Canon Paper Folding Unit-J1 User manual

Revision 3.0
Paper Folding Unit-J1
Service Manual

Introduction
Important Notices
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 consent of Canon Inc.
Copyright CANON INC. 2015
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.
Explanation of Symbols
The following symbols are used throughout this Service Manual.
Symbols Explanation Symbols Explanation
Check.
1x
Remove the claw.
Check visually.
1x
Insert the claw.
Check a sound. Push the part.
Introduction

Symbols Explanation Symbols Explanation
1x
Disconnect the connector. Connect the power cable.
1x
Connect the connector. Disconnect the power cable.
1x
Remove the cable/wire from the
cable guide or wire saddle.
Turn on the power.
1x
Install the cable/wire to the cable
guide or wire saddle.
Turn off the power.
1x
Remove the screw.
1x
Loosen the screw.
1x
Install the screw.
1x
Tighten the screw.
Cleaning is needed. Measurement is needed.
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.
Introduction

Contents
Safety Precautions...............................................................................................1
Points to Note About Turning Off the Main Power Switch...................................................................2
Notes Before Servicing........................................................................................................................2
Points to Note at Cleaning...................................................................................................................2
Notes On Assembly/Disassembly....................................................................................................... 2
1. Product Overview.............................................................................................3
Outline.................................................................................................................................................4
Features...............................................................................................................................................4
Specifications...................................................................................................................................... 5
Specifications....................................................................................................................................... 5
Others..................................................................................................................................................5
Fold Accuracy.......................................................................................................................................5
Names of Parts....................................................................................................................................9
External View........................................................................................................................................9
Cross Section View............................................................................................................................. 11
2. Technical Explanation................................................................................... 12
Basic Configuration........................................................................................................................... 13
Functional Configuration......................................................................................................................13
Electric Circuit Overview......................................................................................................................13
Component Configuration.................................................................................................................... 14
Drive Configuration..............................................................................................................................16
Operation Mode Overview................................................................................................................... 16
Controls.............................................................................................................................................25
Outline of operations........................................................................................................................... 25
Detecting Jams................................................................................................................................... 52
Power Supply..................................................................................................................................... 54
Upgrading..........................................................................................................................................55
Upgrading...........................................................................................................................................55
3. Periodical Service.......................................................................................... 56
List of Work for Scheduled Servicing................................................................................................ 57
4. Disassembly/Assembly................................................................................. 59
List of Parts....................................................................................................................................... 60
List of Parts........................................................................................................................................ 60
Consumable Parts Requiring Periodic Replacement and Cleaning Points............................................... 61
List of Motors / PCBs / Others..............................................................................................................62
List of Sensors....................................................................................................................................63
External / Internal Covers..................................................................................................................64
Removing the Rear Upper Cover..........................................................................................................64
Removing the Rear Cover....................................................................................................................64
Contents
i

Open the Front cover...........................................................................................................................64
Open the Feed Guide..........................................................................................................................65
Removing the Front Cover...................................................................................................................65
Removing the Front Lower Cover.........................................................................................................66
Removing the Rear Inner Cover...........................................................................................................66
Removing the Front Inner Cover.......................................................................................................... 68
Removing the Right Inner Cover.......................................................................................................... 70
Main Units......................................................................................................................................... 71
Drawing out the Folding Unit................................................................................................................71
Removing the Power Supply Unit Base.................................................................................................71
Consumable Parts Requiring Periodic Replacement and Cleaning Points....................................... 73
Removing the Folding Position Adjustment Feed Clutch (CL3)............................................................... 73
Removing the Folding Position Adjustment Back Clutch (CL4)............................................................... 73
Removing the Through/Fold Branch Solenoid(SOL2).............................................................................74
Removing the Fold/Separation Solenoid (SOL3)................................................................................... 75
Removing the Folding Tray Flapper Solenoid (SOL4)............................................................................ 76
Removing the C-fold Stopper Solenoid (SOL5)......................................................................................77
Removing the Through-pass Inlet Antistatic Needle...............................................................................77
Removing the Through-pass Outlet Antistatic Needle............................................................................ 78
Motors............................................................................................................................................... 80
Removing the Folding Tray Motor (M7).................................................................................................80
Removing the Upper Stopper Motor (M8)..............................................................................................80
Removing the C-fold Stopper Motor (M9)..............................................................................................81
Removing the Leading Edge Pushing Guide Motor (M10)...................................................................... 81
Removing the Inlet Motor 2 (M12)........................................................................................................ 82
Removing the Outlet Motor 2 (M13)......................................................................................................83
Removing the Outlet Motor 1 (M14)......................................................................................................84
Removing the Folding Position Adjustment Motor (M15)........................................................................ 85
PCBs................................................................................................................................................. 86
Removing the Folder Controller PCB....................................................................................................86
Others................................................................................................................................................88
Removing the Delivery Feed Roller...................................................................................................... 88
5. Adjustment..................................................................................................... 89
Overview........................................................................................................................................... 90
Adjustment and Functional Setting in Service Mode.............................................................................. 90
Basic Adjustment................................................................................................................................ 91
Action on parts replacement.................................................................................................................91
Major Adjustment.............................................................................................................................. 93
Z-fold/Outer three-fold (1st fold) inclination adjustment (Registration roller inclination adjustment)............ 93
Z-fold/Outer three-fold/C-fold (2nd fold) inclination adjustment (Leading edge stopper inclination
adjustment)..................................................................................................................................... 96
Z-fold/Two-fold paper skew adjustment (Delivery guide protective sheet protrusion adjustment)...............99
C-fold/Two-fold/Four-fold (1st fold) inclination adjustment (Trailing edge stopper inclination).................. 101
Action on parts replacement............................................................................................................105
Actions when Replacing the Folder controller PCB.............................................................................. 105
6. Installation.................................................................................................... 107
How to Check this Installation Procedure........................................................................................108
Contents
ii

Symbols in the Illustration.................................................................................................................. 108
Checking before Installation............................................................................................................109
Checking the Installation Space..........................................................................................................109
Check Items when turning OFF the Main Power..................................................................................109
Points to Note before Installation........................................................................................................ 109
Installation Order of Options...............................................................................................................109
Product Name...................................................................................................................................113
Unpacking....................................................................................................................................... 114
Unpacking Procedure........................................................................................................................ 114
Checking the Contents....................................................................................................................119
Installation Outline Drawing................................................................................................................120
Installation Procedure......................................................................................................................124
Preparation for Installation on Upstream Equipment............................................................................ 124
Connecting to Upstream Equipment................................................................................................... 130
Connecting the Interface Cable.......................................................................................................... 131
Connecting the Intermediate Power Cable.......................................................................................... 133
Connecting the Shunt Cable...............................................................................................................135
Attaching the Label............................................................................................................................139
Adjustment...................................................................................................................................... 141
Height/ Inclination Checking and Adjustment.......................................................................................141
Making Checks after Completion of Installation.............................................................................. 150
Disposal Parts...................................................................................................................................150
Operation Checks..............................................................................................................................151
APPENDICES....................................................................................................152
Service Tools...................................................................................................................................153
Special Tools.................................................................................................................................... 153
Solvents and Oils.............................................................................................................................. 153
General Circuit Diagram..................................................................................................................154
General Circuit Diagram 1/5...............................................................................................................154
General Circuit Diagram 2/5...............................................................................................................155
General Circuit Diagram 3/5...............................................................................................................156
General Circuit Diagram 4/5...............................................................................................................157
General Circuit Diagram 5/5...............................................................................................................158
Contents
iii

Safety Precautions
Points to Note About Turning Off the
Main Power Switch............................2
Notes Before Servicing......................... 2
Points to Note at Cleaning.................... 2
Notes On Assembly/Disassembly.........2

Points to Note About Turning Off the Main Power Switch
This equipment does not have a main power switch, but it has only a leakage breaker.
The power supply of this equipment operates in synchronization with ON/OFF of the power supply of the finisher.
The leakage breaker detects overcurrent and power leakage.
NOTE:
Explain to the customer that the leakage breaker must be checked once a month.
Leakage Breaker
Notes Before Servicing
CAUTION:
At servicing, be sure to turn off the power source according to the specified steps and disconnect the power plug.
CAUTION:
Do not turn off the power switch when downloading is under way. Turning off the main power switch while downloading is
under way can disable the machine.
Points to Note at Cleaning
CAUTION:
When performing cleaning using organic solvent such as alcohol, be sure to check that the component of solvent is
vaporized completely before assembling.
Notes On Assembly/Disassembly
Follow the items below to assemble/disassemble the device.
1. Disconnect the power plug to avoid any potential dangers during assembling/disassembling works.
2. If not specially instructed, reverse the order of disassembly to reinstall.
3. Ensure to use the right screw type (length, diameter, etc.) at the right position when assembling.
4. To keep electric conduction, binding screws with washers are used to attach the grounding wire and the varistor. Ensure to
use the right screw type when assembling.
5. Unless it is specially needed, do not operate the device with some parts removed.
6. Never remove the paint-locked screws when disassembling.
Safety Precautions
2

Product Overview
1Outline...................................................4
Specifications........................................5
Names of Parts..................................... 9

Outline
Features
• Five kinds of the paper folding processing are possible.
Fold types: Z-fold, C-fold, outer three-fold, four-fold, two-fold
1. Product Overview
4

Specifications
Specifications
Item Specification Remarks
Folding method Roller pressure contact method (demand process-
ing while feeding paper)
Folding mode Z-fold , C-fold, Outer three-fold, Four-fold, Two-fold • Z-fold, two-fold: Feeding to the finisher
• C-fold, outer three-fold, four-fold: Delivering to the
folding delivery tray
Paper types Fold section:Thin paper, plain paper, recycled pa-
per, color paper, bond pape, coated paper ,Pre-
punched paper
Feed section:All substrates host machine supports
Paper size Z-fold A3, B4, A4R,
11X17, LGL, LTR-R
C-fold *1 A4R, LTR-R
Outer three-fold A4R, LTR-R
Four-fold A4R, LTR-R, LGL
Two-fold A4R, LTR-R
Feed section:All substrates host machine supports
Paper weighing capacity Z-fold, C-fold, Outer three-
fold, Two-fold
52g/m2 to 105g/m2
Four-fold 52g/m2 to 90g/m2
Feed section: 52 g/m2 to 350 g/m2Different depending on the host machine.
Folding delivery tray
stacking capacity
C-fold Loading height:
60mm
(equivalent to 40
sheets)
Equivalent of 81.4g/m2 paper.
Outer three-fold Loading height: 60
mm (equivalent to
40 sheets)
Four-fold Loading height: 60
mm (equivalent to
25 sheets)
*1: C-fold envelope standard sizes (reference)
A4R 120 mm x 235 mm, 105 mm x 235 mm, 120 mm x 235 mm
LTR-R COM10 (105 mm×241 mm)
Others
Item Specification
Dimensions (W x D x H) 336mm x 793mm x 1190mm
Weight Approx. 71 kg
Power supply Supplied from the connect machine
Power Consumption Standby: 24 W or less
Operating: 150 W or less
Fold Accuracy
Z-fold
1. Product Overview
5

Z2
Z3
Z4
Z1
Z5
Standard Z1 Dimensions Z2 Dimensions
A3 102.0 - 106.0mm 104.0 - 108.0mm
A4R 71.3 - 75.2mm 73.3 - 77.2mm
11x17 105.0 - 109.0mm 107.0 - 111.0mm
LGL 86.0 - 90.0mm 88.0 - 92.0mm
LTR-R 66.8 - 70.7mm 68.8 - 72.7mm
Two-fold
T2
T1
T4
T3
Standard T2 Dimensions
A4R 146.5 - 150.5mm
LTR-R 137.5 - 141.5mm
Four-fold
F2 F1
F4
F3
T2
T1
T3
1. Product Overview
6

Standard F2 Dimensions
A4R 73.8 - 77.7mm
LTR-R 69.3 - 73.2mm
LGL 88.5 - 92.5mm
C-fold
C3
C1
C2
C6
C4
C5
Standard C3 Dimensions
A4R 98.5 - 102.5mm
LTR-R 92.6 - 96.5mm
Outer three-fold
O3
O1
O2
O6
O4
O5
Standard O3 Dimensions
A4R 98.5 - 102.5mm
LTR-R 92.6 - 96.5mm
Item Accuracy of A zone (15-27.5 deg C, 25-75%RH) Remarks
Z1 fold Line length/4-1±2.0mm
Z2 fold Line length/4+1±2.0mm User adjustment is available.
Z3/Z4 oblique fold Within ±1.5mm
Z5 fold height Within 15mm
T1 fold 0±2.0mm(3.5mm)* Reference value
T2 overall length Line length/2±2.0mm(3.5mm)* User adjustment is available.
T3 oblique fold ±1.5mm(2.5mm)*
T4 fold height Within 10mm
Z-fold, Two-fold paper delivery
performance
Delivery Outlet side registration:Within ±3.5mm
Delivery Outlet Cross-feed: Within ±2.5mm/100mm
F1 fold 2.0±2.0mm(3.5mm)*
F2 overall length Line length/4+1.5±2.0mm User adjustment is available.
F3 oblique fold ±1.5mm(±2.0mm)*
1. Product Overview
7

Item Accuracy of A zone (15-27.5 deg C, 25-75%RH) Remarks
F4 fold height Within 30mm Reference value
C1 fold 2.5±2.0mm
C2 fold 2.0±2.0mm
C3 overall length Line length/3+1.5 ±2.0mm
C4, C5 oblique fold Within ±1.5mm
C6 fold stacking capacity Max 40 sheets Equivalent of 80g/m2 paper.
O1 fold 2.5±2.0mm
O2 fold 2.0±2.0mm
O3 overall length Line length/3+1.5 ±2.0mm
O4, O5 oblique fold Within ±1.5mm
O6 fold stacking capacity Max 40 sheets Equivalent of 80g/m2 paper.
*The value in ( ) is for LGL.
1. Product Overview
8

Names of Parts
External View
■ Front
Upper cover
Front cover
Folding delivery tray
Folding Unit
■ Rear
Leakage breaker
Rear cover
Rear Upper cover
1. Product Overview
9

■ Internal
Feed guide
Right folding feed guide
Inlet feed guide
Left folding feed guide (left)
1. Product Overview
10

Cross Section View
[13]
[14]
[15]
[17]
[18]
[19]
[21]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[16]
[20]
[1] Folding/straight flapper [12] Folding tay flapper
[2] Inlet roller [13] Delivery feed roller 4
[3] Feed roller 1 [14] Folding roller 2
[4] Feed roller 2 [15] Registration roller
[5] Leading edge stopper [16] Delivery feed roller 5
[6] Folding roller1 [17] Trailing edge stopper
[7] Leading edge pushing guide [18] Delivery feed roller 6
[8] Folding roller3 [19] Delivery feed roller 7
[9] Delivery feed roller 1 [20] Delivery feed roller 8
[10] Delivery feed roller 2 [21] Delivery roller
[11] Delivery feed roller 3
1. Product Overview
11

Technical
Explanation
2
Basic Configuration.............................13
Controls...............................................25
Upgrading............................................55

Basic Configuration
Functional Configuration
This equipment is organized into two major blocks: folding feed unit and folding tray delivery unit.
Folding feed unit
Folding tray delivery unit
Electric Circuit Overview
The operation sequence of this equipment is controlled by the folder controller PCB.
The folder controller PCB has a CPU.
The CPU on the controller controls DC loads such as motors and solenoids at the predetermined timings according to the signals
from the sensors and the finisher.
The folder controller PCB reports the information about the sensors to the finisher through serial communication.
Finisher
Folder controller PCB Motor
Solenoid/Clutch
Sensor
CPU
2. Technical Explanation
13

Component Configuration
■ Roller Layout
[13]
[14]
[15]
[17]
[18]
[19]
[21]
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[16]
[20]
[1] Folding/straight flapper [12] Folding tay flapper
[2] Inlet roller [13] Delivery feed roller 4
[3] Feed roller 1 [14] Folding roller 2
[4] Feed roller 2 [15] Registration roller
[5] Leading edge stopper [16] Delivery feed roller 5
[6] Folding roller1 [17] Trailing edge stopper
[7] Leading edge pushing guide [18] Delivery feed roller 6
[8] Folding roller3 [19] Delivery feed roller 7
[9] Delivery feed roller 1 [20] Delivery feed roller 8
[10] Delivery feed roller 2 [21] Delivery roller
[11] Delivery feed roller 3
■ Sensor Layout
It describes only sensors on the feed path.
2. Technical Explanation
14