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
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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
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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
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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
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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
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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

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
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INTRODUCTION
1.1.17 Stitching Position
(middle binding) ................ 5-21
1.1.18 Adjusting the Folder Feed Path
Paper Sensor 3 (S8) ........... 5-21
1.1.19 Adjusting the Inserter Paper Set
Sensor (S9) ........................ 5-22
1.2 Mechanical System .................. 5-23
1.2.1 Adjusting the Inserter Pickup
Tray Horizontal Registration
........................................... 5-23
2 Arrangement of Electrical Parts ....... 5-28
2.1 Finisher Unit ............................ 5-28
2.1.1 Sensors............................... 5-28
2.1.2 Microswitches.................... 5-30
2.1.3 Motors................................ 5-32
2.1.4 Solenoids ........................... 5-34
2.1.5 PCBs .................................. 5-36
2.1.6 Fans.................................... 5-38
2.2 Saddle Sticher Unit .................. 5-40
2.2.1 Photointerrupters ............... 5-40
2.2.2 Switches............................. 5-42
2.2.3 Motors................................ 5-44
2.2.4 Solenoids ........................... 5-46
2.2.5 PCBs .................................. 5-48
2.3 Paper Folder unit-B1 (folder)... 5-50
2.4 Cover Inserter-A1 (inserter)..... 5-52
2.5 LEDs and Check Pins by PCB. 5-54
2.5.1 Finisher Controller PCB .... 5-54
2.5.2 Saddle Stitcher Controller PCB
........................................... 5-56
2.5.3 Punch Drive PCB............... 5-58
2.5.4 Folder Drier PCB ............... 5-59
2.5.5 Inserter Driver PCB ........... 5-60
2.5.6 Functions of the DIP Switch
........................................... 5-61
2.6 Upgrading ................................ 5-67
3 Troubleshooting Malfunctions.......... 5-73
3.1 Finisher Unit ............................ 5-73
3.1.1 E500 (communication with
copier) ................................ 5-73
3.1.2 E503 (communication with
saddle stitcher unit)............ 5-73
3.1.3 E505 (checksum fault)....... 5-73
3.1.4 E506................................... 5-75
3.1.5 E510 (inlet motor M1 fault)
........................................... 5-75
3.1.6 E514 (stack delivery motor M7
fault)................................... 5-77
3.1.7 E530 (rear aligning plate motor
M5) .................................... 5-77
3.1.8 E531 (stapler motor M11)
........................................... 5-79
3.1.9 E532 (stapler shift motor M10)
........................................... 5-79
3.1.10 E535 (swing motor M8 fault;
detail code 62) ................... 5-81
3.1.11 E535 (swing motor M8; detail
code 01) ............................. 5-81
3.1.12 E537 (front aligning plate motor
M4) .................................... 5-83
3.1.13 E540 (tray A lifter motor M13)
........................................... 5-83
3.1.14 E542 (tray B lift motor M12;
during operation) ............... 5-83
3.1.15 E551 (activation power supply
fan FM1; detail code 01) ... 5-83
3.1.16 E551 (activation feeder cooling
fan FM2; detail code 02) ... 5-83
3.1.17 E577 (paddle motor M9) ... 5-85
3.1.18 E583 (tray auxiliary plate motor
M6) .................................... 5-85
3.1.19 E584 (shutter) .................... 5-85
3.1.20 E590 (punch rotation) ........ 5-85
3.1.21 E593 (punch registration) .. 5-85
3.1.22 E594 (punch paper edge sensor
horizontal registration) ...... 5-87
3.1.23 E595 (punch waste feeder) 5-87
3.2 Saddle stitcher Controller PCB 5-87
3.2.1 E5F0 .................................. 5-87
3.2.2 E5F1 (folder motor)........... 5-89
3.2.3 E5F2 (guide motor; detail code
01/02)................................. 5-89
3.2.4 E5F3 (alignment motor; detail
code 01/02) ........................ 5-91
3.2.5 E5F4/E5F5 (stitcher; detail code
01/02)................................. 5-91
3.2.6 E5F6 (paper pushing plate
motor; detail code 01/02)... 5-91

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
x
INTRODUCTION
APPENDIX
1 GENERAL TIMING CHART ........... A-1
1.1 Finisher Unit ............................. A-1
1.2 Saddle Stitcher Unit .................. A-2
2 LIST OF SIGNALS/
ABBREVIASTIONS ......................... A-3
2.1.1 Finisher ............................... A-3
2.1.2 Saddle Stitcher .................... A-5
2.1.3 Folder .................................. A-6
2.1.4 Inserter ................................ A-6
3 SADDLE FINISHER GENERAL
CIRCUIT DIAGRAM ....................... A-7
4 PAPER FOLDING UNIT C1 GENERAL
CIRCUIT DIAGRAM ....................... A-9
5 INSERTER B1 ................................. A-11
6 FINISHER CONTROLLER PCB ... A-13
7 SADDLE STITCHER CONTROLLER
PCB.................................................. A-35
8 FOLDER DRIVER PCB ................. A-43
9 INSERTER DRIVER PCB .............. A-45
10PUNCH DRIVER PCB ................... A-49
11 STAPLER DRIVER PCB............... A-52
12 FUSE PCB...................................... A-53
13 SWITCH PCB ................................ A-54
14 AREA SENSOR PCB .................... A-55
15 SOLVENTS AND OILS LIST ....... A-56
16 SPECIAL TOOLS .......................... A-57
3.2.7 E5F6 (paper pushing plate
motor; detail code 03)........ 5-93
3.2.8 E5F6 (paper pushing plate
motor; detail code 04)........ 5-93
3.2.9 E5F7 (saddle tray motor)... 5-95
3.2.10 E5F8 (sensor connector; detail
code 01) ............................. 5-95
3.2.11 E5F8 (sensor connector; detail
code 02) ............................. 5-95
3.2.12 E5F8 (sensor connector; detail
code 03) ............................. 5-95
3.2.13 E5F9 (power supply) ......... 5-97
3.3 Folder ....................................... 5-97
3.3.1 E518 (folder motor) ........... 5-97
3.4 Inserter ..................................... 5-99
3.4.1 E515 (inserter motor) ........ 5-99
4 Self Diagnosis ................................... 5-99
4.1 Self Diagnosis .......................... 5-99
4.1.1 Finisher Unit ...................... 5-99
4.1.2 Saddle stitcher Unit ......... 5-105
4.1.3 Folder ............................... 5-107
4.1.4 Inserter ............................. 5-107
4.2 Alarm ..................................... 5-108
4.2.1 Finisher Unit .................... 5-108
4.2.2 Saddle Stitcher Unit......... 5-108

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
CHAPTER 1
GENERAL DESCRIPTION

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
1-1
CHAPTER 1 GENERAL DESCRIPTION
1 GENERAL DESCRIPTION
1.1 Features
a.Two types of stacking trays
• The product features two different stacking trays, tray A and tray B, which are used for
different purposes.
b. Large stacking capacity
• Tray A can accommodate a stack of paper up to a maximum height of 147mm, while
tray B can .accommodate a stack of paper up to a maximum height of 285mm (small
size) and 147mm (large size).
c.Wide range of paper types
• The product can accommodate a wide range of paper types, from 64 to 200mg/m2.
d. Stack job offset function
• The stack job offset function is available for the sorting of non-stapled stacks.
e.Three types of auto-stapling
• There are three stapling positions (front-slanted, rear-slanted, two-point).
f. Buffer rollers for increased productivity
• The buffer rollers mean that the copier can keep feeding paper even while the finisher is
stapling or off-setting.
g. Punch function
• The punch function allows holes to be punched in the paper before delivery, to allow the
paper to be filed in binders. (Accommodates 64 to 200mg/m2paper. Does not accom-
modate tracing paper or OHP film.)
h. Saddle-stitch function
• Up to 15 sheets of paper can be centre-stapled and folded in half before delivery.
i.Inserter function (requires accessory Inserter B1)
• This function allows the paper to be fed separately from the cassette. (Accommodates
64 to 200mg/m2paper, B5 to A3/279.4 x 431.8mm paper, including coloured paper.
Does not accommodate OHP film.)
j.Folding function (requires accessory paper folding unit C1)
• This function allows A3, B4 or 279.4mm x 431.8mm (11 x 17) size paper to be Z-
folded. Accommodates 64 to 200mg/m2paper.

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
1-2
CHAPTER 1 GENERAL DESCRIPTION
1.2 Specifications
1.2.1 Specifications
a. Saddle Finisher K3/K4
Finisher assembly
Item
Lifting system
Stacking
Stack paper size
Paper weight
Modes
Stack
height
Mixed staple/
non-staple
Stack thickness
with folded
paper mixed
Stacking
condition
Non-
staple
sorting
Staple
sorting
Specification
Tray A
Tray B
Tray A
Tray B
Tray A
Tray B
64 to 200g/m2
Staple stacking, non-staple stacking
Tray A
Tray B
Tray A
Tray B
Tray B
Tray A
Tray B
Tray A
Tray B
up/down
up/down
same as copier delivery method
face-down
Postcard to A3/ 279.4 x 431.8mm
A5/SMT toA3/279.4 x 431.8mm
Equivalent to 1,000 sheets (small/ large
size) 147mm
Equivalent to 2,000 sheets (small size)
285mm, or1,000 sheets (large size) 147mm
Equivalent to 1,000 sheets or 100 sets
(small/ large size)
Equivalent to 2,000 sheets or 100 sets
(small size) 285mm, or1,000 sheets or 100
sets (large size) 147mm
Stops when either of the following condi-
tions is met. 2,000 sheets or 100 sets
(small size)1,000 sheets or 100 sets or 30
folded sheets (large size)
Max. 20 sheets of folded paper
Max. 10 sheets of folded paper per set/ 30
sheets of folded paper per job (1 sheet of
folded paper is counted the same as 5
sheets of plain paper.)
Front/ rear stack offset
Staple (one): 20mm
Staple (two): 30mm (one staple at 5/B4)
Non-staple: 30mm (LTR/11 x 17:36mm)
Remarks
Postcards feed in the R direc-
tion only.
A5/SMT feeds in the R direc-
tion only. B5/A4/LTR feed in
the horizontal direction only.
Mixed stacking possible un-
der certain conditions.
Equivalent to 80g/m2paper
Stacking ability not guaran-
teed. The whole stack is
treated as large size if one
large size sheet is included.
Equivalent to 80g/m2paper
No offset stacking in TrayA
for non-sort delivery
Note1: Small size refers to A4,A5, B5, postcards, LTR and STMT.
Large size refers toA3, B4, 279.4 x 431.8mm (11 x 17) and LGL.
T01-102-01

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
1-3
CHAPTER 1 GENERAL DESCRIPTION
Item
Paper detection
Control panel
Display
Installation method
Measurements
Weight
Power supply
Max. power consumption
Stapling method
Stapling position
Stapling thickness
Staple loading
Staples
Staple cartridge type
detection
Staple detection
Automatic staple reposition
Available
stapling
sizes
Manual stapling
Jogging accuracy
1-point stapling
2-point stapling
Specification
Tray A
Tray B
No
No
Latching with mount (height adjustable with casters)
Approx. 802mm (W) x 738mm (D) x 995 (H)
Approx. 127kg/ approx. 192kg (incl. inserter approx.
16kg, feeder approx. 49kg)
100 to 120V/ 50, 60Hz, 230V/ 50Hz.
60W
Punching by rotating cam (Face-down stapling)
See below
Staple cartridge type A
A4/ B5/ LTR
Staple cartridge type B
A4R/ B4/ A3
B5/ B4/ LTR
LTRR/ LGL
297.4 x 4342.8mm (11 x 17)
Special cartridge (5,000 staples)
Special staples
Yes
Yes
Up to 10 times
Front/rear A3,A4,A4R, B4, B5, 279.4 x 431.8mm,
(11 x 17) LGL, LTR, LTRR
A3, A4, B4, B5, 279.4 x 431.8mm, (11 x 17) LTR
No
Non-sort
Sort
Staple
Yes
Tray A
Tray A/B
Tray B
Note 2: Width with folder connected is 986mm
Height with inserter connected is 1138mm (auxiliary tray open)
T01-102-02
These specifications are subject to change for the purposes of product improvement.
Max. 100mm
Left/right
direction (X)
Front/rear
direction (Y)
2.0mm max.
Max. 60mm
Within stack
Max. 15mm
Between stacks
Min. 15mm
max. 60mm
Remarks
Note 2
20 sheets for
200g/m2) paper
10 sheets for
200g/m2) paper
100 sheets (80g/m2) or 98 sheets (80g/
m2) + 2 sheets (200g/m2)and paper
stack thickness max. 11mm
50 sheets (80g/m2) or 48 sheets (80g/
m2) + 2 sheets (200g/m2) and paper
stack thickness max. 5.5mm

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
1-4
CHAPTER 1 GENERAL DESCRIPTION
F01-102-01
1-point stapling
(Front) 1-point stapling (Rear) 2-point stapling 2-point stapling
A3, A4 B4, B5 279.4mm x
431.8mm
5 2
6 2 6 2 6 2
88.5 4 68.5 4 79.5 4
208.5 4 188.5 4 199.5 4
30
5 2
5 2
30
Unit: mm
*1 Stapling interval may be adjusted in user mode.
*2 Stapling position may be adjusted by DIP switch.
*2 *2 *2 *2 *2
*1 *1 *1
(11x17),
LTR
5 2
Punch related items
Item
Punching method
Paper type
Paper size
Hole diameter
Punch waste capacity
Punch waste 'Full'
display
Punch mode selection
Punch position
Specifications
Press-punch system (paper stops momentarily to be punched)
64 to 200g/m2(OHP film, tracing paper not accommodated)
2 holes: A3/ A4/ A4R/ B4/ B5/ B5R (100/ 230V)
3/2 holes: 279.4 x 431.8 (11 x 17) (280V)
2 holes LGL. LTRR
4 holes: A3,A4 (230V)
2 holes: 6.5mm
3/2 holes: 8mm
4 holes: 6.5mm
2 holes: 20,000 sheets or more (when using 80/m2paper)
3/2 holes: 10,000 sheets or more (when using 80/m2paper)
4 holes: 10,000 sheets or more (when using 80/m2paper)
Displayed on main unit control panel.
Selected on main unit control panel.
80 0.5mm L1
69.85 1mm
108 1mm L1
L1
12 3mm
12 3mm
L1= A4/A3 : 108.5 3mm
B5/B4 : 88.5 3mm
A4R : 65 3mm
B5R : 51 3mm
L1=LTR/279.4 x 431.8mm(11 x 7):
31.5 3mm L1=LGL/LTRR:73 3mm
2 holes (except USA)
3 holes (USA) 2 holes (USA)
108 1mm

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
1-5
CHAPTER 1 GENERAL DESCRIPTION
Item Specifications
T01-102-03
These specifications are subject to change for the purposes of product improvement.
Saddle stitcher
80 1mm 70 1mm
21 1mm21 1mm L1
L1
12 3mm
L1=A4/A3:28.5 3mm L1=A4/A3:29.5 3mm
4 holes (FRN) 4 holes (SWE)
80 1mm
80 1mm
Item
Stapling method
Stapling position
Paper size
No. of sheets
Average paper weight
No. of stacked sets
Staple specifications
Folding specifications
Power supply
Power consumption
Specifications
Middle staple then fold in half.
See F01-201-01.
A3, B4,A4R, 279.4mm x 432.8mm (11 x 17), LTRR
Without stapling, 1 sheet. With stapling, 2 to 15 sheets (incl. 1 cover sheet)
64 to 80g/m2(1 cover sheet 64 to 200g/m2) (special paper, OHP film not
accommodated)
30 sets (special tray, leading edge stopper shift)
Staple position Two
(equidistant from centre, fixed interval)
Staple capacity 2,000 staples
Staple loading Special cartridge
Staples Special staples (Staple D2)
Folding method Roller pressure folding
Folding mode Folding in two (1 unstapled sheet)
Folding position Centre of sheet
Folding position adjustment Yes
Staple detection Yes
Power supplied from finisher.
24V, 2 systems
160W max.
T01-102-04

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
1-6
CHAPTER 1 GENERAL DESCRIPTION
Stapling and folding accuracy (Saddle stitcher)
F01-102-02
Jogging accuracy, folding position accuracy (Saddle stitcher)
F01-102-03
These specifications are subject to change for the purposes of product improvement.
79.7 2mm68.5 2mm
188.5 2mm
88.5 2mm
208.5 2mm
210 1mmL
A3
Fold
182 1mmL
B4
216 1mmL
199.7 2mm 48 2mm
139.7 1.5mmL
168 2mm
LTRR
45 2mm
148.5 1mmL
165 2mm
A4R
Staple
Leading edge
of stack
L (difference
between folding
position and
stapling
position)
= 0.5mm
L (difference
between folding
position and
stapling
position)
= 0.5mm
L (difference
between folding
position and
stapling
position)
= 0.5mm
L (difference
between folding
position and
stapling
position)
= 0.5mm
L (difference
between folding
position and
stapling
position)
= 0.5mm
279mm x 432mm
(11 x 17)
Paper jogging Folding accuracy
L4, 15:1.5mm or less
L4
L5
L7
L6
L6-L7 : 0.75mm or less (1mm or less
under conditions of high
temperature and humidity or
low temperature)

COPYRIGHT © 2001 CANON INC. 2000 2000 2000 2000 CANON SADDLE FINISHER K3/K4 REV.0 MAR. 2001
1-7
CHAPTER 1 GENERAL DESCRIPTION
b. Folder (Paper Folding Unit C1)
Item
Folding method
Paper weight
Paper size
Folding mode
Dimensions
Power consumption
Weight
Power supply
Specifications
Roller pressure folding (sheets folded consecutively
as they pass through)
64 to 80g/m2
A3, B4, 279.4mm x 432.8mm (11 x 17)
Z-fold
Approx. 184mm (W) x 675mm (D) x 995mm (H)
75W max.
Approx. 49kg
Supplied from finisher
Remarks
Including casters
T01-102-05
Folding position
F01-102-04
Z1
Z3
Z4
Z2
Within Z2: cover/2.....
Within Z3, 4 2.0mm under
conditions of high temperature and
humidity, or low temperature.
Within Z1:2 2/1
Within Z3, 4.....