Canon POD Deck Lite-C1 User manual

Revision 2.0
POD Deck Lite-C1
Service Manual

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. 2015
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
Points to Note about Turning Off the Main Power Switch................................................................... 2
Notes Before Servicing........................................................................................................................2
Notes On Assembly/Disassembly....................................................................................................... 2
Points to Note at Cleaning...................................................................................................................3
1. Product Overview.............................................................................................4
Features.............................................................................................................................................. 5
Features...............................................................................................................................................5
Specifications...................................................................................................................................... 6
Specifications....................................................................................................................................... 6
Names of Parts....................................................................................................................................7
External View........................................................................................................................................7
Cross Section....................................................................................................................................... 9
Option Construction...........................................................................................................................10
2. Technology..................................................................................................... 11
Basic Configuration........................................................................................................................... 12
Functional Construction....................................................................................................................... 12
Overview of the Electrical Circuitry....................................................................................................... 12
Component Configuration.................................................................................................................... 13
Controls.............................................................................................................................................15
Overview............................................................................................................................................ 15
Pickup/Feed Control............................................................................................................................15
Paper Presence/Absence Detection Control..........................................................................................16
Paper Surface Detection Control.......................................................................................................... 16
Lifter Control.......................................................................................................................................17
Remaining Paper Level Detection Control.............................................................................................17
Switching the Paper Size.....................................................................................................................18
Compartment Open/Close Control........................................................................................................19
Air Assist Control................................................................................................................................ 20
Cassette Heater Control (Option) ........................................................................................................ 22
Power Supply..................................................................................................................................... 23
Fan.................................................................................................................................................... 24
Jam Detection ....................................................................................................................................24
Upgrading..........................................................................................................................................26
Upgrading...........................................................................................................................................26
3. Periodical Service.......................................................................................... 27
List of Work for Scheduled Servicing................................................................................................ 28
4. Disassembly/Assembly................................................................................. 29
Removing from the Host Machine.....................................................................................................30
Contents
i

Removing from the Host Machine.........................................................................................................30
List of Parts....................................................................................................................................... 32
External Covers.................................................................................................................................. 32
Consumable Parts and Cleaning Points................................................................................................33
Main Units.......................................................................................................................................... 34
Sensors..............................................................................................................................................35
Solenoids........................................................................................................................................... 36
Motors................................................................................................................................................37
Fans...................................................................................................................................................38
PCBs..................................................................................................................................................39
Switches.............................................................................................................................................40
Others................................................................................................................................................ 41
External Covers.................................................................................................................................42
Removing the Left Upper Cover........................................................................................................... 42
Removing the Front Cover...................................................................................................................42
Removing the Right Cover...................................................................................................................43
Removing the Rear Cover....................................................................................................................44
Removing the Upper Cover .................................................................................................................45
Consumable Parts and Cleaning Points............................................................................................47
Removing the Deck Pickup Roller........................................................................................................ 47
Removing the Deck Feed Roller...........................................................................................................49
Removing the Deck Separation Roller.................................................................................................. 51
Main Units......................................................................................................................................... 54
Removing the Pickup Assembly........................................................................................................... 54
Opening the Compartment...................................................................................................................56
Removing the Compartment................................................................................................................ 56
Heaters..............................................................................................................................................60
Removing the Cassette Heater............................................................................................................ 60
Removing the Air Heater .....................................................................................................................61
Solenoids...........................................................................................................................................64
Removing the Compartment Open Solenoid......................................................................................... 64
Removing the Deck Pickup Release Solenoid ...................................................................................... 65
Motors............................................................................................................................................... 67
Removing the Deck Lifter Motor........................................................................................................... 67
Fans.................................................................................................................................................. 69
Removing the Pickup Release Solenoid Cooling Fan ............................................................................69
Lifter Wire .........................................................................................................................................71
Removing the Lifter Wire..................................................................................................................... 71
Installation of the Lifter Wire.................................................................................................................74
PCBs................................................................................................................................................. 84
Removing the Deck Driver PCB........................................................................................................... 84
Removing the Paper Width Detection PCB........................................................................................... 84
5. Adjustment..................................................................................................... 87
Adjustment ....................................................................................................................................... 88
Overview............................................................................................................................................ 88
Actions when Replacing the Parts.....................................................................................................90
Front Cover........................................................................................................................................ 90
Pickup Assembly.................................................................................................................................90
Contents
ii

Compartment......................................................................................................................................93
Deck Driver PCB ................................................................................................................................94
Paper Width Detection PCB.................................................................................................................94
Other Adjustment ............................................................................................................................. 96
Adjusting the Pressure of the Deck Separation Roller............................................................................ 96
Adjusting the Paper Separation ...........................................................................................................96
6. Installation.................................................................................................... 100
How to Utilize this Installation Procedure........................................................................................101
Description on the Parts Included in the Package................................................................................ 101
Symbols in the Illustration.................................................................................................................. 101
Checking before Installation............................................................................................................102
Checking the Installation Space..........................................................................................................102
Points to Note on Installation..............................................................................................................102
Checking the Power Supply............................................................................................................... 103
Check Items When Turning OFF the Main Power................................................................................ 103
Product Name...................................................................................................................................103
Unpacking Procedure......................................................................................................................104
Unpacking Procedure........................................................................................................................ 104
Checking the Contents....................................................................................................................105
imageRUNNER ADVANCE 8500 Series............................................................................................. 105
imagePRESS C10000VP / C8000VP Series....................................................................................... 107
Installation Procedure......................................................................................................................109
imageRUNNER ADVANCE 8500 Series............................................................................................. 109
imagePRESS C10000VP / C8000VP Series....................................................................................... 119
Checking after Installation...............................................................................................................132
imageRUNNER ADVANCE 8500 Series............................................................................................. 132
imagePRESS C10000VP / C8000VP Series....................................................................................... 132
Paper Positioning Check / Adjustment Procedure.......................................................................... 133
imageRUNNER ADVANCE 8500 Series............................................................................................. 133
imagePRESS C10000VP / C8000VP Series....................................................................................... 136
Cassette Heater Assembly..............................................................................................................139
Check Items when Turning OFF the Main Power.................................................................................139
Checking the Supplied Parts.............................................................................................................. 139
Removing from the Host Machine.......................................................................................................139
Installation Procedure........................................................................................................................140
APPENDICES....................................................................................................144
Service Tools...................................................................................................................................145
Solvents and Oils.............................................................................................................................. 145
Special Tools.................................................................................................................................... 145
General Circuit Diagram..................................................................................................................146
General Circuit Diagram (1/3 )............................................................................................................146
General Circuit Diagram (2/3).............................................................................................................147
General Circuit Diagram (3/3).............................................................................................................148
Contents
iii

Safety Precautions
Points to Note about Turning Off the
Main Power Switch............................2
Notes Before Servicing......................... 2
Notes On Assembly/Disassembly.........2
Points to Note at Cleaning.................... 3

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.
NOTE:
Explain to the customer that the leakage breaker must be checked once or twice a month and the result must be recorded.
Leakage Breaker
Notes Before Servicing
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.
Notes On Assembly/Disassembly
Follow the items below to assemble/disassemble the device.
1. Disconnect the power plug to avoid any potential dangers during assembling/disassembling works.
2. If not specially instructed, reverse the order of disassembly to reinstall.
Safety Precautions
2

3. Ensure to use the right screw type (length, diameter, etc.) at the right position when assembling.
4. To keep electric conduction, binding screws with washers are used to attach the grounding wire and the varistor. Ensure to
use the right screw type when assembling.
5. Unless it is specially needed, do not operate the device with some parts removed.
6. Never remove the paint-locked screws when disassembling.
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.
Safety Precautions
3

Product Overview
1Features................................................5
Specifications........................................6
Names of Parts..................................... 7
Option Construction............................ 10

Features
Features
• The various paper sizes from the A5 to 13"X19"(330.0X482.6mm) are supported. In addition, the custom paper size is
supported, too.
• The high stacking of maximum 3,500 sheets (80 g/m2) is possible.
• The user can change the stacking paper size easily by the side and rear guide plates with the free stop mechanism and the
automatic paper size detection function.
• The envelope can be picked up by attaching the optional Envelope Feeder Attachment.
• The replacement work of the consumable parts is easy.
1. Product Overview
5

Specifications
Specifications
Item Specifications Remarks
Pickup method Retard separation + Air assist (switches between warm and cool cur-
rents to suit paper type/environment)
Center reference
Paper accommo-
dation
Front loading
Paper type Thin paper (52 to 79 g/m2), Plain paper (80 to 105 g/ m2), Heavy paper
(106 to 300 g/m2), Color paper, Recycled paper, Pre-punched paper,
Transparency, Label paper, Tab paper, Bond paper, Letterhead, Coat-
ed paper, Textured paper, Vellum paper, Envelopes*1
Different depending on the host machine.
*1: Only when the optional Envelope Feed-
er Attachment is installed.
Paper size 13 X 19 (330.2 X 482.6 mm), SRA3 (320 X 450 mm), 12 X 18 (304.8
X 457.2 mm), A3, A4, A4R, A5R, B4, B5, B5R, 11 X17 (279 X 432 mm),
LGL, LTR, LTRR, EXEC, STMTR, 8K, 16K, 16KR, Envelopes (Mon-
arch, COM10, ISO-C5, DL, Kakugata 2, Nagagata 3, Yougatanaga 3,
10 X 13 (254 X 330.2 mm)*2, 9 X 12 (228.6 X 304.8 mm), 6 X 9 (152.4
X 228.6 mm))*1, Custom size (100 X 148 mm to 330.2 X 487.7 mm)
Different depending on the host machine.
*1: Only when the optional Envelope Feed-
er Attachment is installed.
*2: Do not use the Envelope Feeder At-
tachment.
Paper weight 52 g/m2 to 300 g/m2
Stacking height 385 mm (height to bottom of arrow on stack limit label) Envelope: 100
mm*1
*1: When the paper is Yougatanaga 3, the
stack height is 160 mm or less.
Stacking capacity Approx. 3500 sheets (equivalent of 80 g/m2)
Size switching Switching the guide plates by the user operation
Paper size detec-
tion
Yes (Paper width: detected by the volume sensor, Paper length: de-
tected by the photo-interrupter)*1
*1: The size of envelope and custom size
paper are not detected.
Remaining paper
level detection
Yes
Operation switch Compartment open button
Display None
Ecological consid-
eration
Environment sensor, Air heater (standard), Cassette heater (option,
supplied as the service parts)
Dimensions (W) 717 X (D) 686 X (H) 568 mm
Weight Approx. 76 kg
Power supply AC 100 to 240 V 50/60 Hz 2.4A
Operating noise Host machine noise + 2.5 dB
1. Product Overview
6

Names of Parts
External View
■ Front
[5]
[4]
[1]
[2] [3]
[1] Left upper cover
[2] Upper cover
[3] Compartment open button
[4] Front cover
[5] Deck release lever
1. Product Overview
7

■ Rear
[2]
[1]
[3][4][5]
[1] Rear cover
[2] Right cover
[3] Cassette heater switch
[4] Power socket
[5] Leakage breaker
■ Internal
[4]
[2]
[5]
[1]
[6]
[3]
1. Product Overview
8

[1] Side guide plate (rear)
[2] Rear guide plate
[3] Lifter
[4] Side guide plate (front)
[5] Envelope side guide plate (front)
[6] Envelope side guide plate (rear)
Cross Section
[2] [4] [3]
[1] [5] [6]
[1] Deck pull-out roller
[2] Deck separation roller
[3] Deck feed roller
[4] Deck pickup roller
[5] Blow-out vent (warm air)
[6] Blow-out vent (cool air)
1. Product Overview
9

Option Construction
The following optional equipment can install to the this equipment.
• Envelope Feeder Attachment-G1 : User installation
• Cassette heater : Supplied as the service parts
Cassette Heater
Envelope Feeder Attachment-G1
1. Product Overview
10

Technology
2Basic Configuration.............................12
Controls...............................................15
Upgrading............................................26

Basic Configuration
Functional Construction
The POD Deck Lite is grouped into the following 3 blocks: Pickup/feed system, Compartment system, Deck control system.
1.Pickup/feed system 2.Compartment system
3.Deck control system
Overview of the Electrical Circuitry
The operating sequence for the Paper Deck Unit is controlled by the DC controller PCB in the host machine. The DC controller
PCB is equipped with CPU. The electric control for the Paper Deck Unit is controlled by the deck driver PCB. The deck driver
PCB is equipped with EEPROM.
NOTE:
The EEPROM stores the following adjustment value.
• ID for model discrimination
• Small size AD value/large size AD value (volume value of the free size detection PCB)
• Remaining paper level adjustment value (up/down movement distance of the lifter)
• Wind-power correction value of the warming/cooling fan
2. Technology
12

Host
machine
Deck driver
PCB(PCB1)
Box driver
PCB(PCB2)
Sensor
Motor
Switch
Motor
Sensor
Sensor
Switch
Fan
Solenoid
Fan
ASIC
Motor driver
DC/DC converter
Regulator
EEPROM
Swing driver
PCB(PCB6)
Motor driver
Component Configuration
■ Roller Layout
[2] [4] [3]
[1]
[1] Deck pull-out roller
[2] Deck separation roller
[3] Deck feed roller
[4] Deck pickup roller
2. Technology
13

■ Sensor Layout
Only the optical sensors on the feed path are shown below.
SR6 SR7
SR6 Deck pull-out sensor
SR7 Deck pickup sensor
■ Drive Configuration
M2
SL2
M1 M4
M3
SL1
M1 Deck pickup motor
M2 Deck pull-out motor
M3 Deck lifter motor
M4 Swing motor
SL1 Compartment open solenoid
SL2 Deck pickup release solenoid
2. Technology
14