Canon SADDLE FINISHER K3 User manual

SADDLE
FINISHERK3/K4
REVISION 0
MAR.2001
COPYRIGHT © 2001CANONINC.CANONSADDLEFINISHERK3/K4REV.0MAR.2001PRINTEDINU.S.A.
FY8-13H5-000

Application
This material has been prepared by Canon Inc. for the purposes of making available the
technical information needed for the technical training of technicians responsible for
servicing the product, and to assist them in installation, maintenance and repair. This
material contains information that is pertinent to all regions where the product is to be
sold, and may contain information that is not applicable to individual regions.
Also, the information contained in this material may differ from 'actual machine
specifications', 'machine specifications published in advertising literature' and 'other
printed matter'. Queries regarding the specifications and content of this material should be
directed to the Service Department of the competent sales company.
Revisions
Because of on-going revisions and modifications to the product, some of the details
contained in this material may be inaccurate. For this reason, any revisions or changes in
the information are published as technical information, as and when necessary.
The following statements do not apply in countries or regions where they conflict with
local laws and regulations.
Trademarks
All product names and company names contained in this material are the trademarks or
registered trademarks of those companies.
Copyright
The copyright of this material belongs to Canon Inc. This material may not be
duplicated or reprinted in part or in whole, or translated into other languages, without the
written permission of Canon Inc.
COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
Warning
This manual is confidential and its content is to be handled with due care.
Failure to do so may result in prosecution.
COPYRIGHT © 2001 CANON INC.
Printed in U.S.A.
Imprimé au U.S.A.

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
i
INTRODUCTION
1 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.
Indicates an item intended to provide notes assisting the understanding of the
topic in question.
Memo
Indicates an item of reference assisting the understanding of the topic in ques-
tion.
REF.
Provides a description of a service mode.
Provides a description of the nature of an error indication.
Refers to the Copier Basics Series for a better understanding of the contents.

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
ii
INTRODUCTION
2 Outline of the Sevice Manual
This Service Manual contains basic information needed to service the SADDLE FIN-
ISHER K3/K4 in the field, conducted for the purpose of maintaining its product quality and
a specific level of performance.
This Service Manual consists of the following chapters:
Chapter 1
General Description , shows the features and specifications of the machine,
as well as the names of parts and how to operate it.
Chapter 2
Operations and Timing , explains the mechanical and electrical systems of
the machine by function in relation to the principles of operation and timing
at which they are driven.
Chapter 3
Mechanical Systems , shows how to disassemble/assemble the machine
and make adjustments.
Chapter 4
Maintenance and Inspection , provides tables of periodically replaced
parts and consumables/durables and a scheduled servicing chart.
Chapter 5
Troubleshooting , contains troubleshooting tables and diagrams of electrical
parts, lists of VRs, LEDs, and check pins by PCB, and an outline of self-
diagnosis.
In addition, an appendix is added to offer a general timing chart, list of sig-
nals/abbreviations, general circuit diagrams, and PCB diagrams.
The machine comes with an Installation Procedure. Refer to the instructions in the book-
let when installing the machine.

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
iii
INTRODUCTION
The following rules apply throughout this document:
As a rule, the descriptions in this documentation are based on the following:
1. As needed, the work of each function and its relationship with electrical and me-
chanical parts are explained; where applicable, the timing at which associated parts
are driven are also outlined.
In a diagram, the symbol indicates a path of mechanical drive; the symbol
accompanied by a notation indicates the flow of an electrical signal.
The expression “power-on” means turning on the power switch, closing the front
door, and closing the delivery door so that the parts of the machine are supplied with
power.
2. In a digital circuit, the state of a signal is indicated by ‘1’if its voltage level is high
and by ‘0’if low. The level of voltage, however, differs from circuit to circuit.
The machine uses a CPU; however, since the internal functions of a CPU is outside
the scope of a service person, detailed explanations are omitted from descriptions. In
this document, a circuit diagram may cover from sensors to inputs of a controller
PCB or from outputs of a controller PCB to loads, or it may be a functional diagram.
The descriptions of the machine are subject to change for product improvement, and ma-
jor changes will be communicated in the form of Service Information bulletins.
All service persons are expected to be fully familiar with the contents of this Service
Manual and Service Information bulletins to develop a good understanding of the machine,
equipping themselves with the ability and skill to identify faults and to maintain the machine
in good order.

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
iv
INTRODUCTION
Contents
CHAPTER 1 GENERAL DESCRIPTION
1 GENERAL DESCRIPTION............... 1-1
1.1 Features ...................................... 1-1
1.2 Specifications ............................. 1-3
1.2.1 Specifications....................... 1-3
1.2.2 Cross sections ...................... 1-9
1.3 Module isolation switch........... 1-13
1.4 Operation of the module isolation
switch ....................................... 1-15
2 MAINTENANCE BY THE USER... 1-17
CHAPTER 2 OPERATION OVERVIEW
1 BASIC OPERATIONS ....................... 2-1
1.1 Specifications ............................. 2-1
1.2 Outline of Electrical Circuit....... 2-2
1.2.1 Finisher Assembly ............... 2-2
1.3 Inputs to and Outputs from the
Finisher Controller PCB ............ 2-3
1.3.1 Inputs to the Finisher Controller
PCB...................................... 2-3
1.3.2 Inputs to the Finisher Controller
PCB...................................... 2-4
1.3.3 Inputs to the Finisher Controller
PCB...................................... 2-5
1.3.4 Inputs to the Finisher Controller
PCB (punch-related) ............ 2-6
1.3.5 Inputs to the Finisher Controller
PCB (inserter-related) .......... 2-7
1.3.6 Inputs to the Finisher Controller
PCB (folder-related) ............ 2-8
1.3.7 Outputs to the Finisher
Controller PCB .................... 2-9
1.3.8 Outputs from the Finisher
Controller PCB .................. 2-10
1.3.9 Outputs from the Finisher
Controller PCB .................. 2-11
1.3.10 Outputs from the Finisher
Controller PCB .................. 2-12
1.3.11 Outputs from the Finisher
Controller PCB
(punch-related) .................. 2-13
1.3.12 Outputs of the Finisher
Controller PCB
(folder/inserter-related)...... 2-14
1.3.13 Inputs to and Outputs from the
Finisher Controller PCB .... 2-15
1.3.14 Inputs to and Outputs from the
Finisher Controller PCB .... 2-16
1.3.15 Inputs to the Saddle Stitcher
Controller PCB .................. 2-17
1.3.16 Inputs to the Saddle Stitcher
Controller PCB .................. 2-18
1.3.17 Inputs to the Saddle Stitcher
Controller PCB .................. 2-19
1.3.18 Outputs from the Saddle
Stitcher Controller
PCB/Finisher Controller PCB
(saddle unit-related) ........... 2-20
1.3.19 Outputs from the Saddle
Stitcher Controller PCB..... 2-21
1.3.20 Inputs to and Outputs from the
Finisher Controller PCB .... 2-22
1.3.21 Inputs to and Outputs from the
Finisher Controller PCB .... 2-23
1.3.22 Inputs to and Outputs from the
Finisher Controller PCB .... 2-24
2 FEEDING/DRIVE SYSTEM ........... 2-25
2.1 Overview .................................. 2-25
2.1.1 Normal delivery ................. 2-26
2.2 Feeding/delivery....................... 2-30

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
v
INTRODUCTION
2.2.1 Overview............................ 2-30
2.3 Job offset .................................. 2-34
2.3.1 Overview............................ 2-34
2.3.2 Stacking sheets on the
processing tray................... 2-36
2.3.3 Number of sheets for an offset
job ...................................... 2-39
2.4 Trailing edge drop function ..... 2-41
2.4.1 Overview............................ 2-41
2.5 Controlling the knurled belt ..... 2-42
2.5.1 Overview............................ 2-42
2.5.2 Delivering three sheets ...... 2-43
2.5.3 Multiple sheets on the
processing tray................... 2-45
2.6 Buffer path ............................... 2-47
3 CONTROLLING THE PADDLE ..... 2-52
3.1.1 Overview............................ 2-52
4 CONTROLLING THE TRAY
AUXILIARY PLATE........................ 2-53
4.1.1 Overview............................ 2-53
4.1.2 Operation ........................... 2-54
5 STAPLING ....................................... 2-55
5.1.1 Overview............................ 2-55
5.1.2 Stapling of first sheet ......... 2-56
5.1.3 Stapling of second and
subsequent sheets............... 2-57
5.1.4 Stapling of last sheet.......... 2-58
5.1.5 Stapler ................................ 2-60
5.1.6 Delivery auxiliary rib operation
........................................... 2-62
6 TRAY OPERATION......................... 2-63
6.1.1 Overview............................ 2-63
6.1.2 Trays .................................. 2-63
6.1.3 Sub-tray control ................. 2-65
6.1.4 Shutter control ................... 2-66
6.1.5 Detecting topmost sheet of
paper in tray ....................... 2-67
6.1.6 Tray A/B lifting motor control
........................................... 2-68
6.1.7 Tray motor power supply... 2-69
7 PUNCH UNIT .................................. 2-70
7.1.1 Overview............................ 2-70
7.1.2 Punching Operation ........... 2-70
7.1.3 Overview of Punching
Operation ........................... 2-73
7.1.4 Horizontal registration
operation ............................ 2-76
7.1.5 Paper trailing edge detection
control ................................ 2-78
7.1.6 Punch Waste Feed Control
........................................... 2-78
7.1.7 Punch waste "Full" sensor
........................................... 2-79
7.1.8 Punch Registration Motor
(M17) / Punch Motor (M18)
Drive Control ..................... 2-82
7.1.9 Punch power supply........... 2-83
8 FANS ................................................ 2-84
8.1.1 Overview............................ 2-84
9 POWER SUPPLY ............................. 2-86
9.1.1 AC Power supply ............... 2-86
9.1.2 DC Power Supply .............. 2-86
9.1.3 Protective functions ........... 2-87
9.1.4 Low Power Switch............. 2-88
9.1.5 Fan Interlocking Switch..... 2-88
10 DETECTION JAMS (FINISHER) .. 2-91
10.1.1 Overview............................ 2-91
11 MODULE ISOLATION .................. 2-94
11.1.1 Overview ............................. 2-94
12 SADDLE STITCHER ..................... 2-95
12.1 Basic operation ........................ 2-95
12.1.1 Overview............................ 2-95
12.1.2 Overview of electrical circuit
........................................... 2-96
12.2 Feed and drive system.............. 2-97
12.2.1 Overview............................ 2-97
12.3 Paper collection system ......... 2-103
12.3.1 Overview.......................... 2-103
12.3.2 Inlet flapper control ......... 2-106
12.3.3 Paper feed control ............ 2-110
12.3.4 Alignment control............ 2-112
12.3.5 Crescent roller phase control
......................................... 2-115
12.4 Stitcher System ...................... 2-117
12.4.1 Overview.......................... 2-117
12.4.2 Stitcher unit operation ..... 2-118

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
vi
INTRODUCTION
12.5 Folding and Delivery System
............................................... 2-120
12.5.1 Overview.......................... 2-120
12.5.2 Stack feed control ............ 2-121
12.5.3 Folding ............................. 2-122
12.5.4 Double Folding Operation 2-125
12.5.5 Delivery Tray Control...... 2-128
12.6 Jam Detection ........................ 2-130
12.6.1 Overview.......................... 2-130
12.6.2 Inlet delay jam (0091) ..... 2-131
12.6.3 Inlet stationary jam (00A1)
......................................... 2-131
12.6.4 Delivery Delay Jam (0092)
......................................... 2-133
12.6.5 Delivery stationary jam (00A2)
......................................... 2-134
12.6.6 Saddle Inlet Paper Sensor Delay
Jam (0015) ....................... 2-134
12.6.7 Saddle inlet paper sensor
stationary jam (0025)....... 2-135
12.6.8 Power-on jam (0087) ....... 2-135
12.6.9 Door open jam (0088) ..... 2-135
12.6.10Stitcher staple jam (0086) 2-135
12.7 Power supply.......................... 2-136
12.7.1 Overview.......................... 2-136
12.7.2 Protective function ........... 2-136
13 PAPER FOLDING UNIT C1 ........ 2-137
13.1 Overview ................................ 2-137
13.2 Electrical circuit diagram ....... 2-138
13.3 Basic Operation...................... 2-139
13.3.1 Non-folding mode ........... 2-139
13.3.2 Z-folding Mode ............... 2-140
13.4 Feed drive system .................. 2-141
13.4.1 Overview.......................... 2-141
13.4.2 Feed path ......................... 2-142
13.4.3 Feed speed control ........... 2-143
13.4.4 Folder Motor Control....... 2-143
13.4.5 Folding stopper drive ....... 2-144
13.4.6 Folding Position............... 2-145
13.4.7 Skew correction ............... 2-146
13.4.8 Folding operation............. 2-148
13.4.9 Drive Sequence ................ 2-151
13.5 Jam Detection ........................ 2-152
13.5.1 Overview.......................... 2-152
13.5.2 Jam detection timing........ 2-154
13.6 Power Supply .......................... 2-156
14 INSERTER (COVER INSERTION
UNIT-B1) ...................................... 2-157
14.1 Overview ................................ 2-157
14.2 Electrical circuitry.................. 2-158
14.3 Basic operation ...................... 2-159
14.3.1 Finisher mode .................. 2-159
14.3.2 Saddle stitcher mode........ 2-160
14.4 Feed drive system .................. 2-162
14.5 Inserter pick-up ...................... 2-164
14.5.1 Overview.......................... 2-164
14.5.2 Operation ......................... 2-164
14.6 Saddle stitcher mode feeding
............................................... 2-166
14.7 Jam detection ......................... 2-168
14.8 Power Supply ......................... 2-170
CHAPTER 3 MECHANICAL SYSTEMS
1 Finisher Unit ....................................... 3-1
1.1 Externals and Controls............... 3-1
1.1.1 External Covers ................... 3-1
1.1.2 Removing the Upper Cover
Unit ...................................... 3-2
1.1.4 Adjusting the Height............ 3-4
1.1.5 Correcting the Slope ............ 3-9
1.1.6 Removing the Stack Wall
(upper) ............................... 3-12
1.1.7 Removing the Stack Wall
(lower) ............................... 3-12
1.1.8 Mounting the Stack Wall (lower)
........................................... 3-13
1.2 Handling Tray Unit .................. 3-14
1.2.1 Removing the Handling Tray
Unit .................................... 3-14
1.2.2 Removing the Paddle Unit
........................................... 3-15

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
vii
INTRODUCTION
1.2.3 Removing the Paddle Unit
........................................... 3-16
1.2.4 Removing the Handling Tray
........................................... 3-16
1.2.5 Removing the Alignment Motor
........................................... 3-17
1.3 Tray A Unit/Tray B Unit .......... 3-19
1.3.1 Moving Down the Tray A/B
Unit .................................... 3-19
1.3.2 Removing the Tray A Unit
........................................... 3-20
1.3.3 Removing the Tray B Unit
........................................... 3-20
1.3.4 Removing the Try A/B Lift
Motor (M13/M12) ............. 3-21
1.3.5 Mounting the Tray A/B Lift
Motor (M13/M12) ............. 3-22
1.3.6 Adjusting the Position of the
Sub Tray Solenoid (SL3; with
paper folding unit istalled). 3-23
1.3.7 Position of Tray B at Power-On
........................................... 3-24
1.3.8 Harness of the Tray A/B .... 3-25
1.3.9 Points to Note When Handling
the Stack Wall Rail ............ 3-25
1.4 Knurled Belt Releasing Unit.... 3-26
1.4.1 Removing the Knurled Belt
Releasing Unit ................... 3-26
1.5 Knurled Belt............................. 3-27
1.5.1 Remove the Knurled Belt .. 3-27
1.6 Buffer Roller Unit .................... 3-28
1.6.1 Removing the Buffer Roller
Unit .................................... 3-28
1.7 Stapler Unit .............................. 3-33
1.7.1 Removing the Stapler ........ 3-33
1.7.2 Adjusting the Position of the
Stapler Paper Stopper ........ 3-34
1.7.3 Positioning the Stapler....... 3-35
1.7.4 Adjusting the Position of the
Stapler (front, 1-point)....... 3-38
1.7.5 Adjusting the Stapling Position
(rear, 1-point) ..................... 3-39
1.8 Punch Unit ............................... 3-41
1.8.1 Removing the Punch Slide Unit
........................................... 3-41
1.8.2 Mounting the Punch Waste Case
Holder ................................ 3-44
1.9 PCBs ........................................ 3-45
1.9.1 Removing the Finisher
Controller PCB .................. 3-45
2 Saddle Stitcher Assembly ................. 3-46
2.1 Saddle Unit .............................. 3-46
2.1.1 Removing the Saddle Unit
........................................... 3-46
2.1.2 Removing and Mounting the
Folding Roller .................... 3-49
2.1.3 Adjusting the Position of the
stitcher ............................... 3-54
2.1.4 Mounting the Positioning Plate
Unit .................................... 3-58
2.1.5 Removing the No. 1/No. 2
Paper Deflecting Plate ....... 3-59
2.1.6 Fitting of the Saddle Unit .. 3-60
2.1.7 Removing/Mounting the Paper
Pushing Plate ..................... 3-62
3 Paper Folding Unit-B1 (folder) ........ 3-66
3.1 External Covers........................ 3-66
3.2 Folder ....................................... 3-66
3.2.1 Disconnecting from the Copier
........................................... 3-66
3.2.2 Removing the Folder (upper)
........................................... 3-67
3.3 Feeding System........................ 3-70
3.3.1 Positioning the Folding Stopper
........................................... 3-70
3.3.2 Adjusting the Inlet Guide .. 3-73
3.3.3 Adjusting the Pressure of the
Folding Roller .................... 3-74
3.3.4 Adjusting the No. 1 Folding
Path Guide Plate ................ 3-77
3.3.5 Adjusting the Position of the
Left Guide Static Eliminator
........................................... 3-77
3.4 Drive System ............................ 3-78
3.4.1 Removing the Folder Motor
(M71) ................................. 3-78

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
viii
INTRODUCTION
CHAPTER 4 MAINTENANCE AND INSPECTION
1 Periodically Replaced Parts ................ 4-1
1.1 Finisher Unit .............................. 4-1
1.2 Saddle Stitcher Unit ................... 4-1
1.3 Folder ......................................... 4-1
1.4 Inserter ....................................... 4-1
2 Guide to Durables ............................... 4-2
2.1 Finisher Unit .............................. 4-2
2.2 Saddle Stitcher Unit ................... 4-2
2.3 Folder ......................................... 4-2
2.4 Inserter ....................................... 4-3
3 Scheduled Maintenance ...................... 4-4
3.1 Finisher Unit .............................. 4-4
3.2 Inserter ....................................... 4-4
3.3 Maintenance Procedure.............. 4-5
3.3.1 Cleaning the Components
Inside the Inserter ................ 4-5
CHAPTER 5 TROUBLESHOOTING
1 Making Adjustments ........................... 5-1
1.1 Electrical System ....................... 5-1
1.1.1 Adjusting the Alignment Width
............................................. 5-1
1.1.2 Adjusting the Stapling Position
(front, 1-position) ................ 5-2
1.1.3 Adjusting the Stapling Position
(rear 1-point)........................ 5-4
1.1.4 Adjusting the Wrapping on the
Buffer Roller ........................ 5-5
1.1.5 Sensor Initial Adjustment .... 5-7
1.1.6 Adjusting the Speed of the
Swing Guide ........................ 5-8
1.1.7 Indication for the Swing Guide
Speed ................................... 5-9
1.1.8 Adjusting the Position of Punch
Holes (feed direction) ........ 5-10
1.1.9 Adjusting the Punch Hole
Position (in direction of
horizontal registration) ...... 5-11
1.1.10 Adjusting the Sensitivity of the
Sensors............................... 5-12
1.1.11 After Replacing the EEPROM
(IC102) .............................. 5-14
1.1.12 Replacing the Finisher
Controller (in response to E505)
........................................... 5-15
1.1.13 Initializing the RAM.......... 5-15
1.1.14 Selecting Upward Curl Paper
Mode .................................. 5-16
1.1.15 Selecting Downward Curl Paper
Mode .................................. 5-17
1.1.16 Adjusting the Folding Position
(saddle stitcher assembly).. 5-19
3.4.2 Positioning the Coupling for the
Horizontal Path Drive ........ 3-79
3.4.3 Adjusting the Tension of the
Feeding Belt....................... 3-80
3.4.4 Adjusting the Position of the
Pressure Releasing Solenoid
(SL73) ................................ 3-81
3.4.5 Adjusting the Position of the
Pressure Solenoid (SL74) .. 3-82
3.5 Removing the Folder Driver PCB
................................................. 3-83
4 Inserter .............................................. 3-84
4.1 Externals and Controls............. 3-84
4.1.1 External Covers ................. 3-84
4.1.2 Removing the Inserter ....... 3-84
4.1.3 Fixing the Inserter.............. 3-86
4.1.4 Correcting the Skew .......... 3-88
4.2 Pickup Unit .............................. 3-90
4.2.1 Removing the Pickup Unit
........................................... 3-90
4.2.2 Removing the Pickup Roller
........................................... 3-97
4.2.3 Positioning the Side Guide .......
........................................... 3-97