Download Canon Unit-AE1
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Cassette Feeding Unit-AE1 Service Manual Specifications Installation Technology Parts Replacement Procedure Maintenance F-0-1 1 2 3 4 5 Appendix Contents Safety Precautions Notes Before it Works Serving----------------------------------------------0-2 Specifications Specification---------------------------------------------------------------------1-2 Specifications------------------------------------------------------------------------ 1-2 Specifications--------------------------------------------------------------------------------- 1-2 Names of Parts---------------------------------------------------------------------- 1-2 External View--------------------------------------------------------------------------------- 1-2 Cross-Section View------------------------------------------------------------------------- 1-2 Installation How to Check this Installation Procedure---------------------------------- 2 When using the parts included in the package--------------------------------- 2 Symbols in the illustration------------------------------------------------------------ 2 Points to Note at Installation-------------------------------------------------- 2 Checking the Contents--------------------------------------------------------- 3 CST. Feeding Unit-AE1----------------------------------------------------------------------- 3 Contents of Cassette Spacer-A1----------------------------------------------------------- 3 Turning OFF the Host Machine----------------------------------------------- 5 Unpacking-------------------------------------------------------------------------- 5 Installation Procedure----------------------------------------------------------- 6 Setting the Cassette------------------------------------------------------------12 Adjustment------------------------------------------------------------------------13 Adjustment of Margin (1st side)----------------------------------------------------------- 13 Technology Function--------------------------------------------------------------------------3-2 Basic Configuration----------------------------------------------------------------- 3-2 Sensor / Solenoid---------------------------------------------------------------------------- 3-2 Pickup/Feed System--------------------------------------------------------------- 3-2 Overview--------------------------------------------------------------------------------------- 3-2 Sequence-------------------------------------------------------------------------------------- 3-3 Paper Size Detection----------------------------------------------------------------------- 3-3 Paper level sensor-------------------------------------------------------------------------- 3-5 JAM Detection----------------------------------------------------------------------- 3-7 Delay JAM------------------------------------------------------------------------------------- 3-7 Stationary JAM------------------------------------------------------------------------------- 3-7 Power ON JAM------------------------------------------------------------------------------- 3-7 Door open JAM------------------------------------------------------------------------------- 3-7 Power supply------------------------------------------------------------------------- 3-8 Power connection with each option----------------------------------------------------- 3-8 Parts Replacement Procedure Parts Replacement------------------------------------------------------------4-2 Remove from the host machine------------------------------------------------Removing the Cassette Feed Roller------------------------------------------Removing the Separation Roller-----------------------------------------------Removing the Pickup Roller-----------------------------------------------------Removing the Pickup Assembly Idler Gear---------------------------------Removing the Cassette 3 Pickup Unit----------------------------------------- 4-2 4-5 4-5 4-6 4-6 4-7 When Connecting to 1-Cassette Unit--------------------------------------------------- 4-8 Removing the Cassette Size Detection Unit--------------------------------4-10 Removing the Pickup Motor-----------------------------------------------------4-10 Removing the Cassette Right Lower Cover---------------------------------4-12 Maintenance Maintenance---------------------------------------------------------------------5-2 Periodical maintenance----------------------------------------------------------- 5-2 Periodically replacement parts----------------------------------------------------------- 5-2 Consumables--------------------------------------------------------------------------------- 5-2 Adjustment---------------------------------------------------------------------------- 5-2 Margin Adjustment -------------------------------------------------------------------------- 5-2 Parts Configuration / Role----------------------------------------------------------------- 5-4 Appendix Service Tools--------------------------------------------------------------------6-2 Special Tools------------------------------------------------------------------------- 6-2 General Circuit Diagram (1/3)--------------------------------------------------- 6-3 General Circuit Diagram(2/3)---------------------------------------------------- 6-4 General Circuit Diagram(3/3)---------------------------------------------------- 6-5 Safety Precautions ■ Notes Before it Works Serving 0 Safety Precautions > Notes Before it Works Serving 0-2 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 (of the host machine) when downloading is under way. Turning off the main power switch while downloading is under way can disable the machine. 0 Safety Precautions > Notes Before it Works Serving 0-2 1 1 Specifications Specifications ■ Specifications ■ Names of Parts 1 Specifications > Specification > Names of Parts > Cross-Section View 1-2 Specification Names of Parts ■ External View Specifications External Cover ■ Specifications Item Specification Remarks Paper storage method Front loading method Pickup method Separation retard method Paper stack capacity 550sheets (80g/m2 paper), 680sheets (64g/m2 paper) Cassette 2 Paper feed reference Center reference Paper Type 64g/m2 ~90g/m2 Paper size Standard (universal) A3,B4,A4,B5, LDR,LGL,LTR,A4R,B5R,LTRR, A5R,EX EC,STMTR,12"x18",8K,16K,16KR Paper grammage 64 to 90g/m2 Paper size switch Size auto detection Control Panel None (Use the key on the host machine) Display None (Use the key on the host machine) Environmental measure Heater for paper humidity adjustment Cassette heater is available as an option Power supply No Option power supply of the host machine Size 565(W) - 650(D) - 248(H) [mm] Weight 27.5kg Max. power consumption 100W [1] Left cover [6] Right lower cover [2] Upper tray cover [7] Right rear cover [3] Lower tray cover [8] Rear cover [4] Right front cover [9] Connector cover [5] Pedestal right cover [1]Left cover [2]Upper tray cover [9]Connector cover [4]Right front cover [5]Cassette right [3]Lower tray cover lower cover [8]Rear cover [6]Right lower cover F-1-1 [7]Right rear cover F-1-2 ■ Cross-Section View Pickup Roller 3 Lifter Pickup Roller 4 Lifter Vertical path Roller 3 Feed Roller 3 Detachment Roller 3 Vertical path Roller 4 Feed Roller 4 Detachment Roller 4 T-1-1 F-1-3 1 Specifications > Specification > Names of Parts > Cross-Section View 1-2 2 2 Installation Installation ■ How to Check this Installation Procedure ■ Checking the Contents ■ Installation Procedure ■ Adjustment 2 Installation > Points to Note at Installation How to Check this Installation Procedure Points to Note at Installation • In the case of connecting to the 250 Sheets Cassette Model, the Cassette Spacer-A1 is When using the parts included in the package required. A symbol is described on the illustration in the case of using the parts included in the package of this product. • To enable function of the heater, "Cst Heater Kit-J1" and "Cassette Heater Unit-37" must be installed. Packaged Item F-2-1 Symbols in the illustration The frequently-performed operations are described with symbols in this procedure. Screw Tighten Harness Connector Remove Connect Disconnect Secure Free Claw Insert Remove Push Plug in Turn on Checking instruction Check Visual Check Sound Check F-2-2 2 Installation > Points to Note at Installation 2 Installation > Checking the Contents Checking the Contents ■ CST. Feeding Unit-AE1 [1] Cassette Feeding Unit x 1 [2] Positioning Pin x 2 [5] Size Plate x 2 [6] Screw (RS Tightening; M3X8.5) x 5 [3] Connecting Fixture x 1 < CD/Guides > [4] Connector Cover x 1 F-2-3 • FCC/IC Sheet ■ Contents of Cassette Spacer-A1 MEMO: Use the Cassette Spacer-A1 when connecting to the 250 Sheets Cassette Model. 2 Installation > Checking the Contents 2 Installation > Checking the Contents [1] Cassette Spacer x 1 [2] Positioning Pin (Long) x 2 *; Not use with this procedure. 2 Installation > Checking the Contents [3] Connecting Fixture x 1 [4] Connector Cover x 1 F-2-4 2 Installation > Unpacking Turning OFF the Host Machine Turn OFF the main power switch on the host machine, and then remove the power plug from the outlet. Unpacking 1)Remove the container box. 2)Open the plastics, and remove the 2 pads by lifting the rear side of the equipment. Then, move the plastics toward the pads at the front side. Plastic 3)Remove the 2 remaining pads and the plastics by lifting the front side of the equipment. Pad Pad Pad Plastic F-2-5 4)Lift the equipment and unload it from the pallet. Pad F-2-6 5)Remove all tapes affixed on the outside of the equipment. 6)Remove the all tapes on the cassette and packing materials. F-2-7 2 Installation > Unpacking 2 Installation > Installation Procedure Installation Procedure MEMO: Be sure to execute the following step 1) to 3) only when connecting with the 250-sheet cassette model. 1)When connecting with the 250-sheet cassette model, loosen the 2 Positioning Pins which were installed to the Cassette Feeding Unit. (The removed Positioning Pins are no longer used.) • 4 Screws (The removed screw will be used in step 2).) x2 x2 F-2-8 2)Install the 2 Positioning Pins (Long) packaged with Cassette Spacer-A1. • 4 Screws (Use the screws removed in step 1).) x2 x2 F-2-9 2 Installation > Installation Procedure 2 Installation > Installation Procedure 3)When connecting to the 250 Sheets Cassette Model, install the Cassette Spacer included in the Cassette Spacer-A1 by inserting it into the 2 Positioning Pins. 4)In the case that the Cassette Module (1- Cassette Unit) is installed, remove it with a flat-blade screwdriver. 5)In the case that the Grip Covers are installed, release the claws with a flat-blade screwdriver and remove the Grip Covers. Positioning Pin Claw Claw Claw Positioning Pin F-2-11 F-2-10 F-2-12 6)Open the Right Lower Cover of the Cassette Feeding Unit. 7)Hold the 4 Grips on the host machine, and mount the host machine while aligning the right and left corners of the front of the host machine and the front of the Cassette Feeding Unit. CAUTION: Grip • When mounting the host machine on the Grip 8)Close the Cassette Right Lower Cover. 9)Remove the cassettes to which the Connecting Fixture will be installed in a later step. equipment, be sure to fit the holes on the bottom of the host machine into the 2 Positioning Pins on the top of the equipment. • The host machine weighs maximum approx. 50 to 79 kg. It is recommended to lift it with 2 people or more. However, if there is a standard to handle a heavy load in each sales company, follow it for operation. Also, make sure to lift the machine with keeping it level at operation. 2 Installation > Installation Procedure F-2-13 2 Installation > Installation Procedure 10)Install the Connecting Fixture. • 1 Screw (RS Tightening; M3 x 8.5) < When Connecting to 550 Sheets Cassette Model > • To install the Connecting Fixture, insert it into the hole on the host machine and hook the tab of it to the plate on the host machine. Screw F-2-14 < When Connecting to 250 Sheets Cassette Model > • To install the Connecting Fixture, insert it included in the Cassette Spacer-A1 into the hole on the host machine, and hook the tab of it to the plate on the host machine. Screw F-2-15 < When Connecting to Cassette Module (1- Cassette Unit) > F-2-16 2 Installation > Installation Procedure 2 Installation > Installation Procedure 11) Remove the Connector Cover. (The removed cover will not be used.) • 1 Screw (The removed screw will be used in step 14).) < In the Case of Host Machine > < In the Case of Cassette Module (1- Cassette Unit) > F-2-17 F-2-18 12)Put the 3 cables of the Cassette Feeding Unit through the guide, and connect the 3 connectors to the host machine. MEMO: Connect the connector with black color tube to "Cst Heater Kit-J1" (option). CAUTION: • When securing the 3 cables in place with the guide, be sure to place one cable to one groove of the guide. • Be sure to tuck the extra slack of the cable to the host machine side. < When Connecting to 550 Sheets Cassette Model > < When Connecting to 250 Sheets Cassette Model > < When Connecting to Cassette Module (1- Cassette Unit) > x3 x3 x3 x3 x3 x3 F-2-19 2 Installation > Installation Procedure F-2-20 F-2-21 2 Installation > Installation Procedure 10 13) Loosen the screw on the Connector Cover included in the package, and install the grounding wire between it and the toothed washer. Screw Round Shape Terminal Toothed Washer F-2-22 CAUTION: • Be sure to pay attention to the installation orientation of the grounding wire. • Install from the direction of the arrow marked on the Plate F-2-23 2 Installation > Installation Procedure 10 2 Installation > Installation Procedure 11 14)Install the Connector Cover. • 1 Screw (Use the screw removed in step 11).) < When Connecting to Host Machine > CAUTION: < When Connecting to Cassette Module (1- Cassette Unit) > Be sure not to trap the cable. x2 F-2-24 F-2-25 15)Turn the 4 Adjusters clockwise 4 times, and secure the equipment in place firmly. 16)Install the removed covers. • Grip Cover • Right Lower Sub Cover (In the case that the Cassette Module (1- Cassette Unit) is installed.) 17)Return the cassette of the host machine. 18)Plug the power plug of the host machine to the outlet. 19)Turn ON the main power switch. F-2-26 2 Installation > Installation Procedure 11 2 Installation > Setting the Cassette 12 Setting the Cassette 1)Hold the Side Guide Plate Lever and set the Side Guide Plate to the specified size. At this time, set the Side Guide Plate to the click position (the position where you feel a click) by moving the Side Guide Plate while using the size index (label) of the sheet size to be set as a measure. 3)Set papers. 4)Open the cover at the Size Plate insertion area. Side Guide Plate Trail Edge Guide Plate Lever Side Guide Plate Lever Paper Cover 2)Hold the Trailing Edge Guide Plate Lever and set the Trailing Edge Guide Plate to the specified size. At this time, set the Trailing Edge Guide Plate to the click position (the position where you feel a click) by moving the Trailing Edge Guide Plate while using the size index (label) of the sheet size to be set as a measure. Trail Edge Guide Plate F-2-27 F-2-28 5)Cut the 2 places of the Size Plates with nippers. 6)Insert the Size Plate in accordance with the paper size being set. (Lump the Size Plates not in use together and store them at the rear.) Cut 7)Close the cover at the Size Plate insertion area, and return the cassette to the equipment. MEMO: The paper size setting is recognized automatically. F-2-29 F-2-30 2 Installation > Setting the Cassette 12 2 Installation > Adjustment 13 Adjustment ■ Adjustment of Margin (1st side) MEMO: As for the adjustment method, the same procedure is applied to the Cassette 3 and 4. 2)Pull out the cassette. 3)Check the 2 scale positions of the Adjustment Plate. 1)Make a copy from the Cassette 3 and 4, and check that the left edge margin is 2.5+/-1.5mm. Feed direction of paper L1 image F-2-31 MEMO: In the case of out of specification, execute step 2) through 8) indicated below. F-2-32 4)Loosen the 3 Fixation Screws. F-2-33 2 Installation > Adjustment 13 3 3 Technology Technology ■ Basic Configuration ■ Pickup/Feed System ■ JAM Detection ■ Power supply 3 Technology > Function > Pickup/Feed System > Overview 3-2 Function Pickup/Feed System ■ Overview Basic Configuration Papers in the cassette are lifted up with the Lifter Plate. ■ Sensor / Solenoid Cassette 3 paper presence sensor(PS2) Cassette 3 pickup solenoid(SL1) At pickup, the Pickup Roller picks up a paper by coming down and contact with paper surface. The Pickup Roller comes down when the Pickup Solenoide turns ON. A paper picked up by the Pickup Roller is fed to the feed path with the Separation Roller, and Cassette 3 Retry sensor(PS8) then, is fed to the Registration Roller with the Vertical Path Roller. Cassette 4 Retry sensor(PS9) The Vertical Path Roller, Pickup Roller, Feed Roller and Separation Roller are driven by the Cassette Pickup Motor. Cassette 3 paper level sensorA(PS4) Vertical path Roller 3 Pickup Roller 3 Cassette 3 paper level sensor B(PS5) Cassette 4 pickup solenoid(SL2) Feed Roller 3 Separation Roller 3 Lifter Cassette 4 paper level sensor B(PS7) Cassette 4 Cassette 4 paper presence sensor(PS3) paper level sensor A(PS6) Cassette 3 pickup motor(M1) Pedestal controller Cassette 3 pickup motor(M2) PCB(UN1) SL1 M1 Pickup Roller 4 Lifter SL2 Vertical path Roller 4 Feed Roller 4 Separation Roller 4 M2 Pedestal right cover sensor(PS1) Cassette 3 size switch A(SW1) Cassette 3 size switch B(SW2) F-3-2 Cassette 4 size switch A(SW3) Cassette 4 size switch B(SW4) Cassette heater(H1) F-3-1 3 Technology > Function > Pickup/Feed System > Overview 3-2 3 Technology > Function > Pickup/Feed System > Paper Size Detection ■ Sequence ■ Paper Size Detection At the cassette pickup assembly, since the feed speed is increased, detection cannot catch Print start up with it. Thus, delay and stationary jam detection are not executed at the Cassette 1 Pre- Cassette pedistal PRINT Connect in device 3-3 Registration Sensor. Instead of it, the Vertical Path Sensor executes the delay and stationary jam detection. Since the residual jam should be detected on each cassette, the Cassette 1 Cassette 3 pickup motor (M1) Cassette 3 pickup solenoid(SL1) Cassette 3 retry sensor (PS8) Cassette 1 pickup motor (M3) Vertical path sensor (UN53) Registration sensor (PS33) Registration clutch (CL33) Inner derivery sensor (PS37) First derivery motor (M22) First derivery sensor (PS34) Registration motor (M19) Fixing motor (M21) Pre-Registration Sensor detects it. Because the Vertical Path Sensor is too close and it is unnecessary to execute detection, the Vertical Path Sensor does not execute residual jam detection. Cassette 3 size switch B[SW2] Cassette 3 size switch A [SW1] : Cassette 3: The speed of pickup increases F-3-3 Print start Connect in device Cassette pedistal PRINT Cassette 4 pickup motor (M2) Cassette 4 pickup solenoid(SL2) Cassette 4 retry sensor (PS9) Cassette 1 pickup motor (M3) Vertical path sensor (UN53) Registration sensor (PS33) Registration clutch (CL33) Inner delivery sensor (PS37) First delivery motor (M22) First delivery sensor (PS34) Registration motor (M19) Fixing motor (M21) Cassette 4 size switch A[SW3] Cassette 4 size switch B[SW4] F-3-5 : Cassette 4: The speed of pickup increases F-3-4 3 Technology > Function > Pickup/Feed System > Paper Size Detection 3-3 3 Technology > Function > Pickup/Feed System > Paper Size Detection 3-4 Cassette size switch A Width Rear detection rink B5 EXEC 16K A5-R A4 STMT-R LTR B5-R LTR-R A4-R LGL B4 8K A3 LDR 12x18 Rear guide plate Detection dial Cassette size switch B 257.0 267.0 270.0 148.5 297.0 139.7 279.4 182.0 215.9 210.0 215.9 257.0 270.0 297.0 279.4 304.8 Length 182.0 184.0 195.0 210.0 210.0 215.9 215.9 257.0 279.4 297.0 355.6 364.0 390.0 420.0 431.8 457.2 1 0 0 0 ON 0 ON 0 ON 0 0 0 0 0 0 0 0 Width detection 2 3 ON ON ON 0 ON 0 ON 0 0 0 0 ON ON ON ON ON ON ON ON ON 0 ON ON ON ON ON ON ON ON 0 ON 0 4 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ON ON ON ON ON 0 ON 0 ON ON ON 0 0 0 Length detection 2 3 0 0 0 ON ON ON ON ON 0 ON ON ON ON 0 0 0 0 0 0 0 0 0 0 ON 0 ON 0 ON ON ON ON 0 4 0 0 0 0 0 0 0 ON ON 0 ON 0 ON ON ON ON T-3-1 Also, the cassette presence is detected when the size switch is pushed. (If no switch is pushed, it is determined as no cassette.)) Side guide plate Detection dial Cassette size switch B F-3-6 3 Technology > Function > Pickup/Feed System > Paper Size Detection 3-4 3 Technology > Function > Pickup/Feed System > Paper level sensor 3-5 ● Setting method when the size detection patterns are overlapped Size should be found manually on the check screen for the combination of A5-Rand STMT-R or the combination of B5-R and EXEC. Specify the ecognition method for the special paper with user setting. ■ Paper level sensor Paper level in a cassette is detected with the sensor indicated below. Cassette 3 Cassette 4 The setting size is indicated below. Cassette paper level sensor A PS4 PS6 Cassette paper level sensor B PS5 PS7 Related Service Mode Cassette paper sensor PS2 PS3 COPIER> OPTION> CST> CSTX-UY> Nomber Cassette paper sensor(PS2) X shows Cassette Number. Y shows size category. (X, Y is one of the number 1/2/3/4.) No. U1 U2 U3 U4 Lifter latch Size Cassette paper level sensor A(PS4) OFI, E-OFI, M-OFI, A-OFI, FLSP, A-FLSP, A-LTRR, FA4, G-LGL G-LTR-R, K-LGL-R K-LGL, G-LTR, A-LTR B-OFI T-3-2 No. 22 23 24 25 27 28 29 30 31 32 33 34 36 37 42 T-3-4 Flag Cassette paper level sensor B(PS5) Size K-LGL K-LGLR FLSC A-FLS E-OFI B-OFI A-LTR A-LTRR G-LTR G-LTRR A-LGL G-LGL A-OFI M-OFI FA4 Paper sensor flag Lifter gear T-3-3 in the Cassette 3, Sample: When setting A_LTR COPIER> OPTION> CST> CST3-U3>29 Tray F-3-7 3 Technology > Function > Pickup/Feed System > Paper level sensor 3-5 3 Technology > Function > Pickup/Feed System > Paper level sensor If the paper is full 3-6 Cassette paper level sensor A Cassette paper level sensor B Paper Paper level sensor B Paperl sensor Paper level Display OFF OFF OFF 100% to 50% ON OFF OFF 50% to 50 sheets F-3-9 ON ON OFF 50 sheet or less F-3-10 --- --- ON no paper F-3-11 F-3-12 OFFOFF If the paper is approx. half Paper level sensor A Cassette paper level sensor A T-3-5 Paper Cassette paper level sensor B OFFON If the paper is a little Cassette paper level sensor A Paper Cassette paper level sensor B ONON If the paper is absent Cassette paper Presence sensor Fulg Paper tray F-3-8 3 Technology > Function > Pickup/Feed System > Paper level sensor 3-6 3 Technology > Function > JAM Detection > Door open JAM 3-7 JAM Detection ■ Stationary JAM In case that the corresponding sensor is not turned ON within the specified time after it is ■ Delay JAM In case that the leading edge of paper does not reach to the sensor within the specified time turned ON. Start key ON or Print start after the speed of Cassette 3 and 4 Pickup Motor decreases to half. Start key ON or Print start INTR INTR [1] Pickup motor normal Sensor/PS8/PS9 PRINT Jam check [1] [2] Jam check / :Motor speed up Sensor/PS8/PS9 [2] / PRINT L L+A normal error (L = Paper length feed range A = Provision feed range) F-3-14 error Sensor Cassette 3 retry sensor (PS8) [1]:Provision feed time [2]:Jam margin F-3-13 Cassette Motor Sensor Cassette 3 Cassette 3 pickup motor (M1) Cassette 3 retry sensor (PS8) Cassette 4 Cassette 4 pickup motor (M2) Cassette 4 retry sensor (PS9) Cassette 4 retry sensor (PS9) T-3-7 ■ Power ON JAM Before starting the warm-up rotation at power ON, check that no paper is at the sensor indicated below. Sensor Cassette 3 retry sensor (PS8) T-3-6 Cassette 4 retry sensor (PS9) T-3-8 ■ Door open JAM When it is detected that the door is opened during copy and printing. Sensor Pedestal right cover sensor(PS1) T-3-9 3 Technology > Function > JAM Detection > Door open JAM 3-7 3 Technology > Function > Power supply > Power connection with each option Power supply 3-8 When power is turned ON, the connected equipment supplies 24VDC and 5VDC to the Pedestal Controller PCB. ■ Power connection with each option 25VDC generates 3.3VDC in 3-Terminal Regulator in the Pedestal Control PCB, 5VDC is Indicating the power supply path between the Printer and Option. used for sensors and IC driver and the 3.3VDC is used for the Control IC (Asic) Reader / ADF Unit Connect in device Pedistal controller PCB +24V Controller Power Suplly PCB Built-in Wiring +5V FU1 Solenoid FU3 Motor FU2 3 Terminal Regulator +3.3V Inner finisher-B1 ASiC Sensor Motor Driver Cassette pedestal Unit-W1 F-3-16 Cassette pedestal Unit-AE1 Connector inside the cover is used for the connection with the printer. 3 F-3-15 Technology > Function > Power supply > Power connection with each option 3-8 4 Parts Replacement Procedure ■ Remove from the host machine ■ Removing the Cassette Feed Roller ■ Removing the Separation Roller ■ Removing the Pickup Roller ■ Removing the Pickup Assembly Idler Gear ■ Removing the Cassette 3 Pickup Unit 4 Parts Replacement Procedure ■ Removing the Cassette Size Detection Unit ■ Removing the Pickup Motor ■ Removing the Pedestal Controll PCB ■ Removing the Cassette Right Lower Cover 4 Parts Replacement Procedure > Parts Replacement > Remove from the host machine Parts Replacement 4-2 How to remove 1)Remove the 3 harness from the guides <When Connecting to 550 Sheets Cassette Model> Remove from the host machine Before removing the host machine x3 • Remove the Connecter Cover <In the Case of Host Machine> x3 F-4-3 <When Connecting to 250 Sheets Cassette Model> x3 F-4-1 <In the Case of 1-Cassette Unit> x3 F-4-4 F-4-2 4 Parts Replacement Procedure > Parts Replacement > Remove from the host machine 4-2 4 Parts Replacement Procedure > Parts Replacement > Remove from the host machine <When Connecting to 1- Cassette Unit> 4-3 2)Remove the Cassette 3)Remove the Connecting Fixture • 1-screw < When Connecting to 550 Sheets Cassette Mode> x3 x3 F-4-5 screw F-4-6 4 Parts Replacement Procedure > Parts Replacement > Remove from the host machine 4-3 4 Parts Replacement Procedure > Parts Replacement > Remove from the host machine < When Connecting to 250 Sheets Cassette Mode> 4-4 < When Connecting to 1-Cassette Unit> screw 4) Lift and remove the host machine F-4-8 CAUTION: • The host machine weighs maximum approx. 50 to 79 kg.It is recommended to lift it with 2 people or more. However, if there is a standard to handle a heavy load in each sales company, follow it for operation.Also, make sure to lift the machine with keeping it level at operation. Grip Grip F-4-7 5)Install the cassette 3 and cassette 4 4 Parts Replacement Procedure > Parts Replacement > Remove from the host machine 4-4 4 Parts Replacement Procedure > Parts Replacement > Removing the Separation Roller Removing the Cassette Feed Roller 4-5 Removing the Separation Roller Before removing the Cassette Feed Roller Before removing the Separation Roller • Remove the Cassette • Remove the Cassette MEMO: This procedure describes the removing steps of cassette 1 Feed Roller. Go through the same procedure for the Feed Roller of cassette 3 and cassette 4. How to remove MEMO: This procedure describes the removing steps of cassette 1 Separetion Roller. Go through the same procedure for the Separetion Roller of cassette 3 and cassette 4. Note: Do not touch the surface of Pickup Roller, Feed Roller and the Separation Roller. Note: Do not touch the surface of Pickup Roller, Feed Roller and the Separation Roller. How to remove 1)Remove the Cassette Feed Roller. • 1 tab 1)Removing the Separation Roller • 1 tab F-4-9 F-4-10 4 Parts Replacement Procedure > Parts Replacement > Removing the Separation Roller 4-5 4 Parts Replacement Procedure > Parts Replacement > Removing the Pickup Assembly Idler Gear Removing the Pickup Roller 4-6 Removing the Pickup Assembly Idler Gear Before removing the Cassette Pickup Roller Before removing the Pickup Assembly Idler Gear • Remove the Cassette • Remove the Cassette • Remove the Pickup Roller • Remove the Feed Roller How to remove How to remove MEMO: This procedure describes the removing steps of cassette 1 Pickup Roller. Go through the same procedure for the Pickup Roller of cassette 3 and cassette 4. MEMO: This procedure describes the removing procedure of cassette 1 Pickup Assembly Idler Gear. Go through the same procedure for the Pickup Assembly Idler Gear of cassette 3 and cassette 4. Note: Do not touch the surface of Pickup Roller, Feed Roller and the Separation Roller. Note: Do not touch the surface of Pickup Roller, Feed Roller and the Separation Roller. 1)Removing the Pickup Roller • 1 pin • 1 tab 1)Remove the Pickup Assembly Idler Gear. • 1 tab F-4-11 4 Parts Replacement Procedure > Parts Replacement > Removing the Pickup Assembly Idler Gear F-4-12 4-6 4 Parts Replacement Procedure > Parts Replacement > Removing the Cassette 3 Pickup Unit Removing the Cassette 3 Pickup Unit Before removing the Cassette 3 Pickup Unit 4-7 4) Remove the Right Front Cover of the Cassette Feeding Unit. • 1 screw 1) Open the Cassette Right Lower Cover of the Cassette Feeding Unit. F-4-13 2) Pull out cassette. 3)Remove the Right Front Cover of the Host Machine. • Remove the claw with a flat-blade screwdriver and remove the Right Front Cover. • 1 screw • 1 claw Claw 4 Parts Replacement Procedure > Parts Replacement > Removing the Cassette 3 Pickup Unit 4-7 4 Parts Replacement Procedure > Parts Replacement > Removing the Cassette 3 Pickup Unit > When Connecting to 1-Cassette Unit 4-8 ■ When Connecting to 1-Cassette Unit 5)Remove the Right Rear Cover of the Host Machine. • Remove the claw with a flat-blade screwdriver and remove the Right Rear Cover. • 1 screw MEMO : When Connecting to 1-Cassette Unit, be sure to remove the Cassette Right Lower Cover. Claw 1) Remove the Cassette Right Lower Cover of the 1-Cassette Unit. D-cut 2) Remove the Right Front Cover of the Host Machine and remove Right Front Cover of the 1-Cassette Unit F-4-14 6) Remove the Right Rear Cover of the 2-Cassette Unit. • 1 screw • 1 screw Projection 4 Hook F-4-16 Pin F-4-15 Parts Replacement Procedure > Parts Replacement > Removing the Cassette 3 Pickup Unit > When Connecting to 1-Cassette Unit 4-8 4 Parts Replacement Procedure > Parts Replacement > Removing the Cassette 3 Pickup Unit > When Connecting to 1-Cassette Unit 3) Remove the Right Rear Cover of the Host Machine and remove Right Rear Cover of the 4-9 How to remove 1-Cassette Unit MEMO: This procedure describes the removing procedure of Cassette 3 Pickup Assembly. Go through the same procedure for the Cassette 4 Pickup Assembly. • Remove the Right Front Cover • 1 screw 1) Remove the Sensor Unit. • 1 screw • 1 connector • 1 harness guide Connector Sensor Unit Hook Pin Harness Guide F-4-17 F-4-18 2)Remove the cassette 3 Pickup Unit • 4 screws x4 F-4-19 4 Parts Replacement Procedure > Parts Replacement > Removing the Cassette 3 Pickup Unit > When Connecting to 1-Cassette Unit 4-9 4 Parts Replacement Procedure > Parts Replacement > Removing the Pickup Motor Removing the Cassette Size Detection Unit 4-10 Removing the Pickup Motor Before removing the Cassette Size Detection Unit Before removing the Pickup Motor • Remove the Right Front Cover • Remove the Right Rear Cover • Remove the Cassette Pickup Unit • Remove the Connector Cover • Remove 5 connectors • Remove Rear Cover • 4 screws • 2 hooks How to remove MEMO: This procedure describes the removing steps of Cassette 3 Size Detection Unit. Go through the same procedure for Cassette 4 Size Detection Unit. x3 1) Remove the Cassette 3 Size Detection Unit • 1 connector • 1 wire saddle • 2 screws Hook Hook F-4-21 How to remove MEMO: This procedure describes the removing step of cassette 3 Pickup motor. Go through the same procedure for the Pickup motor of cassette 4. x2 Cassette 3 Size Detection Unit Connector Wire Saddle F-4-20 4 Parts Replacement Procedure > Parts Replacement > Removing the Pickup Motor 4-10 4 Parts Replacement Procedure > Parts Replacement > Removing the Pickup Motor 4-11 Removing the Pedestal Controll PCB 1)Remove the upper pickup motor. • 1 connector • 3 screws Before removing the Pedestal Controll PCB • remove the Connector Cover • Remove the 5 connectors • Remove the Rear Cover How to remove 1)Remove the Pedestal Controll PCB • 7 connectors • 4 screws x3 x7 x4 F-4-22 F-4-23 4 Parts Replacement Procedure > Parts Replacement > Removing the Pickup Motor 4-11 4 Parts Replacement Procedure > Parts Replacement > Removing the Cassette Right Lower Cover 4-12 Removing the Cassette Right Lower Cover Before removing the Cassette Right Lower Cover • Open the cassette right lower cover How to remove 1)Lift up lower guide and remove the arm F-4-24 2)Fit the D-cut and remove the cassette right lower cover D-cut F-4-25 4 Parts Replacement Procedure > Parts Replacement > Removing the Cassette Right Lower Cover 4-12 5 Maintenance ■ Periodical maintenance ■ Adjustment ■ Parts Configuration / Role 5 Maintenance 5 Maintenance > Maintenance > Adjustment > Margin Adjustment Maintenance 5-2 Adjustment ■ Margin Adjustment Periodical maintenance ● First side; Mechanical Adjsutment ■ Periodically replacement parts 1) Make copies using the Cassette 3 and 4, and check that the left edge margin is 2.5±1.5mm. N/A ■ Consumables Parts Number Num Interval Pickup roller FB6-3405 1 120k Feeding roller FC6-7083 1 120k Separation roller FC6-6661 1 120k Pickup idler gear FU3-0280 1 120k Remarks For China only Flying Paper T-5-1 5 image L1 Parts Name Feed direction of paper Maintenance > Maintenance > Adjustment > Margin Adjustment MEMO: Adjsutment method is same for both the Cassette 3 and 4. F-5-1 5-2 5 Maintenance > Maintenance > Adjustment > Margin Adjustment 5-3 2) Pull out the cassette. 3) Check the 2 scale positions on the adjusting plates. 6) Tighten the fixing screw. F-5-2 7) Return the cassette to its original position. MEMO: When the cassette positions are uneven due to the mechanical adjustment, adjust them by loosening the screw at left side. 4) Loosen the 3 fixing screws. F-5-3 8) Make copies using the Cassette 3 and 4, and check that the left edge margin is 2.5±1.5mm. 5) Move the adjusting plates back and forth by referring the scale checked in the step 2. As moving the adjusting plate toward the rear by 1 scale, the left edge margin becomes 1mm smaller. MEMO: When moving the scale, be sure that the amount of the value to be moved are the same for the 2 points. 5 Maintenance > Maintenance > Adjustment > Margin Adjustment 5-3 5 Maintenance > Maintenance > Adjustment > Parts Configuration / Role Parts Configuration / Role Cassette 3 paper presence sensor(PS2) ■ Parts Configuration / Role Mark Name Part No. M1 Cassette 3 pickup motor FK2-7327 M2 Cassette 4 pickup motor FK2-7327 PS4 Cassette 3 paper level sensor A PS5 Cassette 3 paper level sensor B PS8 Cassette 3 retry sensor FK2-0149 FK2-0149 FK2-0149 PS2 Cassette 3 paper sensor FK2-0149 PS6 Cassette 4 paper level sensor A PS7 Cassette 4 paper level sensor B PS9 Cassette 4 retry sensor FK2-0149 FK2-0149 FK2-0149 PS3 Cassette 4 paper sensor FK2-0149 PS1 Pedestal right cover sensor SL1 Cassette 3 pickup solenoid SL2 Cassette 4 pickup solenoid SW1 Cassette 3 size switch A FH7-7312 FK2-0408 FK2-0408 WC2-5680 SW2 Cassette 3 size switch B WC2-5680 SW3 Cassette 4 size switch A WC2-5680 SW4 Cassette 4 size switch B WC2-5680 H1 Cassette heater FH7-4742 UN1 Pedestal controller PCB FH4-2531 5-4 Role Drive the pickup unit 3 Drive the pickup unit 4 Detects the cassette 3 paper level Detects the cassette 3 paper level Cassette 3 Retry Detection Detects whether paper is loaded in the cassette 3 Detects the cassette 4 paper level Detects the cassette 4 paper level Cassette 4 Retry Detection Detects whether paper is loaded in the cassette 4 Detects the right cover open controll the cassette 3 pickup timing controll the cassette 4 pickup timing Detects the cassette 3 paper size Detects the cassette 3 paper size Detects the cassette 4 paper size Detects the cassette 4 paper size FUNCTION Pedestal >PARTcontroller PCB CHK J3006 J3007 Cassette 3 pickup solenoid(SL1) Cassette 3 Retry sensor(PS8) Cassette 4 Retry sensor(PS9) Cassette 3 paper level sensorA(PS4) Cassette 3 paper level sensor B(PS5) Cassette 4 pickup solenoid(SL2) Cassette 4 paper level sensor B(PS7) J3003 Cassette 4 Cassette 4 paper presence sensor(PS3) paper level sensor A(PS6) Cassette 3 pickup motor(M1) Pedestal controller Cassette 3 pickup motor(M2) PCB(UN1) J3003 J3003 J3003 Cassette 3 size switch A(SW1) J3004 Pedestal right cover sensor(PS1) Cassette 3 size switch B(SW2) J3004 J3004 J3004 Cassette 4 size switch A(SW3) J3003 J3003 Cassette 4 size switch B(SW4) J3004 J3003 J3003 Cassette heater(H1) J3004 F-5-4 J3004 Controll the cassette pedestal T-5-2 5 Maintenance > Maintenance > Adjustment > Parts Configuration / Role 5-4 6 Appendix ■ Service Tools ■ General Circuit Diagram (1/3) ■ General Circuit Diagram(2/3) ■ General Circuit Diagram(3/3) 6 Appendix 6 Appendix > Service Tools > Special Tools 6-2 Service Tools Special Tools In addition to the standard tools set, the following special tools are required when servicing the machine: Tool name Digital multimeter Tool No. Ctgr FY9-2002 A Appearance Remarks Used as a probe extension when making electrical checks. T-6-1 Reference: Category A: Must be kept by each service engineer. B: Must be kept by each group of about five engineers. C: Must be kept by each warkshop 6 Appendix > Service Tools > Special Tools 6-2 6-3 9 8 7 6 5 4 3 2 1 F Appendix > Service Tools > General Circuit Diagram (1/3) 10 F UN1 Pedestal controller PCB J3004 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 +5V GND CST4_PICKUP_SL PEDE_DOOR_SNS +5V +24V GND CST4_LEVEL_B_SNS CST4_RETRY_SNS +5V GND +5V GND CST4_LEVEL_A_SNS +5V GND CST3_PICKUP_SL CST4_PAPER_SNS +24V +5V GND CST3_RETRY_SNS CST3_LEVEL_B_SNS CST3_LEVEL_A_SNS +5V GND +5V +5V GND E GND E CST3_PAPER_SNS Appendix > Service Tools > General Circuit Diagram (1/3) General Circuit Diagram (1/3) D D J1D J1LH 14 13 12 11 10 1 2 3 4 5 8 9 6 7 7 6 8 9 5 4 3 2 1 14 13 12 11 10 10 11 12 13 14 1 2 3 4 5 9 6 8 7 7 6 8 9 J2D 5 4 3 2 1 10 11 12 13 14 J2LH J2L J1L C C J3 3 2 1 J109D J109DH J104D B J100 J101 J103 J102 J104L 3 1 2 3 2 1 2 3 2 1 3 2 1 3 2 1 1 3 2 1 3 2 1 3 2 1 1 1 J105 2 J106 3 2 1 J107 3 2 1 J108 3 2 1 1 3 2 PS2 PS4 PS5 Cassette 3 paper level sensor A Cassette 3 paper level sensor B 2 1 2 1 B PS1 J109L Pedestal right cover sensor 3 2 2 1 3 2 1 3 2 1 3 2 1 1 PS8 SL2 Cassette 3 retry sensor Cassette 3 pickup solenoid 2 SL SL Cassette 3 paper sensor 3 1 2 J104DH PS3 Cassette 4 paper sensor PS6 PS7 Cassette 4 paper level sensor A Cassette 4 paper level sensor B PS9 SL3 Cassette 4 retry sensor Cassette 4 pickup solenoid A A Cassette 3 10 9 8 Cassette 4 7 6 5 4 3 2 1 P.1 F-6-1 6-3 6-4 9 8 7 6 5 4 3 2 1 F Appendix > Service Tools > General Circuit Diagram(2/3) 10 F UN1 Pedestal controller PCB E E 9 10 11 12 13 14 15 16 17 18 19 21 20 J3007 1 2 3 4 1 2 3 4 CST4_B* 8 CST4_B 7 CST4_A* 6 CST3_B* 5 CST3_B 4 CST3_A* 3 CST3_A J3006 2 CST4_SIZE_0 CST4_SIZE_1 CST4_SIZE_2 CST_SIZE_PWR_ON CST4_SIZE_3 CST4_SIZE_4 CST4_SIZE_5 CST4_SIZE_6 CST_SIZE_PWR_ON CST4_SIZE_7 CST3_SIZE_0 CST3_SIZE_1 CST3_SIZE_2 CST_SIZE_PWR_ON CST3_SIZE_3 CST3_SIZE_4 CST3_SIZE_5 CST3_SIZE_6 D CST_SIZE_PWR_ON N.C. 1 CST4_A J3005 CST3_SIZE_7 Appendix > Service Tools > General Circuit Diagram(2/3) General Circuit Diagram(2/3) D C C J8D J5D J5LH 11 10 9 8 7 6 5 4 3 2 1 11 10 1 2 3 4 5 6 7 8 9 10 11 1 2 9 3 8 4 7 5 6 6 5 7 4 3 9 8 2 1 10 11 J8LH J8L J5L J12 J11 6 5 4 3 2 1 1 2 3 4 5 6 6 1 M 5 2 4 3 3 4 2 5 1 6 M M1 M2 Cassette 3 pickup motor Cassette 4 pickup motor B B J6 J7 5 4 3 2 1 5 SW7 4 3 2 1 5 SW6 Cassette 3 size switch B 4 3 2 1 J9 5 SW9 Cassette 3 size switch A 4 3 2 1 J10 SW8 Cassette 4 size switch B Cassette 4 size switch A A A 10 9 8 7 6 5 4 3 2 1 P.2 F-6-2 6-4 Appendix > Service Tools > General Circuit Diagram(3/3) Appendix > Service Tools > General Circuit Diagram(3/3) 6-5 General Circuit Diagram(3/3) F-6-3 6-5