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Canon Puncher Unit-P1 Service Manual
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Canon Puncher Unit-P1 Service Manual

Finisher, sorter, deliverytray
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Service Manual
Finisher, Sorter, DeliveryTray
Puncher Unit-P1
Feb 21 2005

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Summary of Contents for Canon Puncher Unit-P1

  • Page 1 Service Manual Finisher, Sorter, DeliveryTray Puncher Unit-P1 Feb 21 2005...
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.

  • Page 7: Table Of Contents

    Contents Contents Chapter 1　Specifications 1.1 Product Specifications............................1- 1 1.1.1Specifications .............................. 1- 1 1.2 Names of Parts..............................1- 3 1.2.1External View.............................. 1- 3 1.2.2Cross Section ............................... 1- 4 Chapter 2　Functions 2.1 Basic Construction ............................2- 1 2.1.1Functional Construction ..........................2- 1 2.2 Feed Drive System ............................
  • Page 8 Contents 3.2.3.2 Removing the Rear Cover........................3- 3 3.2.3.3 Removing the Right Guide Unit ......................3- 4 3.2.3.4 Removing the Upper Cover ......................... 3- 4 3.2.3.5 Removing the Punch Unit........................3- 4 3.3 Electrical System ............................... 3- 7 3.3.1 Punch Unit Harness ............................. 3- 7 3.3.1.1 Notification when dismounting the Punch Unit Harness ..............
  • Page 9 Contents 4.4.1.3 E590; Punch motor error ........................4- 5 4.4.1.4 E591; Scrap full detector sensor error ....................4- 6 4.4.1.5 E592; Trailing edge/Horizontal registration sensor error..............4- 6 4.4.1.6 E593; Horizontal registration motor error................... 4- 6 4.5 Outline of Electrical Components ........................4- 7 4.5.1Sensors.................................

  • Page 11: Chapter 1　Specifications

    Chapter 1　Specifications...
  • Page 13 Contents Contents 1.1 Product Specifications............................1-1 1.1.1 Specifications .............................. 1-1 1.2 Names of Parts..............................1-3 1.2.1 External View.............................. 1-3 1.2.2 Cross Section ............................... 1-4...

  • Page 15: Product Specifications

    A3, A4, A4R, B4, B5, B5R 2 or 3 holes (Puncher Unit-M1): 2 holes/LGL, LTRR 3 holes/279mm x 432mm (11 x 17), LTR 4 holes (FRA)(Puncher Unit-N1): A3, A4 4 holes (SWD)(Puncher Unit-P1): A3, A4 Paper weight Transparenie 64g/m2 to 250g/m2 s not allowed Punched hole 2 holes : 6.5mm...
  • Page 16 80±1 mm / 80±1 mm / 80±1 mm / 3.15±0.04 in 3.15±0.04 in 3.15±0.04 in 12±3 mm / 0.47±0.12 in [4] Puncher unit-P1 (4-Hole (SWD)) 35±3 mm 21±1 mm / 70±1 mm / 21±1 mm / 0.83±0.04 in 2.76±0.04 in 0.83±0.04 in 12±3 mm /...

  • Page 17: Names Of Parts

    Chapter 1 1.2 Names of Parts 1.2.1 External View 0003-4695 F-1-2 T-1-2 [1] Upper cover [2] Upper cover 2 [3] Front door [4] Right guide assembly [5] Rear cover...

  • Page 18: 2Cross Section

    Chapter 1 　 1.2.2 Cross Section 0003-4696 F-1-3 T-1-3 [1] Cam [3] Punch feed roller [2] Hole puncher (Punch blade) [4] Punch waste case...

  • Page 19: Chapter 2　Functions

    Chapter 2　Functions...
  • Page 21 Contents Contents 2.1 Basic Construction ............................. 2-1 2.1.1 Functional Construction ..........................2-1 2.2 Feed Drive System ............................. 2-2 2.2.1 Overview ..............................2-2 2.2.2 Constraction of the Control System ......................2-2 2.2.3 Punch Operation ............................2-4 2.2.4 Horizontal Registration Operation ......................2-7 2.3 Detecting Jams ..............................

  • Page 23: Basic Construction

    Chapter 2 2.1 Basic Construction 2.1.1 Functional Construction 0003-8735 The puncher unit is optionally installed in the delivery path between the host machine and the finisher. When the paper delivered from the host machine reaches the puncher unit, it is fed by the punch feed roller. Then when the trailing edge of the paper is detected, the paper is tempo-rarily stopped and the punch axis rotates to punch holes in the trailing edge of the paper.

  • Page 24: Feed Drive System

    Chapter 2 　 2.2 Feed Drive System 2.2.1 Overview 0003-9479 The puncher unit is located on the feed path between the host machine and the finisher, and successively punches holes when the paper stops temporarily. The paper delivered from the host machine is fed by the punch feed roller. The punch feed roller is driven by the punch feed motor.
  • Page 25 (PI63). To stop the DC punch motor accurately at its home po-sition, the punch motor clock sensor (PI62) counts a predetermined number of clock pulses to stop the punch motor. A single punch operation is performed by rotating the punch shaft 180° from its home position. Five light sensors (photosensor PCB) are located at the upper side of the inlet paper feed path of the puncher unit and a set of five LEDs (LED PCB) are located at the lower side.

  • Page 26: 3Punch Operation

    Chapter 2 　 Punch controller PCB (1/2) PTR1 LED1 Punch controller PCB (2/2) F-2-2 2.2.3 Punch Operation 0003-4699 The hole puncher is driven by the punch motor (M61), and its position is monitored by the punch home position sensor (PI63). The hole puncher makes a single round-trip movement (punching) as the punch shaft rotates 180°　from home position.
  • Page 27 Chapter 2 At the home position, the punch home position sensor is ON. Punching of the first sheet ends when the punch shaft has rotated in the forward direction 180°, and the state of the punch home position sensor has changed from OFF to ON.
  • Page 28 Chapter 2 　 reciprocally in the escape direction (hole puncher rise direction) on the remaining half peripheral area on the punch shaft. To punch three holes, the 2-hole puncher is moved reciprocally in the escape direction (hole puncher rise direction). The following illustrates punching when two sheets are punched with two holes.

  • Page 29: 4Horizontal Registration Operation

    Chapter 2 [punch shaft stopped/ [punch shaft is rotated 90˚ [punch shaft is rotated 180˚ home position] in the reverse direction/ in the reverse direction/ hole punched] punch operation completed] F-2-7 When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction (hole puncher rise direction) as shown below.
  • Page 30 Chapter 2 　 Punch slide unit Horizontal registration motor (M62) Trailing edge detection sensor (LED5,PTR5) Sheet delivery direction Sheet F-2-9 2) After the horizontal registration sensors (LED1 to 4, PTR1 to 4) detect the edge of the paper at its inner side in keeping with the paper size signals arriving from the host ma-chine, the horizontal registration motor (M62) drives the punch slide unit to a predetermined position further towards the front, and stops the unit at this position.
  • Page 31 Chapter 2 Punch F-2-11 4) When punching ends, drive of the punch feed motor (M63) is started, the horizontal registration motor (M62) is operated in the reverse direction, and the punch slide unit is returned to its home position where it comes to a stop. 5) Even if paper to be punched continues to arrive, the punch slide unit returns to its home position for each arriving sheet, and steps 1 to 4 are repeated.

  • Page 32: Detecting Jams

    Chapter 2 　 2.3 Detecting Jams 2.3.1 Detecting Jams 0003-4704 The finisher unit identifies any of the following conditions as a jam, and sends the jam signal to the host machine. In response, the host machine may stop copying operation and indicate the presence of a jam on its control panel. T-2-3 Jam type Sensor...

  • Page 33: Power Supply

    Chapter 2 2.4 Power Supply 2.4.1 Power Supply Route 0003-4702 24V power and 5V power are supplied from the finisher controller PCB when the power switch on the host machine is turned ON. 24V power is used for driving motors, while 5V power is used for driving sensors and the ICs on the punch controller PCB.

  • Page 35: Chapter 3　Parts Replacement Procedure

    Chapter 3　Parts Replacement Procedure...
  • Page 37 Contents Contents 3.1 External Covers ..............................3-1 3.1.1 Rear Cover..............................3-1 3.1.1.1 Removing the Rear Cover ........................3-1 3.1.2 Upper Cover ..............................3-1 3.1.2.1 Removing the Rear Cover ........................3-1 3.1.2.2 Removing the Upper Cover........................3-1 3.1.3 Right Guide Unit ............................3-2 3.1.3.1 Removing the Right Guide Unit......................
  • Page 38 Contents 3.3.5 Punch Controller PCB ..........................3-24 3.3.5.1 Removing the Rear Cover........................3-24 3.3.5.2 Removing the Punch Controller PCB....................3-25...

  • Page 39: External Covers

    Chapter 3 3.1 External Covers 3.1.2.2 Removing the Upper Cover 0003-6791 1) Open the front door [1], remove three screws [2], 3.1.1 Rear Cover and remove the upper cover [3]. 3.1.1.1 Removing the Rear Cover 0003-6789 1) Remove three screws [1] and remove the rear cover [2].

  • Page 40: Drive System

    Chapter 3 　 3.2 Drive System 3.2.1 Punch Motor 3.2.1.1 Removing the Rear Cover 0003-6793 1) Remove three screws [1] and remove the rear cover [2]. F-3-6 3.2.1.3 Removing the Punch Motor 0003-6795 1) Disconnect the connector [1]. 2) Remove two screws [2] and remove the punch F-3-5 motor [3].

  • Page 41: Removing The Rear Cover

    Chapter 3 F-3-10 F-3-8 3.2.3 Punch Unit 3.2.2.2 Removing the Right 3.2.3.1 Notification when Guide Unit 0003-6797 dismounting the Punch Unit 0003-8233 1) Remove four screws [1], and remove the right guide assembly [2]. When removing the punch unit, the punch unit section sometimes opens.

  • Page 42: Removing The Right Guide Unit

    Chapter 3 　 3.2.3.3 Removing the Right 3.2.3.5 Removing the Punch Guide Unit Unit 0003-6799 0003-6802 1) Remove four screws [1], and remove the right 1) Remove E-ring [1], washer [2], and puncher spring guide assembly [2]. [3]. F-3-12 3.2.3.4 Removing the Upper F-3-14 Cover 0003-6801...
  • Page 43 Chapter 3 F-3-16 F-3-18 4) Disconnect the connector [1] and remove the screw 6) Remove the tie wrap with lock [1] while holding its [2], and remove the horizontal registration home claw between your fingers. (The tie wrap must be position sensor [3].
  • Page 44 Chapter 3 　 F-3-20 9) Disconnect the connector [1] on LED PCB. F-3-21 10) Remove the slide shaft support [1], the sensor mount (lower) [2] and the puncher knob [3] from the punch unit section. The slide shaft support [1] is not attached to punch unit section that are currently set as service parts.

  • Page 45: Electrical System

    Chapter 3 3.3 Electrical System 3.3.1 Punch Unit Harness 3.3.1.1 Notification when dismounting the Punch Unit Harness 0003-8728 When removing the punch unit, the punch unit section sometimes opens. If necessary, perform F-3-24 work with the punch unit section in an open state. 3.3.1.4 Removing the Upper Cover 0003-6803...
  • Page 46 Chapter 3 　 F-3-26 2) Remove the two tie wraps with lock [1] while holding its claw between your fingers. (The tie wraps must be removed without being cut.) F-3-28 3) Disconnect the three connectors [2]. 4) Free the harness [4] from the three harness stops 6) Remove the three screws [1] and sensor mount [3].

  • Page 47: Installing The Punch Unit Harness

    Chapter 3 firmly installed at the positions described below. 1) Fasten the punch unit harnesses so that the two tie wraps [1] of the punch unit harnesses are on the outside of the two respective clamps [2]. F-3-30 F-3-32 9) Disconnect the connector [1] of the horizontal registration motor and the connector [2] of the horizontal registration home position sensor, and PI62...

  • Page 48: Removing The Right Guide Unit

    Chapter 3 　 F-3-34 3.3.2.2 Removing the Right Guide Unit 0004-0830 F-3-36 1) Remove four screws [1], and remove the right guide assembly [2]. 3.3.2.4 Removing the Punch Unit 0004-0831 1) Remove E-ring [1], washer [2], and puncher spring [3]. F-3-35 3.3.2.3 Removing the Upper Cover...
  • Page 49 Chapter 3 F-3-40 5) Turn the gear [1] in the direction of the arrow, and move the punch unit section [2] to the far side. F-3-38 3) Remove the three screws [1], and remove the sensor mount (upper) [2]. Then, remove the connector [3] on the photosensor PCB.

  • Page 50: Removing The Led Pcb

    Chapter 3 　 unit section that are currently set as service parts. When replacing the punch unit section, be sure to attach the slide shaft support that was in use beforehand. If you forget to attach the slide shaft support, the machine may malfunction. F-3-42 8) Lift up the front side of the punch unit section [1] first, then move in the direction of the arrow to remove...

  • Page 51: Removing The Upper Cover

    Chapter 3 F-3-49 F-3-47 3.3.4 Scrap Full Detector PCB 3.3.3.2 Removing the Upper 3.3.4.1 Removing the Right Cover 0003-6812 Guide Unit 0003-6817 1) Open the front door [1], remove three screws [2], 1) Remove four screws [1], and remove the right and remove the upper cover [3].

  • Page 52: Punch Controller Pcb

    Chapter 3 　 F-3-51 3.3.5 Punch Controller PCB F-3-53 3.3.5.1 Removing the Rear Cover 0003-6819 1) Remove three screws [1] and remove the rear cover [2]. F-3-52 3.3.5.2 Removing the Punch Controller PCB 0003-6820 1) Remove the two screws [1], disconnect seven connectors [2], and remove the punch controller PCB [3].

  • Page 53: Chapter 4　Maintenance

    Chapter 4　Maintenance...
  • Page 55 Contents Contents 4.1 User Maintenance............................... 4-1 4.1.1 User Maintenance............................4-1 4.2 Maintenance and Inspection ..........................4-2 4.2.1 Periodically Replaced Parts......................... 4-2 4.2.1.1 Periodically Replaced Parts........................4-2 4.2.2 Durables............................... 4-2 4.2.2.1 Durables..............................4-2 4.2.3 Periodical Servicing ............................ 4-2 4.2.3.1 Periodical Servicing ..........................4-2 4.3 Adjustment .................................

  • Page 57: User Maintenance

    Chapter 4 4.1 User Maintenance 4.1.1 User Maintenance 0003-4705 T-4-1 Item Timing Punch waste removal When prompted (indicator on host machine control panel)

  • Page 58: Maintenance And Inspection

    Chapter 4 　 4.2 Maintenance and Inspection 4.2.1 Periodically Replaced Parts 4.2.1.1 Periodically Replaced Parts 0003-4706 The Puncher unit does not have parts that must be replaced on a periodical basis. 4.2.2 Durables 4.2.2.1 Durables 0003-4707 There are no durables that require durables. 4.2.3 Periodical Servicing 4.2.3.1 Periodical Servicing 0003-4708...

  • Page 59: Adjustment

    Chapter 4 4.3 Adjustment attached to the IC on the punch driver PCB so that the puncher unit can be identified by the finisher. For this reason, this operation must be performed when the 4.3.1 Adjustment at Time of Parts punch driver PCB has been replaced.
  • Page 60 Chapter 4 　 5) Press SW603 on the punch controller PCB. The number of punch holes is registered to the punch controller PCB each time the switch is pressed. Registration is complete if LED601 and 602 on the punch controller PCB flashes alternately. 6) Press SW602 or 603 on the punch controller PCB to end the adjustment mode and set all bits of SW601 to OFF.

  • Page 61: Troubleshooting

    Chapter 4 4.4 Troubleshooting 4.4.1 Error Code 4.4.1.1 E503; Puncher unit communication error 0003-4712 <Finisher controller PCB/Punch controller PCB> 1) Does it improve when the host machine power switch is turned OFF/ON? YES : End <Wiring> 2) Is the wiring between the finisher controller PCB and punch controller PCB normal? NO : Repair the wiring.

  • Page 62: E591; Scrap Full Detector Sensor Error

    Chapter 4 　 4.4.1.4 E591; Scrap full detector sensor error 0003-8758 <Wiring> 1) Is the wiring between the scrap full detector PCB and the punch controller PCB normal? NO : Repair the wiring. <Scrap full detector PCB> 2) Does it improve when the scrap full detector PCB is replaced? YES : End NO : Replace the punch controller PCB.

  • Page 63: Outline Of Electrical Components

    Chapter 4 4.5 Outline of Electrical Components 4.5.1 Sensors 0005-8426 PI62 PI61 PI63 F-4-3 T-4-4 Punc Parts Ref. Name contr Error number oller WG8- PI61 Horizontal registration home position sensor J605 E593 5593 FK2- PI62 Punch motor clock sensor J605 E590 0149...

  • Page 64: Microswitches

    Chapter 4 　 Punc Parts Ref. Name contr Error number oller FK2- PI63 Punch home position sensor J605 1644 E590 0149 4.5.2 Microswitches 0005-8427 MSW61 MSW62 F-4-4 T-4-5 Ref. Name Parts number Punch controller PCB Upper door switch WC4-5128 J602...

  • Page 65: Motors

    Chapter 4 Ref. Name Parts number Punch controller PCB Front door switch WC4-5128 J602 4.5.3 Motors 0005-8428 F-4-5 T-4-6 Punch controller Erro Ref. Name Parts number Punch motor FH5-1074 J603 E590 Horizontal registration motor FH5-1075 J605 E593...

  • Page 66: Pcbs

    Chapter 4 　 Punch controller Erro Ref. Name Parts number Punch feed motor FH5-1043 J604 4.5.4 PCBs 0005-8429 F-4-6 T-4-7 Punch Ref. Name Parts number controlle Error r PCB Punch controller PCB FG3-2885 E505 4-10...
  • Page 67 Punch Ref. Name Parts number controlle Error r PCB 1002,1 Photosensor PCB FG3-3108 J605 102,16 E592 LED PCB FG3-3107 J605 E592 Scrap full detector PCB FM2-1521 J606 E591...

  • Page 68: Variable Resistors (Vr), Light-Emitting Diodes (Led), And Check Pins By Pcb

    Chapter 4 　 4.6 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB 4.6.1 Overview 0003-4721 Of the LEDs and check pins used in the machine, those needed during servicing in the field are discussed. Do not touch the check pins not found in the list herein. They are exclusively for factory use, and require special tools and a high degree of accuracy.

  • Page 69: Upgrading

    Chapter 4 4.7 Upgrading 4.7.1 Upgrading 0003-8729 Overview A flash ROM is used for the IC601 (CPU) of the Puncher unit. To upgrade this IC, the downloader PCB (FY9-2034) is used. The operating instructions for it are given below. How to Use the Downloader PCB (FY9-2034) 1.When to Use the Downloader PCB The downloader PCB is used when upgrading the CPU (IC601) of the Punch Controller PCB.
  • Page 70 Chapter 4 　 Description Function Cable B (9 A cable to connect the downloader PCB and the pins)Length: approx. Puncher 50cm RS-232C connector A connector to connect an RS-232C cable to the downloader PCB 3. Necessary Tool The following item needs to be prepared for download. Computer (PC) Prerequisite: The download tool (Ver.
  • Page 71 Chapter 4 F-4-10 5) Select [Register from New ROM folder]. In response, the data will be registered, and the data inside the NewROM folder will be deleted. F-4-11 b. Connection to the Puncher 1) Turn off the power of the host machine. 2) Remove the rear cover of the Puncher.
  • Page 72 Chapter 4 　 4) Connect the RS-232C cable to the RS-232C connectors of the circuit board and the PC. 5) Turn on the power of the host machine. The power LED on the circuit board is lit. c. Download The error code E500 might occur during download. It does not affect the download operation and its results. 1) Start up the Service Support Tool.
  • Page 73 Chapter 4 F-4-13 5) Follow the instructions on the screen to prepare for downloading. A press on [OK] will bring up the next screen. F-4-14 6) Select the version of the ROM to download. 4-17...
  • Page 74 Chapter 4 　 F-4-15 7) Press [Start] so that the computer and the downloaded PCB will start downloading the program. F-4-16 8) If downloading ended normally, press [OK]. 4-18...
  • Page 75 Chapter 4 F-4-17 9) End the session as instructed on the screen. F-4-18 5. Release of Connection 1) Press the START/STOP key. LOAD LED is turned off. 2) Turn off the power of the host machine. 3) Disconnect the cable B from the Puncher. 4-19...
  • Page 76 4) Mount the rear cover to the Puncher. 5) Turn on the power of the host machine.

  • Page 77: Service Tools

    Chapter 4 4.8 Service Tools 4.8.1 Solvents and Oils 0003-4723 T-4-10 Name Description Composition Remarks Vic Clean Cleaning: Hydrocarbon(fluori Do not bring near e.g., glass, ne family) fire. plastic, rubber parts, Alcohol Procure locally. external covers Surface activating Isopropyl alcohol agent may be substituted.

  • Page 79: Chapter 5　Error Code

    Chapter 5　Error Code...
  • Page 81 Contents Contents 5.1 Overview ................................5-1 5.1.1 Overview ..............................5-1 5.2 User Error Code..............................5-2 5.2.1 Punch scrap full ............................5-2 5.2.2 Punch scrap overflow ..........................5-2 5.3 Service Error Code ............................. 5-3 5.3.1 E503................................5-3 5.3.2 E505................................5-3 5.3.3 E590................................5-3 5.3.4 E591................................

  • Page 83: Overview

    Chapter 5 5.1 Overview 5.1.1 Overview 0003-4736 The finisher to which the unit is mounted is equipped with a mechanism (CPU on the finisher controller PCB) that runs a self check, communicating to the host machine any fault it detects in the form of a code and a detail code. In response, the host machine indicates the presence of a fault on its control panel using codes;...

  • Page 84: User Error Code

    Chapter 5 　 5.2 User Error Code 5.2.1 Punch scrap full 0003-4737 T-5-1 Error Occurs when Detection Machine Reset Descript timing operation Punch The amount of During Normal Empty the scrap scrap punch scraps has punching operation will container. full reached the continue.

  • Page 85: Service Error Code

    Chapter 5 5.3 Service Error Code 5.3.1 E503 0003-4739 T-5-3 Code Detail Error Detection timing Description E503 0003 Communication The communication with the puncher unit is error interrupted. 5.3.2 E505 0003-4740 T-5-4 Code Detail Error Detection timing Description E505 0002 Backup RAM The checksum for the punch controller PCB has an error when the power is turned on.

  • Page 86: E591

    Chapter 5 　 5.3.4 E591 0003-8764 T-5-6 Code Detail Error Detection timing Description E591 8001 Scrap full The voltage of the light received is 3.0 V or detector sensor less even when the light emitting duty of the (LED6,PTR6) scrap full detector sensor has been increased to 66% or more.

  • Page 87: E592

    Chapter 5 5.3.5 E592 0003-8767...
  • Page 88 T-5-7...
  • Page 89 Code Detail Error Detection timing Description E592 8001 Trailing edge The voltage of the light received is 2.5 V or sensor(LED5,PT less even when the light emitting duty of the R5)/ trailing edge sensor has been increased to Horizontal 66% or more. registration 8002 The voltage of the light received is 2.0 V or...

  • Page 90: E593

    Chapter 5 　 5.3.6 E593 0003-4742 T-5-8 Code Detail Error Detection timing Description E593 8001 Horizontal At time of horizontal registration motor registration initialization, the punch slide unit does not motor(M62)/ leave the horizontal home position sensor Horizontal even when it has been driven for 9 mm. registration home 8002 At time of horizontal registration motor...
  • Page 91 Feb 21 2005...

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