2 Adjustment at Time of Parts Replacement 5.2.2.1 Adjustment when replacing the Reverse Solenoid (SL1) 0023-9620 [Summary] When forgetting to put a mark where to attach the solenoid at replacing, proceed the adjustment procedure as mentioned below. [Adjustment Procedures] 1) Pull the solenoid until it stops as shown in figure. 2) Adjust the solenoid position by making a gap between reverse flapper and the metal plate of 7.7mm within the limit of +0.0mm/-1.0mm, and secure the solenoid. MEMO: Adjustment done by making estimation on the right lower scale on the reverse solenoid side is recommended. 7.7 0.0 1.0mm F-5-7 5.3 Outline of Electrical Components 5.3.1 Sensors 0023-9630 F-5-6 Symbol Name Parts number Insereter controller PCB S1 Inserter open/close sensor WG8-5696 CN3 Error code S2 Top cover open/close sensor WG8-5696 CN3 S3 Paper feed sensor WG8-5696 CN2 E5E1 S4 Paper registration sensor WG8-5696 CN2 S5 Tray lower limit sensor WG8-5696 CN2 E5E1 S6 Paper set sensor WG8-5696 CN1 S7 Tray paper sensor 1 WG8-5696 CN1 S8 Tray paper sensor 2 WG8-5696 CN1 S9 Tray paper width senor 4H3-0282 CN1 S10 Reverse sensor WG8-5696 CN8 S11 Reverse timing sensor WG8-5696 CN8 S12 Reverse entrance sensor WG8-5696 CN8 S13 Delivery sensor WG8-5696 CN9 SW1 Front upper cover open/close sensor 4H1-6449 CN4 5-5
Chapter 5 S1 S2 S3 S4 S5 S6 S12 S8 SW S S7 S10 S13 F-5-8 5-6
Chapter 5 5.3.2 Motor/ Solenoid/ PCB T-5-3 0023-9633 Symbol Name Parts number Insereter controller PCB M1 Paper feed motor FK2-4580 CN6 Error code M2 Tray lift motor FH5-1040 CN7 E5E1 M3 Reverse unit motor FK2-4580 CN11 M11 Straight path feed motor FK2-4582 CN12 SL1 Reverse solenoid FH6-5136 CN10 Tray LED PCB 4H3-0268 CN27 Inserter controller PCB FM3-1416 E503 [3] Power supply PCB FK2-4627 CN25 M3 M2 M1 SL1 M11 [3] F-5-9 5-7
Chapter 5 5.4 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB 5.4.1 Inserter Controller PCB 0023-9635 CN12 CN6 CN11 CN10CN5 CN27 CN1 CN2 CN3 CN7 CN13 CN18 LED2 LED1 ON CN8 OFF SW1 CN21 SW2 SW3 CN24 CN23 CN22 CN20 CN26 CN14 CN9 CN17 CN19 CN4 CN25 CN16 CN15 1.LED1/LED2 LED1/LED2 display the following state by turning LED on and off in turn. a.normal state indication - standby (normal mode) LED displays the following in a standby state (normal mode). F-5-10 T-5-4 Standby (normal mode) (long flash number, short flash number) LED1 LED2 state (1, 1) (1, 1) normal mode b.error state indication -jam -error LED displays the following in a jam and an error state. T-5-5 Cover open jam (long flash number, short flash number) LED1 LED2 Location (2, 1) (2, 1) Insereter unit (2, 2) Insereter upper cover (2, 3) Insereter front upper cover (2, 4) Not used 5-8
Chapter 5 T-5-6 Delay/stationary/wound jam (long flash number, short flash number) LED1 LED2 Location (3, 1)=delay jam (2, 1) Not used (3, 2)=stationary jam (3, 3)=wound jam (2, 2) Not used (2, 3) Not used (2, 4) Not used (2, 5) Not used (2, 6) Delivery sensor (2, 7) Not used (3, 1) Paper registration sensor (3, 2) Reverse entrance sensor (3, 3) Reverse timing sensor (3, 4) Reverse sensor Error (long flash number, short flash number) LED1 LED2 Location (4, 1) (2, 1) Inserter unit communication (2, 2) EEPROM (2, 3) Not used (3, 1) Not used (3, 2) Not used (3, 3) Not used (3, 4) Not used (4, 1) Not used (4, 2) Not used (4, 3) Not used (4, 4) Tray lift motor (5, 1) Tray paper width senor 2.SW1/SW2/SW3 SW1 SW2 SW3 By default, all DIP switch bits are set to OFF. Not used Not used 5-9
Chapter 5 5.5 Upgrading 5.5.1 Upgrading 0023-9636 Overview A flash ROM is used for the CPU of the this machine. To upgrade this CPU, the downloader PCB (FY9-2034) is used. The operating instructions for it are given below. How to Use the Downloader PCB (FY9-2034) 1.When to Use the Downloader PCB The downloader PCB is used when upgrading the CPU of the this machine's Controller PCB. 2.Member part of the downloader PCB [5] [8] [3] [4] [7] [6] F-5-11 No. Description Function START/STOP key A key to be pressed when you start or stop download LOAD LED To be lit when download is available. [3] Model LED To be lit when this machine is connected. [4] Power LED To be lit when power is supplied from this machine to the downloader PCB [5] RS-232C cable (straight full wiring; 9 pins) A cable to connect the downloader PCB and a PC.Be sure to connect the cable in a way that its ferrite core comes to the PC side. [6] Cable A (9 pins) Length: approx. 70cm A cable to connect the downloader PCB and other products [7] Cable B (9 pins)length: approx. 50cm A cable to connect the downloader PCB and this machine [8] RS-232C connector A connector to connect an RS-232C cable to the downloader PCB 3. Necessary Tool The following item needs to be prepared for download. Computer (PC) Prerequisite: The service support tool (Ver. 4.22E or higher) must be installed to the PC. 5-10
Chapter 5 4. Download Procedures CAUTION: If any error occurs during downloading (for example, you forgot to press the Start key on the downloader PCB), delete the firmware registered in the service support tool and then retry the procedure described in this document from the beginning. a. Registering ROM data 1) Store ROM data to be downloaded in the 'C:\ServTool\NewROM' folder. 2) Start up the Service Support Tool. C:\ProgramFiles\Service Support Tool\bpchost.exe 3) Select [Register Firmware]. 4) Select the data inside the NewROM folder F-5-12 5) Select [Register]. F-5-13 5-11
Chapter 5 F-5-14 6) Select [OK] and register the data. F-5-15 b. Connection to this machine 1) Turn off the power of the host machine. 2) Remove the rear upper cover of the Finisher. 3) Insert the cable B to CN26 on this machine's controller PCB. 4) Connect the RS-232C cable to the RS-232C connectors of the circuit board and the PC. 5) Turn on the power of the host machine. c. Download MEMO: The error code E503 might occur during download. It does not affect the download operation and its results. 1) Start up the Service Support Tool. C:\ProgramFiles\Service Support Tool\bpchost.exe 2) Select the type of host machine and the data. 5-12
Chapter 5 F-5-16 F-5-17 3) Press the START/STOP key of the downloader PCB. LOAD LED is lit. 4)Select the data and press [START]. 5-13
Chapter 5 F-5-18 5) Follow the instructions on the screen to prepare for downloading. A press on [OK] will bring up the next screen. F-5-19 6) Select the data to download. 7) Press [START] to start downloading. 5-14
Chapter 5 F-5-20 8) Press [START] so that the computer and the downloader PCB will start downloading the program. 9) If downloading ended normally, press [OK]. F-5-21 5-15
Chapter 5 F-5-22 10)Return to the main menu and finish the download. F-5-23 5. Release of Connection 1) Press the START/STOP key of the downloader PCB. LOAD LED is turned off. 2) Turn off the power of the host machine. 3) Disconnect the cable B from this machine. 4) Mount the rear upper cover to this machine. 5) Turn on the power of the host machine. 6. Checking the Operation 1)Check to make sure that this machine operates normal. 5-16