Canon Cassette Module-AE1 User manual

SERVICE
MANUAL
COPYRIGHT © 2017 CANON INC.
CANON Cassette Module-AE1 Rev. 1 PRINTED IN U.S.A.
Januay 11, 2017
Rev. 1
Cassette
Module-AE1

Introduction
Important Notices
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.
Copyright CANON INC. 2016
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.
Explanation of Symbols
The following symbols are used throughout this Service Manual.
Symbols Explanation Symbols Explanation
Check.
1x
Remove the claw.
Check visually.
1x
Insert the claw.
Check a sound. Push the part.
Introduction

Symbols Explanation Symbols Explanation
1x
Disconnect the connector. Connect the power cable.
1x
Connect the connector. Disconnect the power cable.
1x
Remove the cable/wire from the
cable guide or wire saddle.
Turn on the power.
1x
Install the cable/wire to the cable
guide or wire saddle.
Turn off the power.
1x
Remove the screw.
1x
Loosen the screw.
1x
Install the screw.
1x
Tighten the screw.
Cleaning is needed. Measurement is needed.
The following rules apply throughout this Service Manual:
1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and
mechanical systems with reference to the timing of operation.
In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol, the arrow
indicates the direction of the electric signal.
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.
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'.
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.
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.
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.
Introduction

Contents
Safety Precautions...............................................................................................1
Notes Before it Works Serving............................................................................................................ 2
1. Product Overview.............................................................................................3
Overview............................................................................................................................................. 4
Specification.........................................................................................................................................4
Parts Name.......................................................................................................................................... 4
2. Technical Explanation..................................................................................... 6
Controls ..............................................................................................................................................7
Paper Size Detection Control.................................................................................................................7
Paper Level Detection Control............................................................................................................... 9
Paper Detection Control...................................................................................................................... 11
Lifter Control.......................................................................................................................................12
Registration Control.............................................................................................................................12
Size Mismatch Detection Control..........................................................................................................13
Jam Detection.....................................................................................................................................13
3. Periodical Service.......................................................................................... 14
List of Periodical Service Works........................................................................................................15
4. Disassembly/Assembly................................................................................. 16
Parts List........................................................................................................................................... 17
External Cover....................................................................................................................................17
Major Units......................................................................................................................................... 18
Electrical Components List................................................................................................................19
Sensor............................................................................................................................................... 19
Motor .................................................................................................................................................19
Switch / PCB.......................................................................................................................................20
Removal from the Connected Equipment......................................................................................... 21
Disengaging the Cassette Unit............................................................................................................. 21
External Cover System......................................................................................................................23
Removing the Rear Cover....................................................................................................................23
Removing the Right Door.....................................................................................................................23
Removing the Right Cover...................................................................................................................24
Controller System..............................................................................................................................25
Removing the Cassette Module Controller PCB.................................................................................... 25
Pickup Feed System......................................................................................................................... 26
Removing the Pickup/Feed/Separation Roller....................................................................................... 26
Removing the Auto Close Unit............................................................................................................. 29
Removing the Pickup Unit....................................................................................................................30
Removing the Pullout Motor.................................................................................................................31
Removing the Pickup Motor................................................................................................................. 32
Contents
i

Removing the Lifter Motor....................................................................................................................32
Removing the Pickup Drive Unit...........................................................................................................33
5. Adjustment..................................................................................................... 35
Pickup Feed System......................................................................................................................... 36
Cassette Left Edge Margin Adjustment (1st Side: Mechanical Adjustment)............................................. 36
Cassette Left Edge Margin Adjustment (1st Side: Software Adjustment)................................................. 38
Cassette Left Edge Margin Adjustment (2nd Side: Software Adjustment)................................................ 39
Leading Edge Margin Adjustment (1st Side of Plain Paper)....................................................................39
Leading Edge Margin Adjustment (2nd Side)........................................................................................ 39
APPENDICES......................................................................................................41
Service Tools.....................................................................................................................................42
Special Tools...................................................................................................................................... 42
Solvents and Oils................................................................................................................................ 42
General Circuit Diagram....................................................................................................................43
Contents
ii

Safety Precautions
Notes Before it Works Serving..............2

Notes Before it Works Serving
• At servicing, be sure to turn off the power source according to the specified steps and disconnect the power plug.
• 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.
Safety Precautions
2

Product Overview
1Overview............................................... 4

Overview
Specification
Item Description
Paper storage method Front loading method
Pickup method Retard separation method
Paper stack capacity 550 sheets (80 g/m2)
Paper feed reference Center reference
Paper size Width: 98.4 mm to 216.0 mm
Length: 148.0 mm to 355.6 mm
A4-R, A5-R, B5-R, LGL, LTR-R, STMT-R, EXEC-R, 16K
Special standard-size
Paper grammage 60 g/m2 to 163 g/m2
Paper size switch By the user
Duplexing method Through path
Parts Name
■ External View
[1]
[2]
[3]
[5]
[4]
No. Parts Name
[1] Front Upper Cover
[2] Tray Cover
[3] Front Lower Cover
[4] Face Cover
[5] Left Cover
1. Product Overview
4

[6]
[7]
[8]
No. Parts Name
[6] Rear Cover
[7] Right Cover
[8] Right Door
■ Cross-section View
[1]
[2]
[4]
[3]
[5]
No. Parts Name
[1] Cassette 2 pickup Roller
[2] Cassette 2 vertical path Roller
[3] Cassette 2 feed Roller
[4] Cassette 2 separation Roller
[5] Cassette 2 Lifting Plate
1. Product Overview
5

Technical
Explanation
2
Controls ................................................7

Controls
Paper inside a cassette is lifted up by the Lifter Plate.
The Lifter Plate is lifted up by rotating the Cassette 2 Lifter Motor (M104). When the Cassette 2 Pickup Roller comes into contact
with the paper surface, the Cassette 2 Pickup Motor (M102) rotates to pick up the surface layer paper, and the Cassette 2 Feed
Roller and Cassette 2 Separation Roller feed only 1 sheet of paper to the feed path. Then, it is moved to the Pre-registration
Roller by the rotation of the Cassette 2 Pullout Motor (M106).
The Cassette 2 Pickup Roller, Cassette 2 Feed Roller, and Cassette 2 Separation Roller are driven by the Cassette 2 Pickup
Motor (M102) while the Cassette 2 Vertical Path Roller is operated by the rotation of the Cassette 2 Pullout Motor (M106).
M106
M104
M102M102
[1]
[2]
[4]
[3]
PS104
PS107
[5]
No. Parts Name
[1] Cassette 2 Pickup Roller
[2] Cassette 2 Vertical Path Roller
[3] Cassette 2 Feed Roller
[4] Cassette 2 Separation Roller
[5] Cassette 2 Lifter Plate
Paper Size Detection Control
The paper size in the cassette is automatically detected by the Cassette 2 Size Detection Switch after the position of the Guide
Plate is adjusted and the cassette is installed in the host machine.
By shifting the Guide Plate, concavo-convex area of the Cassette Size Dial is switched and the Cassette Size Switch at the printer
side is switched. The switch consists of 3 microswitches, and the length is detected in accordance with the combination of
ON/OFF (ON when the switch is pressed). Any standard size paper of AB, inch, or AK configuration can be used. However,
distinction between A5-R and STMT-R (*) should be made manually on the check screen. Distinction between EXEC-R and 16K-
R and between LTR-R and 16K-R is automatically made according to the country setting.
*: Whether to select A5-R or STMT-R can be registered in the user mode setting.
[Settings/Registration] > [Preferences] > [Paper Settings] > [A5R/STMTP Paper Selection]
Specify A5-R or STMT-R for each cassette.
Cassette Size Switch
Size Length Length Detection
1 2 3
A5-R 210.0 ON OFF OFF
STMT-R 215.9 ON OFF OFF
2. Technical Explanation
7

Size Length Length Detection
1 2 3
B5-R 257.0 ON OFF ON
EXEC-R 267.0 ON ON ON
16K-R 270.0 ON ON ON
LTR-R 279.4 ON ON OFF
A4-R 297.0 OFF ON ON
LGL 355.6 OFF OFF ON
(No cassette) - OFF OFF OFF
>@LGL
>@A4-R
>@LTR-R
>@B5-R
A5-R
>@STMT-R
EXEC-R
>@16K-R
16K-R
>@LTR-R
Paper size *1 Length All modes A/B configuration Inch configuration A/K configuration
A5-R 210.0 [1] [1] - [1]
STMT-R 215.9 - [1] -
B5-R 257.0 [2] [2] Improper loading of pa-
per
Improper loading of pa-
per
EXEC-R 267.0 [3] Improper loading of pa-
per
[3] -
16K-R 270.0 [3] Improper loading of pa-
per
- [3]
[4] Improper loading of pa-
per
- [4]
LTR-R 279.4 [4] Improper loading of pa-
per
[4] -
[5] Improper loading of pa-
per
[5] Improper loading of pa-
per
A4-R 297.0 [6] [6] Improper loading of pa-
per
[6]
LGL 355.6 [7] Improper loading of pa-
per
[7] Improper loading of pa-
per
(No cassette) - [8] - - -
*1: The paper size can be registered in user mode.
Settings/Registration > Preferences > Paper Settings > Paper Settings
2. Technical Explanation
8

*2: Presence of the cassette is detected when the size switch is pressed.
(When none of the switches are pressed, it is judged as "no cassette".)
Guide Plate
Link Arm
Size Plate
Cassette
Size Switch
Paper Level Detection Control
Paper level inside the cassette is detected by the sensors shown in the following table.
The level of paper in the cassette is detected by the Cassette 2 Lifter Motor, Cassette 2 Paper Sensor, Cassette 2 Lifter Sensor,
and Cassette 2 Paper Level Sensor.
Cassette 2 Paper
Sensor
Cassette 2 Lifter
Sensor
Cassette 2 Paper
Level Sensor
Paper level Display on the Control
Panel
OFF ON OFF* 100% to 50% of the capacity*
OFF ON OFF Approx. 50% to approx. 50
sheets
OFF ON ON Approx. 50 sheets or less
The control that switches the paper level display on the Control Panel is as follows:
• When the icon displayed on the Control Panel shows 3 bars or 2 bars:
The paper level is detected based on the time for which the Cassette 2 Lifter Motor remains ON. Or, the paper level is detected
based on the time from when the Cassette 2 Paper Sensor is turned ON to when the Cassette 2 Lifter Sensor is turned ON.
The paper level during paper feed is detected based on the signal status of the Cassette Paper Level Sensor that changes
as the Cassette Lifter Plate is lifted up.
• When the icon displayed on the Control Panel shows 2 bars or 1 bar:
The icon displayed on the Control Panel changes to "1 bar" when the Cassette 2 Paper Level Sensor is turned ON.
Related service mode
• Adjustment of the threshold value for detection of the Cassette X paper level (Lv.2):
COPIER > ADJUST > CST-ADJ > CST-VLMX
2. Technical Explanation
9

Lifting Plate
Detection Lever
Paper Detection Lever
Lifting Plate
Lifter Gear
Paper Level
Detection Lever
Cassette
Lifter Motor
Cassette Paper
Level Sensor
Cassette Paper
Surface Sensor
Cassette
Paper Sensor
OFF
OFF
OFF
OFF
OFF
OFF
Cassette
Paper Sensor
Paper
Paper
Cassette Paper
Surface Sensor
Cassette Paper
Level Sensor
2. Technical Explanation
10

OFF
OFF
ON
Cassette
Paper Sensor
Paper
Paper
Cassette Paper
Surface Sensor
Cassette Paper
Level Sensor
Paper Detection Control
Paper is detected by the Cassette 2 Size Detection Switch, Cassette 2 Lifter Sensor and Cassette 2 Paper Level Sensor.
The absence of paper is notified when the Cassette 2 Paper Level Sensor is turned ON at the time the Cassette 2 Size Detection
Switch is turned ON (it is detected that the cassette is in the host machine) and the Cassette 2 Lifter Sensor is turned OFF (the
Lifter Plate is raised to the pickup position).
Lifting Plate
Detection Lever
Paper Detection Lever
Lifting Plate
Lifter Gear
Paper Level
Detection Lever
Cassette
Lifter Motor
Cassette Paper
Level Sensor
Cassette Paper
Surface Sensor
Cassette
Paper Sensor
2. Technical Explanation
11

Lifter Control
When the cassette is set, the Cassette 2 Lifter Motor rotates to raise the Lifter Plate. Then, the paper is raised to the position to
be picked up.
Registration Control
It is a control to align the image on the ITB with the paper at a specified timing.
Based on the leading edge detection by the Pre-Registration Sensor, the following 2 controls are used:
• Non-stop Registration Control
• Stop Registration Control
Basically, non-stop registration control is used. However, if the Pre-Registration Sensor is turned ON later than the period of time
corresponding to the maximum correctable distance of the non-stop registration control, it is not possible to align the image on
the ITB with the paper at the specified timing, and a jam code is generated. (Jam code: 0A90)
On the other hand, if the Pre-Registration Sensor is turned ON earlier than the period of time corresponding to the minimum
correctable distance of the non-stop registration control, the image on the ITB is aligned with the paper at the specified timing by
the stop registration control.
Sensor ON
(early)
Sensor ON
(late)
Jam occurs
Paper feed
Sensor
detection
timing
Non-stop Registration Control
Decelerated Accelerated
Stop Registration
Control
Sensor ON
(ideal)
■ Non-stop Registration Control
It is a control to align paper and image on the ITB at a specified timing by increasing or decreasing the paper feed speed. Since
paper is not stopped at the registration position, paper interval can be shortened and productivity can be improved.
■ Stop Registration Control
It is a control to stop paper at the registration position, align the image on the ITB with the paper at a specified timing, and then
resume paper feed.
Stop registration control stops the Pre-registration Roller. Paper fed by the Pre-registration Roller after being picked up from the
cassette generates an arch due to being pushed against the Registration Roller which has been stopped. In order to align the
image on the ITB with the paper at a specified timing, this control stops paper feed with the paper arched, aligns the image on
the ITB with the paper at the specified timing, and then resumes paper feed.
2. Technical Explanation
12

Registration
Roller
Image
PS04
[1]
[2]
[4]
[3]
Cassette 2
Size Mismatch Detection Control
Whether the size is mismatched is determined by paper length.
The time a sheet of paper passes through the Pre-Registration Sensor is converted into distance. Then, the calculated distance
and the paper size detected by the Cassette 2 Size Detection Switch are compared. If the difference between them is 20 mm or
more, it is judged to be size mismatch.
In this case, paper is not delivered, but stopped instead with a jam detected.
(Jam code: 0D91)
Jam Detection
■ Jam Sensor List
Sensor number Sensor name
PS101 Cassette 2 Pullout Sensor
PS4 Pre-Registration Sensor
2. Technical Explanation
13

Periodical Service
3List of Periodical Service Works..........15

List of Periodical Service Works
This equipment does not have any items that require periodical service.
3. Periodical Service
15