Canon Paper Deck-AF1 User manual

54321
Paper Deck-AF1
Service Manual
November 19, 2009
Revision 2
Product Outline
Technology
Periodic Servicing
Parts Replacement and Cleaning Procedure
Installation
Appendix

0
00-2
0-2
Application
This manual has been issued by Canon Inc. for qualied 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
written consent of Canon Inc.
(C) CANON INC. 2007
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential
information.

0
00-3
0-3
Explanation of Symbols
The following symbols are used throughout this Service Manual.
Symbols Explanation Symbols Explanation
Check. Remove the claw.
Check visually. Insert the claw.
Check the noise. Use the bundled part.
Disconnect the connector. Push the part.
Connect the connector. Plug the power cable.
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.
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.

0
00-4
0-4

0
00-5
0-5
Contents
1Safety Precautions0-1
Points to Note About Turning Off the Main Power Switch ----------0-2
Notes Before it Works Serving---------------------------------------------0-3
2Product Outline 1-1
Features--------------------------------------------------------------------------- 2
A lot of sheets of paper can be fed----------------------------------------------- 2
High productivity ---------------------------------------------------------------------- 2
A variety of media can be fed------------------------------------------------------2
Side guide plate with a free stop mechanism---------------------------------- 2
Specications -------------------------------------------------------------------- 3
Names of Parts------------------------------------------------------------------ 4
External View (Front) ----------------------------------------------------------------4
External View (Rear) -----------------------------------------------------------------4
External View (Internal) -------------------------------------------------------------5
Cross Section--------------------------------------------------------------------------5
Explanation of Basic Operations-------------------------------------------- 6
3Technology 2-1
Basic Conguration------------------------------------------------------------- 2
Functional Conguration ------------------------------------------------------------2
Overview of Electrical Circuitry ---------------------------------------------------- 3
Component Conguration ----------------------------------------------------------3
Drive Conguration -------------------------------------------------------------------4
Basic Operation Outline------------------------------------------------------------- 5
Controls---------------------------------------------------------------------------- 6
Overview --------------------------------------------------------------------------------6
Pickup Block --------------------------------------------------------------------------- 7
Feed Block-----------------------------------------------------------------------------11
Compartment Block ---------------------------------------------------------------- 14
Detecting Jams---------------------------------------------------------------------- 19
Power Supply ------------------------------------------------------------------------ 21
Servicing Work ---------------------------------------------------------------------- 23
4Periodic Servicing 3-1
Periodic Service Works ------------------------------------------------------- 2
5Parts Replacement and Cleaning Procedure 4-1
Removing this Equipment----------------------------------------------------- 2
List of Parts ----------------------------------------------------------------------- 5
External Covers -----------------------------------------------------------------------5
Main Units ------------------------------------------------------------------------------ 6
Consumable Parts Requiring Periodic Replacement and Cleaning
Points ------------------------------------------------------------------------------------7
Solenoids -------------------------------------------------------------------------------8
Clutches---------------------------------------------------------------------------------9
Motors --------------------------------------------------------------------------------- 10
Fans-------------------------------------------------------------------------------------11
Heaters-------------------------------------------------------------------------------- 12
Sensors-------------------------------------------------------------------------------- 13
Switches------------------------------------------------------------------------------- 14
PCBs----------------------------------------------------------------------------------- 15
Other----------------------------------------------------------------------------------- 16
External Covers ----------------------------------------------------------------17
External Covers --------------------------------------------------------------------- 17
Main Units------------------------------------------------------------------------21
Removing the Pickup Unit -------------------------------------------------------- 21
Removing the Deck Unit ---------------------------------------------------------- 22
Periodic Parts Replacement, Consumable Parts, and Cleaning
Parts-------------------------------------------------------------------------------24
Removing the Deck Pickup Roller (front, rear) ------------------------------ 24
Removing the Deck Pickup/Feed Roller -------------------------------------- 25
Removing the Deck Separation Roller ---------------------------------------- 26
Removing the Deck Pull-out Roller--------------------------------------------- 27
Removing the Torque Limiter ---------------------------------------------------- 28
Removing the Deck Pickup Clutch --------------------------------------------- 29

0
00-6
0-6
Removing the Deck Pull-out Clutch-------------------------------------------- 30
Removing the Deck Pickup Roller Release Solenoid---------------------- 31
Removing the Bushing ------------------------------------------------------------ 32
Removing the Solenoids -----------------------------------------------------33
Removing the Deck Pickup Roller Release Solenoid (SL101/SL201/
SL301) --------------------------------------------------------------------------------- 33
Removing the Deck Open/Close Solenoid (SL102/SL202/SL302)----- 34
Removing the Clutches-------------------------------------------------------35
Removing the Deck Pickup Clutch (CL101/CL201/CL301) -------------- 35
Removing the Deck Pull-out Clutch (CL102/CL202/CL302) ------------- 36
Removing the Motors ---------------------------------------------------------37
Removing the Deck Pickup Motor (M001)------------------------------------ 37
Removing the Vertical Path Upper Feed Motor (M002)------------------- 38
Removing the Vertical Path Lower Feed Motor (M003)------------------- 38
Removing the Horizontal Path Feed Motor (M004) ------------------------ 39
Removing the Lifter Motor (M101/M201/M301) ----------------------------- 39
Removing the Swing Motor (M102/M202/M302)---------------------------- 41
Removing the Fans------------------------------------------------------------42
Removing the Power Supply Cooling Fan (FAN001) ---------------------- 42
Removing the Left Flotation Fan (FAN101/FAN201/FAN301)----------- 43
Removing the Right Flotation Fan (FAN102/FAN202/FAN302)--------- 44
Removing the PCBs-----------------------------------------------------------45
Removing the Deck Driver PCB (PCB1)-------------------------------------- 45
Removing the DC Power Supply PCB (PCB2)------------------------------ 46
Removing the AC Distributor PCB (PCB3)----------------------------------- 48
Removing the Noise Filter PCB (PCB4) -------------------------------------- 49
Removing the Deck Open Switch PCB (PCB5/PCB6/PCB7)------------ 50
6Installation 5-1
Procedure for Installing Options--------------------------------------------- 2
Checks to Make before Installation----------------------------------------- 3
Checking the Power Supply--------------------------------------------------------3
Checking the Installation Space---------------------------------------------------3
Installation Precautions--------------------------------------------------------------4
Checking the Supplied Parts------------------------------------------------- 5
How to Utilize This Installation Procedure -------------------------------- 6
When Using the Contained Parts(Bundled Components in the Shipping
Carton)----------------------------------------------------------------------------------- 6
Symbols in the Illustration ----------------------------------------------------------6
Unpacking Procedure ---------------------------------------------------------- 7
Installation Procedure---------------------------------------------------------12
Making Preparations for Installing the Parts on the Paper Deck Side- 12
Making Preparations for Installing Parts on the Host Machine Side--- 14
Checking and Adjusting the Heights ------------------------------------------- 17
Checking and Adjusting the Tilt-------------------------------------------------- 20
Connecting to the Host Machine------------------------------------------------ 22
Securing the Paper Deck Stopper---------------------------------------------- 24
Installing Cables--------------------------------------------------------------------- 26
Switching between Paper Sizes------------------------------------------------- 27
Installing the Size Indication Plate---------------------------------------------- 29
Checking for Operation------------------------------------------------------------ 30
Machine Relocation Work----------------------------------------------------31
Paper Deck Double Deeding Detection Kit-A1 Installation
Procedure------------------------------------------------------------------------33
Separating the Paper Deck from the Host Machine------------------------ 34
Checking the Supplied Parts----------------------------------------------------- 37
Installing the Double Feeding Sensor Unit ----------------------------------- 38
Air Heater Unit Installation Procedure ------------------------------------45
Parts Preparation ------------------------------------------------------------------- 46
Installing the Air Heater Unit ----------------------------------------------------- 47
Cassette Heater Unit Installation Procedure ----------------------------54
Parts Preparation ------------------------------------------------------------------- 55
Installing the Cassette Heater Unit -------------------------------------------- 56
Installing the Cassette Heater Mounting Kit---------------------------------- 59
7Appendix 6-1
Service Tools--------------------------------------------------------------------- 2
General Circuit Diagram-----------------------------------------------------6-3
General Circuit Diagram --------------------------------------------------------- 6-3

Safety Precautions
Points to Note About
Turning Off the Main
Power Switch
Notes Before it Works
Serving
■
■

0
00-2
0-2
Points to Note About Turning Off the Main Power Switch
This equipment does not have a main power switch, but it has only a leakage breaker.
This equipment is powered when the main power switch of the host machine is turned on.
The leakage breaker detects overcurrent and power leakage.
MEMO:
Explain to the customer that the leakage breaker must be checked once or twice a month and
the result must be recorded.
Leakage breaker
F-0-1F-0-1

0
00-3
0-3
Notes Before it Works Serving
Caution
At servicing, be sure to turn off the power source according to the specied 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.

1
1Product Outline
Product Outline
Features
Specications
Names of Parts
Explanation of Basic Op-
erations
■
■
■
■

1
12
2
Product Outline > Features > Side guide plate with a free stop mechanism
Product Outline > Features > Side guide plate with a free stop mechanism
Features
A lot of sheets of paper can be fed
A maximum of 6000 sheets (3 decks x 2000 sheets (80 g/m2).
High productivity
Productivity of a maximum of 110 PPM is assured.
A variety of media can be fed
This equipment can feed coated/thick and handle 52 to 300 g/m2 media.
Side guide plate with a free stop mechanism
You can easily change the position of the side guide plate when setting paper in the deck.

1
13
3
Product Outline > Specications
Product Outline > Specications
Specications
Pickup method Retard separation + Air assist
Source of paper 3 decks (upper, middle, and lower)
Paper accommodation Front loading
Media type Thin, Plain, Heavy, Recycled, Color, Pre-punched, Bond Paper,
Labels, Transparency, Tab Paper, Coated, Texture Paper, Vellum
Media size A3, B4, A4, A4R, B5, B5R, 13" x 19" (330.2 x 482.6 mm), 12"
x 18" (304.8 x 457.2 mm), 11" x 17", LGL, LTR, LTRR, EXEC,
EXECR, 12 5/8" x 17 3/4" (320 x 450 mm) and Irregular Size (7
1/8" x 7 1/8" to 13" x 19 1/4" (182 mm x 182 mm to 330.2 mm x
487.7 mm))
Media size switching Switched by the user (free stop)
Stack height (number
of sheets)
Each deck: 210 mm (2000 sheets, 80 g/m2)
Media type detection No (Input from the control panel of the host machine.)
Media size detection No (Input from the control panel of the host machine.)
Remaining paper level
detection Yes (Displayed on the control panel of the host machine.)
Speed shift between
sections None (Fixed speed)
Operation switch Deck open switch
Display None
Dimensions 985 (W) × 797 (D) × 1098 (D) mm
Weight About 150 kg
Power supply 100 VAC to 240 VAC (50 to 60 Hz)
Options Double feeding sensor unit, air heater unit, cassette heater unit,
and cassette heater mounting kit

1
14
4
Product Outline > Names of Parts > External View (Rear)
Product Outline > Names of Parts > External View (Rear)
Names of Parts
External View (Front)
Escape tray Deck upper rear cover Deck upper front cover
Deck left front cover
Upper deck
Middle deck
Lower deck
Deck open switch
F-1-1F-1-1
External View (Rear)
Power plug
Cassette heater switch
Leakage breaker
Deck Rear Left Cover
Deck Rear Right Cover
Deck Right Cover
F-1-2F-1-2

1
15
5
Product Outline > Names of Parts > Cross Section
Product Outline > Names of Parts > Cross Section
External View (Internal)
Rear guide plate
Side guide plate
F-1-3F-1-3
Cross Section
[1][2][3][4][5]
[6]
[7]
[8]
[9]
[10]
[1][2][3][4]
[1]
[2]
[3]
[4]
[11]
[13]
[12]
[14]
[15]
[11]
[12]
[12]
[1]Deck pickup roller [9]Horizontal path feed right roller
[2]Deck pickup/feed roller [10]Horizontal path feed left roller
[3]Deck separation roller [11]Pickup block
[4Deck pull-out roller [12]Lifter
[5]Vertical path Upper feed roller [13]Upper deck
[6]Vertical path Middle feed roller [14]Middle deck
[7]Vertical path lower feed roller [15]Lower deck
[8]Lower deck feed roller
F-1-4F-1-4

1
16
6
Product Outline > Explanation of Basic Operations
Product Outline > Explanation of Basic Operations
Explanation of Basic Operations
Deck open switch
Cassette heater switch
F-1-5F-1-5
[1] Deck open switch
Used to open the deck.
LED stays lit.: No paper
LED blinks: The lifter is moving up or down.
LED stays unlit: Paper is present with the deck open or closed.
[2]Cassette heater switch
Used to turn on/off the cassette heater.
ON: Always power on
OFF: Always power off
MEMO:
The heater mark shown at the left of the cassette heater switch indicates
that this switch is a cassette heater switch.
Heater mark Cassette heater switch
F-1-6F-1-6

2
2Technology
Technology
Basic Conguration
Controls
■
■

2
22
2
Technology > Basic Conguration > Functional Conguration
Technology > Basic Conguration > Functional Conguration
Basic Conguration
Functional Conguration
This equipment consists of four major blocks: power supply block, deck block, pickup block,
and feed block.
Power supply
block [1]
Supplies power to every block.
Deck block [2] Supplies paper from a deck during printing. It consists of three decks.
Pickup block [3] Picks up sheets one by one from the deck block and hands them over to
the feed unit. It is provided for each deck in the deck block.
Feed block [4] Feeds the paper received from each pickup block to the host machine.
MEMO:
This equipment does not have a microcomputer (CPU). It is controlled by the DC con-
troller PCB of the host machine.
1.Power supply block
4.Feed block 3.Pickup block
2.Deck block
F-2-1F-2-1

2
23
3
Technology > Basic Conguration > Component Conguration > Roller Layout
Technology > Basic Conguration > Component Conguration > Roller Layout
Overview of Electrical Circuitry
The electrical mechanisms of this equipment are controlled by the host machine(DC control-
ler PCB) and deck driver PCB.
DC Power supply PCB
AC distributor PCB
DC/DC
converter
Air heater PCB
(options)
Regulator
Noise filter PCB
Leakage
breaker
Host machine
Motor
Fan
Clutch
switch
Sensor
Solenoid
Sensor
(options)
Deck driver
PCB
Motor
driver
Cassette heater
(options)
Air heater
(options)
F-2-2F-2-2
Component Conguration
Roller Layout
[1][2][3][4][5]
[8] [1][2][3][4]
[1]
[2]
[3]
[4]
[6]
[7]
[9]
[10]
[1]Deck pickup roller [6]Vertical path Middle feed roller
[2]Deck pickup/feed roller [7]Vertical path lower feed roller
[3]Deck separation roller [8]Lower deck feed roller
[4]Deck pull-out roller [9]Horizontal path feed right roller
[5]Vertical path Upper feed roller [10]Horizontal path feed left roller
■
F-2-3F-2-3

2
24
4
Technology > Basic Conguration > Drive Conguration
Technology > Basic Conguration > Drive Conguration
Sensor Layout
Only the optical sensors on the pickup path are shown below.
S102
S101
S202
S201
S302
S301
S001
S002
S003
S009
S005
S010
S004
S001:Vertical path upper sensor
S002:Vertical path middle sensor
S003:Vertical path lower sensor
S004:Lower deck feed sensor
S005:Delivery sensor
S009:Double feeding sensor (Receive)
S010:Double feeding sensor (Transmission)
S101:Upper deck pull-out sensor
S102:Upper deck pickup sensor
S201:Middle deck pull-out sensor
S202:Middle deck pickup sensor
S301:Lower deck pull-out sensor
S302:Lower deck pickup sensor
■
F-2-4F-2-4
Drive Conguration
M004
M003
CL101
CL102
M001
CL202
CL301
SL101 M102
SL201 M202
M302
SL301
M101
M201
M301
SL102
SL202
CL302 SL302
M002
CL201
M001:deck pickup motor SL102:Upper deck open/close solenoid
M002:Vertical path Upper feed motor SL201:Middle deck pickup roller release solenoid
M003:Vertical path Lowerfeed motor SL202:Middle deck open/close solenoid
M004:Horizontal path feed motor SL301:Lowerdeck pickup roller release solenoid
M101:Upper deck lifter motor SL302:Lowerdeck open/close solenoid
M201:Middle deck lifter motor CL101:Upper deck pickup clutch
M301:Lowerdeck lifter motor CL102:Upper deck pull-out clutch
M102:Upper deck swing motor CL201:Middle deck pickup clutch
M202:Middle deck swing motor CL202:Middle deck pull-out clutch
M302:Lowerdeck swing motor CL301:Lowerdeck pickup clutch
SL101:Upper deck pickup roller release solenoid CL302:Lowerdeck pull-out clutch
F-2-5F-2-5

2
25
5
Technology > Basic Conguration > Basic Operation Outline
Technology > Basic Conguration > Basic Operation Outline
Basic Operation Outline
This equipment feeds paper to the host machine.
The unit conguration and pickup operation of the upper, middle, and lower decks are the
same.
The paper picked up from each deck is fed to the host machine via the vertical and horizontal
paths.
The unnecessary paper caused by double feeding is delivered to the escape tray via the
escape path in the host machine.
Paper pickup
Paper feed
Paper delivery to host machine
F-2-6F-2-6