September 9, 2013 Revision 2. Paper Deck Unit-B2. Service Manual

September 9, 2013 Revision 2 Paper Deck Unit-B2 Service Manual 1 2 3 4 5 6

0 0-2 Application This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair of products. This manual covers all localities where the products are sold. For this reason, there may be information in this manual that does not apply to your locality. Corrections This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition of this manual. The following paragraph does not apply to any countries where such provisions are inconsistent with local law. Trademarks The product names and company names used in this manual are the registered trademarks of the individual companies. Copyright This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or translated into another language, in whole or in part, without the consent of Canon Inc. CANON INC. 2013 Caution Use of this manual should be strictly supervised to avoid disclosure of confidential information. 0 0-2

0 0-3 Explanation of Symbols The following rules apply throughout this Service Manual: The following symbols are used throughout this Service Manual. 1. Each chapter contains sections explaining the purpose of specific functions and the Symbols Explanation Check Symbols Explanation Remove the claw. relationship between electrical and mechanical systems with reference to the timing of operation. In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol, the arrow indicates the direction of the electric signal. The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results in supplying the machine with power. Check visually. Insert the claw. 2. In the digital circuits, '1' is used to indicate that the voltage level of a given signal is "High", while '0' is used to indicate "Low". (The voltage value, however, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'. Check the noise. Use the bundled part. In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessors used in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads. Disconnect the connector. Push the part. The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins. Connect the connector. Plug the power cable. All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and be able to identify and isolate faults in the machine. Remove the cable/wire from the cable guide or wire saddle. Turn on the power. Set the cable/wire to the cable guide or wire saddle. Remove the screw. Tighten the screw. 0 0-3

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0 0-5 0 Safety Precautions Contents Notes Before Servicing-------------------------------------------------------0-7 Points to Note at Cleaning---------------------------------------------------0-7 1 Product Outline Features--------------------------------------------------------------------------1-2 Specifications-------------------------------------------------------------------1-2 Specifications--------------------------------------------------------------------------------- 1-2 Names of Parts-----------------------------------------------------------------1-3 External View--------------------------------------------------------------------------------- 1-3 Parts Components-------------------------------------------------------------------------- 1-3 2 Technology Basic Configuration-----------------------------------------------------------2-2 Outline--------------------------------------------------------------------------------- 2-2 Pickup Operation------------------------------------------------------------------- 2-2 Controls--------------------------------------------------------------------------2-4 Paper Detection----------------------------------------------------------------2-5 Detecting the Presence/Absence of Paper---------------------------------- 2-5 Switching the Deck Paper Size------------------------------------------------- 2-5 Detecting the Level of Paper---------------------------------------------------- 2-5 Deck Lifter-----------------------------------------------------------------------2-6 Detecting the Presence/Absence of Paper on the Lifter------------------ 2-6 Opening /Closing the Compartment--------------------------------------2-7 Opening/Closing the Compartment-------------------------------------------- 2-7 Detecting Jams-----------------------------------------------------------------2-8 Overview------------------------------------------------------------------------------ 2-8 Power Supply-------------------------------------------------------------------2-9 Outline--------------------------------------------------------------------------------- 2-9 Diagram of the Power Supply System.------------------------------------------------ 2-9 Protection Function---------------------------------------------------------------- 2-9 Work of Service-------------------------------------------------------------- 2-10 When replacing the parts--------------------------------------------------------2-10 Periodic Servicing-----------------------------------------------------------------2-10 Upgrading---------------------------------------------------------------------------2-10 3 Periodic Servicing List of Work for Scheduled Servicing-------------------------------------3-2 4 Parts Replacement and Cleaning Procedure List of Parts----------------------------------------------------------------------4-2 External Covers--------------------------------------------------------------------- 4-2 Main Units---------------------------------------------------------------------------- 4-2 List of Consumable Parts -------------------------------------------------------- 4-3 Electric Part-------------------------------------------------------------------------- 4-4 External Covers----------------------------------------------------------------4-5 Removing the Left Rear Cover---------------------------------------------------------- 4-5 Removing the Front Cover---------------------------------------------------------------- 4-5 Removing the Left Upper Cover--------------------------------------------------------- 4-5 Removing the Rear Cover---------------------------------------------------------------- 4-5 Removing the Front Cover (upper)----------------------------------------------------- 4-6 Removing the Upper Cover--------------------------------------------------------------- 4-6 Removing the Right Cover---------------------------------------------------------------- 4-6 Main Units-----------------------------------------------------------------------4-8 Removing the Deck Pickup Unit------------------------------------------------ 4-8 Parts Replacement and Cleaning Procedure.--------------------------4-9 Removing the Deck Pickup Roller------------------------------------------------------ 4-9 Points to Note When Mounting the Pickup Roller----------------------------------- 4-9 Removing the Deck Feed Roller-------------------------------------------------------4-10 Points to Note When Mounting the Deck Feed Roller----------------------------4-10 Removing the Deck Separation Roller------------------------------------------------4-10 Electric Part------------------------------------------------------------------- 4-11 Removing the Deck Pickup Clutch (CL2D)------------------------------------------ 4-11 Removing the Deck Main Motor (M1D)----------------------------------------------- 4-11 Removing the Deck Lifter Motor (M2D)-----------------------------------------------4-12 Removing the Deck Driver PCB--------------------------------------------------------4-13 Removing the Open Switch PCB-------------------------------------------------------4-13 Other Parts-------------------------------------------------------------------- 4-14 0 0-5

0 0-6 Removing from the Host Machine---------------------------------------------4-14 Cassette Heater Unit----------------------------------------------------------------------4-14 Previous preparations---------------------------------------------------------------------4-14 Detaching the Deck From Its Host Machine-----------------------------------------4-14 How to open deck--------------------------------------------------------------------------4-14 Lifter part-----------------------------------------------------------------------------4-15 Positioning the Deck Lifter---------------------------------------------------------------4-15 Removing the Lifter Cable (deck front)-----------------------------------------------4-16 Removing the Lifter Cable (deck rear)------------------------------------------------4-17 Routing the Lifter Cable------------------------------------------------------------------4-19 5 Adjustments Adjustment----------------------------------------------------------------------5-2 Basic Adjustment------------------------------------------------------------------- 5-2 Checking the Image Rear/Front Position for Pickup from the Side Paper Deck- 5-2 Adjusting the Rear/Front Registration for the Side Paper Deck----------------- 5-2 Adjusting the Pressure of the Deck Separation Roller----------------------------- 5-2 Adjusting the Position of the Spacer--------------------------------------------------- 5-3 Adjusting the Height of the Side Spacer----------------------------------------------- 5-5 Switching the Paper Size of the Deck-------------------------------------------------- 5-5 Adjusting the Paper Level Indicator---------------------------------------------------- 5-6 Measures at Time of Parts Replacement------------------------------------- 5-8 Position of the Deck Pickup Roller Releasing Solenoid (SL1)------------------- 5-8 Stringing the Lifter Cable------------------------------------------------------------------ 5-8 Points to Note When Mounting the Deck Pickup Roller--------------------------- 5-9 Points to Note When Mounting the Deck Feed Roller----------------------------- 5-9 Points to Note When Mounting the Front Cover------------------------------------5-10 Checking the Supplied Parts------------------------------------------------6-3 Unpacking Procedure---------------------------------------------------------6-4 Installation procedure---------------------------------------------------------6-5 Installation procedure(ir ADVANCE 4000 series)------------------------- 6-5 Preparing at the Host Machine---------------------------------------------------------- 6-5 Connecting with the Host Machine and Preparing at the Paper Deck--------- 6-9 Checking the Remaining Parts---------------------------------------------------------6-14 Installation procedure(ir ADVANCE C5000 series)----------------------6-14 Preparing at the Host Machine---------------------------------------------------------6-14 Connecting with the Host Machine and Preparing at the Paper Deck--------6-19 Checking the Remaining Parts---------------------------------------------------------6-25 Changing the Paper Size-------------------------------------------------- 6-25 Adjustment-------------------------------------------------------------------- 6-26 Adjusting the Left Edge Margin------------------------------------------------6-26 For ir ADVANCE 4000 series-----------------------------------------------------------6-26 For ir ADVANCE C5000 series--------------------------------------------------------6-26 Adjusting the Position of the Front Cover-----------------------------------6-27 Appendix Service Tools-----------------------------------------------------------------------ii Solvents and Oils------------------------------------------------------------------------------- ii Special Tools------------------------------------------------------------------------------------ ii General Circuit Diagram------------------------------------------------------- iii General Circuit Diagram (1/1)---------------------------------------------------------------iii Signal Name List-----------------------------------------------------------------iv 6 Installation How to Utilize This Installation Procedure-------------------------------6-2 When Using the Contained Parts (Bundled Components in the Shipping Carton)-------------------------------------------------------------------------------- 6-2 Symbols in the Illustration-------------------------------------------------------- 6-2 Product Name------------------------------------------------------------------6-2 Checks to Make before Installation---------------------------------------6-2 Check items when Turning OFF the Main Power----------------------6-2 0 0-6

Safety Precautions Notes Before Servicing Points to Note at Cleaning

0 Safety Precautions > Points to Note at Cleaning Notes Before Servicing 0-8 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. Points to Note at Cleaning CAUTION: When performing cleaning using organic solvent such as alcohol, be sure to check that the component of solvent is vaporized completely before assembling. 0 Safety Precautions > Points to Note at Cleaning 0-8

1 Product Outline Features Specifications Names of Parts 1 Product Outline

1 Product Outline > Specifications Features Specifications 1-2 Installation improvement Operation free caster Specifications Item Pickup Paper accomodation Copy paper Paper weight Reproduction type Paper stack Dimensions Weight Power supply Specifications Retard Front loading Plain paper, recycled paper, thick paper, bond paper For ir ADVANCE 4000 Series: 60g/m2 to 128g/m2 For ir ADVANCE C5000 Series: 52g/m2 to 163g/m2 A4, LTR 2700 sheets(80 g/m2) 3000 sheets(60 g/m2) (W) 372mm X (D) 603mm X (H) 473mm 37kg DC from the host machine T-1-1 NOTE: The above specifications are subject to change for product improvement. 1 Product Outline > Specifications 1-2

1 Product Outline > Names of Parts Names of Parts Parts Components 1-3 External View Rear cover [8] M1D [5] [3] [10] [7] Deck release grip Front cover(upper) [4] [11] Compartment open/close switch Upper cover M2D [9] [12] [13] [6] Front cover Right cover F-1-1 [14] [15] Deck lifter upper limit sensor (PS3D) [9] Deck lifter motor (M2D) Deck lifter position sensor (PS4D) [10] Pickup roller [3] Deck paper supply position sensor (PS8D) [11] Feed roller [4] Deck paper level sensor (PS7D) [12] Separation roller [5] Deck open detecting switch (SW1D) [13] Deck lifter cable [6] Deck lifter lower limit detecting switch [14] Lifter (SW2D) [7] Deck open switch (SW100D) [15] Paper [8] Deck main motor (M1D) F-1-2 1 Product Outline > Names of Parts 1-3

2 Technology Basic Configuration Controls Paper Detection Deck Lifter Opening /Closing the Compartment Detecting Jams Power Supply Work of Service 2 Technology

2 Technology > Basic Configuration > Pickup Operation Basic Configuration Outline <If pickup is not detected within a specific period of time> If, for some reason, the deck pickup sensor (PS6D) does not detect paper in the presence of the deck pickup detection signal, the machine will issue an alarm code. 2-2 Number of sheets Operation Drive 2700 (A4/LTR; paper of 80 g/m2) In response to control signals from the host machine s DC controller Deck lifter motor (M2D) for movement of the deck Deck main motor (M1D) for pickup/feeding of paper DC controller PCB (host machine) T-2-1 Deck driver PCB Pickup Operation When the Start key is pressed, the deck pickup clutch (CL2D) goes ON. Then, the deck main motor (M1D) goes ON, and the rotation of the pickup roller moves the paper into the machine. The pickup/feeding roller and the separation roller make sure that no more than a single sheet of paper is picked up. After the deck pickup sensor (PS6D) has detected the presence of paper, the pickup roller leaves the surface of paper when the deck pickup roller releasing solenoid (SL1D) goes ON. When paper is fed, the deck feed roller rotates to move the paper to the registration roller of the host machine, where the paper is looped so that it does not skew. The registration roller is controlled so that the image on the photosensitive drum and the leading edge of the paper will match. Deck feed detection signal (P_OUT_SENS) PS1D Deck pickup detection signal (FEED_SENS) PS6D Deck pickup clutch drive signal (FEED_CL_ON*) CL2D Deck main motor drive signal M1D Deck pickup roller releasing solenoid drive signal (PICKUP_SL_ON*) SL1D F-2-1 2 Technology > Basic Configuration > Pickup Operation 2-2

2 Technology > Basic Configuration > Pickup Operation Start Key ON 2-3 INTR SCAN PRINT LSTR STBY Deck main motor (M1D) Deck pickup clutch (CL2D) Deck pickup roller releasing solenoid (SL1D) Deck pickup paper sensor (PS6D) Deck feed sensor (PS1D) F-2-2 2 Technology > Basic Configuration > Pickup Operation 2-3

2 Controls Technology > Controls 2-4 Item Reference 1.Paper Detection Detecting the Presence/Absence of (Refer to page 2-5) Paper Switching the Deck Paper Size (Refer to page 2-5) Detecting the Level of Paper (Refer to page 2-5) 2.Deck Lifter Detecting the Presence/Absence of (Refer to page 2-6) Paper on the Lifter 3.Opening /Closing Opening/Closing the Compartment (Refer to page 2-7) the Compartment 4.Detecting Jams Detecting Jams (Refer to page 2-8) 5.Power Supply Outline (Refer to page 2-9) Protection Function (Refer to page 2-9) T-2-2 2 Technology > Controls 2-4

2 Technology > Paper Detection > Detecting the Level of Paper Paper Detection Detecting the Presence/Absence of Paper The deck paper absent sensor (PS2D) is used to detect the presence/absence of paper. The paper [3] deposited on the lifter runs out. The paper detecting lever [4] of the pickup roller assembly moves past the deck paper absent sensor. The machine indicates a message to indicate the absence of paper (on the host machine s control panel). [4] Switching the Deck Paper Size Enter the appropriate paper size in service mode (Lv.1) OPTION>ACC>DK-P. Move the guide plate inside the deck to suit the paper size, and enter the size in service mode (at time of installation or at the request of the user). Detecting the Level of Paper The following sensors are used to detect the level of paper: - Deck paper supply position sensor (PS8D) - Deck paper level sensor (PS7D) - Deck paper absent sensor (PS2D) The mechanism of detection can indicate an approximate level of paper inside the compartment on the host machine s control panel. 2-5 [3] Paper level PS2D PS8D PS7D Indication on control panel 100% to about 1 1 1 50% About 50% to 1 1 0 about 10% About 10% or less 1 0 0 No paper 0 0 0 T-2-3 [4] F-2-3 2 Technology > Paper Detection > Detecting the Level of Paper 2-5

2 Technology > Deck Lifter > Detecting the Presence/Absence of Paper on the Lifter 2-6 Deck Lifter Detecting the Presence/Absence of Paper on the Lifter The deck s lifter detects the presence/absence of paper as follows: [8] M1D [5] [3] [10] [7] Operation: Drive: Moved up or down by switching the direction of rotation of the deck lifter motor (M2D). Obtained from the deck lifter motor (M2D) through cable and reel. [4] [11] 1. Moving Up the Lifter The compartment is pushed inside the deck. The deck open detecting switch (SW1D) is pressed. The deck open sensor (PS9D) detects the light-blocking plate. - Stopping the Lifter The deck lifter position sensor (PS4D) detects the top surface of the stack of paper to stop the lifter. <Preventing damage to the deck caused by excess ascent> An upper limit is set, and it is detected using the deck lifter upper limit sensor (PS3D) in consideration of the following: The sensor lever blocks the deck lifter position sensor for some reason (i.e., the lifter fails to stop its ascent). level). M2D [9] [6] [14] [12] [15] [13] 2. Moving Down the Lifter The deck open switch (SW100D) is pressed. - Stopping the Lifter The lifter stops where the lifter moves past the sensor lever of the deck paper supply position sensor (PS8D); i.e., at the falling edge of sensor output. <Addition of paper in this condition> The added paper pushes the lever of the deck paper supply position sensor (PS8D). The lifter moves farther down until the stack of paper moves past the sensor lever. 3. Adding Paper Each time paper is added, the lifter repeats moving down until the deck lifter lower limit detecting switch (SW2D) is pressed (i.e., maximum paper supply Deck lifter upper limit sensor (PS3D) [9] Deck lifter motor (M2D) Deck lifter position sensor (PS4D) [10] Pickup roller [3] Deck paper supply position sensor (PS8D) [11] Feed roller [4] Deck paper level sensor (PS7D) [12] Separation roller [5] Deck open detecting switch (SW1D) [13] Deck lifter cable [6] Deck lifter lower limit detecting switch [14] Lifter (SW2D) [7] Deck open switch (SW100D) [15] Paper [8] Deck main motor (M1D) 2 Technology > Deck Lifter > Detecting the Presence/Absence of Paper on the Lifter 2-6

Deck driver PCB DC controller PCB 2 Technology > Opening /Closing the Compartment > Opening/Closing the Compartment 2-7 Opening /Closing the Compartment Deck open switch ON Compartment set Opening/Closing the Compartment Deck open indicator (LED100D) Flashing ON Flashing OFF <Opening the compartment> The deck open switch (SW100D) is pressed. The deck open solenoid (SL2D) goes on. The compartment is unlocked, and the force of the spring pushes it several centimeters toward the front. The deck lifter motor (M2D) starts to rotate. The lifter inside the compartment moves down. <Closing the compartment> The compartment is pushed inside the deck. The deck open sensor (PS9D) detects the light-blocking plate inside the compartment. The lifter moves up to the pickup motor. <Deck open indicator (LED100D) goes on or flashes> The deck open indicator is used to indicate that the deck lifter motor is rotating to open/close the deck. Deck lifter motor (M2D) Deck paper supply position sensor (PS8D) Deck lifter lower limit detecting switch (SW2D) Deck open solenoid (SL2D) Deck open detecting switch (SW1D) Deck open sensor (PS9D) Deck lifter position sensor (PS4D) * * Compartment open Deck lifter down Deck lifter up *:varies depending on the level of paper. J20-1 SW100D J20-4 LED100D Open switch PCB Deck open signal (DECK_OPEN_SW) Deck open indictor LED ON signal (LEDSW_LEDON) J5A - 4 J5A - 1 F-2-5 (compartment) PS3D Deck lifter upper limit detection signal(lift_m_uplmt) J5A - 9 Deck lifter PS9D SW1D Deck open detection signal (DECK_OPEN_SENS) Deck open detection signal (DOPD*) J6-7 J7-3 Open Direction SL2D SW2D M2D Deck open solenoid J6 drive signal -2 (DECK_LOCKOFF_SL_ON*) Deck lifter lower limit signal (DLLD) Deck lifter motor drive signal 9 : LIFT_M_UP ( 10 : LIFT_M_DOWN) J4-7 J4-9,10 (host machine) F-2-4 2 Technology > Opening /Closing the Compartment > Opening/Closing the Compartment 2-7

2 Technology > Detecting Jams > Overview 2-8 Detecting Jams Overview The paper deck is equipped with 2 sensors. The machine reads the signals from the sensors at such times as programmed in the host machine s DC controller. The machine decides whether the movement of paper is normal or not by using the host machine s DC controller. <if a jam is identified> The machine delivers the paper moving ahead of the jam, and then stops its operation. Thereafter, it indicates instructions on the removal of the jam using the host machine s control panel. The host machine s DC controller identifies a jam in response to the following: 1. There is paper over the deck feed sensor (PS6D) when the host machine is turned on or image stabilization control is being executed. 2. Deck Pickup/Delay Jam Deck pickup clutch (CL2D) Jam check Deck pickup sensor (PS6D) Deck feed sensor (PS1D) Deck main motor (M1D) Start key ON INTR SCAN PRINT Normal Jam indicator ON Error 3. Deck Pickup/Vertical Path Stationery Jam F-2-7 Start key ON Jam indicator ON INTR SCAN PRINT PS1D PS6D Deck pickup clutch (CL2D) Jam check Deck pickup sensor (PS6D) Deck feed sensor (PS1D) Deck main motor (M1D) Normal Error F-2-6 No. Name Function PS1D Deck feed sensor Checks for delay/stationary jams PS6D Deck pickup sensor Checks for delay/stationary jams 2 Technology > Detecting Jams > Overview T-2-4 F-2-8 2-8

2 Power Supply Outline Technology > Power Supply > Protection Function Diagram of the Power Supply System. The following is a diagram of the machine s power supply system. The side deck is supplied with power by its host machine (24V). The 24V power is converted by the side deck driver PCB into for output to sensor and the side deck driver PCB. The 5 V power is generated by side deck driver PCB based on 24V power and supplied for driving sensors and the side deck driver PCB. 2-9 Protection Function The 24 V power supply is equipped with a fuse (FU01) designed to blow when an overcurrent flows. Host machine Side deck driver PCB J02 24V 2 FU01 24V - motors - solenoids - clutch - switches DC5V Power 5V - sensors F-2-9 2 Technology > Power Supply > Protection Function 2-9

2 Work of Service Technology > Work of Service > Upgrading 2-10 When replacing the parts No. Name Description 1 Deck Pickup Roller Releasing Solenoid Mounting position adjustment (SL1) 2 Lifter Cable Stringing the Lifter Cable 3 Deck Pickup Roller Direction attention for installation 4 Deck Feed Roller Direction attention for installation 5 Front Cover Cover gap adjustment for installation T-2-5 Periodic Servicing PR:Replacement (Periodically replaced parts) CR:Replacement (consumable parts) CL:Cleaning LU:Lubrication AD:Adjustment CH:Maintenance No. Name Part No. Qty Life 1 Pickup roller (front) FF5-7829 1 CR/500,000 sheets 2 Pickup roller (rear) FF5-7830 1 CR/500,000 sheets 3 Feed roller FF5-7541 1 CR/500,000 sheets 4 Separation roller FB2-7777 1 CR/500,000 sheets Upgrading T-2-6 None 2 Technology > Work of Service > Upgrading 2-10

3 Periodic Servicing List of Work for Scheduled Servicing 3 Periodic Servicing

3 Periodic Servicing > List of Work for Scheduled Servicing List of Work for Scheduled Servicing 3-2 PR:Replacement (Periodically replaced parts) CR:Replacement (consumable parts) CL:Cleaning LU:Lubrication AD:Adjustment CH:Maintenance As of Nov 2011 No. Name Part No. Qty Life COUNTER Adjusted/Not adjusted Remark Reference 1 Pickup roller (front) FF5-7829 1 CR/500,000 sheets DRBL-2>PD-PU-RL No actual number 250,000 sheets in the HH (Refer to page 4-9) environment (30 degrees, 80% RH) 2 Pickup roller (rear) FF5-7830 1 CR/500,000 sheets DRBL-2>PD-PU-RL No actual number 250,000 sheets in the HH environment (30 degrees, 80% RH) 3 Feed roller FF5-7541 1 CR/500,000 sheets DRBL-2>PD-FD-RL No (Refer to page 4-10) 4 Separation roller FB2-7777 1 CR/500,000 sheets DRBL-2>PD-SP-RL No (Refer to page 4-10) T-3-1 3 Periodic Servicing > List of Work for Scheduled Servicing 3-2

4 Parts Replacement and Cleaning Procedure List of Parts External Covers Main Units Parts Replacement and Cleaning Procedure. Electric Part Other Parts 4 Parts Replacement and Cleaning Procedure

List of Parts 4 Parts Replacement and Cleaning Procedure > List of Parts > Main Units Main Units 4-2 External Covers [6] [7] [5] [4] [3] No. Name Refer to Front cover (upper) (Refer to page 4-6) Front cover (Refer to page 4-5) [3] Right cover (Refer to page 4-6) [4] Upper cover (Refer to page 4-6) [5] Rear cover (Refer to page 4-5) [6] Left rear cover (Refer to page 4-5) [7] Left upper cover (Refer to page 4-5) T-4-1 F-4-1 No. Name Part No Refer to Removing the Deck Pickup Unit FM4-5896 (Refer to page 4-8) F-4-2 T-4-2 4 Parts Replacement and Cleaning Procedure > List of Parts > Main Units 4-2

4 List of Consumable Parts Parts Replacement and Cleaning Procedure > List of Parts > List of Consumable Parts No. Name Part No Refer to 1 Pickup Roller(Front) FF5-7829 (Refer to page 4-9) Pickup Roller(Rear) FF5-7830 2 Feed Roller FF5-7541 (Refer to page 4-10) 3 Separation Roller FB2-7777 (Refer to page 4-10) T-4-3 4-3 [3] 4 Parts Replacement and Cleaning Procedure > List of Parts > List of Consumable Parts 4-3

4 Parts Replacement and Cleaning Procedure > List of Parts > Electric Part 4-4 Electric Part CL2D SL2D PS9D SW1D SL1D M2D M1D [PCB] LED100D PS4D PS2D PS3D SW100D No. Name Refer to CL2D Deck pickup clutch (Refer to page 4-11) SL1D Deck pickup roller release solenoid - SL2D Deck open solenoid - SW1D Deck open sensing switch - SW2D Deck lifter lower limit sensing switch - SW100D Deck open switch (Refer to LED100D Deck open indication page 4-13) M1D Deck main motor (Refer to page 4-11) M2D Deck lifter motor (Refer to page 4-12) PS1D Deck feeder sensor - PS2D Deck paper-out sensor - PS3D Deck lifter upper limit sensor - PS4D Deck lifter position sensor - PS5D Deck set sensor - PS6D Deck pickup sensor - PS7D Deck paper level sensor - PS8D Deck paper replenishing position sensor - PS9D Deck open sensor - [PCB] Deck contoroller PCB (Refer to page 4-13) T-4-4 PS7D SW2D PS8D PS5D PS1D PS6D F-4-3 4 Parts Replacement and Cleaning Procedure > List of Parts > Electric Part 4-4

4 Parts Replacement and Cleaning Procedure > External Covers 4-5 External Covers Removing the Left Rear Cover Removing the Left Upper Cover 1) Remove the 2 screws, and detach the left upper cover. 1) Free the deck from its host machine. 2) Remove the 2 screws and 2 self-tapping screws [3]; then, detach the left rear cover [3]. Removing the Rear Cover F-4-6 1) Remove the 2 binding screws and the 4 RS tightening screws [3]; then,detach the rear cover. Removing the Front Cover F-4-4 1) Remove the 4 screws, and detach the front cover to the front. Do not F-4-7 F-4-5 4 Parts Replacement and Cleaning Procedure > External Covers 4-5

4 Parts Replacement and Cleaning Procedure > External Covers 4-6 Removing the Front Cover (upper) 1) Remove the 3 screws, and disconnect the connector; then, detach the front cover (upper) [3]. Removing the Right Cover 1) Remove the 3 screws, and shift down the right cover, then, detach it toward the front. CAUTION: When mounting the front cover (upper), be sure that the harness to the open switch PCB is not trapped and all connectors are properly connected. F-4-10 Removing the Upper Cover F-4-8 1) Remove the 2 screws, and detach the upper cover. F-4-9 4 Parts Replacement and Cleaning Procedure > External Covers 4-6

4 Parts Replacement and Cleaning Procedure > External Covers 4-7 CAUTION: When mounting the right cover, be sure that the claw on the top of the right cover is in the hole of the paper deck stay and the right edge [3] is inside the rear cover [4]. F-4-11 4 Parts Replacement and Cleaning Procedure > External Covers 4-7

4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Deck Pickup Unit 4-8 Main Units Removing the Deck Pickup Unit CAUTION: When mourning the deck pickup unit, tighten the 3 screws first and then the remaining 2 screws [3]. 1) Remove the left rear cover."removing the Left Rear Cover"(page 4-5). 2) Remove the left upper cover."removing the Left Upper Cover"(page 4-5). 3) Remove the rear cover."removing the Rear Cover"(page 4-5). 4) Remove the front cover (upper)."removing the Front Cover (upper)"(page 4-6). 5) Remove the upper cover."removing the Upper Cover"(page 4-6). 6) Detach the deck release grip in upward direction. 7) Disconnect the 2 connectors, and remove the 5 screws [3]. 8) Detach the pickup harness [4]. 9) Remove the deck pickup unit [5]. F-4-13 F-4-12 4 Parts Replacement and Cleaning Procedure > Main Units > Removing the Deck Pickup Unit 4-8

4 Parts Replacement and Cleaning Procedure > Parts Replacement and Cleaning Procedure. 4-9 Parts Replacement and Cleaning Procedure. Removing the Deck Pickup Roller 1) Remove the left rear cover."removing the Left Rear Cover"(page 4-5). 2) Remove the left upper cover."removing the Upper Cover"(page 4-6). 3) Remove the rear cover."removing the Rear Cover"(page 4-5). 4) Remove the front cover (upper)."removing the Front Cover (upper)"(page 4-6). 5) Remove the upper cover."removing the Upper Cover"(page 4-6). 6) Remove the deck pickup unit."removing the Deck Pickup Unit"(page 4-8). 7) Turn over the deck pickup unit; then, remove the resin ring (1 each) and 2 deck pickup rollers. Points to Note When Mounting the Pickup Roller Front of the Machine The pickup roller has its own orientation. When mounting the deck pickup roller found at the front of the machine, be sure that the marking [4] on the collar [3] is toward the front of the machine and the marking [5] on the side of the roller is toward the rear of the machine. Rear of the Machine The pickup roller has its own orientation [6]. When mounting the deck pickup roller [7] at the rear of the machine, be sure that the marking [9] on the collar [8] and the marking [10] on the side of the roller are toward the rear of the machine. [9] [6] [10] [8] [7] F-4-14 CAUTION: The pickup roller has its own orientation (direction of rotation), requiring care when mounting it. [4] [3] [5] F-4-15 4 Parts Replacement and Cleaning Procedure > Parts Replacement and Cleaning Procedure. 4-9

4 Removing the Deck Feed Roller Parts Replacement and Cleaning Procedure > Parts Replacement and Cleaning Procedure. 1) Remove the left rear cover."removing the Left Rear Cover"(page 4-5). 2) Remove the left upper cover."removing the Left Upper Cover"(page 4-5). 3) Remove the rear cover."removing the Rear Cover"(page 4-5). 4) Remove the front cover (upper)."removing the Front Cover (upper)"(page 4-6). 5) Remove the upper cover."removing the Upper Cover"(page 4-6). 6) Remove the deck pickup unit."removing the Deck Pickup Unit"(page 4-8). 7) Remove the resin ring, and detach the deck pickup/feed roller and the drive belt [3] to the front. Removing the Deck Separation Roller 4-10 1) Free the deck from its host machine, and remove the 2 screws and the separation roller support plate. [3] 2) Detach the pickup roller from the holder. F-4-18 F-4-16 Points to Note When Mounting the Deck Feed Roller When mounting the deck feed roller, be sure that the belt pulley is toward the front of the machine. There is no specific orientation to observe when fitting the feed roller rubber to the feed roller shaft. 3) Detach the shaft in the direction of the arrow. F-4-19 F-4-17 F-4-20 CAUTION: The urethane sponge segment of the deck separation roller is pink immediately after foaming; it changes in color from pink to orange and then to yellow as time passes, accelerated if exposed to light. This is a general characteristic of a urethane sponge, and will not affect its performance. The part is not identified by its color, and there are not multiple parts classified according to color. 4 Parts Replacement and Cleaning Procedure > Parts Replacement and Cleaning Procedure. 4-10

4 Parts Replacement and Cleaning Procedure > Electric Part 4-11 Electric Part Removing the Deck Pickup Clutch (CL2D) 1) Remove the left rear cover."removing the Left Rear Cover"(page 4-5). 2) Remove the left upper cover."removing the Upper Cover"(page 4-6). 3) Remove the rear cover."removing the Rear Cover"(page 4-5). 4) Remove the front cover (upper)."removing the Front Cover (upper)"(page 4-6). 5) Remove the upper cover."removing the Upper Cover"(page 4-6). 6) Remove the deck pickup unit."removing the Deck Pickup Unit"(page 4-8). 7) Disconnect the connector, and remove the E-ring ; then, detach the deck pickup clutch [3]. CAUTION: When mounting the deck pickup clutch, be sure that the clutch is fitted to the stop [4]. Also, be sure that the harness is fitted to the U-groove [5] of the guide. Removing the Deck Main Motor (M1D) 1) Remove the left rear cover."removing the Left Rear Cover"(page 4-5). 2) Remove the rear cover."removing the Rear Cover"(page 4-5). CAUTION: Disconnect the connector, and remove the 2 screws ; then, detach the deck main motor [3]. At this time, take care not to damage the gear found at the tip of the motor spindle [3] [3] [4] [5] F-4-21 4 Parts Replacement and Cleaning Procedure > Electric Part 4-11

4 Parts Replacement and Cleaning Procedure > Electric Part 4-12 Removing the Deck Lifter Motor (M2D) 1) To prevent deformation of the roll support plate, place a stack of paper [3] (A: about 8 cm) on the floor for the placement of the deck. 3) Disconnect the connector found at the rear of the compartment, and remove the screw ; then, detach the harness unit [3]. 8 cm (approx.) [3] [3] [3] 2) Remove the right cover. F-4-22 4) Remove the screw and the stopper plate found at the left rear of the deck; then, slide the compartment [3] farther out to the front. F-4-23 [3] F-4-24 4 Parts Replacement and Cleaning Procedure > Electric Part 4-12

4 Parts Replacement and Cleaning Procedure > Electric Part 4-13 5) Remove the 3 screws each from the left/right of the compartment rail ; then, lift the compartment [3] about 1 cm, and detach it to the front. Removing the Deck Driver PCB 1) Remove the left rear cover."removing the Left Rear Cover"(page 4-5). 2) Remove the rear cover."removing the Rear Cover"(page 4-5). 3) Disconnect the 8 connectors, and remove the 4 screws ; then, detach the deck driver PCB [3]. F-4-25 6) Place the compartment on the stack of paper you have previously pre-pared. Be sure to use the stack of paper to prevent deformation of the roll support plate. 7) Disconnect the connector, and remove the 5 screws ; then, detach the deck lifter motor unit [3]. Removing the Open Switch PCB F-4-27 1) Open the compartment."how to open deck"(page 4-14). 2) Remove the front cover (upper)."removing the Front Cover (upper)"(page 4-6). 3) Remove the 2 screws from inside the front cover (upper), and detach the open switch PCB [3]. [3] [3] F-4-26 F-4-28 4 Parts Replacement and Cleaning Procedure > Electric Part 4-13

4 Parts Replacement and Cleaning Procedure > Other Parts > Removing from the Host Machine > How to open deck 4-14 Other Parts Removing from the Host Machine Cassette Heater Unit When the cassette heater unit is installed in the paper deck, remove it necessarily prior to disassembling. Detaching the Deck From Its Host Machine 1) Remove the the connect acble. 2) Push the deck release grip to free the deck form its host machine. 3) Remove the 3 screws from the left side, and detach the deck. Previous preparations 1) To prevent deformation of the roll support plate, place a stack of paper [3] (A: about 8 cm) on the floor for the placement of the deck. How to open deck F-4-30 A 1) Push the deck release grip to free the deck form its host machine; then,push down the latch plate found at the left rear to open the compartment. [3] [3] F-4-29 F-4-31 4 Parts Replacement and Cleaning Procedure > Other Parts > Removing from the Host Machine > How to open deck 4-14

4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Positioning the Deck Lifter 4-15 Lifter part Positioning the Deck Lifter 1) Push the deck release grip to free the deck form its host machine; then,push down the latch plate found at the left rear to open the compartment. 2) If there is any paper, remove all of it. 3) Connect the power plug, and turn on the host machine. 4) Push the sensor flag of the paper supply position sensor found inside the compartment so that the deck lifter moves down. (The deck lifter will stop as soon as you release the flag.) 6) Insert a hex wrench [3] into the hole of the lifter drive shaft so that it serves to keep the spindle from turning. 7) Disconnect the power plug. F-4-34 F-4-32 NOTE: If the deck lifter is in up position, move it so that distance A from the base plate of the compartment of the deck is about 7cm. A F-4-33 4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Positioning the Deck Lifter 4-15

4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Removing the Lifter Cable (deck front) 4-16 Removing the Lifter Cable (deck front) 1) Open the compartment. 2) If there is any paper, remove all of it. 3) Insert 2 long screwdrivers to keep the lifter in place. 4) Push down the sensor flag of the paper supply position sensor so that the lifter will move down, thus matching the left/right hole in the lifter and the left/right hole in the side plate of the compartment. - Connect the power plug, and turn on the host machine. - Push the sensor flag of the paper supply position so that the deck lifter will move down to reach the screwdrivers. (The deck lifter will stop as soon as you release the flag.) CAUTION: Be sure to adjust the position of the front cover using the 4 screws fitted to it so that the gap A between the front cover and the front cover (upper ) is 3 +1, -1 mm. 6) Remove the 4 screws and detach the roll support plate. F-4-37 F-4-35 5) Loosen the 4 screws, and detach the front cover to the front. Do not remove the screws. F-4-38 F-4-36 4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Removing the Lifter Cable (deck front) 4-16

4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Removing the Lifter Cable (deck rear) 4-17 7) Remove the E-ring, and detach the pulley cover [3]. 8) Remove the 2 screws [4] and the cable fixing plate [5] found on the left side; then, detach the lifter cable [6]. 9) Remove the 2 screws [7] and the cable fixing plate [8] found on the right side; then, detach the lifter cable [9]. 10) Detach the inside lifter cable [9] from the inside pulley by removing the 2 set screws [12] and then the outside pulley [11]. Removing the Lifter Cable (deck rear) 1) Open the compartment. 2) If there is any paper, remove all of it. 3) Remove the screw, and detach the upper sensor cover and the lower sensor cover [3]. 4) Disconnect the 4 connectors [4]. [4] [10] [5] [8] [4] [3] [4] [9] [11] [7] [6] [4] [3] CAUTION: When mounting the pulley cover, be sure to mach the claw [A] against the hole in the front side plate of the compartment.. F-4-39 F-4-41 CAUTION: There are 2 claws on the top of the sensor cover; be sure to take care not to break them when removing the cover. [A] F-4-40 4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Removing the Lifter Cable (deck rear) 4-17

4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Removing the Lifter Cable (deck rear) 4-18 5) Remove the 5 screws, and detach the plate. 8) Remove the bearing, gear, parallel pin [3], E-ring [4], and detach the pulley cover [5]. 9) Remove the 2 screws [6], and detach the right cable fixing plate [7]; then, detach the outside lifter cable [8]. 10) Remove the 2 screws [9], and detach the left cable fixing plate [10]; then, detach the inside lifter cable [11]. 11) Remove the 2 set screws and detach the outside pulley [13] to detach the inside lifter cable [11] from the inside pulley [12]. [11] [8] 6) Insert a hex wrench or the like into the hole of the lifter drive shaft to keep it from turning. F-4-42 CAUTION: If you fail to perform this step, the lifter cable will become slack as soon as you remove the lifter motor unit. [12] [13] [9] [10] [5] [7] [6] [4] [3] F-4-44 7) Remove the lifter motor unit. F-4-43 4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Removing the Lifter Cable (deck rear) 4-18

4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Routing the Lifter Cable 4-19 Routing the Lifter Cable 1) Check to be sure that the lifter driver shaft and the lifter are fixed in place by the 2 hex screwdrivers [4] and a hex wrench [3] or the like. 2) Secure the 4 cable fixing plates [5] in place to the lifter using 2 screws each. 3) Hook the lifter cable [6] on the 4 pulleys [7]. 4) Hook the ball of the lifter cable on the 2 pulleys found at the front/rear of the lifter drive shaft; then, wind the cable about 1.5 times along the groove of the pulley. At this time, see to it that the lifter cable is taut just enough to lift the long screwdrivers used to keep the lifter in place. 5) Secure the 2 pulleys [5] in place to the lifer drive shaft using a set screw [9] (1 each). 6) After mounting all pulleys you have removed to the lifter drive shaft,measure the height A from the base plate of the compartment to the top surface of the lifter at several points, thereby making sure that the lifter is level. [7] [7] [5] [6] [A] [8] [9] [A] [A] [5] [5] [9] [8] [3] [5] [A] [4] F-4-45 4 Parts Replacement and Cleaning Procedure > Other Parts > Lifter part > Routing the Lifter Cable 4-19

5 Adjustments Basic Adjustment Measures at Time of Parts Replacement 5 Adjustments

Adjustment Basic Adjustment 5 Adjustments > Adjustment > Basic Adjustment > Adjusting the Pressure of the Deck Separation Roller Checking the Image Rear/Front Position for Pickup from the Side Paper Deck Make a 100% copy, and check to make sure that the margin on the front of the image is 2.0 -/+1.0 mm; if not, adjust the registration. 3) Close the compartment, and check to make sure that the gap of the front cover is 3 -/+1 mm. 4) If not 3 -/+1 mm, adjust the front cover. 5-2 (-) (+) 3±1mm 2.0±1.5mm 0 2 4 6 8 10 Adjusting the Rear/Front Registration for the Side Paper Deck 1) Push the deck releasing grip to detach the deck from the host machine;1 then, push down the latch plate found at the left rear with a finger to open the compartment. F-5-1 Adjusting the Pressure of the Deck Separation Roller If pickup faults or double feeding occurs when the deck is used as the source of paper, relocate the pressure spring of the deck separation roller : - If pickup faults occur, move the spring in the direction of arrow A. - If double-feeding occurs, move the spring in the direction of arrow B. F-5-3 A B F-5-4 F-5-2 5 Adjustments > Adjustment > Basic Adjustment > Adjusting the Pressure of the Deck Separation Roller 5-2

5 Adjusting the Position of the Spacer Adjustments > Adjustment > Basic Adjustment > Adjusting the Position of the Spacer If the compartment cannot be opened/closed smoothly and, thus, requires adjustment of the spacer mounted to the front of the deck, go through the following: 1) Push the deck releasing grip to detach the deck from the host machine;then, push down the latch plate found at the left rear with a finger to open the compartment. 2) Loosen the 4 screws, and detach the front cover toward the front. Do not remove these screws. CAUTION: When attaching the front cover, be sure that the coupling used to indicate the paper level is correctly matched. 5-3 Adjust the position of the front cover by using 4 screws F-5-6 on it so that gap A between the front cover and the front cover top is 3 -/+1 mm. If you moved the paper level indicator belt or the deck lifter, you must adjust the paper level indicator. F-5-5 A F-5-7 5 Adjustments > Adjustment > Basic Adjustment > Adjusting the Position of the Spacer 5-3

5 Adjustments > Adjustment > Basic Adjustment > Adjusting the Position of the Spacer 5-4 3) Move the drive belt of the paper level indicator found in the front cover in the direction of the arrow [4] lightly by hand (i.e., so that the area of white increases). 4) With the compartment set in the deck, turn the 4 mounting screws [4] of the spacer support plate [3] so that the distance A between the spacer and the floor is about 5 mm. [4] [3] [5] [4] [4] CAUTION: F-5-8 [3] A Keep in mind that you can damage the drive mechanism of the paper level indicator if you operate the deck without correcting the spatial relationship between the paper level indicator and the deck lifter. F-5-9 NOTE: At this time, use the index [5] on the front side plate as a reference. 5 Adjustments > Adjustment > Basic Adjustment > Adjusting the Position of the Spacer 5-4

5 Adjustments > Adjustment > Basic Adjustment > Switching the Paper Size of the Deck 5-5 Adjusting the Height of the Side Spacer a. Before Starting the Work 1) Slide the machine out of its host machine, and then slide it back in. Check to see if the impact of the movement has displaced the host machine or if the machine has wobbled. If so, adjust the height of the side spacer; otherwise,this adjustment may be skipped. b. Making Adjustments 1) Connect the machine to its host machine. 2) Remove all paper from the deck. 3) Remove the machine's right cover. 4) Loosen the 2 fixing screws of the side spacer. 5) Bring the side spacer in contact with the floor, and tighten the fixing screw. Switching the Paper Size of the Deck As needed to suit the user's needs, go through the following to change the deck paper size: 1) Push the deck releasing grip to detach the deck from the host machine;then, push down the latch plate found at the left rear with a finger to open the compartment. 2) Loosen the 4 screws, and detach the front cover toward the front. Do not remove these screws. F-5-11 F-5-10 NOTE: At this time, refer to the indexes so that the left and right screws are at the index. 6) Disconnect and then connect the machine from and to its host machine. If the movement is not heavy, attach the machine's right cover, put paper back in, and then end the work. If the movement is heavy, go to the next step. 7) Check the index of the side spacer. 8) Loosen the side spacer fixing screw. 9) By referring to the index, move the side spacer up by 1 mm; then, tighten the fixing screw. 10) Attach the right, and put paper in the deck 5 Adjustments > Adjustment > Basic Adjustment > Switching the Paper Size of the Deck 5-5