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  • Oct 26 2004

    Service Manual

    CassetteCassette Feeding Unit-Y1/Y2

  • ApplicationThis 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.

    CorrectionsThis 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.

    TrademarksThe product names and company names used in this manual are the registered trademarks of the individual companies.

    CopyrightThis manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied,

    reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc.

    COPYRIGHT 2001 CANON INC.Printed in Japan

    CautionUse of this manual should be strictly supervised to avoid disclosure of confidential information.

  • Introduction

    Symbols Used

    This documentation uses the following symbols to indicate special information:

    Symbol Description

    Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.

    Indicates an item requiring care to avoid electric shocks.

    Indicates an item requiring care to avoid combustion (fire).

    Indicates an item prohibiting disassembly to avoid electric shocks or problems.

    Indicates an item requiring disconnection of the power plug from the electric outlet.

    Indicates an item intended to provide notes assisting the understanding of the topic in question.

    Indicates an item of reference assisting the understanding of the topic in question.

    Provides a description of a service mode.

    Provides a description of the nature of an error indication.

    Memo

    REF.

  • Introduction

    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, theoperations of the microprocessors used in the machines are not discussed: they are explained in terms of fromsensors 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 otherpurposes, 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 relevantService Information bulletins and be able to identify and isolate faults in the machine."

  • ContentsContents

    Chapter 1Specifications

    1.1 Product Specifications....................................................................................................................................... 1- 11.1.1Specifications .............................................................................................................................................. 1- 1

    1.2 Names of Parts................................................................................................................................................... 1- 21.2.1Names of Parts............................................................................................................................................. 1- 21.2.2Section View ............................................................................................................................................... 1- 3

    Chapter 2Functions

    2.1 Basic Construction ............................................................................................................................................ 2- 12.1.1Arrangement of Sensors/Solenoids ............................................................................................................. 2- 1

    2.2 Pick-Up/Feed Systm.......................................................................................................................................... 2- 32.2.1Overview ..................................................................................................................................................... 2- 32.2.2Basic Sequence of Operations ..................................................................................................................... 2- 32.2.3Identifying the Paper Size ........................................................................................................................... 2- 42.2.4Paper Level Sensors .................................................................................................................................... 2- 6

    2.3 Detecting Jams ................................................................................................................................................ 2- 102.3.1Delay Jam .................................................................................................................................................. 2- 102.3.2Common Stationary Jams.......................................................................................................................... 2- 102.3.3Stationary Jam at Power-On...................................................................................................................... 2- 112.3.4Door Open Jam.......................................................................................................................................... 2- 11

    2.4 Power Supply .................................................................................................................................................. 2- 122.4.1Power Supply Route .................................................................................................................................. 2- 12

    Chapter 3Parts Replacement Procedure

    3.1 External Covers ................................................................................................................................................. 3- 13.1.1 Rear Cover .................................................................................................................................................. 3- 1

    3.1.1.1 Removing the Pedestal Rear Cover..................................................................................................... 3- 13.1.2 Right Cover ................................................................................................................................................. 3- 1

    3.1.2.1 Removing the Pedestal Right Cover.................................................................................................... 3- 13.1.3 Rear Right Cover ........................................................................................................................................ 3- 1

    3.1.3.1 Removing the Pedestal Rear Right Cover ........................................................................................... 3- 13.1.4 Front Right Cover ....................................................................................................................................... 3- 1

    3.1.4.1 Removing the Pedestal Front Right Cover.......................................................................................... 3- 13.1.5 Lower Right Cover ..................................................................................................................................... 3- 2

    3.1.5.1 Removing the Pedestal Lower Right Cover ........................................................................................ 3- 23.2 Drive System ..................................................................................................................................................... 3- 3

    3.2.1 Cassette Pickup Motor 3 ............................................................................................................................. 3- 33.2.1.1 Removing the Right Cover (lower rear).............................................................................................. 3- 33.2.1.2 Removing the Right Cover (lower front) ............................................................................................ 3- 33.2.1.3 Removing the Pedestal Rear Right Cover ........................................................................................... 3- 33.2.1.4 Removing the Pedestal Front Right Cover.......................................................................................... 3- 4

  • Contents3.2.1.5 Removing the Pickup Unit 3................................................................................................................3- 43.2.1.6 Removing the Pedestal Rear Cover .....................................................................................................3- 53.2.1.7 Removing the Cassette Pickup Motor 3 ..............................................................................................3- 5

    3.2.2 Cassette Pickup Motor 4 .............................................................................................................................3- 63.2.2.1 Removing the Pedestal Rear Right Cover ...........................................................................................3- 63.2.2.2 Removing the Pedestal Front Right Cover ..........................................................................................3- 63.2.2.3 Removing the Pedestal Lower Right Cover ........................................................................................3- 63.2.2.4 Removing the Pickup Unit 4................................................................................................................3- 73.2.2.5 Removing the Pedestal Rear Cover .....................................................................................................3- 73.2.2.6 Removing the Cassette Pickup Motor 4 ..............................................................................................3- 8

    3.3 Document Feeding System ..............................................................................................................................3- 103.3.1 Pick-up Unit 3 ...........................................................................................................................................3- 10

    3.3.1.1 Removing the Right Cover (lower rear) ............................................................................................3- 103.3.1.2 Removing the Right Cover (lower front)...........................................................................................3- 103.3.1.3 Removing the Pedestal Rear Right Cover .........................................................................................3- 103.3.1.4 Removing the Pedestal Front Right Cover ........................................................................................3- 113.3.1.5 Removing the Pickup Unit 3..............................................................................................................3- 11

    3.3.2 Pick-up Unit 4 ...........................................................................................................................................3- 123.3.2.1 Removing the Pedestal Rear Right Cover .........................................................................................3- 123.3.2.2 Removing the Pedestal Front Right Cover ........................................................................................3- 123.3.2.3 Removing the Pedestal Lower Right Cover ......................................................................................3- 123.3.2.4 Removing the Pickup Unit 4..............................................................................................................3- 12

    3.3.3 Pickup Rollor.............................................................................................................................................3- 133.3.3.1 Removing the Pickup Roller/Separation Roller.................................................................................3- 13

    3.3.4 Separation Rollor.......................................................................................................................................3- 133.3.4.1 Removing the Pickup Roller/Separation Roller.................................................................................3- 13

    3.3.5 Feed Rollor ................................................................................................................................................3- 143.3.5.1 Removing the Pickup Roller/Separation Roller.................................................................................3- 14

    3.3.6 Vertical Path Rollor...................................................................................................................................3- 143.3.6.1 Removing the Right Cover (lower rear) ............................................................................................3- 143.3.6.2 Removing the Right Cover (lower front)...........................................................................................3- 153.3.6.3 Removing the Pedestal Rear Right Cover .........................................................................................3- 153.3.6.4 Removing the Pedestal Front Right Cover ........................................................................................3- 153.3.6.5 Removing the Pickup Unit 3..............................................................................................................3- 163.3.6.6 Removing the Pedestal Lower Right Cover ......................................................................................3- 163.3.6.7 Removing the Pickup Unit 4..............................................................................................................3- 173.3.6.8 Removing the Sensor Base ................................................................................................................3- 173.3.6.9 Removing the Vertical Path Roller....................................................................................................3- 18

    3.3.7 Sensor Mounting .......................................................................................................................................3- 183.3.7.1 Removing the Right Cover (lower rear) ............................................................................................3- 183.3.7.2 Removing the Right Cover (lower front)...........................................................................................3- 193.3.7.3 Removing the Pedestal Rear Right Cover .........................................................................................3- 193.3.7.4 Removing the Pedestal Front Right Cover ........................................................................................3- 193.3.7.5 Removing the Pickup Unit 3..............................................................................................................3- 203.3.7.6 Removing the Pedestal Lower Right Cover ......................................................................................3- 203.3.7.7 Removing the Pickup Unit 4..............................................................................................................3- 213.3.7.8 Removing the Sensor Base ................................................................................................................3- 213.3.7.9 Mounting the Sensor Base .................................................................................................................3- 22

    3.4 Electrical System .............................................................................................................................................3- 24

  • Contents3.4.1 Cassette Size Detection Unit..................................................................................................................... 3- 243.4.1.1 Removing the Pedestal Front Right Cover........................................................................................ 3- 243.4.1.2 Removing the Pedestal Lower Right Cover ...................................................................................... 3- 243.4.1.3 Removing the Pedestal Right Cover.................................................................................................. 3- 243.4.1.4 Removing the Cassette Size Detection Unit...................................................................................... 3- 24

    3.4.2 Pedestal Controller PCB ........................................................................................................................... 3- 253.4.2.1 Removing the Pedestal Rear Cover................................................................................................... 3- 253.4.2.2 Removing the Pedestal Controller PCB ............................................................................................ 3- 25

    3.4.3 Cassette Retry Paper Sensor ..................................................................................................................... 3- 253.4.3.1 Removing the Right Cover (lower rear)............................................................................................ 3- 253.4.3.2 Removing the Right Cover (lower front) .......................................................................................... 3- 263.4.3.3 Removing the Pedestal Rear Right Cover ......................................................................................... 3- 263.4.3.4 Removing the Pedestal Front Right Cover........................................................................................ 3- 263.4.3.5 Removing the Pickup Unit 3 ............................................................................................................. 3- 273.4.3.6 Removing the Pedestal Lower Right Cover ...................................................................................... 3- 273.4.3.7 Removing the Pickup Unit 4 ............................................................................................................. 3- 283.4.3.8 Removing the Sensor Base................................................................................................................ 3- 283.4.3.9 Removing the Cassette Retry Paper Sensor ...................................................................................... 3- 29

    3.4.4 Cassette Paper Sensor ............................................................................................................................... 3- 293.4.4.1 Removing the Right Cover (lower rear)............................................................................................ 3- 293.4.4.2 Removing the Right Cover (lower front) .......................................................................................... 3- 303.4.4.3 Removing the Pedestal Rear Right Cover ......................................................................................... 3- 303.4.4.4 Removing the Pedestal Front Right Cover........................................................................................ 3- 303.4.4.5 Removing the Pickup Unit 3 ............................................................................................................. 3- 303.4.4.6 Removing the Pedestal Lower Right Cover ...................................................................................... 3- 313.4.4.7 Removing the Pickup Unit 4 ............................................................................................................. 3- 313.4.4.8 Removing the Cassette Paper Sensor ................................................................................................ 3- 323.4.4.9 Removing the Sensor Base................................................................................................................ 3- 32

    3.4.5 Cassette Paper Level Sensor (A/B)........................................................................................................... 3- 323.4.5.1 Removing the Right Cover (lower rear)............................................................................................ 3- 323.4.5.2 Removing the Right Cover (lower front) .......................................................................................... 3- 333.4.5.3 Removing the Pedestal Rear Right Cover ......................................................................................... 3- 333.4.5.4 Removing the Pedestal Front Right Cover........................................................................................ 3- 343.4.5.5 Removing the Pickup Unit 3 ............................................................................................................. 3- 343.4.5.6 Removing the Pedestal Lower Right Cover ...................................................................................... 3- 343.4.5.7 Removing the Pickup Unit 4 ............................................................................................................. 3- 353.4.5.8 Removing the Sensor Base................................................................................................................ 3- 353.4.5.9 Removing the Cassette Paper Level Sensor A/B........................................................................ 3- 36

    3.4.6 Cassette Pickup Solenoid .......................................................................................................................... 3- 363.4.6.1 Removing the Right Cover (lower rear)............................................................................................ 3- 363.4.6.2 Removing the Right Cover (lower front) .......................................................................................... 3- 373.4.6.3 Removing the Pedestal Rear Right Cover ......................................................................................... 3- 373.4.6.4 Removing the Pedestal Front Right Cover........................................................................................ 3- 373.4.6.5 Removing the Pickup Unit 3 ............................................................................................................. 3- 373.4.6.6 Removing the Pedestal Lower Right Cover ...................................................................................... 3- 383.4.6.7 Removing the Pickup Unit 4 ............................................................................................................. 3- 383.4.6.8 Removing the Sensor Base................................................................................................................ 3- 393.4.6.9 Removing the Cassette Pickup Solenoid........................................................................................... 3- 39

    3.4.7 Right Door Open/Closed Sensor............................................................................................................... 3- 40

  • Contents3.4.7.1 Removing the Pedestal Rear Right Cover .........................................................................................3- 403.4.7.2 Removing the Right Door Open/Close Sensor ..................................................................................3- 40

    Chapter 4Maintenance

    4.1 Maintenance and Inspection ..............................................................................................................................4- 14.1.1 Periodically Replaced Parts.........................................................................................................................4- 1

    4.1.1.1 Periodically Replaced Parts .................................................................................................................4- 14.1.2 Durables ......................................................................................................................................................4- 1

    4.1.2.1 Durables ...............................................................................................................................................4- 14.2 Outline of Electrical Components .....................................................................................................................4- 2

    4.2.1Arrangement and Functions of Electrical Components...............................................................................4- 2

  • Chapter 1Specifications

  • Contents

    Contents

    1.1 Product Specifications........................................................................................................................................ 1-11.1.1 Specifications .............................................................................................................................................. 1-1

    1.2 Names of Parts.................................................................................................................................................... 1-21.2.1 Names of Parts............................................................................................................................................. 1-21.2.2 Section View ............................................................................................................................................... 1-3

  • Chapter 1

    1-1

    1.1 Product Specifications

    1.1.1 Specifications 0001-6093

    T-1-1

    Item Description Remarks

    Paper

    accommodation front loading

    Pickup retard

    Number of cassettes 2

    cassette 3/4 is of host

    machine (large, small)

    Size switching by user

    Paper type

    plain paper, heavy paper, transparency (64 g/

    m2 to 163 g/m2), envelope

    Paper size A3, B4, A4, A4R, B5, B5R, A5R,

    12 18 (305 457 mm ),

    11 17 (279 432 mm), LGL, LTR,

    LTRR, STMTR, EXE

    Paper stack 550 sheets (equivalent of 80 g/m2 paper) (both upper and lower)

    Control panel none (uses keys on host machine)

    Display none (uses keys on host machine)

    Environmental

    considerations paper heater (used against moisture)

    cassette heater available as

    option

    Power supply none

    from host machine's

    accessories power supply

    Dimensions 565 (W) 700 (D) 251.5 (H) [mm]

    Weight 23 kg (approx.)

    Maximum power

    consumption 100 W

  • Chapter 1

    1-2

    1.2 Names of Parts

    1.2.1 Names of Parts 0001-0973

    External covers[1] Left Cover[2] Right front cover[3] Right lower cover[4] Right rear cover[5] Rear cover[6] Pedestal right cover

    F-1-1

    F-1-2

  • Chapter 1

    1-3

    1.2.2 Section View 0003-3496

    F-1-3

    T-1-2

    No. Name

    [1] Pickup roller (cassette 4)

    [2] Pickup roller (cassette 3)

    [3] Vertical path roller 3

    [4] Feed roller (cassette 3)

    [5] Feed roller (cassette 3)

    [6] Vertical path roller 4

    [7] Feed roller (cassette 4)

    [8] Separation roller (cassette 4)

    [1] [2] [3]

    [4]

    [5]

    [6]

    [7]

    [8]

  • Chapter 2Functions

  • Contents

    Contents

    2.1 Basic Construction ............................................................................................................................................. 2-12.1.1 Arrangement of Sensors/Solenoids ............................................................................................................. 2-1

    2.2 Pick-Up/Feed Systm........................................................................................................................................... 2-32.2.1 Overview ..................................................................................................................................................... 2-32.2.2 Basic Sequence of Operations ..................................................................................................................... 2-32.2.3 Identifying the Paper Size ........................................................................................................................... 2-42.2.4 Paper Level Sensors .................................................................................................................................... 2-6

    2.3 Detecting Jams ................................................................................................................................................. 2-102.3.1 Delay Jam .................................................................................................................................................. 2-102.3.2 Common Stationary Jams.......................................................................................................................... 2-102.3.3 Stationary Jam at Power-On...................................................................................................................... 2-112.3.4 Door Open Jam.......................................................................................................................................... 2-11

    2.4 Power Supply ................................................................................................................................................... 2-122.4.1 Power Supply Route .................................................................................................................................. 2-12

  • Chapter 2

    2-1

    2.1 Basic Construction

    2.1.1 Arrangement of Sensors/Solenoids 0001-5390

    F-2-1

    [1] Cassette 3 paper level sensor (B; PS6C)[2] Cassette 3 paper level sensor (A; PS5C)[3] Cassette 3 paper sensor (PS3C)

    [4] Cassette 3 retry paper sensor (PS1C)[5] Cassette 4 paper level sensor (B; PS8C)[6] Cassette 4 paper level sensor (PS4C)[7] Cassette 4 paper sensor (PS4C)[8] Cassette 4 retry paper sensor (PS2C)[9] Pedestal right cover open/closed sensor (PS9C)

    F-2-2

    [1][2]

    [3]

    [9]

    [4]

    [8]

    [7]

    [6]

    [5]

    SL

    SL

    SL

    SL

    [1]

    [2]

  • Chapter 2

    2-2

    [1] Cassette 3 pickup solenoid (SL1C)[2] Cassette 4 pickup solenoid (SL2C)

  • Chapter 2

    2-3

    2.2 Pick-Up/Feed Systm

    2.2.1 Overview 0001-9309

    The paper inside the cassette is held up by the work of the lifer plate. When pickup takes place, the pickup rollermoves down to come into contact with the stack of paper. The pickup roller starts to move down when the pickupsolenoid goes on. The feed roller and the separation roller make sure that no more than a single sheet of paper ismoved forward to the paper path. The vertical path roller serves to move paper as far as the registration roller.The pickup path roller, pickup roller, feed roller, and separation roller are driven by the pickup motor.

    F-2-3

    [1] Cassette paper sensor[2] Pickup roller (roller A)[3] Feed roller (roller B)[4] Separation roller (roller C)[5] Pickup vertical path roller[6] Cassette retry paper sensor[7] Vertical path guide[8] Lower right cover[9] Holding plate[10] Lifter plate

    2.2.2 Basic Sequence of Operations 0001-9312

    Basic Sequence of Operating (3 prints)

    [9][10]

    [7]

    [8]

    [1] [2] [3] [4] [5] [6]

  • Chapter 2

    2-4

    F-2-4

    2.2.3 Identifying the Paper Size 0001-9314

    The size of paper inside the cassette is detected by the cassette size dial, and is communicated to the cassette sizedetection PCB.As may as 15 positions may be detected with reference to the combinations of on and off states of the array of 4actuators mounted to the cassette size detection PCB on the printer side and operating in conjunction with the cassettesize dial.In the absence of a cassette, all 4 actuators are off, causing the machine to assume there is no cassette.AB/Inch SwitchThe cassette size dial is equipped with a switch operated to change between AB and Inch configurations; the cassettesize detecting switch will detect the configuration as soon as a cassette is fitted in the machine.

    PrintStart

    Cassette 3 pickup motor(M1C)Cassette 3 pickup solenoid(SL1C)Cassette 3 retry sensor(PS1C)

    Registration sensor(PS9)Registration clutch(CL2)Fixing motor(M11)Fixing inlet sensor(PS35)Fixing outlet sensor(PS13)Delivery motor 1(M4)Delivery sensor(PS14)

    *1 *3*2PRINT

    0.8 Sec

    A

    *1 slow-fast pickup

    *3 registration*2 pre-registration

    cassette 3 pickup motor acceleration

    cassette 3 (3 sheets of paper)A longer sheet-to-sheet in full color

    Cassette 2 retry sensor(PS11)Cassette 1 retry sensor(PS10)Main motor(M2)

    Cass

    ette

    pe

    dest

    alH

    ost m

    achi

    ne

  • Chapter 2

    2-5

    F-2-5

    [1] AB/Itch switch[2] Cassette size dial[3] Cassette size detection PCB

    T-2-1

    AB-configuration

    Size SW0 SW1 SW2 SW3 SW4

    (no cassette) OFF OFF OFF OFF OFF

    A5R ON OFF ON ON OFF

    A4 ON ON ON ON OFF

    A4R OFF ON ON ON OFF

    A3 OFF ON OFF ON OFF

    B5 ON ON OFF ON OFF

    B5R OFF OFF OFF ON OFF

    B4 ON OFF OFF ON OFF

    305457mm ON ON OFF OFF OFF

    U1 OFF ON OFF OFF OFF

    U2 OFF ON ON OFF OFF

    Envelope ON OFF ON OFF ON/OFF

    [2]

    SW0SW1SW2SW3

    SW4

    INCH

    SW4-ON=INCH

    [1]

  • Chapter 2

    2-6

    T-2-2

    2.2.4 Paper Level Sensors 0001-9316

    The following sensors are used to check the level of paper found inside the cassette:

    SW4 is used to detect the state of the AB/Inch-configuration switch.The machine will assume the absence of a cassette if it detects a combination not found in the table. At this time, it does not move up the cassette lifter.Since the paper size is not identified, there will be no indication of a paper size on the control panel; when the cassette in question is selected, the machine will indicate a message prompting the supply of paper.

    Inch-configuration

    Size SW0 SW1 SW2 SW3 SW4

    (no cassette) OFF OFF OFF OFF OFF

    STMTR ON OFF ON ON ON

    LTR ON ON ON ON ON

    LTRR OFF ON ON ON ON

    LGL OFF ON OFF ON ON

    1117 ON ON OFF ON ON

    EXEC OFF OFF OFF ON ON

    1218 ON ON OFF OFF ON

    U3 OFF ON OFF OFF ON

    U4 OFF ON ON OFF ON

    Envelope ON OFF ON OFF ON/OFF

    SW4 is used to detect the state of the AB/Inch-configuration switch.The machine will assume the absence of a cassette if it detects a combination not found in the table. At this time, it does not move up the cassette lifter.Since the paper size is not identified, there will be no indication of a paper size on the control panel; when the cassette in question is selected, the machine will indicate a message prompting the supply of paper.

    AB-configuration

  • Chapter 2

    2-7

    T-2-3

    F-2-6

    [1] Flag[2] Cassette paper sensor[3] Lifter clutch[4] Cassette paper level sensor A[5] Cassette paper level sensor B[6] Paper level sensor flag[7] Lifter gear[8] Tray

    Cassette 3 Cassette 4

    Paper level sensor A PS5C PS7C

    Paper level sensor B PS6C PS8C

    Paper sensor PS3C PS4C

    [1]

    [2]

    [3]

    [4]

    [5]

    [6]

    [7]

    [8]

  • Chapter 2

    2-8

    F-2-7

    T-2-4

    Paper level sensor A

    Paper level sensor B

    Paper sensor

    Level of sensor(approx.)

    Control panel indication

    OFF OFF OFF100% to 50% of

    capacity

    OFFOFF

    Full of paper

    PaperCassette paper level sensor B

    Cassette paper level sensor A

    Little paperOFF ON

    Half full of paperPaperCassette paper

    level sensor BCassette paper level sensor A

    PaperCassette paper level sensor B

    Cassette paper level sensor A

    No paperPaper tray

    Cassette paper sensorFlag

    ONON

    Viewed From Front

  • ON OFF OFF 50% to 50 sheets

    ON ON OFF 50 sheets or less

    --- --- ON no paper

    Paper level sensor A

    Paper level sensor B

    Paper sensor

    Level of sensor(approx.)

    Control panel indication

  • Chapter 2

    2-10

    2.3 Detecting Jams

    2.3.1 Delay Jam 0001-0925

    The leading edge of paper does not reach the sensor within a specific period of time after the cassette 3/4 pickupmotor switches to half-speed mode.

    F-2-8

    T-2-5

    2.3.2 Common Stationary Jams 0001-0926

    The sensor in question does not go off within a specific period of time after it has gone ON.

    F-2-9

    Pickup assembly

    Motor Sensor

    Cassette 3 Cassette 3 pickup motor Cassette 3 retry sensor (PS1C)

    Cassette 4 Cassette 4 pickup motor Cassette 4 retry sensor (PS2C)

    Jam check

    Sensor N

    Pickup motor

    Normal

    [1]:specific feed time

    Error

    Start key ON or Print start

    [1] [1]

    INTR / PRINT

    :motor acceleration

    Jam checkSensor (PS1C/PS2C) Normal

    (L = per length feed distance; A = specific feed length)

    Error

    Start key ON or Print start

    L + A L + A

    INTR / PRINT

  • Chapter 2

    2-11

    T-2-6

    2.3.3 Stationary Jam at Power-On 0001-6945

    The machine identifies the absence of paper over the following sensors before it starts initial multiple rotation inresponse to power-on:

    T-2-7

    2.3.4 Door Open Jam 0001-6947

    The machine detects that the door has been opened while it is making copies/prints.

    T-2-8

    Sensor

    Cassette 3 retry sensor (PS1C)

    Cassette 4 retry sensor (PS2C)

    Sensor

    Cassette 3 retry sensor (PS1C)

    Cassette 4 retry sensor (PS2C)

    Sensor

    Pedestal right cover open/closed sensor (PS9C)

  • Chapter 2

    2-12

    2.4 Power Supply

    2.4.1 Power Supply Route 0001-6959

    The power from the printer unit to the accessories is routed as follows:

    F-2-10

    [1] Cassette pedestal I/F cable[2] 2-Case Pedestal-Y1[3] Pickup heater cableWhen the power is turned on, the host machine supplies 24 VDC and 13 VDC to the pedestal controller PCB.The 24VDC power is used to drive the solenoid, while the 13VDC is converted to 5V power by the DC-DC converteron the pedestal controller PCB for use by sensors and ICs.

    [1] [2][3]

  • F-2-11

    Pedestal controller

    PCB

    Host machine

    DCDCDC-DC

    converter +3.3VCPU/IPC

    +5V Motor drivers

    +5U

    13V

    24V

    24V

    IC2

    IC7

    24VFU1

    3-terminal regulator

    SensorsNF1

    To motors, solenoids

    Acce

    ssor

    ies

    pow

    er

    supp

    ly PC

    B

    Side Paper Deck

    -Q1

    Cont

    rolle

    r pow

    er

    su

    pply

    PCB

  • Chapter 3Parts Replacement Procedure

  • Contents

    Contents

    3.1 External Covers .................................................................................................................................................. 3-13.1.1 Rear Cover................................................................................................................................................... 3-1

    3.1.1.1 Removing the Pedestal Rear Cover...................................................................................................... 3-13.1.2 Right Cover ................................................................................................................................................. 3-1

    3.1.2.1 Removing the Pedestal Right Cover..................................................................................................... 3-13.1.3 Rear Right Cover......................................................................................................................................... 3-2

    3.1.3.1 Removing the Pedestal Rear Right Cover ............................................................................................ 3-23.1.4 Front Right Cover........................................................................................................................................ 3-2

    3.1.4.1 Removing the Pedestal Front Right Cover........................................................................................... 3-23.1.5 Lower Right Cover ...................................................................................................................................... 3-3

    3.1.5.1 Removing the Pedestal Lower Right Cover ......................................................................................... 3-33.2 Drive System ...................................................................................................................................................... 3-4

    3.2.1 Cassette Pickup Motor 3.............................................................................................................................. 3-43.2.1.1 Removing the Right Cover (lower rear)............................................................................................... 3-43.2.1.2 Removing the Right Cover (lower front) ............................................................................................. 3-53.2.1.3 Removing the Pedestal Rear Right Cover ............................................................................................ 3-53.2.1.4 Removing the Pedestal Front Right Cover........................................................................................... 3-63.2.1.5 Removing the Pickup Unit 3 ................................................................................................................ 3-63.2.1.6 Removing the Pedestal Rear Cover...................................................................................................... 3-73.2.1.7 Removing the Cassette Pickup Motor 3 ............................................................................................... 3-8

    3.2.2 Cassette Pickup Motor 4............................................................................................................................ 3-103.2.2.1 Removing the Pedestal Rear Right Cover .......................................................................................... 3-103.2.2.2 Removing the Pedestal Front Right Cover......................................................................................... 3-103.2.2.3 Removing the Pedestal Lower Right Cover ....................................................................................... 3-113.2.2.4 Removing the Pickup Unit 4 .............................................................................................................. 3-113.2.2.5 Removing the Pedestal Rear Cover.................................................................................................... 3-123.2.2.6 Removing the Cassette Pickup Motor 4 ............................................................................................. 3-13

    3.3 Document Feeding System............................................................................................................................... 3-163.3.1 Pick-up Unit 3 ........................................................................................................................................... 3-16

    3.3.1.1 Removing the Right Cover (lower rear)............................................................................................. 3-163.3.1.2 Removing the Right Cover (lower front) ........................................................................................... 3-173.3.1.3 Removing the Pedestal Rear Right Cover .......................................................................................... 3-173.3.1.4 Removing the Pedestal Front Right Cover......................................................................................... 3-183.3.1.5 Removing the Pickup Unit 3 .............................................................................................................. 3-18

    3.3.2 Pick-up Unit 4 ........................................................................................................................................... 3-193.3.2.1 Removing the Pedestal Rear Right Cover .......................................................................................... 3-193.3.2.2 Removing the Pedestal Front Right Cover......................................................................................... 3-203.3.2.3 Removing the Pedestal Lower Right Cover ....................................................................................... 3-203.3.2.4 Removing the Pickup Unit 4 .............................................................................................................. 3-21

    3.3.3 Pickup Rollor............................................................................................................................................. 3-223.3.3.1 Removing the Pickup Roller/Separation Roller ................................................................................. 3-22

    3.3.4 Separation Rollor....................................................................................................................................... 3-233.3.4.1 Removing the Pickup Roller/Separation Roller ................................................................................. 3-23

    3.3.5 Feed Rollor ................................................................................................................................................ 3-23

  • Contents

    3.3.5.1 Removing the Pickup Roller/Separation Roller..................................................................................3-233.3.6 Vertical Path Rollor ...................................................................................................................................3-24

    3.3.6.1 Removing the Right Cover (lower rear) .............................................................................................3-243.3.6.2 Removing the Right Cover (lower front)............................................................................................3-253.3.6.3 Removing the Pedestal Rear Right Cover ..........................................................................................3-263.3.6.4 Removing the Pedestal Front Right Cover .........................................................................................3-263.3.6.5 Removing the Pickup Unit 3...............................................................................................................3-273.3.6.6 Removing the Pedestal Lower Right Cover .......................................................................................3-283.3.6.7 Removing the Pickup Unit 4...............................................................................................................3-283.3.6.8 Removing the Sensor Base .................................................................................................................3-293.3.6.9 Removing the Vertical Path Roller.....................................................................................................3-30

    3.3.7 Sensor Mounting........................................................................................................................................3-313.3.7.1 Removing the Right Cover (lower rear) .............................................................................................3-313.3.7.2 Removing the Right Cover (lower front)............................................................................................3-323.3.7.3 Removing the Pedestal Rear Right Cover ..........................................................................................3-323.3.7.4 Removing the Pedestal Front Right Cover .........................................................................................3-333.3.7.5 Removing the Pickup Unit 3...............................................................................................................3-333.3.7.6 Removing the Pedestal Lower Right Cover .......................................................................................3-343.3.7.7 Removing the Pickup Unit 4...............................................................................................................3-353.3.7.8 Removing the Sensor Base .................................................................................................................3-363.3.7.9 Mounting the Sensor Base ..................................................................................................................3-37

    3.4 Electrical System ..............................................................................................................................................3-393.4.1 Cassette Size Detection Unit .....................................................................................................................3-39

    3.4.1.1 Removing the Pedestal Front Right Cover .........................................................................................3-393.4.1.2 Removing the Pedestal Lower Right Cover .......................................................................................3-393.4.1.3 Removing the Pedestal Right Cover...................................................................................................3-393.4.1.4 Removing the Cassette Size Detection Unit .......................................................................................3-40

    3.4.2 Pedestal Controller PCB ............................................................................................................................3-413.4.2.1 Removing the Pedestal Rear Cover ....................................................................................................3-413.4.2.2 Removing the Pedestal Controller PCB..............................................................................................3-41

    3.4.3 Cassette Retry Paper Sensor ......................................................................................................................3-423.4.3.1 Removing the Right Cover (lower rear) .............................................................................................3-423.4.3.2 Removing the Right Cover (lower front)............................................................................................3-433.4.3.3 Removing the Pedestal Rear Right Cover ..........................................................................................3-433.4.3.4 Removing the Pedestal Front Right Cover .........................................................................................3-443.4.3.5 Removing the Pickup Unit 3...............................................................................................................3-443.4.3.6 Removing the Pedestal Lower Right Cover .......................................................................................3-453.4.3.7 Removing the Pickup Unit 4...............................................................................................................3-463.4.3.8 Removing the Sensor Base .................................................................................................................3-473.4.3.9 Removing the Cassette Retry Paper Sensor........................................................................................3-48

    3.4.4 Cassette Paper Sensor ................................................................................................................................3-483.4.4.1 Removing the Right Cover (lower rear) .............................................................................................3-483.4.4.2 Removing the Right Cover (lower front)............................................................................................3-493.4.4.3 Removing the Pedestal Rear Right Cover ..........................................................................................3-493.4.4.4 Removing the Pedestal Front Right Cover .........................................................................................3-503.4.4.5 Removing the Pickup Unit 3...............................................................................................................3-503.4.4.6 Removing the Pedestal Lower Right Cover .......................................................................................3-513.4.4.7 Removing the Pickup Unit 4...............................................................................................................3-523.4.4.8 Removing the Cassette Paper Sensor..................................................................................................3-53

  • Contents

    3.4.4.9 Removing the Sensor Base................................................................................................................. 3-533.4.5 Cassette Paper Level Sensor (A/B) ........................................................................................................... 3-54

    3.4.5.1 Removing the Right Cover (lower rear)............................................................................................. 3-543.4.5.2 Removing the Right Cover (lower front) ........................................................................................... 3-553.4.5.3 Removing the Pedestal Rear Right Cover .......................................................................................... 3-553.4.5.4 Removing the Pedestal Front Right Cover......................................................................................... 3-563.4.5.5 Removing the Pickup Unit 3 .............................................................................................................. 3-563.4.5.6 Removing the Pedestal Lower Right Cover ....................................................................................... 3-573.4.5.7 Removing the Pickup Unit 4 .............................................................................................................. 3-583.4.5.8 Removing the Sensor Base................................................................................................................. 3-593.4.5.9 Removing the Cassette Paper Level Sensor ...................................................................................... 3-60

    3.4.6 Cassette Pickup Solenoid .......................................................................................................................... 3-603.4.6.1 Removing the Right Cover (lower rear)............................................................................................. 3-603.4.6.2 Removing the Right Cover (lower front) ........................................................................................... 3-613.4.6.3 Removing the Pedestal Rear Right Cover .......................................................................................... 3-613.4.6.4 Removing the Pedestal Front Right Cover......................................................................................... 3-623.4.6.5 Removing the Pickup Unit 3 .............................................................................................................. 3-623.4.6.6 Removing the Pedestal Lower Right Cover ....................................................................................... 3-633.4.6.7 Removing the Pickup Unit 4 .............................................................................................................. 3-643.4.6.8 Removing the Sensor Base................................................................................................................. 3-653.4.6.9 Removing the Cassette Pickup Solenoid............................................................................................ 3-66

    3.4.7 Right Door Open/Closed Sensor ............................................................................................................... 3-663.4.7.1 Removing the Pedestal Rear Right Cover .......................................................................................... 3-663.4.7.2 Removing the Right Door Open/Close Sensor................................................................................... 3-66

  • Chapter 3

    3-1

    3.1 External Covers

    3.1.1 Rear Cover

    3.1.1.1 Removing the PedestalRear Cover 0003-3100

    1)Remove the 3 screws [1] and the tapping screw [2];then, detach the pedestal rear cover [3].

    F-3-1

    3.1.2 Right Cover

    3.1.2.1 Removing the PedestalRight Cover 0003-3120

    1)Open the right cover [1], and free the hook inside;then, detach the right cover.

    F-3-2

    3.1.3 Rear Right Cover

    3.1.3.1 Removing the PedestalRear Right Cover 0003-3103

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-3

    3.1.4 Front Right Cover

    3.1.4.1 Removing the PedestalFront Right Cover 0003-3104

    1)Remove the screw, and detach the front right cover[1].

    F-3-4

    [1]

    [1]

    [1]

  • Chapter 3

    3-2

    3.1.5 Lower Right Cover

    3.1.5.1 Removing the PedestalLower Right Cover 0003-3106

    1)Remove the 2 screws, and detach the lower rightcover [1].

    F-3-5[1]

  • Chapter 3

    3-3

    3.2 Drive System

    3.2.1 Cassette Pickup Motor 3

    3.2.1.1 Removing the RightCover (lower rear) 0003-4195

    - If the Cassette Pedestal-Y1/Y2 is installed to an iRC3100 Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].

    3Remove the 2 screws [4], and detach the right cover(lower rear) [3].

    F-3-6

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.

    2Open the lower right cover [2].3Remove the 5 screws [4], and detach the right cover

    (rear) [3].

    F-3-7

    3.2.1.2 Removing the RightCover (lower front) 0003-4255

    1Open the right door [1] (if a 2-Cassette pedestal-Y1 is installed).2Open the lower right cover [2].3Remove the 2 screws, and detach the right cover

    (lower front) [3].

    F-3-8

    3.2.1.3 Removing the PedestalRear Right Cover 0003-3228

    1)Remove the screw, and detach the pedestal rearright cover [1].

    [1][2]

    [4][3]

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

  • Chapter 3

    3-4

    F-3-9

    3.2.1.4 Removing the PedestalFront Right Cover 0003-3246

    1)Remove the screw, and detach the front right cover[1].

    F-3-10

    3.2.1.5 Removing the PickupUnit 3 0003-3294

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-11

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-12

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-13

    [1]

    [1]

  • Chapter 3

    3-5

    3.2.1.6 Removing the PedestalRear Cover 0003-3275

    1)Remove the 3 screws [1] and the tapping screw [2];then, detach the pedestal rear cover [3].

    F-3-14

    3.2.1.7 Removing the CassettePickup Motor 3 0003-3115

    1)Disconnect the connector [1].2)Remove the 3 screws [2]; then, shift the pickup

    motor 3 [3] together with its base slightly to theright, and detach it to the front.

    F-3-15

    3)Remove the 2 screws [2], and detach the pickupmotor 3 [1] from its base [2].

    F-3-16

    You must not free the joint pins [2] from the motorby removing the 2 screws.

    F-3-17

    1)Disconnect the connector [1].2)Remove the 3 screws [2]; then, shift the pickup

    motor 3 [3] together with its base slightly to theright, and detach it to the front.

    F-3-18

    3)Remove the 2 screws [2], and detach the pickupmotor 3 [1] from its base [2].

    [1][2]

    [1]

  • Chapter 3

    3-6

    F-3-19

    You must not free the joint pins [2] from the motorby removing the 2 screws.

    F-3-20

    Points to Note When Installing the MotorBe sure that the timing belt[1] is sucurely fitted to thegear[2] of the motor and the gear [3] of the mountingbase.

    3.2.2 Cassette Pickup Motor 4

    3.2.2.1 Removing the PedestalRear Right Cover 0003-3229

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-21

    3.2.2.2 Removing the PedestalFront Right Cover 0003-3248

    1)Remove the screw, and detach the front right cover[1].

    F-3-22

    3.2.2.3 Removing the PedestalLower Right Cover 0003-3261

    1)Remove the 2 screws, and detach the lower rightcover [1].

    [1][2]

    [1]

    [1]

    [1]

  • Chapter 3

    3-7

    F-3-23

    3.2.2.4 Removing the PickupUnit 4 0003-3317

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-24

    4)Remove the 4 screws [1], and detach the pickup unit4 [2].

    F-3-25

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-26

    3.2.2.5 Removing the PedestalRear Cover 0003-3278

    1)Remove the 3 screws [1] and the tapping screw [2];then, detach the pedestal rear cover [3].

    F-3-27

    [1]

  • Chapter 3

    3-8

    3.2.2.6 Removing the CassettePickup Motor 4 0003-3117

    1)Disconnect the connector [1].2)Remove the 3 screws [2]; then, shift the pickup

    motor 3 [3] together with its base slightly to theright, and detach it to the front.

    F-3-28

    3)Remove the 2 screws [2], and detach the pickupmotor 3 [1] from its base [2].

    F-3-29

    You must not free the joint pins [2] from the motorby removing the 2 screws.

    F-3-30

    1)Disconnect the connector [1].2)Remove the 3 screws [2]; then, shift the pickup

    motor 3 [3] together with its base slightly to theright, and detach it to the front.

    F-3-31

    3)Remove the 2 screws [2], and detach the pickupmotor 3 [1] from its base [2].

    F-3-32

    You must not free the joint pins [2] from the motorby removing the 2 screws.

    [1][2]

    [1]

  • Chapter 3

    3-9

    F-3-33

    Points to Note When Installing the MotorBe sure that the timing belt[1] is sucurely fitted to thegear[2] of the motor and the gear [3] of the mountingbase.

    [1][2]

    [1]

  • Chapter 3

    3-10

    3.3 Document FeedingSystem

    3.3.1 Pick-up Unit 3

    3.3.1.1 Removing the RightCover (lower rear) 0003-4183

    - If the Cassette Pedestal-Y1/Y2 is installed to an iRC3100 Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 2 screws [4], and detach the right cover

    (lower rear) [3].

    F-3-34

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 5 screws [4], and detach the right cover

    (rear) [3].

    F-3-35

    3.3.1.2 Removing the RightCover (lower front) 0003-4199

    1Open the right door [1] (if a 2-Cassette pedestal-Y1 is installed).2Open the lower right cover [2].3Remove the 2 screws, and detach the right cover

    (lower front) [3].

    F-3-36

    3.3.1.3 Removing the PedestalRear Right Cover 0003-3217

    1)Remove the screw, and detach the pedestal rearright cover [1].

    [1][2]

    [4][3]

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

  • Chapter 3

    3-11

    F-3-37

    3.3.1.4 Removing the PedestalFront Right Cover 0003-3237

    1)Remove the screw, and detach the front right cover[1].

    F-3-38

    3.3.1.5 Removing the PickupUnit 3 0003-3107

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-39

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-40

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-41

    [1]

    [1]

  • Chapter 3

    3-12

    3.3.2 Pick-up Unit 4

    3.3.2.1 Removing the PedestalRear Right Cover 0003-3218

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-42

    3.3.2.2 Removing the PedestalFront Right Cover 0003-3239

    1)Remove the screw, and detach the front right cover[1].

    F-3-43

    3.3.2.3 Removing the PedestalLower Right Cover 0003-3336

    1)Remove the 2 screws, and detach the lower rightcover [1].

    F-3-44

    3.3.2.4 Removing the PickupUnit 4 0003-3108

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-45

    4)Remove the 4 screws [1], and detach the pickup unit4 [2].

    [1]

    [1]

    [1]

  • Chapter 3

    3-13

    F-3-46

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-47

    3.3.3 Pickup Rollor

    3.3.3.1 Removing the PickupRoller/Separation Roller 0003-3110

    1)Detach the cassette.2)Open the right roller (if separation roller).3)Pick and remove the following individual rollers:

    pickup roller [1], feed roller [2], separation roller[3].

    F-3-48

    Points to Note 1 When Replacing the Feed/Separation Roller

    The collar (roller core) of the machines feed/separation roller is black. Do not mount a feed/separation roller designed (mint green) for adifferent model; otherwise, ingredients of the rollercan start to build up on the intermediate transferbelt, causing transfer faults.

    Points to Note 2 When Replacing the Feed/Separation Roller

    The collar (roller core) of the machine's separation/feed roller available as a service part is black.

    At times, however, you may find that a separation/feed roller with a gray collar (roller core) used inthe machine; if so, be sure to use a roller with ablack collar (roller core) when you must replace itwith a service part.

    3.3.4 Separation Rollor

    3.3.4.1 Removing the PickupRoller/Separation Roller 0003-3112

    1)Detach the cassette.

    2)Open the right roller (if separation roller).3)Pick and remove the following individual rollers:

    pickup roller [1], feed roller [2], separation roller[3].

  • Chapter 3

    3-14

    F-3-49

    Points to Note 1 When Replacing the Feed/Separation Roller

    The collar (roller core) of the machines feed/separation roller is black. Do not mount a feed/separation roller designed (mint green) for adifferent model; otherwise, ingredients of the rollercan start to build up on the intermediate transferbelt, causing transfer faults.

    Points to Note 2 When Replacing the Feed/Separation Roller

    The collar (roller core) of the machine's separation/feed roller available as a service part is black.

    At times, however, you may find that a separation/feed roller with a gray collar (roller core) used inthe machine; if so, be sure to use a roller with ablack collar (roller core) when you must replace itwith a service part.

    3.3.5 Feed Rollor

    3.3.5.1 Removing the PickupRoller/Separation Roller 0003-3113

    1)Detach the cassette.

    2)Open the right roller (if separation roller).3)Pick and remove the following individual rollers:

    pickup roller [1], feed roller [2], separation roller[3].

    F-3-50

    Points to Note 1 When Replacing the Feed/Separation Roller

    The collar (roller core) of the machines feed/separation roller is black. Do not mount a feed/separation roller designed (mint green) for adifferent model; otherwise, ingredients of the rollercan start to build up on the intermediate transferbelt, causing transfer faults.

    Points to Note 2 When Replacing the Feed/Separation Roller

    The collar (roller core) of the machine's separation/feed roller available as a service part is black.

    At times, however, you may find that a separation/feed roller with a gray collar (roller core) used inthe machine; if so, be sure to use a roller with ablack collar (roller core) when you must replace itwith a service part.

    3.3.6 Vertical Path Rollor

    3.3.6.1 Removing the RightCover (lower rear) 0003-4184

    - If the Cassette Pedestal-Y1/Y2 is installed to an iRC3100 Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 2 screws [4], and detach the right cover

    (lower rear) [3].

  • Chapter 3

    3-15

    F-3-51

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].

    3Remove the 5 screws [4], and detach the right cover(rear) [3].

    F-3-52

    3.3.6.2 Removing the RightCover (lower front) 0003-3174

    1) Open the right door [1] of the pedestal (if a 2-Cassette Pedestal-Y1 is installed).

    2) Open the lower right cover [2].

    3) Remove the 2 screws, and detach the right cover(lower front) [3].

    F-3-53

    3.3.6.3 Removing the PedestalRear Right Cover 0003-3220

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-54

    3.3.6.4 Removing the PedestalFront Right Cover 0003-3240

    1)Remove the screw, and detach the front right cover[1].

    [1][2]

    [4][3]

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

    [1]

  • Chapter 3

    3-16

    F-3-55

    3.3.6.5 Removing the PickupUnit 3 0003-3282

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-56

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-57

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-58

    3.3.6.6 Removing the PedestalLower Right Cover 0003-3254

    1)Remove the 2 screws, and detach the lower rightcover [1].

    [1]

  • Chapter 3

    3-17

    F-3-59

    3.3.6.7 Removing the PickupUnit 4 0003-3299

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-60

    4)Remove the 4 screws [1], and detach the pickup unit4 [2].

    F-3-61

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-62

    3.3.6.8 Removing the SensorBase 0003-3196

    1)Remove the 2 TP screws [1] and the binding screw[2] at the rear of the pickup assembly; then, detachthe bracket [3].

    [1]

  • Chapter 3

    3-18

    F-3-63

    2)Disconnect the connector [1], and remove the screw[2]; then, detach the cassette pickup solenoid [3].

    3) Remove the bushing [4] and the 5 screws [5]; then,detach the sensor base [6].

    F-3-64

    3.3.6.9 Removing the VerticalPath Roller 0003-3203

    1) Free the claw [A] of the gear [1] at the rear; then,detach the gear and the bushing [2].

    F-3-65

    2) Free the claw [A] of the bushing [1] at the front;then, shift it to the rear, and lift the vertical pathroller [2] to detach.

    F-3-66

    3.3.7 Sensor Mounting

    3.3.7.1 Removing the RightCover (lower rear) 0003-4185

    - If the Cassette Pedestal-Y1/Y2 is installed to an iRC3100 Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].

    3Remove the 2 screws [4], and detach the right cover(lower rear) [3].

  • Chapter 3

    3-19

    F-3-67

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].

    3Remove the 5 screws [4], and detach the right cover(rear) [3].

    F-3-68

    3.3.7.2 Removing the RightCover (lower front) 0003-4248

    1Open the right door [1] (if a 2-Cassette pedestal-Y1 is installed).2Open the lower right cover [2].

    3Remove the 2 screws, and detach the right cover(lower front) [3].

    F-3-69

    3.3.7.3 Removing the PedestalRear Right Cover 0003-3222

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-70

    3.3.7.4 Removing the PedestalFront Right Cover 0003-3241

    1)Remove the screw, and detach the front right cover[1].

    [1][2]

    [4][3]

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

    [1]

  • Chapter 3

    3-20

    F-3-71

    3.3.7.5 Removing the PickupUnit 3 0003-3284

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-72

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-73

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-74

    3.3.7.6 Removing the PedestalLower Right Cover 0003-3257

    1)Remove the 2 screws, and detach the lower rightcover [1].

    [1]

  • Chapter 3

    3-21

    F-3-75

    3.3.7.7 Removing the PickupUnit 4 0003-3303

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-76

    4)Remove the 4 screws [1], and detach the pickup unit4 [2].

    F-3-77

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-78

    3.3.7.8 Removing the SensorBase 0003-3194

    1)Remove the 2 TP screws [1] and the binding screw[2] at the rear of the pickup assembly; then, detachthe bracket [3].

    [1]

  • Chapter 3

    3-22

    F-3-79

    2)Disconnect the connector [1], and remove the screw[2]; then, detach the cassette pickup solenoid [3].

    3) Remove the bushing [4] and the 5 screws [5]; then,detach the sensor base [6].

    F-3-80

    3.3.7.9 Mounting the SensorBase 0003-3215

    Take care not to orient the pickup unit facing downwhen mounting the sensor base; otherwise, the gearswill fall out.1) After fitting the bushing [1] to the frame, mount the

    gear shaft [2].

    F-3-81

    2) Fit the 6 points [A] indicated in the figure in theholes of the base; then, mount the sensor base [2]using 4 screws [1].

    F-3-82

    3) Mount the gear [1] and the E-ring [2].

    Be sure not to leave out the pickup solenoid [1]. Whenmounting it, be sure that the stop [2] is fully engagedwith the cam gear [3].

  • Chapter 3

    3-23

    F-3-83

    Try turning the gears to be sure that they turn withoutresistance.

  • Chapter 3

    3-24

    3.4 Electrical System

    3.4.1 Cassette Size Detection Unit

    3.4.1.1 Removing the PedestalFront Right Cover 0003-3250

    1)Remove the screw, and detach the front right cover[1].

    F-3-84

    3.4.1.2 Removing the PedestalLower Right Cover 0003-3268

    1)Remove the 2 screws, and detach the lower rightcover [1].

    F-3-85

    3.4.1.3 Removing the PedestalRight Cover 0003-3272

    1)Open the right cover [1], and free the hook inside;then, detach the right cover.

    F-3-86

    3.4.1.4 Removing the CassetteSize Detection Unit 0001-1271

    1)Detach the 2 cassettes of the cassette pedestal.2) Remove the screw [1] (1 pc. each) of the cassette

    size detecting unit.

    F-3-87

    3)For the upper, remove the 5 clamps [1], anddisconnect the connector [2]; then, detach thecassette size detecting unit [3].

    [1]

    [1]

    [1]

  • Chapter 3

    3-25

    F-3-88

    4For the lower, remove the 2 clamps [1], anddisconnect the connector [2]; then, detach thecassette size detecting unit [3].

    F-3-89

    3.4.2 Pedestal Controller PCB

    3.4.2.1 Removing the PedestalRear Cover 0003-3102

    1)Remove the 3 screws [1] and the tapping screw [2];then, detach the pedestal rear cover [3].

    F-3-90

    3.4.2.2 Removing the PedestalController PCB 0001-1278

    1)Disconnect the connectors; then, remove the 5screws [1], and detach the pedestal control PCB [2].

    F-3-91

    3.4.3 Cassette Retry Paper Sensor

    3.4.3.1 Removing the RightCover (lower rear) 0003-4187

    - If the Cassette Pedestal-Y1/Y2 is installed to an iRC3100 Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 2 screws [4], and detach the right cover

    (lower rear) [3].

  • Chapter 3

    3-26

    F-3-92

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].

    3Remove the 5 screws [4], and detach the right cover(rear) [3].

    F-3-93

    3.4.3.2 Removing the RightCover (lower front) 0003-4250

    1Open the right door [1] (if a 2-Cassette pedestal-Y1 is installed).2Open the lower right cover [2].

    3Remove the 2 screws, and detach the right cover(lower front) [3].

    F-3-94

    3.4.3.3 Removing the PedestalRear Right Cover 0003-3224

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-95

    3.4.3.4 Removing the PedestalFront Right Cover 0003-3242

    1)Remove the screw, and detach the front right cover[1].

    [1][2]

    [4][3]

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

    [1]

  • Chapter 3

    3-27

    F-3-96

    3.4.3.5 Removing the PickupUnit 3 0003-3285

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-97

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-98

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-99

    3.4.3.6 Removing the PedestalLower Right Cover 0003-3258

    1)Remove the 2 screws, and detach the lower rightcover [1].

    [1]

  • Chapter 3

    3-28

    F-3-100

    3.4.3.7 Removing the PickupUnit 4 0003-3306

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-101

    4)Remove the 4 screws [1], and detach the pickup unit4 [2].

    F-3-102

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-103

    3.4.3.8 Removing the SensorBase 0003-3197

    1)Remove the 2 TP screws [1] and the binding screw[2] at the rear of the pickup assembly; then, detachthe bracket [3].

    [1]

  • Chapter 3

    3-29

    F-3-104

    2)Disconnect the connector [1], and remove the screw[2]; then, detach the cassette pickup solenoid [3].

    3) Remove the bushing [4] and the 5 screws [5]; then,detach the sensor base [6].

    F-3-105

    3.4.3.9 Removing the CassetteRetry Paper Sensor 0003-3205

    1) Disconnect the connector [1], and detach thecassette retry paper sensor [2].

    F-3-106

    3.4.4 Cassette Paper Sensor

    3.4.4.1 Removing the RightCover (lower rear) 0003-4189

    - If the Cassette Pedestal-Y1/Y2 is installed to an iRC3100 Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 2 screws [4], and detach the right cover

    (lower rear) [3].

    F-3-107

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 5 screws [4], and detach the right cover

    [1][2]

    [4][3]

  • Chapter 3

    3-30

    (rear) [3].

    F-3-108

    3.4.4.2 Removing the RightCover (lower front) 0003-4251

    1Open the right door [1] (if a 2-Cassette pedestal-Y1 is installed).2Open the lower right cover [2].3Remove the 2 screws, and detach the right cover

    (lower front) [3].

    F-3-109

    3.4.4.3 Removing the PedestalRear Right Cover 0003-3225

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-110

    3.4.4.4 Removing the PedestalFront Right Cover 0003-3243

    1)Remove the screw, and detach the front right cover[1].

    F-3-111

    3.4.4.5 Removing the PickupUnit 3 0003-3286

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

    [1]

    [1]

  • Chapter 3

    3-31

    F-3-112

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-113

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-114

    3.4.4.6 Removing the PedestalLower Right Cover 0003-3259

    1)Remove the 2 screws, and detach the lower rightcover [1].

    F-3-115

    3.4.4.7 Removing the PickupUnit 4 0003-3314

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-116

    4)Remove the 4 screws [1], and detach the pickup unit4 [2].

    [1]

  • Chapter 3

    3-32

    F-3-117

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-118

    3.4.4.8 Removing the CassettePaper Sensor 0003-3206

    1) Disconnect the connector [1], and detach thecassette paper sensor [2].

    F-3-119

    3.4.4.9 Removing the SensorBase 0003-3199

    1)Remove the 2 TP screws [1] and the binding screw[2] at the rear of the pickup assembly; then, detachthe bracket [3].

    F-3-120

    2)Disconnect the connector [1], and remove the screw[2]; then, detach the cassette pickup solenoid [3].

    3) Remove the bushing [4] and the 5 screws [5]; then,detach the sensor base [6].

    F-3-121

    3.4.5 Cassette Paper Level Sensor (A/B)

    3.4.5.1 Removing the RightCover (lower rear) 0003-4194

    - If the Cassette Pedestal-Y1/Y2 is installed to an iR

  • Chapter 3

    3-33

    C3100 Series machine, 1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 2 screws [4], and detach the right cover

    (lower rear) [3].

    F-3-122

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 5 screws [4], and detach the right cover

    (rear) [3].

    F-3-123

    3.4.5.2 Removing the RightCover (lower front) 0003-4252

    1Open the right door [1] (if a 2-Cassette pedestal-Y1 is installed).2Open the lower right cover [2].3Remove the 2 screws, and detach the right cover

    (lower front) [3].

    F-3-124

    3.4.5.3 Removing the PedestalRear Right Cover 0003-3227

    1)Remove the screw, and detach the pedestal rearright cover [1].

    F-3-125

    [1][2]

    [4][3]

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

    [1]

  • Chapter 3

    3-34

    3.4.5.4 Removing the PedestalFront Right Cover 0003-3244

    1)Remove the screw, and detach the front right cover[1].

    F-3-126

    3.4.5.5 Removing the PickupUnit 3 0003-3289

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-127

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-128

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-129

    3.4.5.6 Removing the PedestalLower Right Cover 0003-3260

    1)Remove the 2 screws, and detach the lower rightcover [1].

    [1]

  • Chapter 3

    3-35

    F-3-130

    3.4.5.7 Removing the PickupUnit 4 0003-3316

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-131

    4)Remove the 4 screws [1], and detach the pickup unit4 [2].

    F-3-132

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-133

    3.4.5.8 Removing the SensorBase 0003-3200

    1)Remove the 2 TP screws [1] and the binding screw[2] at the rear of the pickup assembly; then, detachthe bracket [3].

    [1]

  • Chapter 3

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    F-3-134

    2)Disconnect the connector [1], and remove the screw[2]; then, detach the cassette pickup solenoid [3].

    3) Remove the bushing [4] and the 5 screws [5]; then,detach the sensor base [6].

    F-3-135

    3.4.5.9 Removing the CassettePaper Level Sensor A/B 0003-3208

    1) Disconnect the connector [1] (1 pc. each), anddetach the cassette power level sensor (A/B) [2].

    F-3-136

    3.4.6 Cassette Pickup Solenoid

    3.4.6.1 Removing the RightCover (lower rear) 0003-4197

    - If the Cassette Pedestal-Y1/Y2 is installed to an iRC3100 Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].3Remove the 2 screws [4], and detach the right cover

    (lower rear) [3].

    F-3-137

    - If the Cassette Pedestal-Y2 is installed to an iR 2000Series machine,

    1Open the right door [1] of the pedestal.2Open the lower right cover [2].

    [1][2]

    [4][3]

  • Chapter 3

    3-37

    3Remove the 5 screws [4], and detach the right cover(rear) [3].

    F-3-138

    3.4.6.2 Removing the RightCover (lower front) 0003-4257

    1Open the right door [1] (if a 2-Cassette pedestal-Y1 is installed).2Open the lower right cover [2].3Remove the 2 screws, and detach the right cover

    (lower front) [3].

    F-3-139

    3.4.6.3 Removing the PedestalRear Right Cover 0003-3230

    1)Remove the screw, and detach the pedestal rear

    right cover [1].

    F-3-140

    3.4.6.4 Removing the PedestalFront Right Cover 0003-3249

    1)Remove the screw, and detach the front right cover[1].

    F-3-141

    3.4.6.5 Removing the PickupUnit 3 0003-3290

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    [1][2]

    [4]

    [4][4]

    [3]

    [3]

    [2]

    [1]

    [1]

    [1]

  • Chapter 3

    3-38

    F-3-142

    4)Remove the 4 screws [1], and detach the pickup unit3 [2].

    F-3-143

    Be sure that the harness of the pickup unit does notstick out the hook assembly [1] or the cable guidearea [2].

    F-3-144

    3.4.6.6 Removing the PedestalLower Right Cover 0003-3265

    1)Remove the 2 screws, and detach the lower rightcover [1].

    F-3-145

    3.4.6.7 Removing the PickupUnit 4 0003-3320

    1)Detach the cassette 3/4.2)Remove the screw [1],a and detach the sensor base

    [2].3)Disconnect the connector [3], and free the harness

    from the guide.

    F-3-146

    4)Remove the 4 screws [1], and deta


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