Canon iR5870C, iR5870Ci, iR6870C, iR6870Ci saddle finisher-r2 Service Manual

Service Manual

Finisher, Sorter, DeliveryTray Saddle Finisher-R2

Mar 22 2004

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.

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.

Printed in Japan

Caution

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

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.

Introduction

Memo

REF.

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.

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 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."

Contents

Chapter 1 Specifications

1.1 Product Specifications....................................................................................................................................... 1- 1

1.1.1Finisher Unit................................................................................................................................................ 1- 1

1.1.2Saddle Stitcher Unit.....................................................................................................................................1- 4

1.2 Names of Parts................................................................................................................................................... 1- 6

1.2.1External View.............................................................................................................................................. 1- 6

1.2.2Cross Section (FInisher Unit)...................................................................................................................... 1- 7

1.2.3Cross Section (Saddle Stitcher Unit)...........................................................................................................1- 8

Chapter 2 Functions

2.1 Basic Operation.................................................................................................................................................2- 1

2.1.1Basic Operation (Finisher Unit) .................................................................................................................. 2- 1

2.1.2Overview of the Electrical Circuitry (Finisher Unit) .................................................................................. 2- 1

2.1.3Basic Operation (Saddle Stitcher Unit)....................................................................................................... 2- 3

2.1.4Overview of the Electrical Circuitry (Saddle Stitcher Unit) ....................................................................... 2- 4

2.2 Feed Drive System ............................................................................................................................................ 2- 5

2.2.1Overview .....................................................................................................................................................2- 5

2.2.2Constraction of the Control System (Finisher Unit) ................................................................................... 2- 6

2.2.3Paper Delivery Path (Finisher Unit)............................................................................................................ 2- 9

2.2.4Constraction of the Control System (Saddle Stitcher Unit) ...................................................................... 2- 12

2.2.5Paper Delivery Path (Saddle Stitcher Unit)............................................................................................... 2- 15

2.2.6Basic Operation (Saddle Stitcher Unit)..................................................................................................... 2- 16

2.2.7Controlling the Inlet Flappers....................................................................................................................2- 19

2.2.8Controlling the Movement of Sheets......................................................................................................... 2- 22

2.2.9Controlling the Aligning the Sheets.......................................................................................................... 2- 24

2.2.10Controlling the Phase of the Crescent Roller .......................................................................................... 2- 27

2.2.11Overview of Folding Operation .............................................................................................................. 2- 28

2.2.12Controlling the Movement of Stacks.......................................................................................................2- 29

2.2.13Folding a Stack........................................................................................................................................2- 30

2.2.14Double Folding a Stack ...........................................................................................................................2- 32

2.3 Intermediate Process Tray Assembly.............................................................................................................. 2- 35

2.3.1Stack Job Offset......................................................................................................................................... 2- 35

2.3.2Processing Tray Paper Stacking Operation...............................................................................................2- 36

2.3.3Offset Operation........................................................................................................................................2- 36

2.3.4Rear End Assist Operation ........................................................................................................................2- 37

2.3.5Stack Delivery Operation.......................................................................................................................... 2- 38

2.4 Staple Operation..............................................................................................................................................2- 39

2.4.1Overview ................................................................................................................................................... 2- 39

2.4.2Stapler Unit................................................................................................................................................ 2- 39

2.4.3Shifting the Stapler Unit............................................................................................................................2- 41

2.4.4Stapling Operation.....................................................................................................................................2- 43

2.4.5Stitcher Unit ..............................................................................................................................................2- 47

2.4.6Stitching Operation....................................................................................................................................2- 48

2.5 Stack Tray Operation....................................................................................................................................... 2- 49

2.5.1Tray Operation ..........................................................................................................................................2- 49

2.5.2Shutter Operation ...................................................................................................................................... 2- 52

2.6 Detecting Jams ................................................................................................................................................ 2- 53

Contents

2.6.1Detecting Jams (Finisher Unit)..................................................................................................................2- 53

2.6.2Detecting Jams (Saddle Stitcher Unit).......................................................................................................2- 55

2.7 Power Supply...................................................................................................................................................2- 58

2.7.1Power Supply Route (Finisher Unit) .........................................................................................................2- 58

2.7.2Protection Function (Finisher Unit)...........................................................................................................2- 58

2.7.3Power Supply Route (Saddle Stitcher Unit)..............................................................................................2- 59

2.7.4Protection Function (Saddle Stitcher Unit)................................................................................................2- 59

Chapter 3 Installation

3.1 Making Pre-Checks ...........................................................................................................................................3- 1

3.1.1Checking the Contents.................................................................................................................................3- 1

3.1.2Installing the Accessories ............................................................................................................................3- 3

3.1.3Selecting the Site of Installation..................................................................................................................3- 4

3.2 Unpacking and Chacking the Components........................................................................................................3- 5

3.2.1Unpacking....................................................................................................................................................3- 5

3.3 Installation Procedure......................................................................................................................................3- 10

3.3.1Preparing the Finisher for Installation .......................................................................................................3- 10

3.3.2Preparing the Host Machine for Installation..............................................................................................3- 10

3.3.3Connecting to the Host Machine ...............................................................................................................3- 11

3.3.4Checking the Height/Tilt ...........................................................................................................................3- 13

3.4 Making Adjustments........................................................................................................................................3- 14

3.4.1Adjusting the Height/Tilt...........................................................................................................................3- 14

3.4.2Work After Making Checks/Adjustments .................................................................................................3- 17

3.5 Ataching the Labels etc. ..................................................................................................................................3- 19

3.5.1Attaching the Various Labels ....................................................................................................................3- 19

Chapter 4 Parts Replacement Procedure

4.1 External Covers .................................................................................................................................................4- 1

4.1.1 Front Cover .................................................................................................................................................4- 1

4.1.2 Rear Cover...................................................................................................................................................4- 1

4.1.3 Left Upper Cover ........................................................................................................................................4- 2

4.1.4 Upper Door..................................................................................................................................................4- 3

4.1.5 Grate-shaped Upper Guide..........................................................................................................................4- 4

4.1.6 Grate-shaped Lower Guide .........................................................................................................................4- 6

4.1.7 Front Inside Upper Cover..........................................................................................................................4- 10

4.1.8 Front Inside Lower Cover.........................................................................................................................4- 11

4.1.9 PCB Cover.................................................................................................................................................4- 11

4.2 Drive System ...................................................................................................................................................4- 12

4.2.1 Stapler........................................................................................................................................................4- 12

4.2.2 Swing Unit.................................................................................................................................................4- 13

4.2.3 Saddle Unit................................................................................................................................................4- 19

4.2.4 Stitcher Mount Unit...................................................................................................................................4- 26

4.2.5 Positioning Plate Unit................................................................................................................................4- 27

4.3 Document Feeding System..............................................................................................................................4- 29

4.3.1 Process Tray Assembly.............................................................................................................................4- 29

4.3.2 Tray 1 ........................................................................................................................................................4- 35

4.3.3 Tray 2 ........................................................................................................................................................4- 37

4.3.4 Buffer Roller .............................................................................................................................................4- 41

4.3.5 Return Roller.............................................................................................................................................4- 42

4.3.6 Return Roller Unit.....................................................................................................................................4- 49

4.3.7 Saddle Delivery Tray Unit ........................................................................................................................4- 56

4.3.8 Upper Delivery Guide...............................................................................................................................4- 57

Contents

4.3.9 Inlet Feed Unit .......................................................................................................................................... 4- 61

4.3.10 Paper Folding Roller............................................................................................................................... 4- 62

4.3.11 No.1 Flapper ...........................................................................................................................................4- 69

4.3.12 No.2 Flapper ...........................................................................................................................................4- 70

4.4 Electrical System............................................................................................................................................. 4- 73

4.4.1 Finisher Controller PCB ...........................................................................................................................4- 73

4.4.2 Static Charge Eliminator 1........................................................................................................................ 4- 73

4.4.3 Static Charge Eliminator 2........................................................................................................................ 4- 81

4.4.4 Saddle Stitcher Controller PCB ................................................................................................................ 4- 81

Chapter 5 Maintenance

5.1 User Maintenance.............................................................................................................................................. 5- 1

5.1.1User Maintenance (Finisher Unit)............................................................................................................... 5- 1

5.1.2User Maintenance (Saddle Stitcher Unit)....................................................................................................5- 1

5.2 Maintenance and Inspection.............................................................................................................................. 5- 2

5.2.1 Periodically Replaced Parts ........................................................................................................................5- 2

5.2.2 Durables......................................................................................................................................................5- 2

5.2.3 Periodical Servicing....................................................................................................................................5- 3

5.3 Adjustment ........................................................................................................................................................ 5- 4

5.3.1 Adjustment at Time of Parts Replacement ................................................................................................. 5- 4

5.4 Troubleshooting................................................................................................................................................. 5- 8

5.4.1 Error Code...................................................................................................................................................5- 8

5.5 Outline of Electrical Components...................................................................................................................5- 16

5.5.1Sensors (Finisher Unit).............................................................................................................................. 5- 16

5.5.2Microswitches (Finisher Unit)...................................................................................................................5- 19

5.5.3Solenoids (Finisher Unit) .......................................................................................................................... 5- 20

5.5.4Motors (Finisher Unit)...............................................................................................................................5- 21

5.5.5Clutches (Finisher Unit)............................................................................................................................5- 23

5.5.6PCBs (Finisher Unit)................................................................................................................................. 5- 24

5.5.7Sensors (Saddle Stitcher Unit) .................................................................................................................. 5- 25

5.5.8Microswitches (Saddle Stitcher Unit) .......................................................................................................5- 27

5.5.9Motors (Saddle Stitcher Unit) ................................................................................................................... 5- 29

5.5.10Solenoids (Saddle Stitchwe Unit)............................................................................................................ 5- 31

5.5.11PCBs (Saddle Stitcher Unit)....................................................................................................................5- 32

5.6 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB........................................5- 33

5.6.1Overview ................................................................................................................................................... 5- 33

5.6.2Finisher Controller PCB............................................................................................................................5- 33

5.6.3Saddle Stitcher Controller PCB................................................................................................................. 5- 34

5.7 Upgrading........................................................................................................................................................5- 35

5.7.1Upgrading (Finisher Unit)......................................................................................................................... 5- 35

5.7.2Upgrading (Saddle Stitcher Unit)..............................................................................................................5- 42

5.8 Service Tools................................................................................................................................................... 5- 51

5.8.1Solvents and Oils....................................................................................................................................... 5- 51

Chapter 6 Error Code

6.1 Overview ........................................................................................................................................................... 6- 1

6.1.1Overview .....................................................................................................................................................6- 1

6.2 User Error Code.................................................................................................................................................6- 2

6.2.1Staple is absent ............................................................................................................................................6- 2

6.2.2Stapler safety protection function activated................................................................................................ 6- 2

6.2.3Stack tray overstacking ............................................................................................................................... 6- 2

6.2.4Stapler staple jam ........................................................................................................................................ 6- 3

Contents

6.2.5Staple is absent (Saddle Stitcher Unit) ........................................................................................................6- 3

6.2.6Mixed paper sizes (Saddle Stitcher Unit)....................................................................................................6- 3

6.2.7Stack exceeded (Saddle Stitcher Unit) ........................................................................................................6- 4

6.2.8Stitching capacity error (Saddle Stitcher Unit)............................................................................................6- 4

6.3 Service Error Code ............................................................................................................................................6- 5

6.3.1E500.............................................................................................................................................................6- 5

6.3.2E503.............................................................................................................................................................6- 5

6.3.3E505.............................................................................................................................................................6- 5

6.3.4E514.............................................................................................................................................................6- 6

6.3.5E519.............................................................................................................................................................6- 6

6.3.6E530.............................................................................................................................................................6- 6

6.3.7E531.............................................................................................................................................................6- 7

6.3.8E532.............................................................................................................................................................6- 7

6.3.9E535.............................................................................................................................................................6- 7

6.3.10E537...........................................................................................................................................................6- 8

6.3.11E540...........................................................................................................................................................6- 8

6.3.12E542...........................................................................................................................................................6- 9

6.3.13E584...........................................................................................................................................................6- 9

6.3.14E5F0.........................................................................................................................................................6- 10

6.3.15E5F1.........................................................................................................................................................6- 10

6.3.16E5F2.........................................................................................................................................................6- 10

6.3.17E5F3.........................................................................................................................................................6- 11

6.3.18E5F4.........................................................................................................................................................6- 11

6.3.19E5F5.........................................................................................................................................................6- 11

6.3.20E5F6.........................................................................................................................................................6- 12

6.3.21E5F8.........................................................................................................................................................6- 12

6.3.22E5F9.........................................................................................................................................................6- 13

6.3.23Temporary Functional Limit....................................................................................................................6- 13

Chapter 1 Specifications

Contents

1.1 Product Specifications....................................................................................................................................... 1- 1

1.1.1Finisher Unit................................................................................................................................................ 1- 1

1.1.2Saddle Stitcher Unit.....................................................................................................................................1- 4

1.2 Names of Parts................................................................................................................................................... 1- 6

1.2.1External View.............................................................................................................................................. 1- 6

1.2.2Cross Section (FInisher Unit)...................................................................................................................... 1- 7

1.2.3 Cross Section (Saddle Stitcher Unit).......................................................................................................... 1- 8

1.1 Product Specifications

Chapter 1

1.1.1 Finisher Unit

Item Specifications

Stacking method

Stacking orientation

Stacking size

Paper weight

Bins

Modes

Stacking capacity

Mixed stacking capacity

Trays 1 and 2: by lifting tray Face up

Face down A3, A4, A4R, A5, A5R, B4, B5, B5R,

postcard, 279 mm x 432 mm (11 x 17), LGL, LTR, LTRR, STMT, STMTR, elongation size, Envelope

64g/m2 to 250g/m2 2 Non sort: Trays 1 and 2

Sort: Trays 1 and 2 Staple: Trays 1 and 2

Tray 1: Non staple sort Equivalent of

Large size: 74 mm high (500 sheets) Small size: 147 mm high (1000 sheets)

Tray 2: Non staple sort

Large size: 74 mm high (500 sheets) Small size: 147 mm high (1000 sheets)

Tray 1: Staple sort

Large size: 74 mm high (500 sheets)/30 sets Small size: 147 mm high (1000 sheets)/30 sets

Tray 2: Staple sort

Large size: 74 mm high (500 sheets)/30 sets Small size: 147 mm high (1000 sheets)/30 sets

Size mixing: 74 mm high (500 sheets)

0004-8097

T-1-1

Remarks

Feed direction: 139.7 to 482.6 mm: cross feed direction:

98.4 to 330. 2 mm; both maximum

80g/m2 paper.

Stapling: 74 mm high (500 sheets)/30 sets

Stapling

Stapling capacity

By rotating cam Small size: 50 sheets(Thickness 5.7 mm or less) Equivalent of Large size: 30 sheets

80g/m2 paper.

Notes 1 : Stacking capacity is equivalent of 80g/m2 paper. Notes 2 : Alignment may not be correct if 750 or more small-size sheets are stacked. Notes 3 : Stacking capability is not guaranteed for mixed size stacking.

1-1

Chapter 1

Paper Size Definition: Large size (feed length of 216 to 432 mm):A3, A4R, B4, B5R, 279mm x 432mm (11 x 17), LGL, LTRR Small size (feed length of 216 mm or less):A4, A5, A5R, B5, LTR, STMT, STMTR

T-1-2

Item Specifications Remarks

Staple supply Special staple cartridge (5000 staples)

Staple detection

Manual stapling

Stapling size Front 1-point stapling (30 deg.)

Paper detection

Control panel Not provided

Provided 0 to 40 remaining staples

Not provided

A4R, LGL, LTRR

Front 1-point stapling (45 deg.)

A3, B4, A4, B5, 279mm x 432mm (11 x 17), LTR

Rear 1-point stapling (30 deg.)

A4R, LGL, LTRR

Rear 1-point stapling (45 deg.)

A3, B4, A4, B5, 279mm x 432mm (11 x 17), LTR

2-point stapling

A3, A4, B4, B5, 279mm x 432mm (11 x 17), LTR

Provided

1-2

Display Not provided

Dimensions W:648(761) x D:657 x H:928mm If within parentheses,

with the tray extended.

Weight Approx. 64 kg

Power supply From host machine (24VDC/13VDC)

Maximum power consumption

8 W or less during standby/70 W or less operating

Chapter 1

Front 1-point stapling (30deg.) A4R, LGL and LTRR

5 -/+2 mm

Rear 1-point stapling (30deg.) A4R, LGL and LTRR

5 -/+2 mm

2-point stapling

203 -/+4 mm

5 -/+2 mm

A3 and A4

83 -/+4 mm

279mm x 432mm

5 -/+2 mm

Front 1-point stapling (45deg.) A3, A4, B4, B5, 279mm x 432mm (11x17) and LTR

5 -/+2 mm

Rear 1-point stapling (45deg.) A3, A4,B4,B5, 279mm x 432mm (11x17) and LTR

5 -/+2 mm

B4 and B5

(11x17)

and LTR

183

5 -/+2 mm

63 -/+4 mm

-/+4

74 -/+4 mm

194

-/+4

F-1-1

1-3

Chapter 1

1.1.2 Saddle Stitcher Unit

Item

Stapling method

Paper size

Capacity

Paper weight

Stacking capacity

Specifications

Center binding (double folding)

A3, B4, A4R, 279mm x 432mm (11 x 17), LGL, LTRR

Material for color: 1 to 10 sheets Including 1 cover page.

Material for black-and-white: 1 to 15 sheets

64g/m2 to 250g/m2

Material for color: 1 to 5 sheets; 25 copies 6 to 10 sheets; 15 copies Material for black-and-white: 1 to 5 sheets; 25 copies 6 to 10 sheets; 15 copies 11 to 15 sheets; 10 copies

0004-8101

T-1-3

Remarks

Special paper, postcards, transparencies, or elongation size can not be handled

Cover mode; up to 10 copies

Stapling position

Staple

2 points (center distribution; fixed interval)

2000 staples

accommodation

Staple supply

Staples

Staple detection

Manual stapling

Folding method

Folding mode

Folding position

Position

Special cartridge

Special staple (Staple-D3)

Provided

Not provided

Roller contact

Double folding

Paper center

Provided

adjustment

Power supply

From finisher unit (24VDC/13VDC)

Notes 1 : Stacking capability is not guaranteed for mixed size stacking.

1-4

Chapter 1

Folding position

210 -/+1 mm

88.5

-/+2 mm

208.5 -/+2 mm

Stack front edge

279mm x 432mm (11 x 17)

216 -/+1 mm

79.7

-/+2 mm

199.7 -/+2 mm

Staple position

182 -/+1 mm

188.5 -/+2 mm

LGL

177.8 -/+1 mm

48 -/+2 mm

168 -/+2 mm

F-1-2

68.5 -/+2 mm

A4R

148.5 -/+1 mm

165

LTRR

139.7 -/+1 mm

48 -/+2 mm

168

45 -/+2 mm

-/+

2 mm

-/+

2 mm

1-5

Chapter 1

1.2 Names of Parts

1.2.1 External View

[1] Upper cover [7] Grate-shaped lower guide

[2] Front cover [8] Grate-shaped upper guide

[3] Foot cover [9] Left upper cover

[4] Saddle delivery tray [10] Rear cover

[5]

[7]

[6]

[8]

[4]

[1]

[2]

[3]

F-1-3

T-1-4

[9]

0004-8104

[10]

[11]

[12]

[5] Tray 1 [11] Inlet feed unit

[6] Tray 2 [12] PCB cover

1-6

Chapter 1

1.2.2 Cross Section (FInisher Unit)

[3] [7]

[2]

[8]

[9]

[1]

0004-8114

[10][5][6][4]

F-1-4

T-1-5

[1] Delivery tray [6] Return roller

[2] Stack delivery roller [7] Inlet roller

[3] Aligning plate [8] Rear end assist guide

[4] 1st delivery roller [9] Shutter

[5] Buffer roller [10] Stapler

1-7

Chapter 1

1.2.3 Cross Section (Saddle Stitcher Unit)

[1]

0004-8115

[2]

[3]

[4]

[5]

[6]

[7]

[8]

[9]

[12]

[11]

[10]

F-1-5

T-1-6

[1] Saddle stitcher flapper [7] Stitcher mount

[2] Inlet roller 1 [8] Holding roller

[3] Inlet roller 2 [9] Paper pushing plate

[4] No.1 flapper [10] Paper folding roller

[5] No.2 flapper [11] Crescent roller

[6] Stitcher (fromt,rear) [12] Saddle delivery roller

1-8

Chapter 2 Functions