Canon Saddle Finisher-AF2 User manual

SERVICE
MANUAL
Saddle Finisher-AF2
MARCH 6, 2009

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.
Indicates an item intended to provide notes assisting the understanding of the topic in question.
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.
Memo
REF.

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 refer-
ence 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, how-
ever, 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 com-
municated 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 (finisher) ...........................................................................................................................................1- 1
1.1.2 Specifications (saddle stitcher)................................................................................................................................1- 2
1.2 Names of Parts...........................................................................................................................................1- 4
1.2.1 External View...........................................................................................................................................................1- 4
1.2.2 Cross Section ..........................................................................................................................................................1- 5
Chapter 2 Installation
2.1 Making Pre-Checks ....................................................................................................................................2- 1
2.1.1 Points to Note About Installation .............................................................................................................................2- 1
2.1.2 Installation Space ....................................................................................................................................................2- 1
2.2 Unpacking and Checking the Components ................................................................................................2- 2
2.2.1 Checking the Contents ............................................................................................................................................2- 2
2.3 Installation Procedure.................................................................................................................................2- 3
2.3.1 Unpacking................................................................................................................................................................2- 3
2.3.2 A note on Turning ON/OFF the Power of the Host Machine ...................................................................................2- 4
2.3.3 Before Installing the Finisher...................................................................................................................................2- 4
2.3.4 Connecting with the Host Machine..........................................................................................................................2- 6
2.3.5 Connecting with the Multi Drawer Document Insertion Unit ....................................................................................2- 9
2.3.6 Connecting with the the Professional Puncher Integration Unit ............................................................................2- 11
2.3.7 Connecting with the Paper Folding Unit ................................................................................................................2- 13
2.3.8 Connecting with the High Capacity Stacker ..........................................................................................................2- 16
2.3.9 Connecting with the Perfect Binder .......................................................................................................................2- 18
2.3.10 Connecting with the Document Insertion Unit......................................................................................................2- 21
2.3.11 Connecting cable .................................................................................................................................................2- 23
2.3.12 Checking Connection...........................................................................................................................................2- 26
2.4 Making Adjustments .................................................................................................................................2- 26
2.4.1 Height Adjustment .................................................................................................................................................2- 26
2.5 Attaching the Labels etc. ..........................................................................................................................2- 27
2.5.1 Affixing the labels ..................................................................................................................................................2- 27
2.6 Relocationg the Machine ..........................................................................................................................2- 28
2.6.1 A note on moving the machine..............................................................................................................................2- 28
Chapter 3 Functions
3.1 Basic Construction......................................................................................................................................3- 1
3.1.1 Overview..................................................................................................................................................................3- 1
3.2 Electrical Control Unit .................................................................................................................................3- 1
3.2.1 Overview..................................................................................................................................................................3- 1
3.2.2 Finisher Controller PCB...........................................................................................................................................3- 2
3.2.3 Saddle Stitcher Controller PCB ...............................................................................................................................3- 2
3.3 Stacking Unit ..............................................................................................................................................3- 3
3.3.1 Overview..................................................................................................................................................................3- 3
3.3.2 Tray Ascent/Descent Control...................................................................................................................................3- 3
3.3.3 Auxiliary Tray Lift Control ........................................................................................................................................3- 4
3.3.4 Tray Paper Surface Detection .................................................................................................................................3- 5
3.4 Feeding Unit ...............................................................................................................................................3- 6
3.4.1 Overview..................................................................................................................................................................3- 6

Contents
3.4.2 Basic Sequence of Operations ................................................................................................................................3- 8
3.4.3 Horizontal Registration Detection ............................................................................................................................3- 8
3.4.4 Side Registration Correction Operation Shift Operation ........................................................................................3- 10
3.4.5 Buffer Operation.....................................................................................................................................................3- 13
3.4.6 Switching Over the Paper Path..............................................................................................................................3- 15
3.4.7 Interval Speed Control ...........................................................................................................................................3- 16
3.5 Intermediate Process Tray Assembly....................................................................................................... 3- 18
3.5.1 Overview................................................................................................................................................................3- 18
3.5.2 Basic Sequence of Operations ..............................................................................................................................3- 19
3.5.3 Stacking Operation ................................................................................................................................................3- 20
3.5.4 Shift Operation.......................................................................................................................................................3- 24
3.5.5 Stapling Operation .................................................................................................................................................3- 25
3.5.6 Delivery Operation .................................................................................................................................................3- 27
3.6 Saddle Stitcher Unit.................................................................................................................................. 3- 29
3.6.1 Overview................................................................................................................................................................3- 29
3.6.2 Basic Sequence of Operations ..............................................................................................................................3- 30
3.6.3 Paper Feed Operation ...........................................................................................................................................3- 31
3.6.4 Alignment Operation ..............................................................................................................................................3- 35
3.6.5 Staple Operation....................................................................................................................................................3- 37
3.6.6 Paper Folding/Delivery Operations........................................................................................................................3- 38
3.7 Detecting Jams......................................................................................................................................... 3- 43
3.7.1 Jam inspection in Finisher .....................................................................................................................................3- 43
3.7.2 Stitcher area jam detection. ...................................................................................................................................3- 45
Chapter 4 Parts Replacement Procedure
4.1 Removing from the Host Machine .............................................................................................................. 4- 1
4.1.1 Finisher Assembly....................................................................................................................................................4- 1
4.1.1.1 Removing From the Host Machine .......................................................................................................................................... 4- 1
4.2 External Covers.......................................................................................................................................... 4- 2
4.2.1 Rear Cover...............................................................................................................................................................4- 2
4.2.1.1 Removing the Rear Cover ....................................................................................................................................................... 4- 2
4.2.2 Rear Upper Cover....................................................................................................................................................4- 3
4.2.2.1 Removing the Rear Upper Cover (Right)................................................................................................................................. 4- 3
4.2.2.2 Preparation for Removing the Rear Upper Cover (Left) .......................................................................................................... 4- 3
4.2.2.3 Removing the Rear Upper Cover (Left) ................................................................................................................................... 4- 3
4.2.3 Upper Cover Unit .....................................................................................................................................................4- 3
4.2.3.1 Preparation for Removing Upper Cover Unit ........................................................................................................................... 4- 3
4.2.3.2 Removing the Upper Cover Unit .............................................................................................................................................. 4- 3
4.2.4 Delivery Tray............................................................................................................................................................4- 4
4.2.4.1 Preparation for Removing the Tray A/B Unit............................................................................................................................ 4- 4
4.2.4.2 Removing the Tray A/B Unit .................................................................................................................................................... 4- 4
4.2.4.3 Point to Take Caution on Tray A/B Cable ................................................................................................................................ 4- 7
4.2.4.4 Point to Take Caution on Handling Stack Wall Rail ................................................................................................................. 4- 7
4.2.4.5 Tray B Positioning When Inserting the Power Supply ............................................................................................................. 4- 7
4.2.5 Stack Wall (Upper)...................................................................................................................................................4- 8
4.2.5.1 Removing the Stack Wall (Upper)............................................................................................................................................ 4- 8
4.2.6 Stack Wall (Lower)...................................................................................................................................................4- 8
4.2.6.1 Preparation for Removing the Stack Wall (Lower)................................................................................................................... 4- 8
4.2.6.2 Removing the Stack Wall (Lower)............................................................................................................................................ 4- 8
4.2.6.3 Install the Stack Wall (Lower) .................................................................................................................................................. 4- 8
4.2.7 Saddle Inside Cover.................................................................................................................................................4- 9
4.2.7.1 Remove the Saddle Inside Cover (Upper) ............................................................................................................................... 4- 9
4.2.7.2 Removing the Saddle Inside Cover (Lower) ............................................................................................................................ 4- 9
4.2.8 Inside Cover (Upper)................................................................................................................................................4- 9
4.2.8.1 Removing the Inside Cover (Upper) ........................................................................................................................................ 4- 9
4.2.9 Inside Cover (Lower)..............................................................................................................................................4- 10
4.2.9.1 Removing the Inside Cover (Lower) ...................................................................................................................................... 4- 10

Contents
4.3 Drive System ............................................................................................................................................4- 10
4.3.1 Buffer Pass Motor..................................................................................................................................................4- 10
4.3.1.1 Preparation for Removing Buffer Motor ................................................................................................................................. 4- 10
4.3.1.2 Removing the Buffer Motor .................................................................................................................................................... 4- 10
4.3.2 Feed Motor ............................................................................................................................................................4- 11
4.3.2.1 Preparation for Removing Buffer Front Feed Motor............................................................................................................... 4- 11
4.3.2.2 Removing the Buffer Front Feed Motor ................................................................................................................................. 4- 11
4.3.2.3 Preparation Removing the Inlet feed Motor ........................................................................................................................... 4- 11
4.3.2.4 Removing the Inlet Feed Motor.............................................................................................................................................. 4- 11
4.3.3 Paper Trailing Edge Drop Motor............................................................................................................................4- 11
4.3.3.1 Preparation for Removing the Paper Trailing Edge Drop Motor ............................................................................................ 4- 11
4.3.3.2 Removing the Paper Trailing Edge Drop Motor ..................................................................................................................... 4- 11
4.3.4 Stack Delivery Motor .............................................................................................................................................4- 12
4.3.4.1 Preparation for Removing the Stack Delivery Motor.............................................................................................................. 4- 12
4.3.4.2 Removing the Stack Delivery Motor....................................................................................................................................... 4- 12
4.3.5 Staple Unit .............................................................................................................................................................4- 12
4.3.5.1 Preparation for Removing Staple Unit ................................................................................................................................... 4- 12
4.3.5.2 Removing the Staple Unit ...................................................................................................................................................... 4- 12
4.3.6 Saddle Staple Unit.................................................................................................................................................4- 12
4.3.6.1 Removing the Saddle Staple Unit .......................................................................................................................................... 4- 12
4.3.7 Front Alignment Motor ...........................................................................................................................................4- 13
4.3.7.1 Preparation for Removing the Front Alignment Motor ........................................................................................................... 4- 13
4.3.7.2 Removing the Front Alignment Motor .................................................................................................................................... 4- 13
4.3.8 Rear Alignment Motor............................................................................................................................................4- 15
4.3.8.1 Preparation for Removing the Rear Alignment Motor ............................................................................................................ 4- 15
4.3.8.2 Removing the Rear Alignment Motor..................................................................................................................................... 4- 15
4.3.9 Saddle Alignment Motor ........................................................................................................................................4- 17
4.3.9.1 Preparation for Removing Saddle Alignment Motor............................................................................................................... 4- 17
4.3.9.2 Removing the Saddle Alignment Motor ................................................................................................................................. 4- 17
4.3.10 Tray Shift Motor ...................................................................................................................................................4- 17
4.3.10.1 Removing the Tray A/B Shift Motor...................................................................................................................................... 4- 17
4.3.11 Shift Motor ...........................................................................................................................................................4- 18
4.3.11.1 Preparation for Removing Horizontal Registration Shift Unit ............................................................................................... 4- 18
4.3.11.2 Removing the Horizontal Registration Shift Unit .................................................................................................................. 4- 18
4.3.11.3 Preparation for Removing Horizontal Registration Shift Motor ............................................................................................ 4- 21
4.3.11.4 Removing Side Registration Shift Motor .............................................................................................................................. 4- 21
4.3.11.5 Preparation for Removing Shift Motor.................................................................................................................................. 4- 21
4.3.11.6 Removing the Shift Motor..................................................................................................................................................... 4- 22
4.3.12 Positioning Plate Unit...........................................................................................................................................4- 22
4.3.12.1 Preparation for removing positioning plate unit.................................................................................................................... 4- 22
4.3.12.2 Removing the Positioning Plate Unit.................................................................................................................................... 4- 22
4.3.13 Belt Controller Unit...............................................................................................................................................4- 22
4.3.13.1 Preparation for Removing Belt Controller Unit ..................................................................................................................... 4- 22
4.3.13.2 Removing Belt Controller Unit.............................................................................................................................................. 4- 22
4.4 Document Feeding System ......................................................................................................................4- 24
4.4.1 Engaging Roller .....................................................................................................................................................4- 24
4.4.1.1 Preparation for Engaging Roller............................................................................................................................................. 4- 24
4.4.1.2 Removing the Engaging Roller .............................................................................................................................................. 4- 25
4.4.2 Stack Delivery Roller .............................................................................................................................................4- 25
4.4.2.1 Preparation for Removing Stack Delivery Upper Roller......................................................................................................... 4- 25
4.4.2.2 Removing Stack Delivery Upper Roller.................................................................................................................................. 4- 25
4.4.3 Process Tray Assembly.........................................................................................................................................4- 26
4.4.3.1 Preparation for Removing the Process Tray Assembly ......................................................................................................... 4- 26
4.4.3.2 Removing the Process Tray Assembly .................................................................................................................................. 4- 26
4.4.4 Process Tray .........................................................................................................................................................4- 28
4.4.4.1 Preparation for Removing the Process Tray (Front/Rear) ..................................................................................................... 4- 28
4.4.4.2 Removing the Process Tray (Front)....................................................................................................................................... 4- 28
4.4.4.3 Removing the Process Tray (Rear) ....................................................................................................................................... 4- 28
4.4.5 Feed Belt ...............................................................................................................................................................4- 29

Contents
4.4.5.1 Preparation for Removing the Feed Belt................................................................................................................................ 4- 29
4.4.5.2 Removing the Feed Belt ........................................................................................................................................................ 4- 29
4.4.5.3 Before Removing the Belt Roller............................................................................................................................................ 4- 30
4.4.5.4 Removing the Belt Roller ....................................................................................................................................................... 4- 30
4.4.6 Paddle Unit ............................................................................................................................................................4- 32
4.4.6.1 Preparation for Removing Paddle Unit .................................................................................................................................. 4- 32
4.4.6.2 Removing the Paddle Unit ..................................................................................................................................................... 4- 32
4.4.7 Paddle....................................................................................................................................................................4- 32
4.4.7.1 Preparation for Removing Paddle.......................................................................................................................................... 4- 32
4.4.7.2 Removing the Paddle............................................................................................................................................................. 4- 32
4.4.8 Saddle Unit ............................................................................................................................................................4- 32
4.4.8.1 Pull Out the Saddle Unit (Service Position) ........................................................................................................................... 4- 32
4.4.8.2 Removing the Saddle Unit ..................................................................................................................................................... 4- 33
4.4.9 Alignment Roller.....................................................................................................................................................4- 34
4.4.9.1 Preparation for Removing the Alignment Roller..................................................................................................................... 4- 34
4.4.9.2 Removing the Alignment Roller ............................................................................................................................................. 4- 34
4.4.10 Thrust Unit............................................................................................................................................................4- 35
4.4.10.1 Preparation for Removing the Thrust Unit............................................................................................................................ 4- 35
4.4.10.2 Removing the Thrust Unit .................................................................................................................................................... 4- 35
4.4.11 Thrust Plate..........................................................................................................................................................4- 35
4.4.11.1 Preparation for Removing the Thrust Plate.......................................................................................................................... 4- 35
4.4.11.2 Removing the Thrust Plate................................................................................................................................................... 4- 36
4.4.12 Pressing Unit........................................................................................................................................................4- 36
4.4.12.1 Preparation for Removing Pressing Unit.............................................................................................................................. 4- 36
4.4.12.2 Removing the Pressing Unit................................................................................................................................................. 4- 36
4.4.13 Pressing Roller Unit .............................................................................................................................................4- 37
4.4.13.1 Preparation for Removing the Pressing Roller Unit ............................................................................................................. 4- 37
4.4.13.2 Removing the Pressing Roller Unit. ..................................................................................................................................... 4- 38
4.4.14 Folding Roller.......................................................................................................................................................4- 39
4.4.14.1 Preparation for Removing the Folding Roller ....................................................................................................................... 4- 39
4.4.14.2 Removing the Folding Roller................................................................................................................................................ 4- 39
4.5 Electrical System...................................................................................................................................... 4- 41
4.5.1 Feed Motor Driver PCB..........................................................................................................................................4- 41
4.5.1.1 Preparation for Removing Feed Motor Driver PCB................................................................................................................ 4- 41
4.5.1.2 Remove the Feed Motor Driver PCB ..................................................................................................................................... 4- 41
4.5.2 Finisher Controller PCB .........................................................................................................................................4- 41
4.5.2.1 Finisher Controller PCB ......................................................................................................................................................... 4- 41
4.5.3 Static Charge Eliminator ........................................................................................................................................4- 42
4.5.3.1 Preparation for Removing the Stack Delivery Roller Upper Static Charge Eliminator ........................................................... 4- 42
4.5.3.2 Remove the Stack Delivery Roller Upper Static Charge Eliminator....................................................................................... 4- 42
4.5.3.3 Preparation for Removing the Stack Delivery Roller Lower Static Charge Eliminator ........................................................... 4- 42
4.5.3.4 Removing the Stack Delivery Roller Lower Static Charge Eliminator.................................................................................... 4- 42
4.5.3.5 Preparation for Removing Saddle Inlet Static Charge Eliminator .......................................................................................... 4- 42
4.5.3.6 Removing the Saddle Inlet Static Charge Eliminator ............................................................................................................. 4- 42
4.5.3.7 Removing the Saddle Inlet Roller Static Charge Eliminator................................................................................................... 4- 43
4.5.3.8 Preparation for Removing the Feed Guide Lower Static Charge Eliminator.......................................................................... 4- 43
4.5.3.9 Removing the Feed Guide Lower Static Charge Eliminator .................................................................................................. 4- 43
4.5.3.10 Removing the Saddle Intermediary Static Charge Eliminator.............................................................................................. 4- 43
4.5.3.11 Removing the Delivery Static Charge Eliminator ................................................................................................................. 4- 44
4.5.4 Horizontal Registration Sensor Unit.......................................................................................................................4- 44
4.5.4.1 Preparation for Removing the Horizontal Registration Sensor Unit....................................................................................... 4- 44
4.5.4.2 Removing the Horizontal Registration Sensor Unit................................................................................................................ 4- 44
4.5.5 Horizontal Registration Sensor PCB......................................................................................................................4- 46
4.5.5.1 Preparation for Removing the Horizontal Registration Sensor PCB...................................................................................... 4- 46
4.5.5.2 Removing the Horizontal Registration Sensor PCB............................................................................................................... 4- 46
Chapter 5 Maintenance
5.1 User Maintenance ...................................................................................................................................... 5- 1
5.1.1 User Maintenance Items (finisher)...........................................................................................................................5- 1