CANON LBP 3260 PD-82 Service Manual

SERVICE MANUAL

REVISION 0

RY8-1395-000

JAN. 1999

2000 SHEET PAPER DECK

Printed in Japan

Imprimé au Japon

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

Prepared by

PERIPHERAL PRODUCTS QUALITY PLANNING DIV.

PERIPHERAL PRODUCTS TECHNICAL DOCUMENTATION DEPT.

CANON INC.

5-1, Hakusan 7-chome, Toride-City, Ibaraki-Pref. 302-8501, Japan

PREFACE

This Service Manual contains basic information required for after-sales service of 2000 sheet paper deck PD-82. This information is vital to the service technician in maintaining the high print quality and performance of the paper deck.

This manual consists of the following chapters:

Chapter 1: Product information

Features, specifications, parts of the deck, and installation

Chapter 2: Operation and Timing

A description of the operating principles and timing sequences of the electrical and mechanical systems.

Chapter 3: The Mechanical System

Explanation of mechanical operation, disassembly, reassembly, and adjustment procedures

Chapter 4: Troubleshooting

Maintenance and servicing, measurement and adjustments, troubleshooting procedures, etc.

Appendix: General circuit diagram and list of signals.

Information in this manual is subject to change as the product is improved or redesigned. All relevant information in such cases will be supplied in Service Information Bulletins. A thorough understanding of this deck, based on information in this Manual and Service Information Bulletins is required for maintaining its performance and for locating and repairing malfunctions.

DTP system

This manual was produced on an Apple PowerMacintosh 9500/200 personal computer and output by an Apple LaserWriter 16/600 PS laser beam printer; final pages were printed on AGFA Selectset avantra 25.

All graphics were produced with Macromedia FreeHand (J), and all documents and page layouts were

created with QuarkXPress (E).

The video images were captured with SONY degital video camcorder and Radius PhotoDV capture

board system, and modified with Adobe Photoshop (J).

CHAPTER 1 PRODUCT INFORMATION

I. FEATURES ............................. 1-1

II. SPECIFICATIONS.................... 1-2

III. PARTS OF THE PAPER DECK.. 1-3

A. Appearance........................ 1-3

B. Cross Sectional Views........ 1-4

IV. INSTALLATION ....................... 1-5

A. Notes................................. 1-5

B. Unpacking and Installation 1-5

CHAPTER 2 OPERATION AND TIMING

CHAPTER 3 THE MECHANICAL SYSTEM

I. BASIC OPERATION................. 2-1

A. Outline.............................. 2-1

B. Paper Deck Driver Inputs... 2-2 C. Paper Deck Driver Outputs 2-3

II. PICK-UP/FEED SYSTEM ......... 2-4

A. Outline.............................. 2-4

B. Paper Pick-up and Feeding. 2-7

C. Lifter Operation................. 2-9

D. Paper Jam Detection ......... 2-10

III. POWER SUPPLIES .................. 2-11

A. Outline.............................. 2-11

B. Protective Function........... 2-11

I. PREFACE .............................. 3-1

II. EXTERNALS .......................... 3-2

A. Locations ......................... 3-2

B. External Covers ................ 3-3

III. MAIN UNITS .......................... 3-5

A. Drive Unit ......................... 3-5

B. Pick-up Unit ..................... 3-5

C. Paper Feed Unit ................ 3-6

D. Tray ................................. 3-6

IV. MAIN PARTS .......................... 3-7

A. Locations ......................... 3-7

B. Lifter ................................ 3-8

V. SWITCHES ............................ 3-13

A. Locations ......................... 3-13

B. Paper Level Detection

Switches ........................... 3-14

C. Paper-size Detection

Switches ........................... 3-14

VI. SENSORS .............................. 3-15

A. Locations ......................... 3-15

B. Registration Paper Sensor 3-16

C. Paper Jam Sensor ............. 3-16

D. Tray Paper-out Sensor/

Paper Surface Sensor/

Door Sensor ...................... 3-17

VII. SOLENOID/CLUTCH .............. 3-18

A. Locations ......................... 3-18

B. Registration Clutch .......... 3-19

C. Pick-up Solenoid ............... 3-19

VIII.MOTORS ............................... 3-20

A. Locations ......................... 3-20

B. Lifter Motor ...................... 3-21

C. Pick-up Motor ................... 3-21

D. Feed Motor ....................... 3-22

IX. ELECTRICAL PARTS .............. 3-23

A. Locations ......................... 3-23

B. Paper Deck Driver PCB ..... 3-24

C. Power Supply .................... 3-24

D. Paper-size Detection

Switch PCB ....................... 3-25

E. Paper-level Detection

Switch PCB ....................... 3-25

F. LED PCB ........................... 3-26

I. PREFACE ............................... 4-1

A. Malfunction Diagnosis

Flowchart .......................... 4-1

B. Initial Checks.................... 4-3

C. Service Checkpoints.......... 4-3

D. Service Mode ..................... 4-5

II. PAPER JAMS.......................... 4-9

III. PAPER TRANSPORT

TROUBLESHOOTING .............. 4-12

IV. MALFUNCTION

TROUBLESHOOTING .............. 4-13

V. MALFUNCTION STATUS

TROUBLESHOOTING .............. 4-14

VI. MEASUREMENT AND

ADJUSTMENT ........................ 4-17

A. Mechanical Adjustment ..... 4-17

B. Electrical Adjustment........ 4-17

C. LEDs, test pins, jumpers, and

switches on PCB ................ 4-17

VII. MAINTENANCE AND

SERVICING............................. 4-20

A. Periodic Replacement

Parts ................................. 4-20

B. Expected Lives of

Consumable Parts.............. 4-20

C. Regular Servicing

Schedule ........................... 4-20

D. Standard Tools .................. 4-20

E. Special Tools ..................... 4-20

F. List of Lubricants and

Cleaners ............................ 4-20

VIII.LOCATION OF CONNECTORS.. 4-21

APPENDIX

I. GENERAL CIRCUIT DIAGRAM. A-1

II. LIST OF SIGNALS ................... A-3

A. Input/output signals to paper

deck driver PCB................. A-3

CHAPTER 4 TROUBLESHOOTING

CHAPTER 1

PRODUCT INFORMATION

I. FEATURES ............................ 1-1

II. SPECIFICATIONS .................. 1-2

III. PARTS OF THE PAPER DECK 1-3

IV. INSTALLATION ...................... 1-5

1 - 1

CHAPTER 1

I. FEATURES

1. Large capacity

The paper deck is capable of accommodating up to 2,000 sheets of paper (64g/m2paper), enabling you to make continuous printing in large volume.

2. Status LED

The LED on the front of the paper deck allows the user to check the status of the paper deck easily.

3. Stand alone mode switch

The paper deck can be operated without printer by turning ON the stand alone mode switch, allowing the service technician to perform the service mode easily.

II. SPECIFICATIONS

1. Print paper types A3, B4, A4, Ledger, Legal, and Letter size plain paper (recommended paper, 64 to 105 g/m2)

2. Capacity Depth: 200 mm (About 2000 sheets of paper (64g/m2) can be stacked.)

3. Maximum power About 36 W or less (Room temperature: 20°C; Rated power supply

consumption voltage)

4. Noise (Published noise Sound power level (1B=10dB) 7.1 B or less (during printing)

level based on ISO 9296) 6.4 B or less (standby) (Note) Sound pressure level 53 dB or less (during printing)

(Bystander position) 48 dB or less (standby)

5. Dimensions 629 (width) × 520 (depth) × 651 (height) mm

6. Weight About 30 kg

7. Power supply 100 to 127 V (50/60 Hz) 220 to 240 V (50 Hz) (Voltage tolerance ±10%)

Note Value when the printer is equipped with the paper deck

Specifications are subject to change with product modification.

1 - 2

CHAPTER 1

III. PARTS OF THE PAPER

DECK

A. Appearance

Figure 1-3-1

Figure 1-3-2

1: Positioning pins 2: Paper feed unit 3: Paper size regulation plates 4: Lifter 5: Status LED

6: Interface connector 7: Power receptacle

1 - 3

CHAPTER 1

➀

➁

➂

➃

➄

➅

➆

B. Cross Sectional Views

Figure 1-3-3

1: Lifter 2: Paper size regulation plates 3: Pick-up roller 4: Feed roller 1 5: Feed roller 2 6: Registration rollers 7: Separation roller

1 - 4

CHAPTER 1

➀

➁

➃

➂

➄

➆

➅

IV. INSTALLATION

A. Notes

Use the following power supplies;

• Line voltage (AC): ±10% of the rated voltage

• Power frequency: 50/60 Hz ± 2Hz

B. Unpacking and Installation

Condensation will form on the metal surfaces when brought into a warm room from the cold. Therefore, when moving the unit into a warm environment, leave it packed in its box for at least an hour to acclimatize to room temperature.

1. Opening the paper deck packaging

1) Undo the paper deck packaging, and remove the box.

2) Take out the accessories. Confirm that the power cord, outrigger kit, interface cables and manual are included.

3) Remove the top pads (left/right) and remove the paper deck from the box.

4) Take the plastic bag off from around the deck and peel off the tape holding the various parts. Check that none of the covers were scratched or deformed during shipment.

5) Open the tray, remove the 2 spacers, and peel off the tape.

6) Peel off the tape holding the latch of the paper guide.

2. Connecting to the printer

1) Carry the paper deck to the installation location and lock the casters.

2) Rotate the adjusters to install on the floor.

3) Open the feed unit.

4) Line up the printer and paper deck in the same direction, and have 4 people lift the printer. Lower the printer onto the paper deck while aligning the 3 positioning pins on the paper deck with the printer.

5) Close the feed unit.

6) Remove the cassette from the printer. Put the snap pins (for earthquake countermeasure) to the positioning pins.

7) Install the outriggers to the 2 guides at the bottom of the paper deck.

8) Put the covers to the 5 outriggers.

9) Connect the printer and paper deck with the interface cable.

10) Plug the power cord into the paper deck and the outlet.

Figure 1-4-1

1 - 5

CHAPTER 1

• Snap pin insertion location

Feed unit

snap pin

CHAPTER 2

OPERATION AND TIMING

1. This chapter describes the paper deck functions, the relationships between mechanisms and circuits, and the timing of operations. Mechanical linkages are indicated by black and white lines ( ), the flow of control signals by solid arrows ( ), and the flow of groups of signals by outline arrows ( ).

2. An active-high signal is indicated by "H" or by a signal name without a slash in front of it, such as "PSNS." An active-low signal is indicated by "L" or by a signal name with a slash in front of, such as "/SCNON."

A signal that is "H" or has a name without a slash is active at the supply voltage level (indicating that the signal is being output), and inactive at ground level (indicating that the signal is not being output).

A signal that is "L" or has a slash in front of its name is active at ground level, and inac-

tive at the supply voltage level.

There is a microcomputer in this paper deck. But as the internal operation of the microcomputer cannot be checked, an explanation of the operation of the microcomputer has been left out.

As it is assumed that no repair will be made to customer circuit boards, the explanation of board circuits is limited to an outline using block diagrams. So there are two types of circuit explanations; (1) everything from the sensor to the input sections of the major circuit boards, (2) everything from the output sections of the major circuit boards to the loads. These are explained with block diagrams according to the function.

I. BASIC OPERATION................. 2-1

II. PICK-UP/FEED SYSTEM......... 2-4

III. POWER SUPPLIES .................. 2-11

I. BASIC OPERATION

A. Outline

The paper deck feeds print paper to the printer.

The sequence of paper deck operations is controlled by the paper deck driver PCB. This PCB contains an eight-bit microcomputer (IC201) to control the sequence of operations and serial communication with the option controller PCB.

The paper deck driver drives the solenoids and motors according to various commands coming from the option controller through the serial communication line. The paper deck driver sends sensor and switch data to the option controller through the serial communication line.

Figure 2-1-1

2 - 1

CHAPTER 2

Option

controller PCB

Option driver PCBs

Paper deck driver

PCB

IC 201

Registration clutch

Pick-up solenoid

Sensor / Switch

Pick-up motor

Lifter motor

Feed motor

LED PCB

Power supply

B. Paper Deck Driver Inputs

Figure 2-1-2

2 - 2

CHAPTER 2

Paper deck driver PCB

Registration paper sensor

Paper jam sensor

Tray paper-out sensor

Paper surface sensor

Door sensor

PS1

PS2

PS3

PS4

PS5

J309-3

-1

-2

J310-3

-1

-2

J312-3

J313-3

-1

-2

J314-3

-1

-2

-1

-2

J304a-4

J304a-1

J307a-7

J307a-4

J307a-1

-6

-5

-3

-2

-3

-2

-9

-8

-6

-5

J304-5

-3

-4

J304-8

-6

-7

J307-3

-1

-2

J307-6

-4

-5

J307-9

-7

-8

J209-4

J209-1

J212-7

J212-4

J212-1

-6

-5

-3

-2

-9

-8

-6

-5

-3

-2

+5V REGS

+5V JAMS

+5V

PAP-EXISTS

+5V LIFTS

+5V DOORS

"L" when the sensor detects paper.

"H" when there is no paper in the tray.

"H" when paper is detected.

"H" when the paper feed unit is opened.

Paper-level detection switch

Paper-size detection switch

Paper-level detection switch PCB

SW601 SW602

Paper-size detection switch PCB

SW701 SW702 SW703 SW704

-1

-3

-2

-3

-4

-5

J205-2

-3

-1

J204-5

-4

-3

-2

-1

J601-2

J701-1

PAP-VOL1 PAP-VOL2

PAP-SIZE1 PAP-SIZE2 PAP-SIZE3 PAP-SIZE4

Detects the level of paper.

Detects the size of the paper

C. Paper Deck Driver Outputs

Figure 2-1-3

2 - 3

CHAPTER 2

Paper deck driver PCB

Lifter motor

Feed motor

Pick-up motor

Registration clutch

Pick-up solenoid

SPM1

SPM2

SPM3

CL1

SL1

J303a-1

-2

J315a-1

J305a-1

J303-1

-2

J306a-2

J315-5

-2

-3

-4

J305-4

-2

-3

-4

J304a-8

-7

J306-1-2J211-2

-1

-4

-3

-2

-3

-2

-1

J304-1

-2

J206-1

-2

-3

-4

J207-1

-2

-3

-4

J210-1

-2

-3

-4

J207-2

-1

DRVAD DRVAND DRVBD DRVBND

FED1AD FED1AND FED1BD FED1BND

FED2AD FED2AND FED2BD FED2BND

+24V

REGCLD

+24V

PUPSLD

LIFTER MOTOR ROTATION CONTROL signal.

FEED MOTOR ROTATION CONTROL signal.

PICK-UP MOTOR ROTATION CONTROL signal.

Registration roller rotates when "L".

Arm is lowered when "L".

LED PCB

J301-3

-2

-1

J213-1

-2

-3

LEDR LEDG

STATUS LED CONTROL signal

II. PICK-UP/FEED SYSTEM

A. Outline

The paper in the paper deck is detected by the tray paper-out sensor (PS3). The paper level in the tray is detected by a combination of outputs from paper-level detection switch 1 (SW601) and paper-level detection switch 2 (SW602). The paper size is detected by a combination of outputs from paper size detection switches (SW701 to SW704). The combinations of paperlevel detection switches and paper size detection switches are listed in Table 2-2-1.

When the option controller sends a pick-up command to the paper deck, the paper deck driver runs the pick-up motor (SPM3) which rotates the pick-up roller, feed roller 1 and separation roller.

At the same time, the paper deck driver turns ON the pick-up solenoid (SL1). This lowers the pick-up roller to the print paper surface. As the pick-up roller turns, the paper is fed to the paper feed unit.

The paper passes through the registration paper sensor (PS1) and stops when it touches the registration roller. When the registration clutch (CL1) turns ON, the paper is fed to the printer.

There are two photointerrupters (PS1 and PS2) in the paper path to detect paper. If the paper does not reach or pass through each sensor within the prescribed period of time, the paper deck driver assumes that a paper jam has occurred, stops the operation, and reports the jam to the option controller.

Table 2-2-1

2 - 4

CHAPTER 2

Paper-level detection switch

SW601

OFF

ON ON

OFF

SW602

OFF OFF

ON ON

Remaining paper %

100

75 50 25

Paper size

Ledger

Legal

Letter (horizontal)

A4 (horizontal)

Tray open

Paper-size detection switch

SW701

OFF

SW702

OFF

SW703

OFF

SW704

OFF

2 - 5

CHAPTER 2

Figure 2-2-1

Option controller PCB

Serial line

Paper deck driver PCB

LIFTER MOTOR DRIVE signal

SPM1

SPM1:Lifter motor SPM2:Feed motor SPM3:Pick-up motor SL1:Pick-up solenoid

CL1:Registration clutch

PICK-UP MOTOR DRIVE signal

SPM3

Pick-up roller

Lifter

(PUPSLD)

PICK-UP SOLENOID DRIVE signal

SL1

FEED MOTOR DRIVE signal

SPM2

Feed roller

CL1

Feed

roller 1

Separation

roller

(REGICL)

REGISTRATIONCLUTCH DRIVE signal

Registration

roller

Paper deck

Figure 2-2-2

2 - 6

CHAPTER 2

P APER-LEVELDETECTION signal

Option controller PCB

Serial line

Paper deck driver PCB

P APER-SIZEDETECTION signal

SW701

SW702

SW703 SW704

SW601 SW602

PS1: Registration paper sensor PS2: Paper jam sensor PS3: Tray paper-out sensor PS4: Paper surface sensor SW601: Paper-level detection switch 1 SW602: Paper-level detection switch 2 SW701: Paper-size detection switch 1 SW702: Paper-size detection switch 2 SW703: Paper-size detection switch 3 SW704: Paper-size detection switch 4

P APERSURFACEDETECTION signal(LIFTS)

Feed roller 2

TRA YP APER-OUTDETECTION signal(PAP-EXISTS)

Feed roller 1

PS4 PS3

Pick-up roller

Registration

roller

P APERJAM DETECTION signal(JAMS)

REGISTRA TIONP APERDETECTION signal(REGS)

PS2

PS1

Separation roller

B. Paper Pick-up and Feeding

When the paper deck driver receives a paper pick-up command from the option controller, the driver runs the feed motor (SPM2) and pick-up motor (SPM3). SPM2 rotates feed roller 2 and registration roller, and SPM3 rotates the pick-up roller, feed roller 1 and separation roller. The paper deck driver turns ON the pick-up solenoid (SL1). This rotates the pick-up cam and operates the pick-up arm. The rotating pick-up roller lowers to the print paper surface and picks up the paper. The separation roller removes any excessive sheets of paper and only one sheet of paper is fed to the paper feed unit with feed roller 1.

The print paper passes through the registration paper sensor (PS1) and reaches the registration roller. Since the registration roller is not turning at this time, the print paper stops and its leading edge is looped to correct skews. When the registration clutch (CL1) turns ON, SPM2 power is transmitted to the registration roller and it rotates. The print paper is fed to the printer.

Figure 2-2-3

2 - 7

CHAPTER 2

Pick-up roller

Feed roller 1

Separation roller

Pick-up arm

Pick-up cam

Pick-up solenoid

Figure 2-2-4

2 - 8

CHAPTER 2

Pick-up command

Feed motor (SPM2)

Pick-up motor (SPM3)

Pick-up solenoid (SL1)

Registration clutch (CL1)

Registration paper sensor (PS1)

Paper jam sensor (PS2)

(Unit:Seconds)

about 0.4

0.2

about 0.1

about 0.4

about 0.8

C. Lifter Operation

The lifter in the tray is suspended by two wires. The wires are wound on four pulleys by the lifter motor (SPM1: stepping motor), and the lifter lifts. When the tray is pulled out, the pulley gears are disengaged from the motor gears, and the lifter lowers by its own weight.

The presence or absence of the tray in the paper deck is detected by paper size detection switches (SW701 to SW704).

The paper deck driver turns SMP1 ON when it detects that the tray is installed correctly with the paper size detection switches. The lifter lifts to the position where the paper surface sensor (PS4) goes “H.” When the print paper is picked up, the number of sheets decreases, and PS4 goes “L”, the paper deck driver turns SPM1 ON again, and lifts the lifter until PS4 goes “H.”

If PS4 does not go “H” within the prescribed period of time after the lifter begins lifting, the paper deck driver assumes that the lifter has failed and reports it to the option controller.

Figure 2-2-5

2 - 9

CHAPTER 2

PS4:Paper surface sensor

Wire

PS4

Wire

Lifter

D. Paper Jam Detection

The following paper sensors are installed to detect the presence of paper and ensure that the paper is fed correctly.

• Registration paper sensor (PS1)

• Paper jam sensor (PS2) The CPU determines whether or not a paper jam has occurred by monitoring the paper at each of the sensors according to the pre-set 'check timing' in the memory. When the CPU assesses that a jam has occurred, the feed operation to the printer is stopped, and notification of the jam is sent to the option controller.

1. Pick-up delay jam

If the registration sensor (PS1) cannot detect the paper within 1.0 second after receiving the pick-up command, the CPU assesses a pick-up delay jam.

Paper pick-up retry function

If the CPU cannot detect the paper when executing the first jam check, it performs the paper pick-up operation again. If the CPU cannot detect the paper for the second time, it assesses a pick-up delay jam.

2. Feed unit delay jam

If the paper jam sensor (PS2) cannot detect the paper within 1.6 seconds after the registration clutch (CL1) is driven, the CPU assesses a feed unit delay jam.

3. Feed unit stationary jam

If trailing edge of the paper does not pass through the paper jam sensor (PS2) within the prescribed period of time (T) after PS2 detects the leading edge of the paper, the CPU assumes a feed unit stationary jam. T=about 2.1 seconds (A4 landscape), about 3.6 seconds (Ledger)

2 - 10

CHAPTER 2

III. POWER SUPPLIES

A. Outline

The power supply unit uses a remote switch.

When the printer power switch is turned ON, the printer outputs a command to the option controller through the video controller. The option controller outputs a POWER ON signal (PWRON-IN) to the power supply unit through the paper deck driver according to the command. When the PWRON-IN signal is “H”, the power supply unit provides +24 V and +5 V to the paper deck driver.

+24 V is used to drive the lifter motor, feed motor, pick-up motor, clutches and solenoids, and +5 V is used for sensors and ICs on the paper deck driver PCB.

The power supply unit uses the stand alone mode switch (SW1). This allows the paper deck to be ON while the printer is OFF.

A block diagram of the power supply unit is shown below.

Figure 2-3-1

B. Protective Function

The +24V and +5V power supply circuits have the overcurrent protection function and the overvoltage protection function that interrupt the output voltage automatically to prevent failure of the power supply circuits if a trouble, such as a short, occurs in the load and results in overcurrent flow or occurance of abnormal voltage.

Therefore, if the overcurrent or overvoltage protection function is activated and the DC voltage is not output from the power supply circuit, turn the printer OFF, correct the trouble in the load, and turn the printer ON again.

2 - 11

CHAPTER 2

Power supply

Fuse

Noise filter

SW1

Remote contorol circuit

Smoothing circuit

Transformer

Control IC Overcurrent protection curcuit

Smoothing circuit

Overvoltage protection curcuit

PWRON-IN

+24V

+5V

Paper dec driver PCB

PWRON-IN

+24V

+5V

Option controller PCB

Switchs /sensors

Solenoids

Clutchs

Motors

+ 61 hidden pages

CANON LBP 3260 PD-82 Service Manual

CONTENTS

CHAPTER 1

I. FEATURES

II. SPECIFICATIONS

IV. INSTALLATION

CHAPTER 2

I. BASIC OPERATION

II. PICK-UP/FEED SYSTEM

III. POWER SUPPLIES