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May 1, 2010
Revision 0
Document Insertion Unit-K1
Service Manual
Product Outline
Technology
Periodic Servicing
Parts Replacement/Cleaning Procedure
Adjustment
Installation
Appendix
1
2
3
4
5
6

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Table of Contents

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  • Page 1 May 1, 2010 Revision 0 Document Insertion Unit-K1 Service Manual Product Outline Technology Periodic Servicing Parts Replacement/Cleaning Procedure Adjustment Installation Appendix...
  • Page 2 Canon will release technical information as the need arises. In the event of not be copied, reproduced or translated into another language, in whole or in part, without the major changes in the contents of this manual over a long or short period, Canon will issue written consent of Canon Inc.
  • Page 3 Explanation of Symols The following rules apply throughout this Service Manual: The following symbols are used throughout this Service Manual. Each chapter contains sections explaining the purpose of specific functions and the Symols Explanation Symols Explanation relationship between electrical and mechanical systems with reference to the timing of operation.
  • Page 5: Table Of Contents

    External / Internal Covers -------------------------------------------------------- 4-2 Contents Consumale Parts Requiring Periodic Replacement and Cleaning Points --------------------------------------------------------------------------------- 4-3 Motors/PCBs/Others -------------------------------------------------------------- 4-4 List of Sensors ---------------------------------------------------------------------- 4-5 Safety Precautions 0-1 External/Innernal Covers ----------------------------------------------------4-6 Removing the Rear Upper Cover ---------------------------------------------- 4-6 Points to Note About Turning Off the Main Power Switch ----------0-2 Removing the Rear Lower Cover ---------------------------------------------- 4-7 Notes Before it Works Serving ---------------------------------------------0-3 Removing the Front Upper Cover --------------------------------------------- 4-7...
  • Page 6 Removing the PCB --------------------------------------------------------- 4-24 General Circuit Diagram -----------------------------------------------------7-3 Removing the DC Controller PCB -------------------------------------------4-24 General Circuit Diagram --------------------------------------------------------- 7-3 Removing the Upper Tray LED PCB -----------------------------------------4-25 Removing the Lower Tray LED PCB -----------------------------------------4-25 Removing the Sensor ------------------------------------------------------ 4-27 Removing the Upper tray empty sensor (S9) -----------------------------4-27 Removing the Upper tray width sensor (S10) -----------------------------4-28 Removing the Upper tray last paper sensor (S11) -----------------------4-29 Removing the Low tray empty sensor (S12) -------------------------------4-29...
  • Page 7: Safety Precautions

    Safety Precautions ■ P o i n t s t o N o t e A  o u t Tu r n i n g O ff t h e M a i n Power Switch ■ Notes Before it Works Serving...
  • Page 8: Points To Note About Turning Off The Main Power Switch

    Points to Note About Turning Off the Main Power Switch Points to Note About Turning Off the Main Power Switch This machine has two switches related to power supply, the Power switch and the breaker. Turning on the Power switch powers this machine. The reaker detects an excess current and electric leakage to protect you against an electric shock.
  • Page 9: Notes Before It Works Serving

    Points to Note About Turning Off the Main Power Switch Notes Before it Works Serving CAUTION: At servicing, be sure to turn off the power source according to the specified steps and disconnect the power plug. CAUTION: Do not turn off the power switch when downloading is under way. Turning off the main power switch while downloading is under way can disable the machine.
  • Page 10 Product Outline ■ Features Specifications ■ ■ Names of Parts Product Outline...
  • Page 11: Product Outline Features

    Product Outline > Features Features ● A free-standing inserter with a reversal feature, supporting a set of two large tray bins. ● Each tray has a capacity of 200 sheets. Product Outline > Features...
  • Page 12: Specifications

    Product Outline > Specifications Specifications Description Remarks Item Upward separation by Paperpickup Auto paper pickup/delivery method a cassette separation roller Paper pickup Single-sided a u t o m a t i c r e v e r s a l mode mode supported Plain paper,recycled paper,colored paper,heavy...
  • Page 13: Names Of Parts

    Product Outline > Names of Parts > External View(Rear) Names of Parts External View(Rear) External View(Front) Upper tray Upper cover Power switch Rear cover Front upper cover Rear upper cover Low tray Rear low cover Leakage breaker F-1-1 F-1-1 F-1-2 F-1-2 Product Outline >...
  • Page 14: External View(internal)

    Product Outline > Names of Parts > External View(Internal) External View(Internal) Jam clearing lever(through-feed unit) Horizontal feed guide Jam clearing lever F-1-3 F-1-3 Product Outline > Names of Parts > External View(Internal)
  • Page 15: Technology

    Technology ■ Basic Configuration ■ Controls ■ Jam Detection ■ Power Supply ■ Work of service Technology...
  • Page 16: Functional Configuration

    Technology > Basic Configuration > Overview of Electrical Circuitry Basic Configuration Overview of Electrical Circuitry The machine's sequence of operations is controlled by the DC controller PCB. Functional Configuration The DC controller PCB is a CPU used to interpret input signals from sensors and host machine and generate signals to drive such loads as motors and clutches at such times as programmed in The components of this fold unit are organized into three major blocks: tray unit,Paper feed advance.
  • Page 17: Component Configuration

    Technology > Basic Configuration > Component Configuration > Sensor Layout Component Configuration ■ Sensor Layout Roller Layout ■ It descries only all optical sensors on the feed path. [10] [11] [14] [12] [13] S3 Upper tray regist sensor S7 Low tray regist sensor [1]Pickup roller(upper) [8]Feed roller1 F-2-3...
  • Page 18: Drive Configuration

    Technology > Basic Configuration > Basic movement outline > Surface insert operation Drive Configuration Basic movement outline ■ Surface insert operation Transfers the paper loaded in the inserter tray to the downstream equipment so the upper surface of the paper will face up. Drive switchover gear CL1 CL2 *Paper is fed from atray via a reversing pass to the straight pass.
  • Page 19 Technology > Basic Configuration > Basic movement outline > Insetrter pickup tray switch operation ■ ■ Insetrter pickup tray switch operation Back insert operation Transfers the paper loaded in the inserter tray to the downstream equipment so the upper surface of the paper will face down.
  • Page 20: Various Modes Of Control

    Technology > Various Modes of Control > Outline of operations > Sequence of surface insert operation Various Modes of Control Outline of operations When a paper feed signal is received from the host machine after paper is loaded in the tray, the following three sequences of operations are performed: 1.Sequence of surface insert operation 2.Sequence of ack insert operation...
  • Page 21 Technology > Various Modes of Control > Outline of operations > Sequence of surface insert operation (2) First paper feeding for reversal - The tray feed motor turns in the normal direction at a speed of 400 mm/s and the reverse motor turns in the normal direction at a speed of 400 mm/s to start feeding the paper to the reversal standy position.
  • Page 22 Technology > Various Modes of Control > Outline of operations > Sequence of surface insert operation F-2-14 F-2-14 (5) First paper feeding to horizontal feed lock F-2-16 F-2-16 - When an Entry signal for the first paper is received, the entrance motor 1 turns in the reverse direction at the same speed as that of the motor in the host machine and the reverse motor turns in the reverse direction at the same speed as that of the motor in the host machine, thus feeding the paper to the horizontal feed lock.
  • Page 23 Technology > Various Modes of Control > Outline of operations > Sequence of surface insert operation (7) Second paper feeding to standy position - The reverse motor turns in the reverse direction at a speed of 800 mm/s to start feeding the paper to the standy position.
  • Page 24 Technology > Various Modes of Control > Outline of operations > Sequence of ack insert operation 2-10 ■ Sequence of ack insert operation The following operations are performed when two papers are fed from the inserter paper feed unit. (1) First paper feeding for separation - The upper tray lift motor turns in the reverse direction at a speed of 533 pps to move the paper feed tray upward.
  • Page 25 Technology > Various Modes of Control > Outline of operations > Sequence of ack insert operation 2-11 (3) Second paper feeding for separation (4) First paper feeding to horizontal feed lock - After the paper feed motor stops as mentioned above, the upper tray lift motor turns in the reverse - When an Entry signal for the first paper is received, the entrance motor 1 turns in the reverse direction at a speed of 533 pps to move the paper feed tray upward.
  • Page 26 Technology > Various Modes of Control > Outline of operations > Sequence of inserter pickup tray switch operation 2-12 ■ Sequence of inserter pickup tray switch operation This section describes switching of the upper tray to the lower tray that take place when two papers are fed to the upper tray and one paper is fed to the lower tray respectively from the inserter paper feed unit.
  • Page 27 Technology > Various Modes of Control > Outline of operations > Sequence of inserter pickup tray switch operation 2-13 Drive switchover gear F-2-32 F-2-32 F-2-34 F-2-34 F-2-35 F-2-35 F-2-33 F-2-33 (4) Lower tray paper feeding for separation (2) Upper tray paper feeding to standy position or upper tray paper feeing for reversal - The lower tray motor turns in the reverse direction at a speed of 533 pps to move the paper feed * The figure shows feeding of the paper to the standby position.
  • Page 28 Technology > Various Modes of Control > Outline of operations > Sequence of inserter pickup tray switch operation 2-14 S7 M1 S7 M1 F-2-36 F-2-36 F-2-38 F-2-38 Drive switchover gear F-2-37 F-2-37 F-2-39 F-2-39 (5) Lower tray paper feeding to standby position or lower tray paper feeing for reversal * The figure shows feeding of the paper to the standby position.
  • Page 29: Jam Detection

    Technology > Various Modes of Control > Jam Detection > Jam Type 2-15 Jam Detection Overview ■ The following paper sensors are used to detect whether paper is present and whether paper is fed normally. S3 Upper tray registration sensor S7 Lower tray registration sensor S8: Middle feed sensor S9: Upper tray empty sensor...
  • Page 30 Technology > Various Modes of Control > Jam Detection > Jam Type 2-16 The detection sensor and detection timing, and displayed code are indicated as follows. Jam type Sensor Detection timing Displayed code EntryStart OFF is not detected even when the specified time has lapsed since EntryStartAck ON was replied. EntryStart time-out jam 2FC0 EjectStartAck ON is not detected even when the specified time has lapsed since EjectStart ON was reported.
  • Page 31: Power Supply

    Technology > Various Modes of Control > Power Supply > Protection Function 2-17 Power Supply The external AC power supplied to this machine passes through the filter PCB, and the filtered AC power is converted to 24 VDC. The 24 VDC is supplied to the DC control PCB from which it is supplied to the load-related parts (motors, solenoids, fans, and clutches) as it is or converted to 5 VDC or 3.3 VDC y the DC-DC to e supplied to logic-related parts (sensors).
  • Page 32 Technology > Various Modes of Control > Power Supply > Protection Function 2-18 Red: Exclusive for AF1/AF2 Blue: Exclusive for AG1/AG2 Power Supply PCB (24V) Filter PCB PCB6 PCB7 Circuit Breaker Arcnet PCB Option Controller PCB4 PCB5 Remote Signal (24V) Finisher-AG1/AG2 DC Controller PCB Remote Signal (3.3V)
  • Page 33: Work Of Service

    Technology > Various Modes of Control > Work of service > Upgrading 2-19 Work of service ■ Scheduled Servicing When the endurance time of a part expires soon, replace and/or clean it as required. Item Part name Expected Operation Reference service life Periodically re- None...
  • Page 34: Periodic Servicing

    P e r i o d i c Servicing ■ Periodic services items Periodic Servicing...
  • Page 35: List Of Work For Scheduled Servicing

    Periodic Servicing > List of Work for Scheduled Servicing List of Work for Scheduled Servicing PR:Replacement (Periodically replaced parts) CR:Replacement (consumable parts) CL: Cleaning LU:Lubrication AD:Adjustment CH:Maintenance As of January 2009 Category Part name Part numer Interval Remarks Adjusted/ Counter Reference adjusted FL3-1472...
  • Page 36: Parts Replacement/cleaning Procedure

    R e p l a c e m e n t / C l e a n i n g Procedure List of Parts ■ ■ External / Internal Covers ■ Main Units ■ C o n s u m a  l e P a r t s R e q u i r i n g P e r i o d i c R e p l a c e m e n t a n d Cleaning Points...
  • Page 37: External / Internal Covers

    Parts Replacement/Cleaning Procedure > List Of Parts > External / Internal Covers List Of Parts Name Part No. Refer to Rear Upper Cover FC9-1851/FC9-1776 Rear Lower Cover FC9-1766 External / Internal Covers Front Upper Cover FC9-1764/FC9-1767/FC6-5697 Front Inner Cover FC9-1765 Rear Cover FC9-1882 Front Cover...
  • Page 38: Consumale Parts Requiring Periodic Replacement And Cleaning Points

    Parts Replacement/Cleaning Procedure > List Of Parts > Consumable Parts Requiring Periodic Replacement and Cleaning Points Consumale Parts Requiring Periodic Replacement Name Part No. Refer to FL3-1472 Through-pass inlet antistatic needle and Cleaning Points FL3-1470 Through-pass outlet antistatic needle Inserter pickup roller (upper) 4A3-3870 4-15 Inserter separation roller (upper)
  • Page 39: Motors/pcbs/others

    Parts Replacement/Cleaning Procedure > List Of Parts > Motors/PCBs/Others Motors/PCBs/Others Name Part No. Refer to Tray Paper feed motor FK2-4580 4-21 Upper tray lift motor FH5-1040 4-23 Low tray lift motor FH5-1040 4-23 Drive switchover motor FH5-1041 4-22 Entrance motor 1 FK2-4582 Reverse motor FK2-4580...
  • Page 40: List Of Sensors

    Parts Replacement/Cleaning Procedure > List Of Parts > List of Sensors List of Sensors Name Part No. Refer to Drive switchover sensor WG8-5696 Upper tray pick sensor WG8-5696 Upper tray regist sensor WG8-5696 Upper tray lower limit sensor WG8-5696 Low tray lower limit sensor WG8-5696 Low tray pick sensor WG8-5696...
  • Page 41: External/innernal Covers

    Parts Replacement/Cleaning Procedure > External/Innernal Covers > Removing the Rear Upper Cover External/Innernal Covers Removing the Rear Upper Cover 1) Remove four screws to remove the rear upper cover. F-4-7 F-4-7 Parts Replacement/Cleaning Procedure > External/Innernal Covers > Removing the Rear Upper Cover...
  • Page 42: Removing The Rear Lower Cover

    Parts Replacement/Cleaning Procedure > External/Innernal Covers > Removing the Front Upper Cover Removing the Rear Lower Cover 2) Remove four screws to remove the rear lower cover. 1) Remove the rear upper cover. (Refer to:4-6) F-4-8 F-4-8 Removing the Front Upper Cover 2) Remove two resin E-rings to remove the upper front cover.
  • Page 43: Removing The Front Inner Cover

    Parts Replacement/Cleaning Procedure > External/Innernal Covers > Removing the Front Inner Cover Removing the Front Inner Cover 2) Holding the jam removal lever, open the transfer 3) Remove two screws to remove the front inner cover (small). 1) Open the front upper cover. guide.
  • Page 44: Removing The Inserter Rear Cover

    Parts Replacement/Cleaning Procedure > External/Innernal Covers > Changing the Inserter Top Cover Open/Close Angle Removing the Inserter Rear Cover 1) Remove two screws to remove the inserter rear cover. F-4-15 F-4-15 Changing the Inserter Top Cover Open/Close Angle 2) Remove one screw, remove the inserter top cover angle regulating shaft, and then open the top cover. 1) Remove the rear cover.
  • Page 45: Removing The Inserter Front Cover

    Parts Replacement/Cleaning Procedure > External/Innernal Covers > Changing the Middle Guide Open/Close Angle 4-10 Removing the Inserter Front Cover 3) Remove two screws to remove the inserter front cover. 1) Remove the inserter rear cover. (Refer to:4-9) 2) Increase the inserter top cover open/close angle.
  • Page 46: Changing The Inserter Open Angle

    Parts Replacement/Cleaning Procedure > External/Innernal Covers > Changing the Inserter Open Angle 4-11 Changing the Inserter Open Angle 2) Remove one screw to remove the support plate 1. 1) Remove the inserter rear cover. (Refer to:4-9) F-4-19 F-4-19 3) Remove one screw to remove the cover. 4) Remove one screw to remove the support plate 2.
  • Page 47: Removing The Main Unit

    Parts Replacement/Cleaning Procedure > Removing the Main Unit > Removing the Upper Tray Unit 4-12 Removing the Main Unit Removing the Upper Tray Unit 4) Remove four screws and three connectors to remove the upper tray unit. 1) Remove the rear cover. (Refer to:4-9) 2) Increase the top cover open/ close angle.
  • Page 48: Removing The Lower Tray Unit

    Parts Replacement/Cleaning Procedure > Removing the Main Unit > Removing the Inserter Pickup Unit 4-13 Removing the Lower Tray Unit 5) Remove four screws and one connector to remove the lower tray unit. 1) Remove the rear cover. (Refer to:4-9) 2) Increase the top cover open/ close angle.
  • Page 49 Parts Replacement/Cleaning Procedure > Removing the Main Unit > Removing the Inserter Pickup Unit 4-14 4) Remove two screws from the hinge. 5) Remove two stepped screws, and then slide the inserter pickup unit backward, and then lift it to remove it. F-4-25 F-4-25 F-4-26...
  • Page 50: Consumale Parts Requiring Periodic Replacement And Cleaning Points

    Parts Replacement/Cleaning Procedure > Consumale Parts Requiring Periodic Replacement and Cleaning Points > Removing the Inserter pickup rollers (upper) 4-15 Consumale Parts Requiring Periodic Replacement and Cleaning Points Removing the Inserter pickup rollers (upper) 3) Remove two screws to remove the front transfer guide. 4) Remove two resin E-rings to remove two 1) Remove the rear cover.
  • Page 51: Removing The Inserter Pickup Roller (lower)

    Parts Replacement/Cleaning Procedure > Consumale Parts Requiring Periodic Replacement and Cleaning Points > Removing the Inserter separation roller (upper) 4-16 Removing the Inserter pickup roller (lower) 4) Remove two resin E-rings to remove two 1) Remove the rear cover. inserter pickup rollers (Refer to:4-9) (lower).
  • Page 52: Removing The Inserter Separation Roller (lower)

    Parts Replacement/Cleaning Procedure > Consumale Parts Requiring Periodic Replacement and Cleaning Points > Removing the Inserter feed roller (upper) 4-17 Removing the Inserter separation roller (lower) 4) ) Remove five screws to remove the transfer guide. 5) Remove two E-rings and one bearing to remove the 1) Remove the rear cover.
  • Page 53: Removing The Inserter Feed Roller (lower)

    Parts Replacement/Cleaning Procedure > Consumale Parts Requiring Periodic Replacement and Cleaning Points > Removing the Inserter torque limiter (upper) 4-18 Removing the Inserter feed roller (lower) 4) Remove six screws to remove the rear transfer 5) Remove one spring, two resin E-rings, and two 6) Remove three E-rings, one pickup roller, and one lever to 1) Remove the rear cover.
  • Page 54: Removing The Inserter Torque Limiter (lower)

    Parts Replacement/Cleaning Procedure > Consumale Parts Requiring Periodic Replacement and Cleaning Points > Removing the Inserter electromagnetic clutch (upper) 4-19 Removing the Inserter torque limiter (lower) 4) Remove five screws to remove the transfer guide. 5) Remove three E-rings, one gear, one parallel pin, two bearings, 1) Remove the rear cover.
  • Page 55: Removing The Inserter Electromagnetic Clutch (lower)

    Parts Replacement/Cleaning Procedure > Consumable Parts Requiring Periodic Replacement and Cleaning Points > Removing the Inserter electromagnetic clutch (lower) 4-20 Removing the Inserter electromagnetic clutch (lower) 4) Remove one screw and one connector, and the remove the 1) Remove the rear cover. (Refer to:4-9) inserter electromagnetic clutch (lower) 2) Increase the top cover open/...
  • Page 56: Removing The Motor

    Parts Replacement/Cleaning Procedure > Removing the Motor > Removing the Tray Pickup Motor (M1) 4-21 Removing the Motor Removing the Tray Pickup Motor (M1) 2) Remove one connector and two wire saddles to remove the harness 1) Remove the rear cover. (Refer to:4-9) from the harness guide.
  • Page 57: Removing The Drive Switchover Motor (m4)

    Parts Replacement/Cleaning Procedure > Removing the Motor > Removing the Drive Switchover Motor (M4) 4-22 Removing the Drive Switchover Motor (M4) 2) Remove four connectors and two clamps. 2) Loosen one screw to remove the harness guide. 1) Remove the rear cover.
  • Page 58: Removing The Upper Tray Lift Motor (m2)

    Parts Replacement/Cleaning Procedure > Removing the Motor > Removing the Lower Tray Lift Motor (M3) 4-23 Removing the Upper Tray Lift Motor (M2) 2) Remove two screws and one connector to remove the upper tray lift motor. 1) Remove the rear cover. (Refer to:4-9) F-4-53 F-4-53...
  • Page 59: Removing The Pcb

    Parts Replacement/Cleaning Procedure > Removing the PCB > Removing the DC Controller PCB 4-24 Removing the PCB Removing the DC Controller PCB 2) Remove one screw, three locking supports, and all connectors on the PCB, and 1) Remove the rear cover. (Refer to:4-9) then remove the DC controller PCB.
  • Page 60: Removing The Upper Tray Led Pcb

    Parts Replacement/Cleaning Procedure > Removing the PCB > Removing the Lower Tray LED PCB 4-25 Removing the Upper Tray LED PCB 2) Remove two screws to remove the LED cover. 3) Remove one screw and one connector to remove the upper 1) Remove the upper tray tray LED PCB.
  • Page 61 Parts Replacement/Cleaning Procedure > Removing the PCB > Removing the Lower Tray LED PCB 4-26 5) Remove two screws to remove the LED cover. 6) Remove one screw and one connector to remove the lower tray LED PCB. F-4-60 F-4-60 F-4-61 F-4-61 4-26...
  • Page 62: Removing The Sensor

    Parts Replacement/Cleaning Procedure > Removing the Sensor > Removing the Upper tray empty sensor (S9) 4-27 Removing the Sensor Removing the Upper tray empty sensor (S9) 5) Remove one screw to remove the sensor cover. 1) Remove the rear cover. 6) Remove one connector to remove the upper tray empty sensor.
  • Page 63: Removing The Upper Tray Width Sensor (s10)

    Parts Replacement/Cleaning Procedure > Removing the Sensor > Removing the Upper tray width sensor (S10) 4-28 Removing the Upper tray width sensor (S10) 5) Remove two screws to remove the tray lower cover (small). 1) Remove the rear cover. (Refer to:4-9) 2) Increase the top cover open/ close angle.
  • Page 64: Removing The Upper Tray Last Paper Sensor (s11)

    Parts Replacement/Cleaning Procedure > Removing the Sensor > Removing the Low tray empty sensor (S12) 4-29 Removing the Upper tray last paper sensor (S11) 5) Remove two screws to remove the tray lower cover (small). 1) Remove the rear cover. 6) Remove one connector to remove the Upper tray last paper (Refer to:4-9) sensor.
  • Page 65: Removing The Low Tray Width Sensor (s13)

    Parts Replacement/Cleaning Procedure > Removing the Sensor > Removing the Low tray width sensor (S13) 4-30 8) Remove one screw to remove the sensor cover. 9) Remove one connector to remove the Low tray empty sensor F-4-70 F-4-70 F-4-69 F-4-69 Removing the Low tray width sensor (S13) 6) Remove four screws to remove the tray lower cover (large).
  • Page 66: Removing The Low Tray Last Paper Sensor 1 (s14)

    Parts Replacement/Cleaning Procedure > Removing the Sensor > Removing the Low tray last paper sensor 1 (S14) 4-31 8) Remove two screws to remove the tray lower cover (small). 9) Remove two screws and one connector to remove the low tray width sensor. MEMO: After replacing with the low tray width sensor with a new one, adjust the sensor output...
  • Page 67: Removing The Low Tray Last Paper Sensor 2 (s15)

    Parts Replacement/Cleaning Procedure > Removing the Sensor > Removing the Low tray last paper sensor 2 (S15) 4-32 8) Remove two screws to remove the tray lower cover (small). 9) Remove one connector to remove the low tray last paper sensor1.
  • Page 68 Parts Replacement/Cleaning Procedure > Removing the Sensor > Removing the Low tray last paper sensor 2 (S15) 4-33 8) Remove two screws to remove the tray lower cover (small). 9) Remove two screws to remove the sensor unit. F-4-82 F-4-82 F-4-81 F-4-81 10) Remove one connector to remove the low tray last paper...
  • Page 69: Adjustment

    Adjustment ■ Adjustment at Time of Parts Replacement Adjustment...
  • Page 70 Adjustment > Adjustment at Time of Parts Replacement 2. Remove one screw to remove the retaining plate. Adjustment at Time of Parts Replacement ■ Inserter opening/closing adjustment (after replacing the inserter unit) <Pre-check> Close the inserter and check whether the positioning pin [1] enters the frame hole in at the bottom of the inserter.(If the pin enters the frame hole by the inserter's own weight although it does not enter the hole smoothly, it is OK.) 3.
  • Page 71 Adjustment > Adjustment at Time of Parts Replacement 5. Open the inserter, and then loosen the two hinge fixing screw (M4) [1]. F-5-8 F-5-8 6. Loosen the two screws securing the hinge. F-5-6 F-5-6 F-5-9 F-5-9 F-5-7 F-5-7 7. Remove the nut cap, loosen the hexagon nut, and turn the adjusting screw [3] using an Allen wrench.
  • Page 72 Adjustment > Adjustment at Time of Parts Replacement ■ 2. Increase the top cover open/close angle. Inserter height adjustment (after replacing the inserter unit) Remove one screw to remove the upper cover angle restriction shaft [1].Open the top cover. <Pre-check> With the inserter closed, check whether the gap between the right side of the inserter and the finisher is within ±1 mm at the front and back (A and B).
  • Page 73 Adjustment > Adjustment at Time of Parts Replacement ■ Document tray width adjustment (after replacing the document 4. Loosen the screw [3] and nut [2] that secure the right height adjusting mechanism. 5. Using an Allen wrench [1], turn the adjusting screw to adjust the gap between the right side of the inserter pickup unit and the inserter base is within 1 mm at the front and back.
  • Page 74 Adjustment > Adjustment at Time of Parts Replacement 9. Place A4-size paper on the inserter lower tray in the portrait orientation, and move the side guide plates so that they touch the side edges of the paper. 10. Press the SW1 (to complete the fourth adjustment). F-5-17 F-5-17 ■...
  • Page 75: Installation

    Installation ■ Making Pre-installation Checks ■ C h e c k i n g B u n d l e d Components ■ Unpacking ■ Installation Procedure...
  • Page 76: Making Pre-installation Checks

    Installation > Making Pre-installation Checks > Checking the Installation Space Making Pre-installation Checks Checking the Installation Space The following illustration describes the necessary space for the The following conditions are required for the installation site. maintenance. It is recommended to make a preliminary inspection of the installation site efore delivering 1000 mm or more the equipment to the user.
  • Page 77: Cautions At The Time Of Installation

    Installation > Making Pre-installation Checks > Cautions at the Time of Installation Cautions at the Time of Installation 1. Turn off the host machine. CAUTION Before installing this equipment, be sure to perform the following steps in the specified order. 1) Turn OFF the main power switch of the host machine.
  • Page 78: Checking Bundled Components

    Installation > Checking Bundled Components Checking Bundled Components [1]RS tight screw (M4x8) 8pcs. [2]Ground plate 1pce. [3]Bearing clip 2pcs. [4]Positioning pin 1pce. [5]Binding-head screw (M4x10) 2pcs. [6]Shunt cale 1pce. [7]Power cord(US/EUR/AUS) 120V model:1pce. 230V model:3pce. [8]Index lael 2pcs. [9]Don’ts Form Label 230V model:1pce.
  • Page 79: Unpacking

    Installation > Unpacking > Unpacking Procedure Unpacking Unpacking Procedure MEMO 1) Take out the accessory ox from the package. The equipment ships, secured by tapes, cush- CAUTION ioning and other materials to protect it from Leave the four cushioning materials attached to the inserter in position. viration and impact during transit.
  • Page 80 Installation > Unpacking > Unpacking Procedure 2) Allow a team of two workers at least to lift and erect the inserter, along with the cushioning materials 3)Remove the pallet,and cushioning materials shown in the figure.Then,put the plastic cover down. F-6-4 F-6-4 F-6-3 F-6-3...
  • Page 81: Installation Procedure

    Installation > Installation Procedure > Preparation for Installation on Upstream Connection Machine Side Installation Procedure Preparation for Installation on Upstream Connection Machine Side 1) .Remove two covers. 2) Secure the two bundled clamp plates and positioning pin to the host machine each with two bundled RS tight screws(M4 x 8).At this time,secure the supplied ground plate along with the rear latch catch.
  • Page 82: Connecting To Connection Machine

    Installation > Installation Procedure > Connecting to Connection Machine Connecting to Connection Machine 1) Stow the left overturning prevention stay by removing a wing screw and lifting the stay up. 2) After stowing the overturning prevention stay, clamp it with the wing screw CAUTION removed.
  • Page 83 Installation > Installation Procedure > Connecting to Connection Machine 5) With the Upper front cover open, remove one screw and press the lock lever to hook on the bearing clip. Reinstall the screw removed to secure the lock lever. F-6-12 F-6-12 6) Close the Upper front cover.
  • Page 84: Height/inclination Checks

    Installation > Installation Procedure > Height/Inclination Checks 6-10 Height/Inclination Checks Height Check 1) Check to see if there is a height difference of 22±3mm between the right upper surface of the inserter and the left upper surface of the connected equipment. MEMO An improperly adjusted height or inclination...
  • Page 85 Installation > Installation Procedure > Height/Inclination Checks 6-11 2) Check that the difference of clearances at the two positions as shown in the figure. The difference should be within 0±2mm. F-6-16 F-6-16 Height Adjustment 2) Remove the wrench from the front upper cover. 1) Open the front upper cover and remove the jam recovery map.
  • Page 86 Installation > Installation Procedure > Height/Inclination Checks 6-12 3)Turn the nut [1] on the front caster assembly (connected equipment side) clockwise to loosen 4)Turn the nut [1] on the rear caster assembly (connected equipment side) clockwise to loosen it.Then it.Then turn the nut [2] to adjust the height. turn the nut [2] to adjust the height.
  • Page 87: Connecting The Cales

    Installation > Installation Procedure > Connecting the Cales 6-13 3)Return the wrench to the front upper cover. 4)Return the jam recovery map and close the front upper cover. F-6-23 F-6-23 F-6-24 F-6-24 Connecting the Cales Connecting the Connecting the 1)Connect the installed interface cable to the finisher with two bundled RS Power Cord 1)Insert the bundled power cord into the inserter to connect.Insert Interface cale...
  • Page 88: Connecting The Wire Saddle

    Installation > Installation Procedure > Connecting the Wire saddle 6-14 Connecting the Shunt 1)Remove the Buffer Pass Unit the screw Cale 2)Attach the undled shunt cale at the rear ottom of the Connection Machine and the connected equipment using the Bundled binding-head screw(M4x10) and step 1) to the supplied screw.
  • Page 89: Making Checks After Completion Of Installation Work

    Installation > Installation Procedure > Operation Checks 6-15 Making Checks after Completion of Installation Work Take back the following parts which are no longer necessary: [1]Cover of the Buffer Pass Unit 2pcs. [2]Power cord 2pcs.(230Vmodel) [3]Binding-head screw(M4x10) 1pce. Operation Checks 1) After completion of installation, connect the power plug of the host machin and equipment to the power outlet.
  • Page 90 Appendix ■ Service Tools ■ General Circuit Diagram Appendix...
  • Page 91: Appendix 7-1 Service Tools

    Appendix > Service Tools Service Tools ■ Solvents and Oils Name Uses Composition Remarks Cleaning: Hydrocarbon (fluorine Do not bring near fire. Vic Clean e.g., glass, plastic, family), Alcohol, Surface Procure locally. rubber parts, external activating agent, Water Isopropyl alcohol may e covers sustituted.
  • Page 92 General Circuit Diagram General Circuit Diagram General Circuit Diagram1/4 * *=44 * *=43 C N * * - 3 + 5 V C N * * - 1 C N * * - 2 S G N D C N * * - 2 DC controller PCB * *=52 C N * * - 1...
  • Page 93 General Circuit Diagram2/4 DC controller PCB * *=171 * *=172 P C B 3 C N 3 0 - 1 K M O T _ * A C N 1 7 5 - 6 K M O T _ * A C N 2 0 1 - 6 C N * * - 2 K M O T _ * A...
  • Page 94 General Circuit Diagram3/4 DC controller PCB P C B 3 3 . 3 V C N 3 - 1 R E S E T C N 3 - 2 C N 8 3 - 3 + 5 V S 1 6 Reverse timing sensor C N 3 - 3 C N 8 3 - 2...
  • Page 95 General Circuit Diagram4/4 DC controller PCB P C B 3 + 2 4 V C N 8 0 - 3 C N 2 8 - 6 + 2 4 V + 2 4 V C N 8 0 - 4 C N 2 8 - 5 + 2 4 V + 2 4 V...

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