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Canon POD Deck Lite-C1 Service Manual

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Revision 2.0
POD Deck Lite-C1
Service Manual

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  Summary of Contents for Canon POD Deck Lite-C1

  • Page 1 Revision 2.0 POD Deck Lite-C1 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 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............................
  • Page 5 Contents 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........................
  • Page 6 Contents 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................
  • Page 7: Safety Precautions

    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...
  • Page 8: Points To Note About Turning Off The Main Power Switch

    Safety Precautions 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.
  • Page 9: Points To Note At Cleaning

    Safety Precautions 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.
  • Page 10: Product Overview

    Product Overview Features..........5 Specifications........6 Names of Parts........7 Option Construction......10...
  • Page 11: Features

    1. Product Overview 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.
  • Page 12: Specifications

    1. Product Overview Specifications Specifications Item Specifications Remarks Pickup method Retard separation + Air assist (switches between warm and cool cur- Center reference rents to suit paper type/environment) Paper accommo- Front loading dation Paper type Thin paper (52 to 79 g/m2), Plain paper (80 to 105 g/ m2), Heavy paper Different depending on the host machine.
  • Page 13: Names Of Parts

    1. Product Overview Names of Parts External View ■ Front [1] Left upper cover [2] Upper cover [3] Compartment open button [4] Front cover [5] Deck release lever...
  • Page 14 1. Product Overview ■ Rear [1] Rear cover [2] Right cover [3] Cassette heater switch [4] Power socket [5] Leakage breaker ■ Internal...
  • Page 15: Cross Section

    1. Product Overview [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 [1] Deck pull-out roller [2] Deck separation roller [3] Deck feed roller [4] Deck pickup roller [5] Blow-out vent (warm air)
  • Page 16: Option Construction

    1. Product Overview 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 Envelope Feeder Attachment-G1 Cassette Heater...
  • Page 17: Technology

    Technology Basic Configuration......12 Controls..........15 Upgrading..........26...
  • Page 18: Basic Configuration

    2. Technology 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.
  • Page 19: Component Configuration

    2. Technology Motor Deck driver PCB(PCB1) Host Sensor ASIC machine Switch Motor driver Solenoid DC/DC converter Regulator EEPROM Sensor Box driver PCB(PCB2) Switch Sensor Swing driver PCB(PCB6) Motor driver Motor Component Configuration ■ Roller Layout [1] Deck pull-out roller [2] Deck separation roller [3] Deck feed roller [4] Deck pickup roller...
  • Page 20 2. Technology ■ Sensor Layout Only the optical sensors on the feed path are shown below. Deck pull-out sensor Deck pickup sensor ■ Drive Configuration Deck pickup motor Deck pull-out motor Deck lifter motor Swing motor Compartment open solenoid Deck pickup release solenoid...
  • Page 21: Controls

    2. Technology Controls Overview Item Reference 1. Pickup/Feed System Pickup/feed control “Pickup/Feed Control” on page 15 Paper presence/absence detection control “Paper Presence/Absence Detection Control” on page Paper surface detection control “Paper Surface Detection Control” on page 16 2. Compartment system Lifter control “Lifter Control”...
  • Page 22: Paper Presence/Absence Detection Control

    2. Technology Paper Presence/Absence Detection Control The presence/absence of paper inside the compartment is checked by the deck paper sensor (SR15) of the pickup assembly. When the paper runs out and the paper detecting lever of the pickup assembly passed the deck paper sensor (SR15) as a result, the host machine indicates the absence of paper on its control panel.
  • Page 23: Lifter Control

    2. Technology Lifter Control ■ Moving Up the Lifter The lifter starts to move up when the compartment open/close switch (SW4) and the compartment open/close sensor (SR9) detect that the compartment has been set in place.The lifter then stops when the paper level sensor (SR3) detects the top surface of the stack of paper placed on the lifter.The deck lifter upper limit sensor 1/2 (SR4/5) is used to prevent damage otherwise caused by the failure of the lifter to stop after the sensor lever blocks the paper level sensor (SR3).The machine is also equipped with a protective mechanism by means of an obstacle sensor (SR8) used to prevent damage to the lifter cable and resin gears lest a...
  • Page 24: Switching The Paper Size

    2. Technology Deck lifter motor (M3)) Encoder SR14 Lifter motor rotation sensor(SR14) SR13 Switching the Paper Size Paper size can be automatically detected by adjusting the position of the guide plate. Sensor name Description Detection method Paper size sensor 1/2/3 (SR10/11/12) Size for feed direction ON / OFF combination of sensors Paper width detection PCB (PCB7)
  • Page 25: Compartment Open/Close Control

    2. Technology NOTE: Service mode • Adjsutment of POD Deck Lite A4 paper width (Lv1) COPIER> ADJUST> CST-ADJ> PDK-A4 < Use case > • When replacing the DC Controller PCB/clearing RAM data. • When replacing the Paper Width Sensor PCB or registering a new value. <...
  • Page 26: Air Assist Control

    2. Technology Compartment open/close sensor(SR9) Compartment open/close detection switch(SW4) Compartment open solenoid(SL1) Fan safety switch(SW5) Compartment open/close arm Spring Air Assist Control ■ Overview To facilitate separation of paper, the machine executes air assist control. The fans (FM2, FM3) are combined to blow air against the paper so that the paper is shifted slightly to lose attraction, ultimately preventing double-feeding.
  • Page 27 2. Technology Air heater(H2) Warming fan(FM2) Cooling fan(FM3) Pickup direction Paper Pickup roller Feed roller Separation rolle Warm air Cool air ■ Air Assist Control The air assist control mechanism is turned on by the DC controller PCB of the host machine and by way of the deck driver PCB. The air assist mechanism consists of the following control items: Paper type*3 Warming fan...
  • Page 28: Cassette Heater Control (Option)

    2. Technology NOTE: Service Mode • ON/OFF of POD Deck Lite air assist (Lv.2) COPIER > OPTION > FEED-SW > DK1-AIR • Deck Air Float Fan airflow amnt: dwstm (Lv.2) COPIER > OPTION > FEED-SW > DK1-ALVD • Deck Air Float Fan airflow amnt: upstream (Lv.2) COPIER >...
  • Page 29: Power Supply

    2. Technology Power Supply The machine's AC power is supplied by an external power outlet, and it is sent through a leakage breaker (ELCB1) to reach the AC relay PCB.The machine's DC power supply is sent to the individual loads from the DC power supply PCB through the deck driver PCB (or directly).
  • Page 30: Fan

    2. Technology ■ Location of Fans ■ Function of Fans Name Function Power supply cooling fan Cool the DC power supply PCB Warming fan Improve separating performance of the paper Cooling fan Improve separating performance of the paper Pickup release solenoid cooling fan Cool the deck pickup release solenoid (SL2) Jam Detection The machine uses the following 2 sensors to make sure that paper moves smoothly inside it.The presence/absence of a jam is...
  • Page 31 2. Technology Jam code Jam type Sensor No. Sensor name 0A18 Power ON Deck pull-out sensor 0218 Stationary Deck pull-out sensor 0118 Delay Deck pull-out sensor 0117 Delay Deck pickup sensor...
  • Page 32: Upgrading

    2. Technology Upgrading Upgrading Since this equipment does not incorporate a CPU, upgrade is not required. Carry out upgrade on the host machine side.
  • Page 33: Periodical Service

    Periodical Service List of Work for Scheduled Servicing ............28...
  • Page 34: List Of Work For Scheduled Servicing

    3. Periodical Service List of Work for Scheduled Servicing PR:Replacement(Periodical replacement) CR:Replacement (consumable parts) CL:Cleaning LU:Lubrication AD:Adjustment CH:Maintenance Category Part Part Interval Adjust- Counter Reference name number ment(Yes/N Pickup as- Deck FL0-450 (LV1) DRBL-2 >PD-PU- “Removing the Deck Pickup sembly pickup 1,000,000sheets, Roller”...
  • Page 35: Disassembly/Assembly

    Disassembly/ Assembly Removing from the Host Machine..30 List of Parts......... 32 External Covers........42 Consumable Parts and Cleaning Points..........47 Main Units........... 54 Heaters..........60 Solenoids..........64 Motors..........67 Fans............ 69 Lifter Wire ...........71 PCBs........... 84...
  • Page 36: Removing From The Host Machine

    4. Disassembly/Assembly Removing from the Host Machine Removing from the Host Machine 1. Turn OFF the main power on the host machine. 2. Turn OFF the cassette heater switch when it is installed. 3. Remove the power cord. 4. Remove the cable. •...
  • Page 37 4. Disassembly/Assembly 6. Remove the base stay unit. • 3 Screws...
  • Page 38: List Of Parts

    4. Disassembly/Assembly List of Parts External Covers Name Reference Left upper cover “Removing the Left Upper Cover” on page 42 Front cover “Removing the Front Cover” on page 42 Right cover “Removing the Right Cover” on page 43 Rear cover “Removing the Rear Cover”...
  • Page 39: Consumable Parts And Cleaning Points

    4. Disassembly/Assembly Consumable Parts and Cleaning Points Name Reference Deck pickup roller “Removing the Deck Pickup Roller” on page 47 Deck feed roller “Removing the Deck Feed Roller” on page 49 Deck separation roller “Removing the Deck Separation Roller” on page 51 Deck pull-out roller...
  • Page 40: Main Units

    4. Disassembly/Assembly Main Units Name Reference Pickup assembly “Removing the Pickup Assembly” on page 54 Compartment “Removing the Compartment” on page 56...
  • Page 41: Sensors

    4. Disassembly/Assembly Sensors SR18 SR16 SR15 SR14 SR12 SR11 SR10 SR13 Name Main unit Reference Separation roller sensor Pickup assembly Relay paper sensor Compartment Paper level sensor Pickup assembly Deck lifter upper limit sensor 1 Pickup assembly Deck lifter upper limit sensor 2 Pickup assembly Deck pull-out sensor Pickup assembly...
  • Page 42: Solenoids

    4. Disassembly/Assembly Solenoids Name Main unit Reference Compartment open solenoid “Removing the Compartment Open Solenoid” on page 64 Deck pickup release solenoid Pickup assembly “Removing the Deck Pickup Release Solenoid ” on page...
  • Page 43: Motors

    4. Disassembly/Assembly Motors Name Main unit Reference Deck pickup motor Deck pull-out motor Pickup assembly Deck lifter motor Compartment “Removing the Deck Lifter Motor” on page 67 Swing motor Compartment...
  • Page 44: Fans

    4. Disassembly/Assembly Fans Name Main unit Reference Power supply cooling fan Warming fan Compartment Cooling fan Compartment Pickup release solenoid cool- “Removing the Pickup Release Solenoid Cooling Fan ” on page 69 ing fan...
  • Page 45: Pcbs

    4. Disassembly/Assembly PCBs PCB3 PCB6 PCB1 PCB5 PCB4 PCB2 PCB7 Name Main unit Reference PCB1 Deck driver PCB “Removing the Deck Driver PCB” on page 84 PCB2 Box driver PCB Compartment PCB3 Swing driver PCB Compartment PCB4 AC relay PCB PCB5 Air heater driver PCB PCB6...
  • Page 46: Switches

    4. Disassembly/Assembly Switches ELCB1 Name Main unit Reference ELCB1 Leakage breaker Deck connection switch Cassette heater switch Deck lifter lower limit switch Compartment Compartment open/close switch Fan safety switch...
  • Page 47: Others

    4. Disassembly/Assembly Others Name Main unit Reference Cassette heater (option) “Removing the Cassette Heater” on page 60 Air heater Compartment “Removing the Air Heater ” on page 61 Lifter wire Compartment “Removing the Lifter Wire” on page 71...
  • Page 48: External Covers

    4. Disassembly/Assembly External Covers Removing the Left Upper Cover ■ Procedure 1. Loosen the 2 screws and then remove the Left Upper Cover. Removing the Front Cover ■ Preparation 1. Open the Compartment. “Opening the Compartment” on page 56...
  • Page 49: Removing The Right Cover

    4. Disassembly/Assembly ■ Procedure 1. Remove the Front Cover. • 7 Screws NOTE: Mark with lines on the 4 marking-off lines to fit the Front Cover onto the original position. ■ Actions when Replacing the Parts “Front Cover” on page 90 Removing the Right Cover ■...
  • Page 50: Removing The Rear Cover

    4. Disassembly/Assembly ■ Procedure 1. Remove the Right Cover. • 5 Screws Removing the Rear Cover ■ Procedure 1. Remove the Rear Cover. • 5 Screws...
  • Page 51: Removing The Upper Cover

    4. Disassembly/Assembly Removing the Upper Cover ■ Preparation 1. Remove the Door Stopper. • 1 Screw 2. Open the Compartment. “Opening the Compartment” on page 56 3. Remove the Right Cover. “Removing the Right Cover” on page 43 4. Remove the Rear Cover. “Removing the Rear Cover”...
  • Page 52 4. Disassembly/Assembly ■ Procedure 1. Remove the Upper Cover. • 5 Screws...
  • Page 53: Consumable Parts And Cleaning Points

    4. Disassembly/Assembly Consumable Parts and Cleaning Points Removing the Deck Pickup Roller ■ Preparation CAUTION: Be sure not to touch the surface of the roller at disassembling/assembling. 1. Remove the Left Upper Cover. “Removing the Left Upper Cover” on page 42 ■...
  • Page 54 4. Disassembly/Assembly 2. Remove the Deck Pickup Roller. • 1 Claw NOTE: How to install the Deck Pickup Roller Be sure to align the protrusion [2] of the Deck Pickup Roller [1] with the groove [3] of the gear to install the roller. Be sure to insert the Deck Pickup Roller [1] until the claw [2] is hooked.
  • Page 55: Removing The Deck Feed Roller

    4. Disassembly/Assembly Removing the Deck Feed Roller ■ Preparation CAUTION: Be sure not to touch the surface of the roller at disassembling/assembling. 1. Remove the Left Upper Cover. “Removing the Left Upper Cover” on page 42 ■ Procedure 1. Slide the Slide Guide (Upper) in the direction of the arrow until it stops. NOTE: When attaching the Left Upper Cover, return the Slide Guide (Upper) to the original position as shown in the figuer.
  • Page 56 4. Disassembly/Assembly 2. Remove the Deck Feed Roller. • 1 Claw NOTE: How to install the Deck Feed Roller Be sure to align the groove [2] of the Deck Feed Roller [1] with the protrusion [3] of the Torque Limiter to install the roller. Be sure to insert the Deck Feed Roller [1] until the claw [2] is hooked.
  • Page 57: Removing The Deck Separation Roller

    4. Disassembly/Assembly Removing the Deck Separation Roller ■ Preparation CAUTION: Be sure not to touch the surface of the roller at disassembling/assembling. 1. Remove the Left Upper Cover. “Removing the Left Upper Cover” on page 42 2. Remove the Deck Feed Roller. “Removing the Deck Feed Roller”...
  • Page 58 4. Disassembly/Assembly 2. Remove the Deck Separation Roller. • 1 Claw NOTE: How to install the Deck Separation Roller Be sure to align the groove [2] of the Torque Limiter[1] with the spring pin [3] to install the roller. Be sure to align the groove [2] of the Deck Separation Roller [1] with the protrusion [4] of the Torque Limiter[3] to install the roller. Be sure to insert the Deck Separation Roller [2] until the claw [1] is hooked.
  • Page 59 4. Disassembly/Assembly ■ Actions when Replacing the Parts 1. Clear the parts counter. Service Mode > COPIER > COUNTER > DRBL-2 > PD-SP-RL (LV1)
  • Page 60: Main Units

    4. Disassembly/Assembly Main Units Removing the Pickup Assembly ■ Preparation 1. Open the Compartment. “Opening the Compartment” on page 56 2. Remove the Left Upper Cover. “Removing the Left Upper Cover” on page 42 ■ Procedure 1. Remove the Connector Holder. •...
  • Page 61 4. Disassembly/Assembly 2. Remove the Pickup Assembly while releasing the Coupling toward the direction of the arrow. • 4 Screws CAUTION: Slide Guide (Upper) must be positioned as shown in the figure when replacing the Pickup Assembly. NOTE: Release the Coupling when the Pickup Assembly is installed. CAUTION: Be sure to keep opening the Compartment while attaching the Pickup Assembly.
  • Page 62: Opening The Compartment

    4. Disassembly/Assembly Opening the Compartment ■ Procedure 1. Insert the screwdrivers into the hole of the rear right side and then uplift the Release Lever to open it. Removing the Compartment ■ Preparation 1. Open the Compartment. “Opening the Compartment” on page 56 ■...
  • Page 63 4. Disassembly/Assembly 3. Remove the 2 screws. • 2 Screws 4. Remove the 3 screws. • 3 Screws 5. Lift the Compartment and then remove the 2 Guide Pins on the left rail. 6. Store the left rail in the POD Deck Lite.
  • Page 64 4. Disassembly/Assembly 7. Lift the Compartment and then remove the 2 Guide Pins on the right rail. 8. Store the right rail in the POD Deck Lite. 9. Remove the Lifter Motor Assembly Cover. • 1 Screw...
  • Page 65 4. Disassembly/Assembly 10. Remove the Connection Flat Cable. • 1 Screw • 1 Flat Cable ■ Actions when Replacing the Parts “Compartment” on page 93...
  • Page 66: Heaters

    4. Disassembly/Assembly Heaters Removing the Cassette Heater ■ Preparation 1. Remove the Right Cover. “Removing the Right Cover” on page 43 2. Remove the Rear Cover. “Removing the Rear Cover” on page 44 ■ Procedure 1. Open the Compartment while unlocking the release lever. 2.
  • Page 67: Removing The Air Heater

    4. Disassembly/Assembly 3. Remove the connector for the Cassette Heater Assembly. • 1 Connector 4. Remove the Cassette Heater Assembly. • 1 Screw • 3 Points Cassette Heater Unit Points Bottom Plate Removing the Air Heater ■ Preparation 1. Remove the Rear Cover. “Removing the Rear Cover”...
  • Page 68 4. Disassembly/Assembly 2. Remove the connector for the Air Heater Assembly. • 2 Connectors • 1 Guide 3. Open the Compartment while unlocking the release lever. 4. Remove the Support Cover from top of the Compartment. • 3 Screws...
  • Page 69 4. Disassembly/Assembly 5. Remove the Air Heater from rear of the Compartment. • 2 Screws...
  • Page 70: Solenoids

    4. Disassembly/Assembly Solenoids Removing the Compartment Open Solenoid ■ Preparation 1. Remove the Rear Cover. “Removing the Rear Cover” on page 44 ■ Procedure 1. Remove the connector from the Compartment Open Solenoid. • 1 Connector 2. Mark the line on the plate to reattach the Compartment Open Solenoid onto the original position.
  • Page 71: Removing The Deck Pickup Release Solenoid

    4. Disassembly/Assembly 3. Remove the Compartment Open Solenoid. • 2 Screws NOTE: Hook the Compartment Open Solenoid on the Release Lever at assembling. Removing the Deck Pickup Release Solenoid ■ Preparation 1. Remove the Pickup Assembly. “Removing the Pickup Assembly” on page 54 ■...
  • Page 72 4. Disassembly/Assembly 2. Remove the Deck Pickup Release Solenoid. • 2 Screws...
  • Page 73: Motors

    4. Disassembly/Assembly Motors Removing the Deck Lifter Motor ■ Preparation CAUTION: The Lifter Plate must be moved to the bottom before removing the Deck Lifter Motor. 1. Open the Compartment with the open button and then remove all sheets of paper from it. 2.
  • Page 74 4. Disassembly/Assembly 2. Remove screws from the access hole of the Lifter Motor Assembly. • 4 Screws 3. Remove the Deck Lifter Motor Cover. • 1 Connector • 1 Wire Saddle • 2 Screws 4. Remove the Deck Lifter Motor.
  • Page 75: Fans

    4. Disassembly/Assembly Fans Removing the Pickup Release Solenoid Cooling Fan ■ Preparation 1. Remove the Rear Cover. “Removing the Rear Cover” on page 44 2. Remove the Pickup Assembly. “Removing the Pickup Assembly” on page 54 ■ Procedure 1. Disconnect the connector from rear and then remove the cable from the guide. •...
  • Page 76 4. Disassembly/Assembly 3. Remove the Pickup Release Solenoid Cooling Fan. • 2 Screws CAUTION: Align the direction of the arrow on the fan and the fixing plate at assembling of the Pickup Release Solenoid Cooling Fan.
  • Page 77: Lifter Wire

    4. Disassembly/Assembly Lifter Wire Removing the Lifter Wire ■ Preparation CAUTION: The Lifter Plate must be moved to the bottom before removing the Lifter Wire. 1. Open the Compartment with the open button and then remove all sheets of paper from it. 2.
  • Page 78 4. Disassembly/Assembly ● Rear 1. Remove the 2 Lifter Wire Pulleys (small and large) from top of the Compartment. • 2 Screws 2. Remove the Lifter Wire Shaft Gear. • 1 E-ring • 1 Parallel Key 3. Remove the fixing parts from the Lifter Shaft. •...
  • Page 79 4. Disassembly/Assembly 4. Remove the 2 Pulleys (small and large). • 2 Parallel Pins 5. Remove the Lifter Wire. ● Front 1. Remove the 2 Lifter Wire Pulleys from top of the Compartment. • 2 Screws 2. Remove the Lifter Wire Fixing Cover from the Lifter Shaft. •...
  • Page 80: Installation Of The Lifter Wire

    4. Disassembly/Assembly 3. Remove the Pulley Fixing Plate. • 1 E-ring 4. Remove the 2 Pulleys (small and large). • 2 Parallel Pins 5. Remove the Lifter Wire. Installation of the Lifter Wire ■ Rear 1. Slide the Side Guide Plate to the minimum paper size position. 2.
  • Page 81 4. Disassembly/Assembly 3. Put the Long Lifter Wire through the Small Pulley and then fix it on top left part of the Compartment. • 1 Screw (RS tightening; M4x8)
  • Page 82 4. Disassembly/Assembly 4. Set the Long Lifter Wire on front side of the Large Pulley. Set the Short Lifter Wire on rear side of it. CAUTION: The Lifter Wire may be disconnected by wrong assembling. Put the Short Lifter Wire between the roller and the fixing plate from the left side.
  • Page 83 4. Disassembly/Assembly 5. Fix the Large Pulley on top right of the Compartment. • 1 Screw (RS tightening; M4x8) • 1 Washer 6. Attach the Large Pulley and then put the Short Lifter Wire along the groove. • 1 Parallel Pin CAUTION: Put the Short Lifter Wire in the groove R side.
  • Page 84 4. Disassembly/Assembly 7. Attach the Small Pulley and then put the Long Lifter Wire along the groove. • 1 Parallel Pin CAUTION: Put the Long Lifter Wire in the groove R side. NOTE: Pull the Long Lifter Wire from bottom left of the Compartment and attach it without slackness. 8.
  • Page 85 4. Disassembly/Assembly 9. Attach the Lifter Wire Shaft Gear. • 1 Parallel Key • 1 E-ring ■ Front 1. Slide the Side Guide Plate to the minimum paper size position. 2. Put the Lifter Wires through the right and the left lifter holes on the Lifter Plate. •...
  • Page 86 4. Disassembly/Assembly 4. Set the Long Lifter Wire on front side of the Large Pulley. Set the Short Lifter Wire on rear side of it. CAUTION: The Lifter Wire may be disconnected by wrong assembling. Put the Short Lifter Wire between the roller and the fixing plate from the right side.
  • Page 87 4. Disassembly/Assembly 5. Fix the Large Pulley on top left of the Compartment. • 1 Screw (RS tightening; M4x8) • 1 Washer 6. Attach the Large Pulley and then put the Short Lifter Wire in the groove. • 1 Parallel Pin CAUTION: Put the Short Lifter Wire in the groove F side.
  • Page 88 4. Disassembly/Assembly 7. Attach the Small Pulley and then put the Long Lifter Wire in the groove. • 1 Parallel Pin CAUTION: Put the Long Lifter Wire in the groove F side. NOTE: Pull the Long Lifter Wire from bottom right of the Compartment to attach it without slackness. 8.
  • Page 89 4. Disassembly/Assembly 9. Attach the Lifter Wire Fixing Cover. • 1 Screw (RS tightening; M4x8) CAUTION: Do not nip the Lifter Wire between the Lifter Wire Fixing Cover and the pole.
  • Page 90: Pcbs

    4. Disassembly/Assembly PCBs Removing the Deck Driver PCB ■ Preparation 1. Remove the Rear Cover. “Removing the Rear Cover” on page 44 ■ Procedure 1. Remove the Deck Driver PCB. • 11 Connectors • 4 Screws ■ Actions when Replacing the Parts “Deck Driver PCB ”...
  • Page 91 4. Disassembly/Assembly ■ Procedure 1. Slide the Side Guide Plate to the maximum paper size position. 2. Remove the 2 screws from the Paper Width Detection PCB assembly. • 2 Screws 3. Remove the Paper Width Detection PCB Upper Cover.
  • Page 92 4. Disassembly/Assembly 4. Remove the Paper Width Detection PCB. • 1 Connector • 1 Wire saddle ■ Actions when Replacing the Parts “Paper Width Detection PCB” on page 94...
  • Page 93: Adjustment

    Adjustment Adjustment ......... 88 Actions when Replacing the Parts..90 Other Adjustment ....... 96...
  • Page 94: Adjustment

    5. Adjustment Adjustment Overview ■ Adjustment/Function Setting Items on the Service Mode For details, refer to the service manual of the host machine. Service mode Contents Service Mode_COPIER > ADJUST > CST-ADJ > PDK-A4 (*1) Adjustment of POD Deck Lite A4 paper width (LV1) Service Mode_COPIER >...
  • Page 95 5. Adjustment Parts Contents Reference Paper width detection Adjusting the paper width “Paper Width Detection PCB” on page 94 ■ Other Adjustment Parts Contents Reference Deck separation roller Adjusting the pressure of the “Adjusting the Pressure of the Deck Separation Roller” on page deck separation roller Deck air float fan Adjusting the deck air float fan...
  • Page 96: Actions When Replacing The Parts

    5. Adjustment Actions when Replacing the Parts Front Cover ■ Actions at Replacement “Removing the Front Cover” on page 42 ■ Actions after Replacement 1. Adjust the gap in 4 +/- 1mm between the front cover and upper cover, the front cover and right cover. Pickup Assembly ■...
  • Page 97 5. Adjustment 5. Execute the following item on the service mode. • Initialization when replacing the parts Service Mode > COPIER > FUNCTION > CST > DK1-INT1 (LV1) • Setting of Deck Lifter stop position Service Mode > COPIER > FUNCTION > CST > DK1-SPAD (LV1) DK1-SPAD = 1 *Even DK1-SPAD is set to 1, the value is returned to 0 when the Compartment is opened.
  • Page 98 5. Adjustment 8. Slide up or down the left side of the Pre-Separation Plate to adjust the position between the Pre-Separation Plate and the Lifter Plate within L=+/-0.5 mm. NOTE: • Check the position scale on the left edge of the Pre-Separation Plate to record the adjusted value. •...
  • Page 99: Compartment

    5. Adjustment 10. Slide up or down the right side of the Pre-Separation Plate with the same value as procedure 8. NOTE: • Check the position scale on the right edge of the Pre-Separation Plate to adjust it. • Check that plain paper passes smoothly. L=+/-0.5mm 11.
  • Page 100: Deck Driver Pcb

    5. Adjustment Deck Driver PCB ■ Actions at Replacement “Removing the Deck Driver PCB” on page 84 ■ Actions after Replacement 1. Remove all sheets of paper from the Compartment. 2. Turn ON the host machine. The fan wind-power correction sequence is performed automatically. 3.
  • Page 101 5. Adjustment 6. Execute the following item on the service mode. Service Mode_COPIER > FUNCTION > CST > PDK-A5R (LV1) 7. After automatic adjustment, the value is stored in the following item. Service Mode_COPIER > ADJUST > CST-ADJ > PDK-A5R (LV1)
  • Page 102: Other Adjustment

    5. Adjustment Other Adjustment Adjusting the Pressure of the Deck Separation Roller In case that the pickup failure or double feeding occurs, change the hook position of the pressure spring on the Deck Separation Roller. ■ Preparation 1. Remove the Pickup Assembly. “Removing the Pickup Assembly”...
  • Page 103 5. Adjustment ■ Procedure 1. Print out from the POD Deck Lite while checking paper separation from right side. NOTE: Enter "1" on the following service mode when the fan does not drive automatically in the specific paper type. Service Mode > COPIER > OPTION > FEED-SW > DK1-AIR (LV2)
  • Page 104 5. Adjustment 1-1. Optimum air flow amount • Keep distance between floating sheets of paper. • 10 to 20 sheets of paper keep floating. • The top paper keeps optimum distance about 10mm from the sail in the compartment. 1-2. High pressure air flow amount •...
  • Page 105 5. Adjustment ■ Adjustment Procedure 1. Execute the following service mode and set amount of the airflow between -10 to 10. The airflow is increased by an increment of the setting value. • upstream Service Mode > COPIER > OPTION > FEED-SW > DK1-ALVU (LV2) •...
  • Page 106: Installation

    Installation How to Utilize this Installation Procedure........101 Checking before Installation....102 Unpacking Procedure....... 104 Checking the Contents......105 Installation Procedure....... 109 Checking after Installation....132 Paper Positioning Check / Adjustment Procedure........133 Cassette Heater Assembly....139...
  • Page 107: How To Utilize This Installation Procedure

    6. Installation How to Utilize this Installation Procedure Description on the Parts Included in the Package The parts with a diagonal line in the contents list will not be used. Symbols in the Illustration The frequently-performed operations are described with symbols in this procedure. Screw Tighten Loosen...
  • Page 108: Checking Before Installation

    6. Installation Checking before Installation Requirements for the installation place are shown below. It is recommended to look over the installation place before delivering the equipment to the user. CAUTION: • Install the host machine first and then install the POD Deck Lite. •...
  • Page 109: Checking The Power Supply

    6. Installation Checking the Power Supply Check that the POD Deck Lite is connectable to the outlet independently which supplies the rated voltage within +10/-15% at the specified ampere or higher. Check Items When Turning OFF the Main Power Check that the main power switch is OFF. 1.
  • Page 110: Unpacking Procedure

    6. Installation Unpacking Procedure 3. Remove the fixing plate and 2 tags (the removed tags, fixing plate and screws are not used). Unpacking Procedure • 2 Screws NOTE: POD Deck Lite is secured with packaging tapes and cushioning materials to protect it against vibration and shock during transportation.
  • Page 111: Checking The Contents

    6. Installation Checking the Contents imageRUNNER ADVANCE 8500 Series □ [2] Latch Plate (Front) x1 □ [1] POD Deck Lite x1 □ [3] Latch Plate (Rear) x1 □ [4] Screw □ [5] Screw □ [6] Screw (RS Tightening;M4x8) x6 (Binding;M4x5) x5 (P Tightening;M3x8) x1 Use 3 of them □...
  • Page 112 6. Installation [10] Foreign Language [11] Paper Size Overlay [12] Paper Size Label x1 □ □ □ Label x1 Label x1 [15]Total Map Label x1 [13] Paper Size Plate x1 [14] Cassette No. Label x1 □ □ □ [17] *1 Power Cord x3 [18] *1 Power Cord x1 [16] JAM Label x1 □...
  • Page 113: Imagepress C10000Vp / C8000Vp Series

    6. Installation imagePRESS C10000VP / C8000VP Series [2] Latch Plate (Front) x1 □ [1] POD Deck Lite x1 □ [3] Latch Plate (Rear) x1 □ [6] Screw □ [5] Screw [4] Screw □ □ (Binding;M4x5) x5 (RS Tightening;M4x8) x6 (P Tightening;M3x8) x1 Use 3 of them [9] Wire Saddle x2 [7] Door Stopper x1...
  • Page 114 6. Installation [10] Foreign Language [11] Paper Size Overlay [12] Paper Size Label x1 □ □ □ Label x1 Label x1 [15]Total Map Label x1 [13] Paper Size Plate x1 [14] Cassette No. Label x1 □ □ □ [17] *1 Power Cord x3 [18] *1 Power Cord x1 [16] JAM Label x1 □...
  • Page 115: Installation Procedure

    6. Installation Installation Procedure 3. Cut the blindfold covers (front /rear) with a side cutter. NOTE: Keep the removed fixing materials as they are used to transport for relocation. imageRUNNER ADVANCE 8500 Series ■ Preparation of the Host Machine 1. Remove the feed cover (the removed cover is not used).
  • Page 116 6. Installation 4. Attach the latch plates (front / rear) to the host 5. Remove the connector cover from rear of the host machine. machine (the removed connector cover is not used). • 4 Screws (RS tightening; M4x8) CAUTION: • Positioning hole shape is different between the latch plates (front and rear).
  • Page 117 6. Installation 2. Attach the slope guide. 4. Fix the removed screw at procedure 3 to the original position. • 2 Screws ( Binding screws; M4x5) NOTE: The screw is used to fix the base stay unit when the POD Deck Lite is transported.
  • Page 118 6. Installation 3. Remove the sheet and tapes from the compartment. 6. Affix the foreign language label by language over the original label as shown in the figure (the remaining labels are not used). 4. Remove the stay guide. Removed 1 screw and the stay guide are used at procedure 25.
  • Page 119 6. Installation 9. Insert the 2 positioning pins to the holes of the host 10. Connect the POD Deck Lite with the host machine. machine and then fix the base stay. • 3 Screws (Binding screws; M4x5) Binding M4x5 NOTE: •...
  • Page 120 6. Installation 11. Loosen the 2 screws on the bottom right side wheel. 12. Match position(a) with position(b) by adjusting the height of the POD Deck Lite with the 2 adjusters. • 2 Screws • Position (a) : 2 fixing screw tapped holes (middle) of the POD Deck Lite.
  • Page 121 6. Installation 14. Loosen the 2 screws on the 2 front bottom wheels for each and touch them to the floor. 13. Fix the bottom right side wheel with Screw A and • 4 Screws Screw B. • Screw A: Supplied 2 Screws ( RS tightening; M4x8) •...
  • Page 122 6. Installation 16. Adjust tilt with the 2 adjusters until a top gap [1] and a bottom gap [2] between the POD Deck Lite and the 17. Attach the wire saddle to the hole on rear side of the host machine are same width. POD Deck Lite and then clamp the cable with it.
  • Page 123 6. Installation 20. Check that the circuit breaker is ON. 23. Press the open button of the POD Deck Lite to open the compartment. 24. Press the relay paper sensor until the lifter reaches to the bottom position. 21. Turn ON the cassette heater in high humidity or low temperature environment.
  • Page 124 6. Installation 25. Fix the stay guide inside of the front frame with the 28. Affix the paper size label on the size plate (the screw removed at procedure 4. remaining labels are not used). • 1 Screw (TP; M3x6) 29.
  • Page 125: Imagepress C10000Vp / C8000Vp Series

    6. Installation imagePRESS C10000VP / 3. Remove the outer cover from the vertical path cover C8000VP Series (the removed outer cover is not used). ■ Preparation of the Host Machine 1. Open the vertical path cover by pressing the button. 2.
  • Page 126 6. Installation 5. Attach the front/rear latch plates to the host 6. Remove the main station lower right cover (the machine. removed cover and screws are not used). • 4 Screws (RS tightening; M4x8) • 2 Screws CAUTION: • Positioning hole shape is different between the latch plates (front and rear).
  • Page 127 6. Installation ■ Preparation of the POD Deck Lite 8. Install the machine connection stay bundled in the host machine. • 4 Screws (Flat Head Screw; M4x6) (bundled in the 1. Remove the screw and spacer from the base stay host machine) unit.
  • Page 128 6. Installation ■ Connection with the Host Machine 4. Remove the stay guide. Removed 2 screws are used at procedure 5. Removed 1 screw and the stay guide are used at procedure 29. 1. Insert screwdrivers into the hole of the rear right side and then release the lever to open the compartment.
  • Page 129 6. Installation 6. Affix the foreign language label by language over the 8. Affix the total map label(b) on the base stay unit original label as follows (the remaining labels are not while fitting it to the marking-off line (the remaining used).
  • Page 130 6. Installation 10. Remove the 2 marked "A" wheel guide plates (the 12. Move the 2 positioning pins as shown in the figure. removed screws are used at procedure 11. The removed wheel guide plates are not used). 11. Attach the 2 marked "B" wheel guide plates bundled in the host machine with screws removed at procedure 10.
  • Page 131 6. Installation 13. Insert the 2 positioning pins to the holes of the host 14. Connect the POD Deck Lite with the host machine. machine and then fix the base stay. • 3 Screws (Binding screws; M4x5) NOTE: • Do not nip the cable between the POD Deck Lite and the host machine when connecting.
  • Page 132 6. Installation 15. Loosen the 2 screws on the bottom right side wheel. 16. Match position(a) with position(b) by adjusting the height of the POD Deck Lite with the 2 adjusters. • 2 Screws • Position (a) : 2 fixing screw tapped holes (middle) of the POD Deck Lite.
  • Page 133 6. Installation 17. Fix the bottom right side wheel with Screw A and 18. Loosen the 2 screws on the 2 front bottom wheels Screw B. for each and touch them to the floor. • Screw A : Supplied 2 Screws ( RS tightening; •...
  • Page 134 6. Installation 19. Fasten the 2 screws loosened at procedure 18. 20. Adjust tilt with the 2 adjusters until a top gap [1] and a bottom gap [2] between the POD Deck Lite and the • 4 Screws host machine are same width. •...
  • Page 135 6. Installation CAUTION: • In case that the gap between the top [1] and the 22. Attach the wire saddle to the hole on rear side of the bottom [2] is not in parallel, connection may not be POD Deck Lite and then clamp the cable with it. detected.
  • Page 136 6. Installation 24. Check that the circuit breaker is ON. 27. Press the open button of the POD Deck Lite to open the compartment. 28. Press the relay paper sensor until the lifter reaches to the bottom position. 25. Turn ON the cassette heater in high humidity or low temperature environment.
  • Page 137 6. Installation 29. Fix the stay guide inside of the front frame with the 32. Affix the paper size label on the size plate (the screw removed at procedure 4. remaining labels are not used). • 1 Screw (TP; M3x6) 33.
  • Page 138: Checking After Installation

    6. Installation Checking after Installation imagePRESS C10000VP / C8000VP Series imageRUNNER ADVANCE ■ Disposal Parts 8500 Series 1. Following disposal parts are remained after the installation procedure. ■ Disposal Parts Screw (Binding; M4x5) 2pcs. 1. Following disposal parts are remained after the Screw (TP;...
  • Page 139: Paper Positioning Check / Adjustment Procedure

    6. Installation ■ Adjustment Procedure (manual) Paper Positioning Check / Adjustment Procedure 1. Press the open button of the POD Deck Lite to open the compartment. imageRUNNER ADVANCE 8500 Series ■ Adjusting the Left Edge Margin(L1) of the Image 1. Print sheets of paper from the POD Deck Lite. Check that L1 is 2.5+/-1.5mm.
  • Page 140 6. Installation 3. Loosen the 2 screws at the latch plate on the right 5. Loosen the 2 screws at the latch plate on the left side side of the compartment. of the compartment. • 2 Screws • 2 Screws Loosen Loosen 6.
  • Page 141 6. Installation NOTE: Loosen the 7 screws on the front cover to adjust the gap 9. Print sheets of paper from the POD Deck Lite. Check in 4+/-1mm. that L1 is 2.5+/-1.5mm. Re-adjust L1 in case that it is out of standard. ■...
  • Page 142: Imagepress C10000Vp / C8000Vp Series

    6. Installation imagePRESS C10000VP / 2. Open the compartment until it stops while releasing C8000VP Series stoppers with pressing left and right latches. ■ Adjusting the Left Edge Margin(L1) of the Image 1. Print sheets of paper from the POD Deck Lite. Check that L1 is 2.5+/-1.5mm.
  • Page 143 6. Installation 4. Move the latch plate toward front [A] or rear [B] (1 6. Move the latch plate in the same scale position as scale = 1mm) and then fasten the 2 screws. The procedure 4 and then fasten the 2 screws (1 scale = adjusted value is used at procedure 6.
  • Page 144 6. Installation ■ Front Cover Positioning NOTE: Adjustment Loosen the 7 screws on the front cover to adjust the gap in 4+/-1mm. 1. Check that the gap is 4 +/- 1mm between the front cover and upper cover, the front cover and right Loosen cover.
  • Page 145: Cassette Heater Assembly

    6. Installation Cassette Heater Assembly Parts name Parts Q'ty Number Cassette Heater Assem- FM1- 1pc. D634-000 Check Items when Turning Screw (TP ; M3x6) XB6-7300- 1pc. OFF the Main Power Cassette Heater Harness FM1- 1pc. (120V) E857-000 Check that the main power of the POD Deck Lite is OFF. Cassette Heater Harness FM1- 1pc.
  • Page 146: Installation Procedure

    6. Installation 4. Slide the POD Deck Lite until it stops with holding 3. Remove the Right Cover. the release lever. • 5 Screws 4. Open the Compartment until it stops while releasing stoppers with pressing the left and right Latches. Installation Procedure 1.
  • Page 147 6. Installation 6. Install the Cassette Heater Assembly. 8. Install the Heater Connector Cover removed at procedure 5. • 3 Claws • 1 Screw (TP; M3x6) • 2 Protrusions • 1 Claw Protrusion Boss Claw Base Plate 9. Install the Cassette Heater Harness. •...
  • Page 148 6. Installation 10. Install the Switch Unit. 12. Fix the Switch Unit Harness as follows. • 2 Wire saddles • 1 Connector NOTE: (o) symbol must be positioned at the bottom. 13. Attach the external covers. 14. Connect the POD Deck Lite with the host machine. 11.
  • Page 149 6. Installation 16. Connect the power cord to the inlet of the POD Deck 18. Turn ON the Cassette Heater Switch. Lite and then plug it to the external source. CAUTION: Make sure that the power cord is fully connected to the outlet.
  • Page 150: Appendices

    APPENDICES Service Tools........145 General Circuit Diagram....146...
  • Page 151: Service Tools

    Service Tools Service Tools Solvents and Oils Name Uses Composition Remarks Alcohol Cleaning; e.g., plastic, Fluoride-family hydrocarbon, Alcohol, Sur- • Do not bring near fire. rubber, external cov- face activating agent, Water • Procure locally. • Substitute: IPA (isopropyl alcohol) Alcohol Cleaning;...
  • Page 152: General Circuit Diagram

    General Circuit Diagram General Circuit Diagram General Circuit Diagram (1/3 ) Deck pickup Deck pull-out Deck lifter upper Paper level Relay paper Separation Deck lifter upper Compartment Deck connection limit sensor 1 Obstacle sensor sensor sensor sensor roller sensor Deck pickup limit sensor2 Compartment open/close sensor...
  • Page 153: General Circuit Diagram (2/3)

    General Circuit Diagram General Circuit Diagram (2/3) Deck driver PCB AC relay PCB PCB1 PCB4 J405 13 12 11 10 9 Deck pickup J-CN3 J-CN1 J-CN2 motor J301 Box driver PCB Air heater driver PCB J303 J304 PCB5 PCB2 18 17 16 15 14 13 12 11 10 9 J-CN4 Cooling fan Swing motor...
  • Page 154: General Circuit Diagram (3/3)

    General Circuit Diagram General Circuit Diagram (3/3) Deck driver PCB PCB2 J302 J306 J728 J780D J731D J734D SR13 J770D J730 J780DH J731DH J770DH Deck lifter lower position sensor J780L J731L J734L J770L J734LH SR15 Deck paper sensor SOLD6 SOLD7 J733 J732 J727 J726...