SM Pro Pucnher A1cover.qxp 11/29/2005 10:36 AM Page 1 Professional Puncher-A1 SERVICE MANUAL DU7-1175-000 NOVEMBER 2005 REV. 0 COPYRIGHT ©2005 CANON INC. CANON Professional Puncher-A1 REV. 0 PRINTED IN U.S.A.
TABLE OF CONTENTS 1. INTRODUCTION............................................................................... 3 1.1 INTRODUCTION ............................................................................................ 3 1.2 PROFESSIONAL PUNCHER-A1 FAQ’S ....................................................... 3 2. INSTALLATION................................................................................ 5 2.1 UNPACKING.................................................................................
1. INTRODUCTION 1.1 INTRODUCTION The Professional Puncher-A1 is an innovative solution for punching paper and offers the following design features: • Quick-change die sets that are self-latching without tools or levers. • All Professional Puncher-A1 die sets include an Identifying Label providing user with the hole pattern and name. • Convenient storage area for three extra Die Sets located above the sheet bypass. 1.
8.5” x 11” (LEF) Only: Professional Puncher-A1 is designed to punch this size only (LEF) no exceptions. Attempting to punch a sheet size other than 8.5” x 11” (LEF) will cause a jam. • Professional Puncher-A1 cannot punch tabs. Tabs will have to be run, punched and inserted offline. • Use a colored sheet insert (instead of the tab) in the job workflow for easier tab insertion after the job has been run.
2. 2.1 INSTALLATION UNPACKING UNPACKING • Inspect the outside of the package for shipping damage. If there is evidence of shipping damage, contact the shipping carrier immediately. • Remove the punch from its shipping carton. • Inspect for any concealed damage to unit. If there is evidence of concealed shipping damage, contact the shipping carrier immediately. • Remove all shipping tape from doors and levers. 2.2 UNIT SET-UP Step One: Step Two: 2.3 Connect the communication cable.
CANON PROFESSIONAL PUNCHER-A1 DIE SET - INFORMATION SHEET IMPORTANT NOTICE REGARDING THE DIE SETS PLEASE READ Your CANON Professional Puncher-A1 die set (C4, W2 and W3 versions), is supplied with a felt pad containing oil, a pad retaining magnet and shield*. Do not throw these items away! The felt pad will provide lubrication to the punch pins under normal usage and will help to keep the punch pins clean. The magnet is intended to keep the felt pad in place during typical handling.
3. 3.1 MAINTENANCE INSPECTION, CLEANING AND LUBRICATION The following maintenance should be performed once annually, under normal use. Operational Inspection 1. If operating properly, the Professional Puncher-A1 will punch the same types of copy paper and cover materials handled by the copier/printer. It will run at the speed of the printer. 2. Hole quality will vary between different grades of paper. External Cleaning 1.
GREASING CRANKS Die Sets Professional Puncher-A1 Die Sets have an average expected life of approximately 500,000 sheets of paper. This life may vary depending on variables such as following the lubrication schedule described above, the type of paper being punched, the cover stocks being punched and the typical length of the average job. 3.2 DIE SET MAINTENANCE Die sets have a minimum life expectancy of 500,000 cycles depending on application, environmental factors and maintenance.
3.3 PREVENTATIVE MAINTENANCE SCHEDULE The following preventative maintenance should be performed during the regular printer inspection intervals. • Disconnect the main cord set and retain it in your control for your safety. • Remove the rear cover. • Perform a visual inspection; clean, adjust and replace components as required. • Vacuum Paper Chad out of Back Gage Mechanism and Die Guide as well as base. • Optical Sensors; Remove dust and particles from the lens using a soft cloth.
4. 4.1 ADJUSTMENT AND SPECIAL PROCEDURES TOOL RECOMMENDATIONS What you need to service the CANON Professional Puncher-A1: 1. Standard Measure Tools (English as opposed to metric) a. Open End Ignition Wrench – ¼” (required only for Chad Kit installation) b. Open the End Wrench 9/16”(for adjustable casters) c. Nut Driver, 5/16” d. Nut Driver, ¼” (see note below) e. Allen Wrench, 3/32” (comes with Chad Control Kit) f. Allen Wrench, 5/64” g. Allen Wrench, 9/64” 2. Other recommended tools a.
PUNCHED HOLE ALIGNMENT CHECKING • The back cover on the Professional Puncher-A1 must be removed to access the die set position cradle. CRADLE • Before adjusting the die set position cradle, you must first note what direction the die set cradle must move. • Before you adjust the die set position cradle, you must loosen the lock-down screw.
PRESS HERE TO TILT ADJUSTMENT SCREW LOCK-DOWN SCREW LOOSEN SCREW • Observe the punched paper; if the punched-holes are too close to the rear of the machine, then you must turn the adjustment screw counter-clockwise. TURN COUNTERCLOCKWISE • If the punched-holes are too close to the front of the machine, then you must turn the adjustment screw clockwise.
TURN CLOCKWISE • Using a flat-head screwdriver, turn the adjustment screw clockwise or counterclockwise to move the die set position cradle. NOTE: Seven full turns of the adjustment screw result in a ¼” change in the punched hole position. • Before tightening the lock-down screw, tilt or bias the assembly towards the bottom of the machine and tighten the lock-down screw. This will ensure positive engagement between the locking lever and the die set.
2. Remove 4 screws in front and 2 in back 3. Cut any wire ties that may prevent freedom of movement to slide the Punch Module (A) outward 4. Remove the Back Gauge Assembly (B). 5. Remove the black Knob (C) at the front (customer side) of the Punch Module Drive Shaft. A C FRO NT SIDE B 6. Slide the Punch Module unit part way out to reach and unplug the Punch Sensor Harness (Red, Black, White wires) 7. Slide the entire Punch Assembly (C) out and lay it beside the Professional Puncher-A1.
PROCEDURE TO REPLACE ALIGNER BELTS Replacement of the Green Belt from the Aligner, Paper Entrance Side. Replacement of the Green Belt from the Aligner, Paper Exit Side. 4.
A BINDER SIDE B Step 6: To remove the Rear Cabinet/Cover (C) of the Professional Puncher-A1, 1. Remove the “5” screws on Exit side and “3” screws on Entrance side. 2. Slide the Rear Sheet Metal Cabinet/Cover off of the Professional Puncher-A1. NOTE: You do not need to lift upward and you do not need to remove the Top Cover. Step 7: Disconnect the Entrance Sensor Wire from the Side Frame. Step 8: Remove the “4” screws that secure the Front Paper Chute (D), set aside.
Step 11: To remove Entrance Aligner Panel, Idler Paper Guide Assembly (item 19) A. Remove “2” E-Rings from the Pivot Shaft (G). B. Slide the Shaft (G) all the way out through the front of the Professional Puncher-A1. C. Remove the Fan (H) that prevents access to the Flexible Cable. To remove it simply pull it off of the Shaft. D. Remove the Flexible Cable using an Alan Wrench. E. Remove the rear top Pulley (I). F. Loosen the Belt Idler (J). G. Remove the Belt and Pulley. H.
and the metal (w/o a belt) Green Belt Aligner Roller itself. Note that the two metal surfaces are flush. Step 14: Remove the Green Belt Aligner Roller Assembly by removing the “4” screws (S). Important: Leave the Flex Shaft (FS) attached. Step 15: Stretch the new Belt (B) onto the Aligner Roller Assembly, green side out. Rotate the Shaft (S) to confirm that the belt tracks properly. S B STRETCH FS Slide the Aligner into place, loosely attach the “4” Pan Head Screws with the “4” Lock Washers.
Step 17: To install the Paper Guide Assembly into the Professional Puncher-A1. 1. As you slide the Paper Guide Assembly into place, a. Hook up the Sensor Harness to the Sensor on the back. b. Lift it up slightly to clear the lower Transition Paper Guide. c. Be sure to clear the Sensor Bracket at the top left. d. Be sure that the Flex Coupling Shaft is sticking out of the rear of the Professional Puncher-A1 properly. 2.
Step 21: Install the J2 Shaft back into place by inserting it first into the front, then the back. INSTAL J2 SHAFT Step 22: Close the J2 Flipper Latch. Repeat the test of rotating the pulleys to ensure smooth rotation of the Idler Rollers. Step 23: Attach the J2 Shaft Spring. Install the front E-Ring to secure J2. Step 24: To install the Idler Aligner Paper Guide. A. Hold it loosely in place. B.
AFTER ASSEMBLY 4.6 GREEN BELT REPLACEMENT, PAPER EXIT SIDE The following step-by-step directions inform you how to remove and then assembly the components necessary to access the Paper Exit Side Aligner Green Belt, P/N FC3-3633-0000 It will help you to reference your Professional Puncher-A1 Service Manual part drawings as you follow this process. Special Tools Required: • Twelve inch metal ruler or similar straight edge. • Phillips Head Screw Driver 7” or less in total length. • Alan wrenches.
BINDER SIDE A Step 5: To remove the Rear Cabinet/Cover (B) of the Professional Puncher-A1, 1. Remove the 5 screws on Exit side and 2 screws on Entrance side. 2. Slide the Rear Sheet Metal Cabinet/Cover off of the Professional Puncher-A1. NOTE: You do not need to lift upward and you do not need to remove the Top Cover. B Step 6: To remove the J2 Flipper (C), Door Latch. A. Remove only one (the one closest to the frame) of the “E” Rings of the J2 Flipper on the right end (front Door side). B.
Step 7: Unhook spring from the Docking Plate (D) and Door. Remove the “4” screws that secure the Docking Bracket. Remove, and set aside. PAPER ENTERANCE SIDE FRONT DOOR SIDE PAPER EXIT SIDE Step 8: To remove the Rear Aligner, Idler Paper Guide Assembly A. Remove “2” E-Rings from the Pivot Shaft. B. Slide the Shaft all the way out through the front of the Professional Puncher-A1. C. Remove the “2” Nylon Bearings. Step 9: D. Remove and set aside the Rear Aligner, Idler Paper Guide Assembly.
Step 10: To remove the Rear, Drive Side, and Paper Guide Aligner Assembly. This is the large Sheet Metal Assembly within the Professional PuncherA1 that actually contains the Green Belt Aligner itself. IMPORTANT: Walk the Belt off of the Aligner Pulley at the rear. A. Remove the “2” screws that hold the Block to the Frame. Now – the Coupler is loose and the Rear Panel will come out. B. Remove the “6” Screws that secure the face of this Assembly. C.
metal (w/o a belt) Green Belt Aligner Roller itself. Note that the two metal surfaces are flush. Step 12: Remove the Green Belt Aligner Roller Assembly by removing the “4” screws. Important: Leave the Coupler attached. Assembly Process Step 13: Stretch the new green belt onto the Aligner Roller Assembly, green side out. • Take care when handling the Aligner Roller Assembly so as not to damage the Flex Coupling. • Rotate the shaft to confirm that the belt tracks properly.
As a double check, hold the entire Paper Guide assembly up so that you can visually inspect the alignment between the sheet metal surface and the metal surface of the Aligner. The Green Belt should appear to be even and just floating above the surface of the sheet metal. ALIGN & FIX SCREWS Step 15: To install the Paper Guide Assembly into the Professional Puncher-A1. ASSEMBLE BACK A. As you slide the Paper Guide Assembly into place, a. Hook up the Sensor Harness to the Sensor on the back. b.
Step 16: Step 17: Step 18: Step 19: Step 20: Step 21: Step 22: Step 23: Step 24: Step 25: Step 26: Step 27: Step 28: E. Once all “8” mounting screws have been properly started you have good alignment. You may now go back and tighten the screws until they are snug. Do not over tighten the “2” screws on top! Install the “2” Screws to secure the Bearing Block for the Pulley arrangement at the rear of the Professional Puncher-A1.
This entire process takes approximately 60 minutes. First time maybe a little longer. AFTER ASSEMBLY 4.7 BACK GAGE AND CHAD CONTROL MECHANISM ADJUSTMENT, ASSEMBLY / DISASSEMBLY PROCEDURE The Back Gage with Chad Control Mechanism is available as a kit service. General Description: The Professional Puncher-A1 Chad Control Mechanism directs Paper Chad into the Chad Disposal Container, significantly reducing the amount of Chad that could flow through the paper path.
NOTE: Step 3: Step 4: Step 5: Once you remove the screws that secure the rear cover, it will slide out from under the top cover. You do not need to remove the top cover. Remove the two screws holding the Die rail at the front of the Professional Puncher-A1. Remove the four screws holding the Die rail at the rear of the Professional Puncher-A1. Remove the wire that attaches the solenoid to the PC board. After all the screws and the wire are removed you can now remove the back gage and rail as an assembly.
Step 8: Install the die set. Test the Professional Puncher-A1 system running first one page at a time, then two pages then 5 pages, then 10 pages and lastly run 50 test pages. Step 9: Replace the cover and run a few more test jobs. Step 10: Skew Adjustment: Check for proper Hole alignment to paper edge. The back gage is designed to give you some adjustment when the three screws are loosened. It will give you up and down play, which allows you to remove skew.
8. Clear paper from all these areas by turning knobs as shown. 9. When all the paper is cleared turn on power shut the door make sure the jam light is out if not go back to step 1. And find the paper that is not clear. 10. When all the paper is cleared from the punch and the light is out follow the steps used above to clear the printer and finisher. 11. Hit the punch green button and then the resume button on the printer, operation should start. 12.
Following the steps above, the Hyper Terminal Screen should look like this: BOOTLOADER>V Professional Puncher A1 Ver.: XX.XX BOOTLOADER> Downloading ... 0xF00000 Successful download of Professional Punch A1 Ver.: XX.XX Begin downloading .hex file or enter a command listed below in <>: o execute the new downloaded code or display code ersion BOOTLOADER>V Professional Puncher A1 Ver.: XX.XX BOOTLOADER>G Executing Professional Puncher A1 Ver.: XX.
Executing Professional Punch A1 Ver.: 04.15 Press to run Bootloader or if machine is always BUSY New Software is installed Disconnect cable Restart Professional Punch The yellow items are commands typed by the user to run the boot loader. The green items are the responses from the boot loader in the Hyper Terminal window. Following the steps above, the Hyper Terminal Screen should look like this: BOOTLOADER>V Pro Punch A1 Ver.: 04.14 BOOTLOADER> Downloading ...
5. TECHNICAL TROUBLESHOOTING 5.1 THEORY OF OPERATION The CANON Stream Punch is a machine that punches various die set hole patterns into single sheets of paper. The machine is placed between a printer / copier and a finisher. There are two paper paths. One is the bypass section, which does not punch paper. The other is the punch path. The punch path can be selected by pressing the green button on the top of the Stream Punch.
SERIAL EEPROM CONTROL: 1 Input 3 Outputs Counts number of punches for die set full, Saves value For the Stream Punch to operate, all optical sensors must be clear. Any blocked sensor or open door will prevent operation. The machine may operate in bypass mode with or without a chip tray or die set. Both of these must be present to punch. Stepper #1 Control: If punch is not enabled, the Professional Puncher-A1 will run in bypass mode (no punching).
5.2 TROUBLESHOOTING GUIDE CHART The Troubleshooting Guide Chart that follows is arranged in order of the normal operational sequence. When a malfunction occurs, read down the SYMPTOM column until you reach the appropriate description for your symptom. Read the corresponding PROBABLE CAUSE and then perform the recommended procedure in the CORRECTIVE ACTION column.
TROUBLESHOOTING GUIDE CHART (CONTINUED) SYMPTOM Paper Jam indication on printer display, customer / operator has been unable to locate the jam PROBABLE CAUSE A small piece of chad or torn paper is blocking a sensor and/or the paper path CORRECTIVE ACTION Separate the Professional Puncher-A1 from the Printer and the Finisher, clean out the entire paper path Paper Jam, not able to find any large sheets, removed sheets are torn Suspect a small piece of paper is hidden somewhere in the paper path Run a hea
OUBLRevHOOTING GUIDE CHART (CONTINUED) SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Punched holes are not centered Die Set positioning bracket is out of adjustment Inspect and adjust as required, see adjustment procedure Punched holes are not parallel to the edge of the paper Back Stop (Back Gauge) is not functioning properly Inspect and adjust as required, see adjustment procedure Rev.
6. 6.1 OPERATING CONTROLS PUNCHING PATTERNS The Professional Puncher-A1 uses a variety of easily interchangeable die sets that allow you to punch documents in line for several different binding styles. By selecting the appropriate die set, you can use your Professional Puncher-A1 to punch documents in any of the binding styles.
Step 7: Step 8: Step 9: Step10: Select the desired Die Set for your new job and slide it into the Die Set slot. Push Die Set in firmly until it latches. Set the Professional Puncher-A1 to the ON (I) mode. Close the Access Door Panel. Enable punch and proceed with your printing and punching job. CAUTION: POSSIBLE PINCH POINT HAZARD.
6.4 SERVICE • Should your Professional Puncher-A1 require service contact your local authorized service representative. • There are NO user-serviceable parts inside the machine. To avoid potential personal injury and/or property damage, DO NOT REMOVE THE MACHINE’S COVER. • It is recommended that your Professional Puncher-A1 receives preventative maintenance every 6 months or sooner depending on usage. 6.
7. 7.1 SPECIFICATIONS SPECIFICATIONS, 208V & 230/240V PROFESSIONAL PUNCHER-A1 (North America) 208V MACHINES (Europe) 230/240V MACHINES Speed Up to 105 sheets per minute Up to 105 sheets per minute Sheet Size Letter – 8.
