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Canon AJ1 Service Manual
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Canon AJ1 Service Manual

Cassette feeding unit
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Revision 2.0
Cassette Feeding Unit-AJ1
Service Manual

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Summary of Contents for Canon AJ1

  • Page 1 Revision 2.0 Cassette Feeding Unit-AJ1 Service Manual...
  • Page 2 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.
  • Page 3 Introduction Symbols Explanation Symbols Explanation Disconnect the connector. Connect the power cable. Connect the connector. Disconnect the power cable. Remove the cable/wire from the Turn on the power. cable guide or wire saddle. Install the cable/wire to the cable Turn off the power. guide or wire saddle.

  • Page 4: Table Of Contents

    Contents 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 Basic Configuration..........................7 Parts Configuration..........................7 Paper Path............................9 Controls............................. 10 Paper Size Detection Control....................... 10 Paper Level Detection Control......................12 Paper Detection Control........................
  • Page 5 Contents Removing the Auto Close Unit......................37 Removing the Pickup Unit........................39 Removing the Pullout Motor (M106)..................... 40 Removing the Pickup Motor (M102)......................40 Removing the Lifter Motor (M104)......................41 Removing the Pickup Drive Unit......................41 5. Adjustment..................... 43 Pickup Feed System......................... 44 Cassette Left Edge Margin Adjustment (1st Side: Mechanical Adjustment)..........

  • Page 6: Safety Precautions

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

  • Page 7: Notes Before It Works Serving

    Safety Precautions 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.

  • Page 8: Product Overview

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

  • Page 9: Overview

    1. Product Overview Overview Specification Item Description Paper storage method Front loading method Pickup method Retard separation method Paper stack capacity 550 sheets (80 g/m 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...
  • Page 10 1. Product Overview Parts Name Connector Cover Rear Cover Right Lower Cover Cassette Right Cover Right front cover ■ Cross-section View Parts Name Cassette 2 pickup Roller Cassette 2 vertical path Roller Cassette 2 feed Roller Cassette 2 separation Roller Cassette 2 Lifting Plate...

  • Page 11: Technical Explanation

    Technical Explanation Basic Configuration....... 7 Controls..........10...

  • Page 12: Basic Configuration

    2. Technical Explanation Basic Configuration Parts Configuration ■ Rollers Layout Drawing Parts Name Cassette 2 pickup Roller Cassette 2 vertical path Roller Cassette 2 feed Roller Cassette 2 separation Roller ■ Sensors Layout Drawing PS101 PS104 SW101 PS107 PS110 SW104 Parts Name PS101 Cassette 2 Pullout Sensor...
  • Page 13 2. Technical Explanation Parts Name PS107 Cassette 2 Paper Surface Sensor PS110 Cassette 2 Paper Level Sensor SW101 Cassette 2 Size Detection Switch SW104 Cassette Right Door Open/ Close Detection Switch ■ Route of Drive M102 M106 M104 Parts Name M102 Cassette 2 pickup Motor M104...

  • Page 14: Paper Path

    2. Technical Explanation Paper Path Cassette 2...

  • Page 15: Controls

    2. Technical Explanation 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.
  • Page 16 2. Technical Explanation Cassette Size Switch Size Length Length Detection A5-R 210.0 STMT-R 215.9 B5-R 257.0 EXEC-R 267.0 16K-R 270.0 LTR-R 279.4 A4-R 297.0 355.6 (No cassette) A5-R STMT-R B5-R EXEC-R 16K-R 16K-R LTR-R LTR-R A4-R Paper size *1 Length All modes A/B configuration Inch configuration...

  • Page 17: Paper Level Detection Control

    2. Technical Explanation Paper size *1 Length All modes A/B configuration Inch configuration A/K configuration 16K-R 270.0 Improper loading of pa- Improper loading of pa- LTR-R 279.4 Improper loading of pa- Improper loading of pa- Improper loading of pa- A4-R 297.0 Improper loading of pa- 355.6...
  • Page 18 2. Technical Explanation 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.
  • Page 19 2. Technical Explanation Cassette Paper Sensor Cassette Paper Surface Sensor Paper Paper Cassette Paper Level Sensor...

  • Page 20: Paper Detection Control

    2. Technical Explanation Cassette Paper Sensor Cassette Paper Surface Sensor Paper Paper 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).

  • Page 21: Lifter Control

    2. Technical Explanation 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: •...

  • Page 22: Size Mismatch Detection Control

    2. Technical Explanation Image Registration PS04 Roller 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.

  • Page 23: Periodical Service

    Periodical Service List of Periodical Service Works..19...

  • Page 24: List Of Periodical Service Works

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

  • Page 25: Disassembly/Assembly

    Disassembly/ Assembly Parts List..........21 Electrical Components List....23 Removal from the Connected Equipment ........26 External Cover System....... 28 Controller System........33 Pickup Feed System......34...

  • Page 26: Parts List

    4. Disassembly/Assembly Parts List External Cover / Internal Parts Name Front Upper Cover Upper Tray Cover Lower Tray Cover Left Cover Connector Cover Rear Cover Right Lower Cover Right Cover Right front cover...

  • Page 27: Major Units

    4. Disassembly/Assembly Major Units Parts Name Right Cover Pickup Unit Auto Close Unit Lifter Drive Unit Pickup Drive Unit...

  • Page 28: Electrical Components List

    4. Disassembly/Assembly Electrical Components List Sensor PS107 PS104 PS101 PS110 Parts Name PS101 Pullout Sensor PS104 Paper Sensor PS107 Paper Surface Sensor PS110 Paper Level Sensor Motor M102 M106 M104 Parts Name M102 Pickup Motor M104 Lifter Motor...

  • Page 29: Switch /Pcb /Motor /Solenoid

    4. Disassembly/Assembly Parts Name M106 Pullout Motor Switch /PCB /Motor /Solenoid SW104 SW101 UN101 Parts Name UN101 Cassette Module Controller PCB SW101 Size Detection Switch SW104 Right Door Open/Close Detection Switch List of Connectors J5972 J5971 J5955 J5551 J5974 J5968 J652 J651 J5954...
  • Page 30 4. Disassembly/Assembly J No. Symbol Name Relay con- J No. Symbol Name nector J651 UN101 Controller PCB J5958 J5973 SW101 Size Detection Switch J651 UN101 Controller PCB J5962 J5974 SW104 Right Door Open/Close Detection Switch J652 UN101 Controller PCB J5931 J5954 PS101 Pullout Sensor...

  • Page 31: Removal From The Connected Equipment

    4. Disassembly/Assembly Removal from the Connected Equipment Procedure 1. Remove the Cassette 1 [1]. 2. Remove the Front Upper Cover [1]. • 1 Claw [2] • 1 Hook [3] 3. Remove the Connecting Plate [1]. • 1 Knurled Screw [2]...
  • Page 32 4. Disassembly/Assembly 4. Remove the 2 Face Covers [1]. • 2 Claws [2] • 2 Hooks [3] 5. Remove the 2 Connecting Plates [1]. • 2 Knurled Screws [2] 6. Hold the indented area [A] of the host machine and lift it down from the equipment. CAUTION: •...

  • Page 33: External Cover System

    4. Disassembly/Assembly External Cover System Removing the Rear Cover ■ Procedure 1. Remove the Rear Cover [1]. • 3 Screws [2] • 4 Hooks [3] Removing the Right Cover ■ Preparation “Removing the Rear Cover” on page 28 ■ Procedure 1.
  • Page 34 4. Disassembly/Assembly 2. Remove the Right Lower Cover [1]. • 3 Screws [2] • 5 Hooks [3] CAUTION: Be careful not to drop the Right Cover [1] when disassembling/assembling. 3. Remove the screw [2] while supporting the Right Cover [1].
  • Page 35 4. Disassembly/Assembly 4. Remove the Arm Holder [2] while supporting the Right Cover [1]. • 1 Shaft [3] • 2 Bosses [4] 5. Remove the Right Cover [1]. • 2 Shafts [2]...

  • Page 36: Removing The Cassette Receptacle

    4. Disassembly/Assembly NOTE: How to install the Arm Holder 1. Align the 2 bosses [3] of the Arm Holder with the 2 holes [A] of the Right Cover. 2. While closing the Right Cover [1], align the hole [B] of the Arm Holder with the shaft [2], and keep on being similar. Then, secure the holder with the screw removed in step 3.
  • Page 37 4. Disassembly/Assembly NOTE: How to install the Receptacle Be sure to fit the 4 protrusions [1] at the rear side of the receptacle to the 4 holes [B] of the Rear Plate and fit the hole [A] at the rear side of the receptacle to the protrusion [2] of the Right Front Cover.

  • Page 38: Controller System

    4. Disassembly/Assembly Controller System Removing the Cassette Module Controller PCB ■ Preparation “Removing the Rear Cover” on page 28 ■ Procedure 1. Remove the Cassette Module Controller PCB [1]. • 4 Connectors [2] • 2 Screws [3] • 2 Hooks [4]...

  • Page 39: Pickup Feed System

    4. Disassembly/Assembly Pickup Feed System Removing the Pickup/ Feed/ Separation Roller ■ Procedure NOTE: The layout for the Pickup Roller [1] /Separation Roller [2] /Feed Roller [3] is shown below. CAUTION: Be sure not to touch the surface [A] of the roller when disassembling/assembling. 1.
  • Page 40 4. Disassembly/Assembly ■ When removing the Pickup Roller. 1. Move the Pickup Guide Holder [1]. 2. Remove the Pickup Roller [1]. • 1 Claw [2] NOTE: How to install the Pickup Roller • Be sure to align the groove [A] of the Pickup Roller [1] with the protrusion [B] of the gear to install the roller. •...
  • Page 41 4. Disassembly/Assembly ■ When removing the Feed Roller. 1. Move the Pickup Guide Holder [1]. 2. Remove the Feed Roller [1]. • 1 Claw [2] NOTE: How to install the Feed Roller • Be sure to align the groove [A] of the Feed Roller [1] with the protrusion [B] of the coupling to install the roller. •...

  • Page 42: Removing The Auto Close Unit

    4. Disassembly/Assembly ■ When removing the Separation Roller 1. Remove the Separation Roller [1]. • 1 Claw [2] NOTE: How to install the Separation Roller. • Be sure to align the groove [A] of the coupling with the spring pin [3] of the shaft to install the roller. •...
  • Page 43 4. Disassembly/Assembly ■ Procedure 1. Pull out the Cassette [1]. 2. Remove the Auto Close Unit [1]. • 1 Wire Saddle [2] • 1 Connector [3] • 2 Screws [4] • 1 Boss [5] • 1 Hook [6] CAUTION: How to install the Auto Close Unit Be sure to install the spring [1] of the Auto Close Unit to the inner side of the plate [A] of the Rear Plate.

  • Page 44: Removing The Pickup Unit

    4. Disassembly/Assembly Removing the Pickup Unit ■ Preparation “Removing the Rear Cover” on page 28 ■ Procedure 1. Disconnect the connector [1] and remove the Edge Saddle [2]. 2. Open the Right Cover [1], and remove the Cassette [2]. 3. Open the Wire Saddle [1] and pull out the harness [2] from the hole [A].

  • Page 45: Removing The Pullout Motor (M106)

    4. Disassembly/Assembly 4. Remove the Pickup Unit [1]. • 4 Screws [2] Removing the Pullout Motor (M106) ■ Preparation “Removing the Rear Cover” on page 28 ■ Procedure 1. Remove the Pullout Motor [1]. • 1 Connector [2] • 2 Screws [3] Removing the Pickup Motor (M102) ■...

  • Page 46: Removing The Lifter Motor (M104)

    4. Disassembly/Assembly ■ Procedure 1. Remove the Pickup Motor [1]. • 1 Connector [2] • 2 Screws [3] Removing the Lifter Motor (M104) ■ Preparation “Removing the Rear Cover” on page 28 ■ Procedure 1. Remove the Lifter Motor [1]. •...
  • Page 47 4. Disassembly/Assembly “Removing the Pickup Unit” on page 39 ■ Procedure 1. Disconnect the connector [1] and remove the 2 screws [2]. 2. Remove the Pickup Drive Unit [1]. • 1 Boss [2] • 3 Hooks [3] NOTE: How to install the Pickup Drive Unit [1] Be sure to pass the connector [2] of the Pickup Drive Unit through the hole [A] of the Rear Plate.

  • Page 48: Adjustment

    Adjustment Pickup Feed System......44...

  • Page 49: Pickup Feed System

    5. Adjustment Pickup Feed System Cassette Left Edge Margin Adjustment (1st Side: Mechanical Adjustment) Copy from the cassette, and check that the left edge margin is within 2.5 +/- 1.5mm (in the case of LTR/LGL: 4.2 +/- 1.5 mm). When it is out of the specified range, perform the following procedure. Feeding direction of paper image...
  • Page 50 5. Adjustment 3. Loosen the Fixation Screw. 4. Move the Adjustment Plate to the left or right according to the scale value checked in step 3. As the Adjustment Plate is moved toward the left of the machine by 1 scale mark, the left edge margin is increased by 0.5 mm. 5.

  • Page 51: Cassette Left Edge Margin Adjustment (1St Side: Software Adjustment)

    5. Adjustment 6. Return the cassettes to their original positions. NOTE: If you are concerned with the difference in level of the cassettes after mechanical adjustment, adjust it by loosening the 2 screws. 7. Copy from the cassette, and check that the left edge margin is within 2.5mm +/- 1.5mm. Cassette Left Edge Margin Adjustment (1st Side: Software Adjustment) Copy from the cassette, and check that the left edge margin is within 2.5 +/- 1.5mm (in the case of LTR/LGL: 4.2 +/- 1.5 mm).

  • Page 52: Cassette Left Edge Margin Adjustment (2Nd Side: Software Adjustment)

    5. Adjustment 3. Write the new adjustment value on the service label. • ADJ-C1 Cassette Left Edge Margin Adjustment (2nd Side: Software Adjustment) Execute duplex copy from the cassette, and check that the left edge margin on the 2nd side is within 2.5 +/- 2.0mm (in the case of LTR/LGL: 4.2 +/- 2.0 mm).
  • Page 53 5. Adjustment 1. Change the leading edge margin adjustment value for the 2nd side of the cassette. • Service mode > COPIER > ADJUST > FEED-ADJ > REG-DUP1 As the setting value is incremented by 1, the leading edge margin is increased by 0.1 mm: the image moves to the trailing edge side.

  • Page 54: Appendices

    APPENDICES Service Tools........50 General Circuit Diagram......51...

  • Page 55: Service Tools

    Service Tools Service Tools Special Tools In addition to the standard tools set, the following special tools are required when servicing the machine: Tool name Tool No. Ctgr Appearance Remarks Digital multimeter FY9-2002 Used as a probe extension when making electrical checks.

  • Page 56: General Circuit Diagram

    General Circuit Diagram General Circuit Diagram Cassette 2 Cassette 2 Cassette Right Door Cassette 2 Pullout Motor pickup Motor OPCST_HEATER Cassette 2 Cassette 2 Cassette 2 Cassette 2 Open/Close Detection Switch Size Detection Switch Paper Level Sensor Pullout Sensor Paper Surface Sensor Paper Sensor J5970M M106...

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