Canon GP605, Gp-605v, Gp-600 Service Manual Finisher D2

SADDLE FINISHER - D2

SERVICE MANUAL

REVISION 0

AUG. 1999

FY8-13G9-000

IMPORTANT

THE INFORMATION CONTAINED HEREIN IS PUBLISHED BY CANON, INC., JAPAN. SPECIFICATIONS AND OTHER INFORMATION CONTAINED HEREIN MAY DIFFER SLIGHTLY FROM ACTUAL MACHINE VALUES OR THOSE FOUND IN ADVERTISING AND OTHER PRINTED MATTER.

ANY QUESTIONS REGARDING INFORMATION CONTAINED HEREIN SHOULD BE DIRECTED TO THE COPIER SERVICE DEPARTMENT OF THE SALES COMPANY.

Printed in Japan

Imprimé au Japon

Use of this manual should be strictly supervised to avoid disclosure of confidential information.

Prepared by

OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIVISION

CANON INC.

5-1, Hakusan 7-chome, Toride-City, Ibaraki, 302-8501 Japan

INTRODUCTION

This Service Manual contains basic data and figures on the Saddle Finisher-D2

needed to service the machine in the field.

CHAPTER 1 General Description introduces the finisher's features and specifications,

and shows how to operate the finisher.

CHAPTER 2 Basic Operation provides outlines of the finisher's various mechanical workings, and explains the principles used for the finisher's various control mechanisms in view of the functions of electrical and mechanical units and in relation to their timing of operation.

CHAPTER 3 Mechanical System shows how the finisher's various mechanical workings are constructed, and how the finisher may be disassembled/assembled and adjusted.

CHAPTER 4 Maintenance and Servicing provides tables of periodically replaced parts and consumables/durables and scheduled servicing charts.

CHAPTER 5 Troubleshooting provides tables of maintenance/inspection, standards/ adjustments, and problem identification (image fault/malfunction).

APPENDIX contains a general timing chart and general circuit diagrams.

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.

CHAPTER 1

GENERAL DESCRIPTION

I. FEATURES.................................1-1

II. SPECIFICATIONS......................1-2

A. Specifications.........................1-2

B. Cross Section ......................1-10

III. OPERATING THE FINISHER...1-14

A. Removing Jams from the Finisher

.............................................1-14

B. Removing Jams from the Saddle

Stitcher Unit ......................... 1-19

C. Removing Jams from the Paper

Folding Unit..........................1-23

D. Removing Jams from the Cover

Inserter.................................1-26

E. Replacing the Staple Case in the

Stapler Unit ..........................1-28

F. Removing Jammed Staples from

the Stapler Unit ....................1-30

G. Replacing the Saddle Stitcher

Unit Staple Cartridges..........1-32

H. Removing Jammed Staples from

the Saddle Stitcher Unit.......1-34

I. Removing Punch waste.......1-37

J. Module Separation Switch...1-38 K. Operating the Module Separation

Switch ..................................1-39

IV. MAINTENANCE BY THE USER

..................................................1-41

CHAPTER 1 GENERAL DESCRIPTION

I . FEATURES

1. Two Types of Stacking Trays

• There are two types of stacking trays, tray A and tray B, which are used for different purposes.

2. Large Capacity

• Tray B is capable of holding a stack of sheets 285 mm in height (small size)/145 mm in height (large size), while tray A is capable of holding a stack of sheets 145 mm in height.

3. Wide-Ranging Paper Types

2

• The sheets may be of 64 to 200 g/m

paper.

4. Stack Job Offset Function

• The stack job offset function is offered for sorting non-staple stacks.

5. Three Types of Auto Stapling

• As many as three different types (position) are offered (front slant, rear slant, 2-point).

6. High Productivity by a Buffer Roller

• The use of a buffer roller has enabled continuous feeding of sheets from the copier while stapling or offset operation is taking place.

7. Punching Function

• The use of a punch unit enables holes for filing the paper in a binder to be punched in the paper prior to delivery. (This function can be used with 64-200 g/m

2

paper, but not with

intermediate paper or OHP paper.)

8. Saddle Stitcher Function

• Up to 15 sheets can be delivered stapled in the middle and folded in half.

9. Inserter Function

• The cover can be picked up from the inserter which is separate from the cassette.

10. Folding Function

• This function enables Z-folding to be carried out of paper of A3, B4 or 279.4 x 431.8mm (11 x 17) size. Paper of 64-80 g/m

2

can be folded.

1-1

CHAPTER 1 GENERAL DESCRIPTION

II . SPECIFICATIONS

A. Specifications

1. Saddle Finisher D2

1-a. Finisher

SpecificationsItem Remarks

Lifting system

Stacking

Stack size

Paper weight Modes

Stack thickness

Nonstaple sort

Tray A Up/down Tray B Tray A Tray B Tray A

Tray B

64 to 200 g/m Staple stacking, non-staple stacking

Tray A

Tray B

Up/down Same as the copier delivery method. Face-down Postcard to A3/

279.4mm × 431.8mm A5/STMT to A3/

279.4mm × 431.8mm

2

1000-sheet equivalent (small/large size) 145mm

2,000-sheet equivalent (small-size) 285mm 1,000-sheet equivalent (large-size) 145mm

Postcards are for R feeding only.

A5/STMT is for R feeding only. B5/A4/LTR is for horizontal feeding only.

Mixed stacking is possible under certain conditions

Paper equivalent to 80 g/m

2

Staple sort

Staple/non-staple mix

1-2

Tray A

Tray B

1,000-sheet equivalent or 100 sets (small/large size)

2,000-sheet equivalent or 100 sets (small-size) 1,000-sheet equivalent or 100 sets (large-size)

Stops when either of the conditions below is met 2,000-sheet equivalent or 100 sets (small-size) 1,000-sheet equivalent or 100 sets or 30 folded sheets (large-size)

Stacking ability is not guaranteed. Treated as large size when 1 large-size sheet is included.

Table 1-201

The specifications are subject to change for product improvement.

CHAPTER 1 GENERAL DESCRIPTION

SpecificationsItem Remarks

Folded paper mix stack thickness

Tray A Max. 20 sheets of folded paper Tray B

Max. 10 sheets of folded paper per

Paper equivalent to 80 g/m

2

stack / Max. 30 sheets of folded paper per 1 job (1 folded sheet is regarded as 5 sheets of normal paper)

Stacking condition

Paper detection

Tray A Tray B

Tray A

Front/rear stack offset Staple: 20 mm Non-staple: 30 mm (LGL: 36mm)

Yes

No offset stacking on tray A for non-sort delivery

Tray B

Control panel

No Display No Installation Latching with mount (height adjusted by caster) Dimensions 802 mm (W) × 738 mm (D) × 995 mm (H) /

5

31 -

/8" (W) × 29 - 1/8" (D) × 39 - 3/8" (H)

Note 2

Note 1: The term “small-size” refers to A4, A5, B5, postcard, LTR, and STMT, while the term “large-

size” refers to A3, B4, 279.4 mm × 431.8 mm, and LGL. Note 2: Width when folder is connected: 986mm / 38 -

13

/16"

Height when inserter is connected:1,138mm / 44 - 13/16" (auxiliary tray open)

Table 1-201-2

The specifications are subject to change for product improvement.

1-3

CHAPTER 1 GENERAL DESCRIPTION

SpecificationsItem Remarks

W eight

Power supply Maximum power

consumption (230V) Stapling Stapling position Stapling thickness

Staple compartment

Staples Staple detection automatic staple

reposition Stapling

size

1-point stapling

2-point stapling

Approx. 106 kg (233 b) Approx. 170 kg (373.7

b) (including inserter and folder) 100 to 120V/50; 60Hz, 230V/50Hz During wait : 160W / during stand-by : 60W / during

operation : 200W (staple sort) Punching by a rotating cam. (face-down stapling) See figure below.

2

48 sheets (80 g/m

) + 2 sheets (200 g/m2), or thick paper

of 5.5 mm or less Special cartridge (5,000 staples)

Special staples Yes Within 10 times

Front/rear

A3, A4, B4, B5, 279.4mm × 431.8 mm, LGL, LTR

A3, A4, B4, B5, 279.4mm × 431.8 mm, LTR

Manual stapling

1-point stapling (front)

45˚

*2

5±2

None

1-point stapling (rear)

*2

5±25±2

Unit: mm

Table 1-202

2-point stapling

279.4mm×

431.8mm (11×17),

6±2

45˚

5±2

A3, A4 B4, B5

88.5±4 68.5±4 79.5±4

6±2

208.5±4 188.5±4 199.5±4

*2 *2 *2 *1 *1 *1

6±2

*1 The stapling interval may be adjusted in user mode. *2 The stapling position may be adjusted using a DIP switch.

Figure 1-201

LTR

1-4

The specifications are subject to change for product improvement.

CHAPTER 1 GENERAL DESCRIPTION

12±3mm

31.5±3mm

108±0.5mm 108±0.5mm

Feed direction

12±3mm

80±0.5mm

*1

*1 : A4/A3=108.5±3mm

: B4/B5=88.5±3mm

Feed direction

Item Specifications

Punching method Rotary punch (one after another as paper passes) Paper type 64 to 200 g/m

2

(Not possible with OHP paper)

Punch position 100/230V 115V

Paper size 100 V / 230 V : A3, B4, A4, B5

115 V : 279.4 mm × 431.8 mm, LTR

Maximum power consumption (230V)

200W (punch staple sort)

Punch (No. and diameter of holes)

100/230V : 2 holes, 6.5mm 115V : 3 holes, 8mm

Punch waste capacity 100/230V : Approx. 20,000 sheets or more (when using 80 g/m2 paper)

115V : Approx. 10,000 sheets or more (when using 80 g/m

2

paper)

Punch waste “full” indicator

Displayed on main control panel

Punch mode designation method

Designated on main control panel

Punch unit-related items

Table 1-203

The specifications are subject to change for product improvement.

1-5

CHAPTER 1 GENERAL DESCRIPTION

1-b.Saddle Stitcher

Item Specifications

Stapling method Stapling position Paper size No. of sheets Paper weight

No. of sets for stacking

Stapling specifications

Folding specifications

Staple in middle, then fold in half See Figure 1-202. A3, B4, A4R, 279 mm × 432 mm (11 × 17), LTRR 15 sheets (including cover) (Note 1) 64 g/m

2

to 80 g/m2 (1 cover up to 200 g/m2) (Not possible with special paper or

OHP paper) 30 sets (special tray, front stop shift)

Stapling position Staple capacity

Staple loading

2 points (equidistant from center, fixed interval) 2000 staples

Special cartridge

method Staples Staple detection Folding method Folding mode Folding position

Special staples (Staple Cartridge D2) Yes Folding by roller pressure Folding in two (1 sheet is not stapled) Center of paper

Folding position

Yes adjustment function

Power supply

Supplied from finisher 24V, 2-systems

Trimmer (Note 2) Power consumption

No 190W (book mode)

(230 V)

Note 1: When using thick paper over 90 g/m2 in cover mode, depending on the type of paper, feeding may

not go smoothly with stacks of 14 sheets or over. If this happens, change the setting to 13 sheets or less.

Note 2: The term “trimmer” refers to the function for trimming the edges of the stacks.

Table 1-204

The specifications are subject to change for product improvement.

1-6

Stapling and folding position (saddle stitcher)

CHAPTER 1 GENERAL DESCRIPTION

A3

Stapling position

L

Folding position

210±1mm

88.5±2mm

208.5±2mm

Front edge of stack L (difference between folding position and stapling position) = ± 0.5mm

B4

L

182±1mm

68.5±2mm

188.5±2mm

L (difference between folding position and stapling position) = ± 0.5mm

A4R

L

148.5±1mm

45±2mm

165±2mm

L (difference between folding position and stapling position) = ± 0.5mm

279mm×432mm (11×17)

L

216±1mm

79.7±2mm

199.7±2mm

L (difference between folding position and stapling position) = ± 0.5mm

Figure 1-202

The specifications are subject to change for product improvement.

LTRR

L

139.7±1.5mm

48±2mm

163±2mm

L (difference between folding position and stapling position) = ± 0.5mm

1-7

CHAPTER 1 GENERAL DESCRIPTION

2. Folder (Paper Folding Unit B1)

SpecificationsItem Remarks

Folding method Paper weight Paper size Folding mode Dimensions

Power consumption (230V)

Weight Power supply

Folding Position

Roller pressure (folded one after another as paper passes) 64 to 80 g/m

2

A3, B4, 297 mm × 432 mm (11 × 17) Z-folding 184 mm (W) × 675 mm (D) × 995 mm (H) /

1

7 -

/4" (W) × 26 - 5/8" (D) × 39 - 1/4" (H)

240 W (Z-fold, punch staple mode)

Approx. 45 kg / 99.2

b

Supplied from finisher

Table 1-205

Z3

Including casters

Z1

Z2

Z4

Z1: Within 2 mm Z2: Within

+2

-1

paper length

2

± 2 mm

Z3, Z4: Within ± 1.5 mm In case of high temperature/high humidity or low temperature Z3, Z4: Within ± 2.0 mm

Figure 1-203

The specifications are subject to change for product improvement.

1-8

3. Inserter (Cover Insertion Unit-A1)

SpecificationsItem Remarks

Stacking capacity

Paper weight

100 sheets (small-size) / 50 sheets (large-size)

64 to 200 g/m

2

(including colored copy paper)

CHAPTER 1 GENERAL DESCRIPTION

2

Face-up, 80 g/m paper

Not possible with OHP paper

Paper size

Mixed stacking Separation method Position standard Weight Power consumption

(230V) Dimensions

Power supply

The specifications are subject to change for product improvement.

B5 to A3/ 279mm × 432mm (11 × 17)

No Upper separation by belt Center standard Approx. 20kg / 44

b

240 W (Z-fold, cover mode, pumch, staple-sort)

Auxiliary tray open: 561mm (W) × 584mm (D) × 144mm (H) / 22 -

1

/8" (W) × 23" (D) × 5 - 5/8" (H) Auxiliary tray closed: 402mm (W) × 584mm (D) × 132mm (H) / 15 -

7

/8" (W) × 23" (D) × 5 - 1/4" (H) Supplied from finisher

Table 1-206

B5 is for standard feeding only

1-9

CHAPTER 1 GENERAL DESCRIPTION

B. Cross Section

1. Finisher

[1] [1A] [2] [3] [4] [5] [6] [7] [8] [9] [10][11] [12] [13]

[1] Tray B [1A] Sub tray (attached when folder at-

tached) [2] Swing guide [3] Paddle [4] Tray A [5] Non-sort delivery roller [6] Upper path switching flapper [7] Buffer roller [8] Inserter (Cover Insertion Unit-A1) [9] Buffer switching flapper [10] Punch unit [11] Inlet roller

[22][23][24] [17][19][20][21] [18]

[12] Saddle inlet paper deflector [13] Folder (Paper Folding Unit-B1) [14] Pre-delivery roller [15] Mobile roller [16] Stapler [17] Delivery roller [18] Saddle stitcher [19] Knurled belt [20] Processing tray [21] Jogging plate (front, rear) [22] Shutter [23] Tray auxiliary plate [24] Stack delivery roller

Figure 1-204

[16] [15][14]

1-10

2. Saddle Stitcher Unit

[11] [10]

CHAPTER 1 GENERAL DESCRIPTION

[9]

[8] [7] [6]

[5] [4]

[3] [2] [1]

[1] Saddle delivery tray [2] Delivery guide roller [3] Guide plate [4] Delivery guide [5] Delivery roller [6] Folding roller (top, bottom) [7] Intermediate roller 2 [8] Stitcher (front, rear) [9] Intermediate roller 1

[12] [13]

[14] [15]

[16] [17]

[18]

[10] Saddle inlet paper deflector [11] Saddle inlet roller [12] Paper deflector 1 [13] Paper deflector 2 [14] Stitch support [15] Jogging plate (front, rear) [16] Pressure plate [17] Crescent roller [18] Positioning plate

Figure 1-205

1-11

CHAPTER 1 GENERAL DESCRIPTION

3. Folder

[13]

[12] [11] [10]

[9] [8]

[7]

[1] [2]

[3]

[4] [5] [6]

[1] Folder inlet flapper [2] Feed roller 1 [3] Folding roller 2 [4] Folding roller C [5] Folding roller A [6] 1st stopper

(A3/279.4mm × 431.8mm (11 × 17)) [7] 1st stopper (B4) [8] Folding roller B [9] 2nd stopper (B4)

[10] 2nd stopper

(A3/279.4mm × 431.8mm (11 × 17)) [11] Skew correction roller [12] Pressure roller [13] Feed roller 2

Figure 1-206

1-12

4. Inserter

CHAPTER 1 GENERAL DESCRIPTION

[1] [2] [3] [4] [5] [6] [7] [8]

[1] Auxiliary tray [2] Side guide (front, rear) [3] Pick-up roller [4] Feed roller

[5] Separation belt [6] Extraction roller [7] Intermediate feed roller [8] Inserter lower feed roller

Figure 1-207

1-13

CHAPTER 1 GENERAL DESCRIPTION

III . OPERATING THE

FINISHER

A. Removing Jams from the

Finisher

1. Paper Jam in the Top Cover

A paper jam has occurred in the area which appears in the display. Follow the procedure described below to remove the jammed paper.

1) Remove any paper protruding from the

output tray.

Figure 1-301

2) Open the cover inserter.

• This procedure is not necessary if the cover

inserter is not attached to the finisher.

3) Open the front cover.

Figure 1-302

Figure 1-303

1-14

Figure 1-304

4) Push the knob to the back and align the of the knob to the range of .

5) Open the top cover and check the inside of the finisher.

CHAPTER 1 GENERAL DESCRIPTION

Figure 1-305

6) Turn the green knob and remove any jammed paper.

7) Close the top cover.

Figure 1-306

Figure 1-307

Figure 1-308

1-15

CHAPTER 1 GENERAL DESCRIPTION

8) Close the front cover.

9) Close the cover inserter.

• This procedure is not necessary if the cover inserter is not attached to the finisher.

Figure 1-309

10) Follow the instructions in the display.

Figure 1-310

1-16

2. Paper Jam in the Front Cover

A paper jam has occurred in the area which appears in the display. Follow the procedure described below to remove the jammed paper.

1) Open the front cover.

CHAPTER 1 GENERAL DESCRIPTION

Figure 1-311

2) Push the knob to the back and align the

of the knob to the range of .

3) Open the paper delivery guide and re-

move any jammed paper.

Figure 1-312

Figure 1-313

Figure 1-314

1-17

CHAPTER 1 GENERAL DESCRIPTION

4) Lift the lever and remove any jammed paper.

5) Pull open the guide, and remove any jammed paper.

• This procedure is not necessary if the sheet

is not fed from the cover inserter.

Figure 1-315

6) Open the open/close guide, and remove any jammed paper from inside of the finisher.

• Do not remove any paper from the tray while

a copy job is being performed.

7) Close the cover inserter.

Figure 1-316

Figure 1-317

8) Follow the instructions in the display.

1-18

Figure 1-318

B. Removing Jams from the

Saddle Stitcher Unit

1. Paper Jam in the Saddle Stitcher Unit

A paper jam has occurred in the area which appears in the display. Follow the procedure described below to remove the jammed paper.

1) Open the front cover.

CHAPTER 1 GENERAL DESCRIPTION

Figure 1-319

2) Open the guide, and remove any jammed

paper.

• This procedure is not necessary if the sheet

is not fed from the cover inserter.

3) Pull the upper guide of the saddle stitcher

unit to the left, and remove any jammed

paper.

• This procedure is not necessary if the sheet

is not fed from the cover inserter.

Figure 1-320

Figure 1-321

Figure 1-322

1-19

CHAPTER 1 GENERAL DESCRIPTION

4) Return the upper guide to its original position.

5) Pull up the lower guide of the saddle stitcher unit, and remove any jammed paper.

Figure 1-323

6) Turn the right knob to the left until it stops.

7) Push in and turn the left knob to the right until the lamp turns off.

Figure 1-324

Figure 1-325

Lamp

1-20

Figure 1-326

Canon GP605, Gp-605v, Gp-600 Service Manual Finisher D2

CONTENTS

CHAPTER 1

I . FEATURES

II . SPECIFICATIONS