Service Manual iR C3200 Series iR C3220N PRT Dec 3 2004 Application This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair of products. This manual covers all localities where the products are sold. For this reason, there may be information in this manual that does not apply to your locality. Corrections This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition of this manual. The following paragraph does not apply to any countries where such provisions are inconsistent with local law. Trademarks The product names and company names used in this manual are the registered trademarks of the individual companies. Copyright This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc. COPYRIGHT © 2001 CANON INC. Printed in Japan Caution Use 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. Memo Indicates an item of reference assisting the understanding of the topic in question. REF. Provides a description of a service mode. Provides a description of the nature of an error indication. 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, the arrow represents the path of mechanical drive; where a signal name accompanies the symbol , indicates the direction of the electric signal. The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results in supplying the machine with power. 2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to indicate "Low".(The voltage value, however, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'. In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessors used in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads. The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins. All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and be able to identify and isolate faults in the machine." Contents Contents Chapter 1 Introduction 1.1 System Construction .......................................................................................................................................... 1-1 1.1.1 System Construction of the Pickup/Delivery Options ............................................................................... 1-1 1.1.2 System Configuration and Print/Transmission Accessories ...................................................................... 1-2 1.1.3 Functions of Printing/Transmission Accessories ....................................................................................... 1-3 1.1.4 Overview of Printing/Transmitting Accessories ........................................................................................ 1-4 1.2 Product Specifications ....................................................................................................................................... 1-5 1.2.1 Names of Parts ............................................................................................................................................ 1-5 1.2.1.1 External View ...................................................................................................................................... 1-5 1.2.1.2 Cross Section ....................................................................................................................................... 1-7 1.2.2 Using the Machine ...................................................................................................................................... 1-8 1.2.2.1 Turning On the Power ......................................................................................................................... 1-8 1.2.2.2 Points to Note When Turning Off the Main Power Switch ................................................................. 1-9 1.2.2.3 Control Panel ..................................................................................................................................... 1-11 1.2.3 User Mode Items ....................................................................................................................................... 1-12 1.2.3.1 Common Settings .............................................................................................................................. 1-12 1.2.3.2 Timer Settings ................................................................................................................................... 1-13 1.2.3.3 Adjustments and Cleaning ................................................................................................................. 1-13 1.2.3.4 Report Generation ............................................................................................................................. 1-14 1.2.3.5 System Control Settings .................................................................................................................... 1-15 1.2.3.6 Copier Specifications Settings ........................................................................................................... 1-16 1.2.3.7 Transmission/Reception Specifications Settings ............................................................................... 1-16 1.2.3.8 Box Specifications Settings ............................................................................................................... 1-17 1.2.3.9 Printer Specifications Settings ........................................................................................................... 1-18 1.2.3.10 Destinations Table Specifications Settings ..................................................................................... 1-19 1.2.4 User Maintenance ..................................................................................................................................... 1-19 1.2.4.1 Cleaning ............................................................................................................................................. 1-19 1.2.4.2 Inspection .......................................................................................................................................... 1-20 1.2.5 Safety ........................................................................................................................................................ 1-20 1.2.5.1 Safety of the Laser System ................................................................................................................ 1-20 1.2.5.2 Regulations by the Center for Devices and Radiational Heath(CDRH) ........................................... 1-21 1.2.5.3 Handling the Laser Assembly ........................................................................................................... 1-21 1.2.5.4 Safety of Toner .................................................................................................................................. 1-21 1.2.6 Product Specifications .............................................................................................................................. 1-22 1.2.6.1 Type and Functions ........................................................................................................................... 1-22 1.2.7 Function List ............................................................................................................................................. 1-23 1.2.7.1 Print Speed ......................................................................................................................................... 1-23 1.2.7.2 Print Size ........................................................................................................................................... 1-25 1.2.7.3 Others ................................................................................................................................................ 1-27 1.2.7.4 Reader Unit Specifications ................................................................................................................ 1-28 Chapter 2 Installation 2.1 Making Pre-Checks ........................................................................................................................................... 2-1 2.1.1 Selecting the Site ........................................................................................................................................ 2-1 2.1.2 Site Space ................................................................................................................................................... 2-3 2.1.3 Sequence of Installing Accessories ............................................................................................................ 2-5 2.1.4 Connecting the Power Cables ..................................................................................................................... 2-6 Contents 2.1.5 Points to Note Before Starting the Work .................................................................................................... 2-6 2.2 Unpacking and Installation ................................................................................................................................ 2-7 2.2.1 Checking the Contents ................................................................................................................................ 2-7 2.2.2 Configuring the Cassette ............................................................................................................................. 2-7 2.2.3 Connecting the Reader Unit ........................................................................................................................ 2-8 2.2.4 Removing the Fixing Members from the Printer ........................................................................................ 2-9 2.2.5 Installing the Reader Unit ......................................................................................................................... 2-10 2.2.6 Installing the Secondary Transfer Outside Roller Unit ............................................................................ 2-16 2.2.7 Connecting the Power Cord ...................................................................................................................... 2-17 2.2.8 Mounting the Transfer Cleaning Unit ....................................................................................................... 2-17 2.2.9 Fitting the Toner Container ...................................................................................................................... 2-18 2.2.10 Fitting the Drum Unit ............................................................................................................................. 2-19 2.2.11 Connecting to the Network ..................................................................................................................... 2-21 2.3 Checking the Connection to the Network ........................................................................................................ 2-22 2.3.1 Checking the Connection to the Network ................................................................................................. 2-22 2.3.2 Using PING .............................................................................................................................................. 2-22 2.3.3 Making Checks Using a Remote Host Address ........................................................................................ 2-23 2.4 Troubleshooting the Network .......................................................................................................................... 2-24 2.4.1 Troubleshooting the Network ................................................................................................................... 2-24 2.4.2 Checking the Connection of the Network Cable ...................................................................................... 2-24 2.4.3 Making Checks Using a Loopback Address ............................................................................................. 2-24 2.4.4 Making a Check Using a Local Host Address .......................................................................................... 2-24 2.5 Checking the Images/Operations ..................................................................................................................... 2-25 2.5.1 Checking the Images/Operations .............................................................................................................. 2-25 2.5.2 PASCAL Setting ....................................................................................................................................... 2-28 2.5.3 Preventing Anti-Condensation .................................................................................................................. 2-29 2.6 Relocating the Machine ................................................................................................................................... 2-30 2.6.1 Preparing for Relocation ........................................................................................................................... 2-30 2.7 Installing the Card Reader ............................................................................................................................... 2-31 2.7.1 Checking the Contents .............................................................................................................................. 2-31 2.7.2 Installation Procedure ............................................................................................................................... 2-31 2.7.3 Making Settings If Net Spot Accountant (NSA) Is Used ......................................................................... 2-33 2.8 Installing the NE Controller-A1 ...................................................................................................................... 2-34 2.8.1 Installing the NE Controller-A1 ............................................................................................................... 2-34 2.9 Installing the Original Tray ............................................................................................................................. 2-43 2.9.1 Checking the Contents .............................................................................................................................. 2-43 2.9.2 Installation Procedure ............................................................................................................................... 2-43 2.10 Installing the Key Switch Unit-A1 ................................................................................................................ 2-45 2.10.1 Checking the Contents ............................................................................................................................ 2-45 2.10.2 Installation Procedure ............................................................................................................................. 2-45 2.10.3 Making Checks After Installation ........................................................................................................... 2-47 2.11 Installing the Reader Heater .......................................................................................................................... 2-48 2.11.1 Checking the Contents ............................................................................................................................ 2-48 2.11.2 Installation Procedure ............................................................................................................................. 2-49 2.12 Installing the Cassette Heater ........................................................................................................................ 2-59 2.12.1 Checking the Contents ............................................................................................................................ 2-59 2.12.2 Installation Procedure ............................................................................................................................. 2-60 2.12.3 Installing the Cassette Heater Kit to a Copier ........................................................................................ 2-61 2.12.4 Installing the Cassette Heater Kit to a 2-Cassette Pedestal-X1 .............................................................. 2-63 2.13 Replacing the Drum Unit ............................................................................................................................... 2-64 2.13.1 Preparing for the Work ........................................................................................................................... 2-64 2.13.2 Installation Procedure ............................................................................................................................. 2-65 Contents Chapter 3 Basic Operation 3.1 Construction ...................................................................................................................................................... 3-1 3.1.1 Functional Construction ............................................................................................................................. 3-1 3.1.2 Arrangement of Major PCBs ...................................................................................................................... 3-2 3.2 Basic Sequence .................................................................................................................................................. 3-5 3.2.1 Basic Sequence of Operations at Power-On ............................................................................................... 3-5 3.2.2 Basic Sequence of Operations .................................................................................................................... 3-7 Chapter 4 Basic Operations (As a Printer) 4.1 Construction ...................................................................................................................................................... 4-1 4.1.1 Functional Construction ............................................................................................................................. 4-1 4.2 Construction of the Electrical Circuitry ............................................................................................................ 4-2 4.2.1 Arrangement of Major PCBs ...................................................................................................................... 4-2 4.2.2 DC Controller PCB .................................................................................................................................... 4-4 4.3 Basic Sequence .................................................................................................................................................. 4-5 4.3.1 Basic Sequence of Operations at Power-On ............................................................................................... 4-5 4.3.2 Basic Sequence of Operations .................................................................................................................... 4-7 Chapter 5 Main Controller 5.1 Construction ...................................................................................................................................................... 5-1 5.1.1 Outline ........................................................................................................................................................ 5-1 5.1.2 Functional Construction ............................................................................................................................. 5-2 5.2 Construction of the Electrical Circuitry ............................................................................................................ 5-3 5.2.1 Outline ........................................................................................................................................................ 5-3 5.2.2 Main Controller PCB .................................................................................................................................. 5-3 5.2.3 SRAM board ............................................................................................................................................... 5-4 5.2.4 HDD ........................................................................................................................................................... 5-4 5.2.5 Composition of the System Software ......................................................................................................... 5-5 5.3 Start-Up Sequence ............................................................................................................................................. 5-7 5.3.1 Outline ........................................................................................................................................................ 5-7 5.3.2 Startup Sequence ........................................................................................................................................ 5-7 5.4 Actions when HDD Error .................................................................................................................................. 5-9 5.4.1 E602 in Detail ............................................................................................................................................. 5-9 5.5 Image Processing ............................................................................................................................................. 5-14 5.5.1 Flow of Images ......................................................................................................................................... 5-14 5.5.2 Construction of the Image Processing Module ........................................................................................ 5-15 5.5.3 Reader Input Image Processing ................................................................................................................ 5-16 5.5.4 Compression/Decompression and Edit Processing Black ........................................................................ 5-17 5.5.5 Printer Output Image Processing .............................................................................................................. 5-18 5.6 Flow of Image Data ......................................................................................................................................... 5-19 5.6.1 Flow of Image Data for Copier Functions ................................................................................................ 5-19 5.6.2 Flow of Image Data for Box Functions .................................................................................................... 5-20 5.6.3 Flow of Image data for SEND function ................................................................................................... 5-21 5.6.4 Flow of Image Data for Fax Transmission Functions .............................................................................. 5-22 5.6.5 Flow of Image Data for Fax Reception Functions ................................................................................... 5-23 5.6.6 Flow of Image Data for PDL Functions ................................................................................................... 5-24 5.7 Parts Replacement Procedure .......................................................................................................................... 5-25 5.7.1 Main Controller PCB (main) .................................................................................................................... 5-25 5.7.1.1 Removing the Upper Rear Cover ...................................................................................................... 5-25 5.7.1.2 Removing the Left Upper Rear Cover ............................................................................................... 5-25 5.7.1.3 Removing the DC Controller PCB Cover ......................................................................................... 5-25 Contents 5.7.1.4 Removing the Controller Box Cover ................................................................................................. 5-25 5.7.1.5 Removing the HDD ........................................................................................................................... 5-26 5.7.1.6 Removing the Hard Disk Mounting Plates ........................................................................................ 5-26 5.7.1.7 Removing the Ethernet Board ............................................................................................................ 5-26 5.7.1.8 Removing the UFR Board ................................................................................................................. 5-27 5.7.1.9 Removing the SRAM PCB ................................................................................................................ 5-27 5.7.1.10 Removing the Main Controller PCB (sub) ...................................................................................... 5-27 5.7.1.11 Removing the Main Controller PCB (main) .................................................................................... 5-28 5.7.1.12 When Replacing the Main Controller PCB (main) .......................................................................... 5-28 5.7.2 Main Controller PCB (sub) ....................................................................................................................... 5-28 5.7.2.1 Removing the Upper Rear Cover ....................................................................................................... 5-28 5.7.2.2 Removing the Left Upper Rear Cover ............................................................................................... 5-28 5.7.2.3 Removing the Controller Box Cover ................................................................................................. 5-28 5.7.2.4 Removing the HDD ........................................................................................................................... 5-29 5.7.2.5 Removing the Hard Disk Mounting Plates ........................................................................................ 5-29 5.7.2.6 Removing the SRAM PCB ................................................................................................................ 5-30 5.7.2.7 Removing the Main Controller PCB (sub) ........................................................................................ 5-30 5.7.2.8 When Replacing the Main Controller PCB (sub) .............................................................................. 5-30 5.7.3 SRAM PCB ............................................................................................................................................... 5-31 5.7.3.1 Removing the Upper Rear Cover ....................................................................................................... 5-31 5.7.3.2 Removing the Controller Box Cover ................................................................................................. 5-31 5.7.3.3 Removing the HDD ........................................................................................................................... 5-31 5.7.3.4 Removing the SRAM PCB ................................................................................................................ 5-31 5.7.3.5 When Replacing the SRAM PCB ...................................................................................................... 5-31 5.7.4 UFR Board ................................................................................................................................................ 5-32 5.7.4.1 Removing the Upper Rear Cover ....................................................................................................... 5-32 5.7.4.2 Removing the Left Upper Rear Cover ............................................................................................... 5-32 5.7.4.3 Removing the Controller Box Cover ................................................................................................. 5-32 5.7.4.4 Removing the UFR Board ................................................................................................................. 5-32 5.7.5 Ethernet Board ........................................................................................................................................... 5-33 5.7.5.1 Removing the Upper Rear Cover ....................................................................................................... 5-33 5.7.5.2 Removing the Left Upper Rear Cover ............................................................................................... 5-33 5.7.5.3 Removing the Controller Box Cover ................................................................................................. 5-33 5.7.5.4 Removing the Ethernet Board ............................................................................................................ 5-33 5.7.6 Differential PCB ........................................................................................................................................ 5-34 5.7.6.1 Removing the Upper Rear Cover ....................................................................................................... 5-34 5.7.6.2 Removing the Left Upper Rear Cover ............................................................................................... 5-34 5.7.6.3 Removing the Controller Box Cover ................................................................................................. 5-34 5.7.6.4 Removing the Differential PCB ......................................................................................................... 5-34 5.7.7 Power Distribution PCB ............................................................................................................................ 5-35 5.7.7.1 Removing the Upper Rear Cover ....................................................................................................... 5-35 5.7.7.2 Removing the Power Distribution PCB ............................................................................................. 5-35 5.7.8 HDD .......................................................................................................................................................... 5-35 5.7.8.1 Removing the Upper Rear Cover ....................................................................................................... 5-35 5.7.8.2 Removing the Controller Box Cover ................................................................................................. 5-35 5.7.8.3 Removing the HDD ........................................................................................................................... 5-35 5.7.8.4 When Replacing the HDD ................................................................................................................. 5-36 5.7.9 Controller Fan ........................................................................................................................................... 5-37 5.7.9.1 Removing the Upper Rear Cover ....................................................................................................... 5-37 5.7.9.2 Removing the Controller Box Cover ................................................................................................. 5-37 5.7.9.3 Removing the Controller Fan ............................................................................................................ 5-37 Contents Chapter 6 Original Exposure System 6.1 Construction ...................................................................................................................................................... 6-1 6.1.1 Specifications, Control Mechanisms, and Functions ................................................................................. 6-1 6.1.2 Major Components ..................................................................................................................................... 6-1 6.1.3 Construction of the Control System ........................................................................................................... 6-4 6.1.4 Reader Controller PCB ............................................................................................................................... 6-4 6.2 Basic Sequence .................................................................................................................................................. 6-5 6.2.1 Basic Sequence of Operations at Power-On ............................................................................................... 6-5 6.2.2 Basic Sequence of Operations in Response to a Press on the Start Key (book mode, 1 original) ............. 6-6 6.3 Various Control Mechanisms ............................................................................................................................ 6-7 6.3.1 Controlling the Scanner Drive System ....................................................................................................... 6-7 6.3.1.1 Outline ................................................................................................................................................. 6-7 6.3.1.2 Controlling the Scanner Motor ............................................................................................................ 6-8 6.3.2 Enlargement/Reduction ............................................................................................................................... 6-9 6.3.2.1 Changing the Reproduction Ratio ....................................................................................................... 6-9 6.3.2.2 Changing the Reproduction Ratio in Main Scanning Direction .......................................................... 6-9 6.3.2.3 Changing the Reproduction Ratio in Sub Scanning Direction ............................................................ 6-9 6.3.3 Controlling the Scanning Lamp .................................................................................................................. 6-9 6.3.3.1 Outline ................................................................................................................................................. 6-9 6.3.3.2 Scanning Lamp .................................................................................................................................. 6-10 6.3.3.3 Turning On/Off the Lamp ................................................................................................................. 6-10 6.3.3.4 Checking for an Error ........................................................................................................................ 6-10 6.3.4 Detecting the Size of Originals ................................................................................................................. 6-10 6.3.4.1 Outline ............................................................................................................................................... 6-10 6.3.4.2 Points of Detection (original size) ..................................................................................................... 6-11 6.3.4.3 Outline of Detection Operations ........................................................................................................ 6-11 6.4 Parts Replacement Procedure .......................................................................................................................... 6-14 6.4.1 Copyboard Glass ....................................................................................................................................... 6-14 6.4.1.1 Removing the Copyboard Glass ........................................................................................................ 6-14 6.4.1.2 After Replacing the Copyboard Glass ............................................................................................... 6-14 6.4.2 Exposure Lamp ......................................................................................................................................... 6-15 6.4.2.1 Removing the Copyboard Glass ........................................................................................................ 6-15 6.4.2.2 Removing the Reader Left Cover/Reader Right Cover/Reader Front Cover .................................... 6-15 6.4.2.3 Removing the CCD Unit Cover ........................................................................................................ 6-15 6.4.2.4 Removing the Scanning Lamp .......................................................................................................... 6-16 6.4.3 Reader Controller PCB ............................................................................................................................. 6-17 6.4.3.1 Removing the Copyboard Glass ........................................................................................................ 6-17 6.4.3.2 Removing the CCD Unit Cover ........................................................................................................ 6-17 6.4.3.3 Removing the Original Size Detection Unit ...................................................................................... 6-18 6.4.3.4 Removing the Reader Controller PCB .............................................................................................. 6-18 6.4.3.5 When Replacing the Reader Controller PCB .................................................................................... 6-18 6.4.4 Interface PCB ............................................................................................................................................ 6-19 6.4.4.1 Removing the Copyboard Glass ........................................................................................................ 6-19 6.4.4.2 Removing the Reader Rear Cover ..................................................................................................... 6-20 6.4.4.3 Removing the Interface PCB ............................................................................................................. 6-20 6.4.5 Inverter PCB ............................................................................................................................................. 6-21 6.4.5.1 Removing the Copyboard Glass ........................................................................................................ 6-21 6.4.5.2 Removing the CCD Unit Cover ........................................................................................................ 6-22 6.4.5.3 Removing the Inverter PCB .............................................................................................................. 6-22 6.4.6 CCD Unit .................................................................................................................................................. 6-22 6.4.6.1 Removing the Copyboard Glass ........................................................................................................ 6-22 6.4.6.2 Removing the CCD Unit Cover ........................................................................................................ 6-23 6.4.6.3 Removing the Original Size Detection Unit ...................................................................................... 6-23 6.4.6.4 Removing the CCD Unit ................................................................................................................... 6-24 Contents 6.4.6.5 After Replacing the CCD Unit ........................................................................................................... 6-24 6.4.7 Fuse PCB (option) ..................................................................................................................................... 6-24 6.4.7.1 Removing the Reader Rear Cover ..................................................................................................... 6-24 6.4.7.2 Removing the Copyboard Cover Open/Closed Sensor Mounting ..................................................... 6-24 6.4.7.3 Removing the Fuse PCB Unit (option; 100/230v model only) ......................................................... 6-25 6.4.8 Scanner Motor ........................................................................................................................................... 6-25 6.4.8.1 Removing the Copyboard Glass ........................................................................................................ 6-25 6.4.8.2 Removing the Reader Rear Cover ..................................................................................................... 6-26 6.4.8.3 Removing the Interface PCB ............................................................................................................. 6-26 6.4.8.4 Removing the Scanner Motor ............................................................................................................ 6-27 6.4.8.5 Mounting the Scanner Motor ............................................................................................................. 6-27 6.4.9 Original Cover Sensor ............................................................................................................................... 6-28 6.4.9.1 Removing the Reader Rear Cover ..................................................................................................... 6-28 6.4.9.2 Removing the Copyboard Cover Open/Closed Sensor Mounting ..................................................... 6-28 6.4.9.3 Removing the Copyboard Cover Open/Closed Sensor Cover ........................................................... 6-29 6.4.9.4 Removing the Copyboard Cover Open/Closed Sensor ..................................................................... 6-29 6.4.10 Scanner HP Sensor .................................................................................................................................. 6-29 6.4.10.1 Removing the Reader Rear Cover ................................................................................................... 6-29 6.4.10.2 Removing the Copyboard Cover Open/Closed Sensor Mounting ................................................... 6-29 6.4.10.3 Removing the Mirror Base Home Position Sensor .......................................................................... 6-30 6.4.11 Original Sensor ........................................................................................................................................ 6-30 6.4.11.1 Removing the Copyboard Glass ...................................................................................................... 6-30 6.4.11.2 Removing the CCD Unit Cover ....................................................................................................... 6-31 6.4.11.3 Removing the Original Size Detection Unit .................................................................................... 6-31 6.4.11.4 Removing the Original Size Sensor ................................................................................................. 6-31 6.4.12 Reader Heater (option) ............................................................................................................................ 6-31 6.4.12.1 Removing the Copyboard Glass ...................................................................................................... 6-31 6.4.12.2 Removing the Reader Rear Cover ................................................................................................... 6-32 6.4.12.3 Removing the Fuse PCB Unit .......................................................................................................... 6-33 6.4.12.4 Removing the Reader Heater (option; 100/230V model only) ........................................................ 6-33 Chapter 7 Image Processing System 7.1 Outline ............................................................................................................................................................... 7-1 7.1.1 Specifications, Control Mechanisms, and Functions .................................................................................. 7-1 7.1.2 Functional Construction of the PCBs ......................................................................................................... 7-1 7.2 Analog Image Processing .................................................................................................................................. 7-2 7.2.1 Outline ........................................................................................................................................................ 7-2 7.2.2 CCD Drive .................................................................................................................................................. 7-3 7.2.3 CCD Output Gain Correction and Offset Correction ................................................................................. 7-3 7.2.4 A/D Conversion of CCD Putput ................................................................................................................. 7-3 7.3 Digital Image Processing ................................................................................................................................... 7-4 7.3.1 Outline ........................................................................................................................................................ 7-4 7.3.2 Shading Correction ..................................................................................................................................... 7-4 Chapter 8 Laser Exposure 8.1 Construction ....................................................................................................................................................... 8-1 8.1.1 Specifications, Control Mechanisms, and Functions .................................................................................. 8-1 8.1.2 Major Components ..................................................................................................................................... 8-2 8.1.3 Construction of the Control System ........................................................................................................... 8-3 8.2 Basic Sequence .................................................................................................................................................. 8-4 8.2.1 Basic Sequence of Operations .................................................................................................................... 8-4 8.3 Various Control ................................................................................................................................................. 8-5 Contents 8.3.1 Controlling the Laser Activation Timing .................................................................................................... 8-5 8.3.1.1 Turning On/Off the Laser .................................................................................................................... 8-5 8.3.1.2 BD Signal ............................................................................................................................................ 8-7 8.3.1.3 Controlling Synchronization in Main Scanning Direction .................................................................. 8-8 8.3.1.4 Controlling Synchronization in Sub Scanning Direction .................................................................... 8-8 8.3.2 Controlling the Intensity of Laser Light ..................................................................................................... 8-9 8.3.2.1 APC Control ........................................................................................................................................ 8-9 8.3.2.2 PWM Control ...................................................................................................................................... 8-9 8.3.3 Controlling the Laser Scanner Motor ....................................................................................................... 8-10 8.3.3.1 Controlling the Laser Scanner Motor ................................................................................................ 8-10 8.3.4 Controlling the Laser Shutter .................................................................................................................... 8-10 8.3.4.1 Controlling the Laser Shutter ............................................................................................................ 8-10 8.3.5 Correcting Image Displacement ................................................................................................................ 8-11 8.3.5.1 Outline ............................................................................................................................................... 8-11 8.3.5.2 Timing of Color Displacement Detection/Correction ....................................................................... 8-12 8.3.5.3 Detecting/Correcting Color Displacement in Sub Scanning Direction ............................................. 8-13 8.3.5.4 Detecting/Correcting the Angle in Main Scanning Direction ........................................................... 8-14 8.3.5.5 Detecting/Correcting Color Displacement in Main Scanning Direction ........................................... 8-16 8.3.5.6 Detecting/Correcting Changes in the Reproduction Ratio in Main Scanning Direction ................... 8-17 8.4 Parts Replacement Procedure .......................................................................................................................... 8-19 8.4.1 Laser Unit .................................................................................................................................................. 8-19 8.4.1.1 Removing the Center Delivery Tray ................................................................................................. 8-19 8.4.1.2 Removing the Laser Unit ................................................................................................................... 8-19 8.4.1.3 After Replacing the Laser Unit .......................................................................................................... 8-20 Chapter 9 Image Formation 9.1 Construction ...................................................................................................................................................... 9-1 9.1.1 Specifications, Control Mechanisms, and Functions ................................................................................. 9-1 9.1.2 Major Components of the Image Formation System ................................................................................. 9-3 9.1.3 Charging Specifications ............................................................................................................................. 9-4 9.2 Image Formation Process .................................................................................................................................. 9-6 9.2.1 Image Formation Process (general) ............................................................................................................ 9-6 9.2.2 Image Formation Process (image formation) ............................................................................................. 9-7 9.2.3 Image Formation Process (transfer) ........................................................................................................... 9-7 9.3 Basic Sequence .................................................................................................................................................. 9-8 9.3.1 At Power-On (1) ......................................................................................................................................... 9-8 9.3.2 At Power-On (2) ......................................................................................................................................... 9-8 9.3.3 During Copying/Printing Operations (normal speed) ................................................................................ 9-9 9.3.4 Making Copies/Prints (half speed) ........................................................................................................... 9-10 9.3.5 After Replacing the Drum Unit (D-UNIT) ............................................................................................... 9-10 9.3.6 Printing Originals Containing a Color Page ............................................................................................. 9-11 9.3.7 Driving and Controlling the Image Formation System and the High-Voltage System ............................ 9-11 9.4 Image Stabilization Control ............................................................................................................................. 9-13 9.4.1 Outline of Image Quality Control ............................................................................................................ 9-13 9.4.2 Automatic Image Stabilization Control .................................................................................................... 9-13 9.4.3 ATR Control ............................................................................................................................................. 9-17 9.4.4 Discharge Current Level Control ............................................................................................................. 9-17 9.4.5 ATVC Control (transfer bias level correction) ......................................................................................... 9-18 9.4.6 PASCAL Control (image gradation) ........................................................................................................ 9-18 9.4.7 SALT-Dmax Control (development characteristics correction) .............................................................. 9-19 9.4.8 SALT-Dhalf Control (development characteristics correction) ............................................................... 9-20 9.4.9 Auto Gradation Control ............................................................................................................................ 9-22 9.5 Drum Unit ........................................................................................................................................................ 9-24 Contents 9.5.1 Outline of the Drum Unit .......................................................................................................................... 9-24 9.5.1.1 Outline of the Drum Unit ................................................................................................................... 9-24 9.5.1.2 Controlling the Drive of the Drum Unit (D-UNIT) ........................................................................... 9-25 9.5.2 Developing Assembly ............................................................................................................................... 9-26 9.5.2.1 Construction of the Developing Assembly ........................................................................................ 9-26 9.5.2.2 Controlling the Developing Bias ....................................................................................................... 9-27 9.5.3 Auxiliary Brush ......................................................................................................................................... 9-29 9.5.3.1 Construction of the Auxiliary Brush .................................................................................................. 9-29 9.5.3.2 Controlling the Auxiliary Bias ........................................................................................................... 9-30 9.5.4 Charging Mechanism ................................................................................................................................ 9-34 9.5.4.1 Construction of the Charging Mechanism ......................................................................................... 9-34 9.5.4.2 Controlling the Charging Bias ........................................................................................................... 9-35 9.6 Toner Container ............................................................................................................................................... 9-37 9.6.1 Outline of the Toner Container ................................................................................................................. 9-37 9.6.2 Controlling the Toner Container Drive ..................................................................................................... 9-37 9.6.3 Checking the Level of Toner .................................................................................................................... 9-38 9.6.4 Controlling the Supply of Toner ............................................................................................................... 9-39 9.7 Transfer Unit .................................................................................................................................................... 9-40 9.7.1 Outline of the Transfer Unit ...................................................................................................................... 9-40 9.7.1.1 Outline of the Transfer Unit ............................................................................................................... 9-40 9.7.1.2 Controlling the Drive of the Transfer Unit ........................................................................................ 9-40 9.7.2 Controlling the Transfer Bias .................................................................................................................... 9-42 9.7.2.1 Controlling the Transfer Bias ............................................................................................................ 9-42 9.7.3 Cleaning .................................................................................................................................................... 9-44 9.7.3.1 Intermediate Transfer Belt (ITB) ....................................................................................................... 9-44 9.7.3.2 Secondary External Roller ................................................................................................................. 9-45 9.7.3.3 Collecting Waste Toner ..................................................................................................................... 9-45 9.7.4 Separation Mechanism .............................................................................................................................. 9-46 9.7.4.1 Separation .......................................................................................................................................... 9-46 9.8 Parts Replacement Procedure .......................................................................................................................... 9-48 9.8.1 Drum ITB Motor ....................................................................................................................................... 9-48 9.8.1.1 Slide Out the Drum Unit .................................................................................................................... 9-48 9.8.1.2 Removing the Upper Rear Cover ....................................................................................................... 9-48 9.8.1.3 Removing the Lower Rear Cover ...................................................................................................... 9-48 9.8.1.4 Removing the Controller Box Cover ................................................................................................. 9-48 9.8.1.5 Removing the DC Controller PCB Cover .......................................................................................... 9-48 9.8.1.6 Removing the Left Upper Rear Cover ............................................................................................... 9-48 9.8.1.7 Opening the Main Controller Box ..................................................................................................... 9-49 9.8.1.8 Removing the DC Controller Mounting ............................................................................................ 9-50 9.8.1.9 Removing the Fixing Heat Discharge Fan ......................................................................................... 9-50 9.8.1.10 Removing the Machine Heat Discharge Fan ................................................................................... 9-50 9.8.1.11 Removing the Developing Drive Unit ............................................................................................. 9-51 9.8.1.12 Removing the Lattice Connector Mounting .................................................................................... 9-51 9.8.1.13 Removing the High-Voltage Unit .................................................................................................... 9-52 9.8.1.14 Removing the Manual Feed Cooling Fan Duct ............................................................................... 9-52 9.8.1.15 Removing the Drum ITB Motor Mounting ..................................................................................... 9-52 9.8.1.16 Removing the Drum ITB Motor ...................................................................................................... 9-53 9.8.2 Drum Drive Unit ....................................................................................................................................... 9-53 9.8.2.1 Slide Out the Drum Unit .................................................................................................................... 9-53 9.8.2.2 Removing the Upper Rear Cover ....................................................................................................... 9-53 9.8.2.3 Removing the Lower Rear Cover ...................................................................................................... 9-53 9.8.2.4 Removing the Controller Box Cover ................................................................................................. 9-53 9.8.2.5 Removing the DC Controller PCB Cover .......................................................................................... 9-54 9.8.2.6 Removing the Left Upper Rear Cover ............................................................................................... 9-54 Contents 9.8.2.7 Opening the Main Controller Box ..................................................................................................... 9-54 9.8.2.8 Removing the DC Controller Mounting ............................................................................................ 9-55 9.8.2.9 Removing the Fixing Heat Discharge Fan ........................................................................................ 9-56 9.8.2.10 Removing the Machine Heat Discharge Fan ................................................................................... 9-56 9.8.2.11 Removing the Developing Drive Unit ............................................................................................. 9-56 9.8.2.12 Removing the Lattice Controller Base ............................................................................................ 9-57 9.8.2.13 Removing the High-Voltage Unit ................................................................................................... 9-57 9.8.2.14 Removing the Drum ITB Motor Mounting Base ............................................................................ 9-58 9.8.2.15 Removing the Drum Drive Unit ...................................................................................................... 9-58 9.8.3 Drive Roller .............................................................................................................................................. 9-59 9.8.3.1 Pressure Release of the Intermediate Transfer Unit .......................................................................... 9-59 9.8.3.2 Removing the Intermediate Transfer Unit ......................................................................................... 9-59 9.8.3.3 Removing the Intermediate Transfer Belt ......................................................................................... 9-60 9.8.3.4 Removing the Drive Roller ............................................................................................................... 9-62 9.8.4 Developing Motor (Bk) ............................................................................................................................. 9-63 9.8.4.1 Removing the Upper Rear Cover ...................................................................................................... 9-63 9.8.4.2 Removing the Lower Rear Cover ...................................................................................................... 9-63 9.8.4.3 Removing the Left Upper Rear Cover ............................................................................................... 9-63 9.8.4.4 Removing the Controller Box Cover ................................................................................................. 9-63 9.8.4.5 Removing the DC Controller PCB Cover ......................................................................................... 9-63 9.8.4.6 Opening the Main Controller Box ..................................................................................................... 9-64 9.8.4.7 Removing the DC Controller Mounting ............................................................................................ 9-65 9.8.4.8 Removing the Developing Motor (Bk) .............................................................................................. 9-65 9.8.5 Developing Motor (Y/M/C) ...................................................................................................................... 9-65 9.8.5.1 Removing the Upper Rear Cover ...................................................................................................... 9-65 9.8.5.2 Removing the Lower Rear Cover ...................................................................................................... 9-65 9.8.5.3 Removing the Left Upper Rear Cover ............................................................................................... 9-65 9.8.5.4 Removing the Controller Box Cover ................................................................................................. 9-65 9.8.5.5 Removing the DC Controller PCB Cover ......................................................................................... 9-66 9.8.5.6 Opening the Main Controller Box ..................................................................................................... 9-66 9.8.5.7 Removing the DC Controller Mounting ............................................................................................ 9-67 9.8.5.8 Removing the Developing Motor (Y/M/C) ....................................................................................... 9-67 9.8.6 Secondary Transfer Unit ........................................................................................................................... 9-68 9.8.6.1 Removing the Fixing Unit ................................................................................................................. 9-68 9.8.6.2 Removing the Duplex Open/Close Guide ......................................................................................... 9-68 9.8.6.3 Removing the Secondary Transfer Unit ............................................................................................ 9-68 9.8.7 Intermediate Transfer Unit ........................................................................................................................ 9-69 9.8.7.1 Pressure Release of the Intermediate Transfer Unit .......................................................................... 9-69 9.8.7.2 Removing the Intermediate Transfer Unit ......................................................................................... 9-69 9.8.8 Transfer Cleaning Unit ............................................................................................................................. 9-69 9.8.8.1 Removing the Waste Toner Container .............................................................................................. 9-69 9.8.8.2 Removing the Transfer Cleaning Unit .............................................................................................. 9-70 9.8.9 Intermediate Transfer Belt ........................................................................................................................ 9-70 9.8.9.1 Pressure Release of the Intermediate Transfer Unit .......................................................................... 9-70 9.8.9.2 Removing the Intermediate Transfer Unit ......................................................................................... 9-70 9.8.9.3 Removing the Intermediate Transfer Belt ......................................................................................... 9-71 9.8.10 Primary Transfer Roller .......................................................................................................................... 9-73 9.8.10.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-73 9.8.10.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-73 9.8.10.3 Removing the Intermediate Transfer Belt ....................................................................................... 9-74 9.8.10.4 Removing the Primary Transfer Roller ........................................................................................... 9-76 9.8.11 Secondary Transfer External Roller ........................................................................................................ 9-77 9.8.11.1 Removing the Fixing Unit ............................................................................................................... 9-77 9.8.11.2 Removing the Secondary Transfer External Roller ......................................................................... 9-77 Contents 9.8.12 Secondary Transfer Internal Roller ......................................................................................................... 9-78 9.8.12.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-78 9.8.12.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-78 9.8.12.3 Removing the Intermediate Transfer Belt ....................................................................................... 9-79 9.8.12.4 Removing the Secondary Transfer Internal Roller .......................................................................... 9-81 9.8.13 Toner Container Drive Unit .................................................................................................................... 9-82 9.8.13.1 Removing the Waste Toner Container ............................................................................................. 9-82 9.8.13.2 Removing the Upper Rear Cover ..................................................................................................... 9-82 9.8.13.3 Removing the Lower Rear Cover .................................................................................................... 9-82 9.8.13.4 Removing the Left Upper Rear Cover ............................................................................................. 9-82 9.8.13.5 Removing the Controller Box Cover ............................................................................................... 9-82 9.8.13.6 Removing the DC Controller PCB Cover ........................................................................................ 9-83 9.8.13.7 Opening the Main Controller Box ................................................................................................... 9-83 9.8.13.8 Removing the DC Controller Mounting .......................................................................................... 9-84 9.8.13.9 Removing the Toner Container Drive Unit ..................................................................................... 9-84 9.8.14 Waste Toner Detection PCB ................................................................................................................... 9-85 9.8.14.1 Removing the Waste Toner Container ............................................................................................. 9-85 9.8.14.2 Removing the Front Cover .............................................................................................................. 9-85 9.8.14.3 Removing the Intermediate Transfer Unit Releasing Lever ............................................................ 9-85 9.8.14.4 Removing the Cleaner Fan Cover .................................................................................................... 9-86 9.8.14.5 Removing the Inside Cover (lower) ................................................................................................. 9-86 9.8.14.6 Removing the Waste Toner Detection PCB .................................................................................... 9-86 9.8.15 Feedscrew Rotation Sensor ..................................................................................................................... 9-86 9.8.15.1 Removing the Waste Toner Container ............................................................................................. 9-86 9.8.15.2 Removing the Upper Rear Cover ..................................................................................................... 9-87 9.8.15.3 Removing the Lower Rear Cover .................................................................................................... 9-87 9.8.15.4 Removing the Left Upper Rear Cover ............................................................................................. 9-87 9.8.15.5 Removing the Controller Box Cover ............................................................................................... 9-87 9.8.15.6 Removing the DC Controller PCB Cover ........................................................................................ 9-87 9.8.15.7 Opening the Main Controller Box ................................................................................................... 9-88 9.8.15.8 Removing the DC Controller Mounting .......................................................................................... 9-89 9.8.15.9 Removing the Toner Container Drive Unit ..................................................................................... 9-89 9.8.15.10 Removing the Toner Container Drive Assembly Upper Plate ...................................................... 9-89 9.8.15.11 Removing the Feedscrew Rotation Sensor .................................................................................... 9-90 9.8.16 Tone Container Motor ............................................................................................................................. 9-90 9.8.16.1 Removing the Waste Toner Container ............................................................................................. 9-90 9.8.16.2 Removing the Upper Rear Cover ..................................................................................................... 9-91 9.8.16.3 Removing the Lower Rear Cover .................................................................................................... 9-91 9.8.16.4 Removing the Left Upper Rear Cover ............................................................................................. 9-91 9.8.16.5 Removing the Controller Box Cover ............................................................................................... 9-91 9.8.16.6 Removing the DC Controller PCB Cover ........................................................................................ 9-91 9.8.16.7 Opening the Main Controller Box ................................................................................................... 9-92 9.8.16.8 Removing the DC Controller Mounting .......................................................................................... 9-93 9.8.16.9 Removing the Toner Container Drive Unit ..................................................................................... 9-93 9.8.16.10 Removing the Toner Container Drive Assembly Upper Plate ...................................................... 9-93 9.8.16.11 Removing the Toner Container Motor ........................................................................................... 9-94 9.8.17 Waste Toner Feedscrew Case .................................................................................................................. 9-94 9.8.17.1 Removing the Waste Toner Container ............................................................................................. 9-94 9.8.17.2 Removing the Transfer Cleaning Unit ............................................................................................. 9-95 9.8.17.3 Removing the Waste Toner Feedscrew Case .................................................................................. 9-95 9.8.18 Pattern Reader Unit ................................................................................................................................. 9-95 9.8.18.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-95 9.8.18.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-96 9.8.18.3 Removing the Upper Right Cover ................................................................................................... 9-96 Contents 9.8.18.4 Removing the Pattern Reader Unit .................................................................................................. 9-96 9.8.19 Auto Registration Sensor PCB ................................................................................................................ 9-97 9.8.19.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-97 9.8.19.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-98 9.8.19.3 Removing the Upper Right Cover ................................................................................................... 9-98 9.8.19.4 Removing the Pattern Reader Unit .................................................................................................. 9-98 9.8.19.5 Removing the Auto Registration Sensor PCB ................................................................................. 9-99 9.8.20 SALT Sensor ......................................................................................................................................... 9-100 9.8.20.1 Pressure Release of the Intermediate Transfer Unit ...................................................................... 9-100 9.8.20.2 Removing the Intermediate Transfer Unit ..................................................................................... 9-101 9.8.20.3 Removing the Upper Right Cover ................................................................................................. 9-101 9.8.20.4 Removing the Pattern Reader Unit ................................................................................................ 9-101 9.8.20.5 Removing the SALT Sensor .......................................................................................................... 9-103 Chapter 10 Pickup/Feeding System 10.1 Construction .................................................................................................................................................. 10-1 10.1.1 Specifications, Control Mechanisms, and Functions ............................................................................. 10-1 10.1.2 Arrangement of he Units ........................................................................................................................ 10-2 10.1.3 Arrangement of Rollers .......................................................................................................................... 10-3 10.1.4 Diagram of the Paper Paths .................................................................................................................... 10-4 10.1.5 Arrangement of Sensors ......................................................................................................................... 10-5 10.1.6 Arrangement of the Clutches and Solenoids .......................................................................................... 10-6 10.1.7 Route of Dive ......................................................................................................................................... 10-7 10.2 Basic Sequence .............................................................................................................................................. 10-8 10.2.1 Basic Sequence of Operations at Power-On ........................................................................................... 10-8 10.2.2 Basic Sequence of Operations in Response to a Press on the Start Key ................................................ 10-8 10.3 Detecting Jams .............................................................................................................................................. 10-9 10.3.1 Delay Jams .............................................................................................................................................. 10-9 10.3.1.1 Delay Jam in the Cassette Pickup Assembly ................................................................................... 10-9 10.3.1.2 Delay Jam Outside the Cassette Pickup Assembly ......................................................................... 10-9 10.3.2 Stationary Jams ..................................................................................................................................... 10-10 10.3.2.1 Stationary Jams .............................................................................................................................. 10-10 10.3.2.2 Stationary Jams at Power-On ........................................................................................................ 10-11 10.4 Cassette ........................................................................................................................................................ 10-12 10.4.1 Identifying the Paper Size .................................................................................................................... 10-12 10.4.2 Detecting the Level of Paper ................................................................................................................ 10-14 10.5 Cassette Pick-Up Unit ................................................................................................................................. 10-16 10.5.1 Outline .................................................................................................................................................. 10-16 10.5.2 Basci Sequence of Operations .............................................................................................................. 10-17 10.6 Manual Feed Pickup Unit ............................................................................................................................ 10-18 10.6.1 Outline .................................................................................................................................................. 10-18 10.6.2 Basic Sequence of Operations .............................................................................................................. 10-19 10.6.3 Identifying the Size of Paper ................................................................................................................ 10-20 10.6.4 Detecting the Presence/Absence of Paper ............................................................................................ 10-21 10.6.5 Detecting the Last paper ....................................................................................................................... 10-22 10.7 Registration Unit ......................................................................................................................................... 10-23 10.7.1 Outline .................................................................................................................................................. 10-23 10.8 Duplex Feeding Unit ................................................................................................................................... 10-25 10.8.1 Outline .................................................................................................................................................. 10-25 10.8.2 Controling Horizontal Registration ...................................................................................................... 10-26 10.8.3 Face-Down Delivery, A4, 5 Sheets in Circulation ............................................................................... 10-27 10.8.4 Face-Down Delivery, A3, 3 Sheets in Cirucilation .............................................................................. 10-29 10.9 Delivery ....................................................................................................................................................... 10-32 Contents 10.9.1 Delivery ................................................................................................................................................ 10-32 10.9.2 Movement in the Direction of Face-Down Delivery ............................................................................ 10-33 10.9.3 Movement in the Direction of Face-Up Delivery ................................................................................. 10-34 10.9.4 Movement for CenterTray delivery ...................................................................................................... 10-34 10.9.5 Moement for Copy Tray Dievyer ......................................................................................................... 10-35 10.10 Parts Replacement Procedure .................................................................................................................... 10-36 10.10.1 Cassette Pickup Unit ........................................................................................................................... 10-36 10.10.1.1 Removing the Cassette ................................................................................................................. 10-36 10.10.1.2 Removing the Front Right Cover ................................................................................................. 10-36 10.10.1.3 Removing the Rear Right Cover .................................................................................................. 10-36 10.10.1.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-36 10.10.1.5 Removing the Pickup Unit ........................................................................................................... 10-37 10.10.2 Cassette Size Detection Unit ............................................................................................................... 10-37 10.10.2.1 Removing the Cassette ................................................................................................................. 10-37 10.10.2.2 Removing the Cassette Size Detection Unit ................................................................................ 10-37 10.10.3 Pickup Roller ....................................................................................................................................... 10-38 10.10.3.1 Removing the Cassette ................................................................................................................. 10-38 10.10.3.2 Removing the Pickup Roller ........................................................................................................ 10-38 10.10.4 Feed Roller .......................................................................................................................................... 10-38 10.10.4.1 Removing the Cassette ................................................................................................................. 10-38 10.10.4.2 Removing the Feeding Roller ...................................................................................................... 10-38 10.10.5 Separation Roller ................................................................................................................................. 10-38 10.10.5.1 Removing the Cassette ................................................................................................................. 10-38 10.10.5.2 Removing the Separation Roller .................................................................................................. 10-39 10.10.6 Cassette Pickup Motor ........................................................................................................................ 10-39 10.10.6.1 Removing the Upper Rear Cover ................................................................................................. 10-39 10.10.6.2 Removing the Lower Rear Cover ................................................................................................ 10-39 10.10.6.3 Removing the Left Upper Rear Cover ......................................................................................... 10-39 10.10.6.4 Removing the DC Power Supply Unit ......................................................................................... 10-39 10.10.6.5 Removing the Controller Box Cover ........................................................................................... 10-39 10.10.6.6 Removing the DC Controller PCB Cover .................................................................................... 10-39 10.10.6.7 Removing the Fixing Heat Discharge Fan ................................................................................... 10-40 10.10.6.8 Removing the Developing Drive Unit ......................................................................................... 10-40 10.10.6.9 Removing the Lattice Controller Base ......................................................................................... 10-41 10.10.6.10 Removing the High-Voltage Unit .............................................................................................. 10-41 10.10.6.11 Removing the Manual Feed Cooling Fan Duct ......................................................................... 10-41 10.10.6.12 Removing the Rear Right Cover ................................................................................................ 10-42 10.10.6.13 Removing the Cassette Pickup Motor ....................................................................................... 10-42 10.10.7 Cassette Retry Paper Sensor ................................................................................................................ 10-43 10.10.7.1 Removing the Cassette ................................................................................................................. 10-43 10.10.7.2 Removing the Front Right Cover ................................................................................................. 10-43 10.10.7.3 Removing the Rear Right Cover .................................................................................................. 10-43 10.10.7.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-43 10.10.7.5 Removing the Pickup Unit ........................................................................................................... 10-44 10.10.7.6 Removing the Pick-up System Sensor Mounting Plate ............................................................... 10-44 10.10.7.7 Removing the Cassette Retry Paper Sensor ................................................................................. 10-44 10.10.7.8 Mounting the Pick-up System Sensor Mounting Plate ................................................................ 10-44 10.10.8 Cassette Paper Sensor .......................................................................................................................... 10-45 10.10.8.1 Removing the Cassette ................................................................................................................. 10-45 10.10.8.2 Removing the Front Right Cover ................................................................................................. 10-45 10.10.8.3 Removing the Rear Right Cover .................................................................................................. 10-45 10.10.8.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-46 10.10.8.5 Removing the Pickup Unit ........................................................................................................... 10-46 10.10.8.6 Removing the Pick-up System Sensor Mounting Plate ............................................................... 10-46 Contents 10.10.8.7 Removing the Cassette Paper Sensor .......................................................................................... 10-47 10.10.8.8 Mounting the Pick-up System Sensor Mounting Plate ................................................................ 10-47 10.10.9 Cassette Paper Level Sensor (A/B) ..................................................................................................... 10-48 10.10.9.1 Removing the Cassette ................................................................................................................ 10-48 10.10.9.2 Removing the Front Right Cover ................................................................................................ 10-48 10.10.9.3 Removing the Rear Right Cover ................................................................................................. 10-48 10.10.9.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-48 10.10.9.5 Removing the Pickup Unit .......................................................................................................... 10-48 10.10.9.6 Removing the Pick-up System Sensor Mounting Plate ............................................................... 10-49 10.10.9.7 Removing the Cassette Paper Level Sensor (A/B) ...................................................................... 10-49 10.10.9.8 Mounting the Pick-up System Sensor Mounting Plate ................................................................ 10-49 10.10.10 Slide Resistor .................................................................................................................................... 10-50 10.10.10.1 Removing the Manual Feed Unit .............................................................................................. 10-50 10.10.10.2 Removing the Manual Feed Tray Unit ...................................................................................... 10-50 10.10.10.3 Removing the Manual Feed Tray Upper Cover/Lower Cover .................................................. 10-51 10.10.10.4 Removing the Slide Resistor ..................................................................................................... 10-52 10.10.11 Cassette Pickup Solenoid .................................................................................................................. 10-52 10.10.11.1 Removing the Cassette .............................................................................................................. 10-52 10.10.11.2 Removing the Front Right Cover .............................................................................................. 10-52 10.10.11.3 Removing the Rear Right Cover ............................................................................................... 10-52 10.10.11.4 Removing the Pickup Vertical Path Cover ................................................................................ 10-53 10.10.11.5 Removing the Pickup Unit ........................................................................................................ 10-53 10.10.11.6 Removing the Cassette Pickup Solenoid ................................................................................... 10-53 10.10.12 Manual Feed Tray Unit ..................................................................................................................... 10-53 10.10.12.1 Removing the Manual Feed Unit Cover .................................................................................... 10-53 10.10.12.2 Removing the Manual Feed Tray Unit ...................................................................................... 10-54 10.10.13 Manual Feed Unit ............................................................................................................................. 10-54 10.10.13.1 Removing the Manual Feed Unit .............................................................................................. 10-54 10.10.14 Manual Feed Roller ........................................................................................................................... 10-55 10.10.14.1 Removing the Manual Feed Unit .............................................................................................. 10-55 10.10.14.2 Removing the Manual Feed Unit Cover .................................................................................... 10-55 10.10.14.3 Removing the Manual Feed Roller ............................................................................................ 10-56 10.10.15 Manual Feed Separation Roller ........................................................................................................ 10-57 10.10.15.1 Removing the Manual Feed Unit .............................................................................................. 10-57 10.10.15.2 Removing the Manual Feed Unit Cover .................................................................................... 10-57 10.10.15.3 Removing the Motor Cover ....................................................................................................... 10-58 10.10.15.4 Removing the Manual Feed Roller ............................................................................................ 10-58 10.10.15.5 Removing the Manual Feed Separation Roller ......................................................................... 10-59 10.10.16 Manual Feed Last Paper Sensor ........................................................................................................ 10-60 10.10.16.1 Removing the Manual Feed Unit .............................................................................................. 10-60 10.10.16.2 Removing the Manual Feed Tray Unit ...................................................................................... 10-61 10.10.16.3 Removing the Manual Feed Tray Upper Cover/Lower Cover .................................................. 10-61 10.10.16.4 Removing the Manual Feed Last Paper Sensor ......................................................................... 10-62 10.10.17 Manual Feed Sensor .......................................................................................................................... 10-62 10.10.17.1 Removing the Manual Feed Unit .............................................................................................. 10-62 10.10.17.2 Removing the Manual Feed Unit Cover .................................................................................... 10-62 10.10.17.3 Removing the Manual Feed Roller ............................................................................................ 10-63 10.10.17.4 Removing the Motor Cover ....................................................................................................... 10-64 10.10.17.5 Removing the Manual Feed sensor ........................................................................................... 10-64 10.10.18 Transparency Sensor (Front/Rear) .................................................................................................... 10-66 10.10.18.1 Removing the Manual Feed Unit .............................................................................................. 10-66 10.10.18.2 Removing the Transparency Sensor Mounting Plate ................................................................ 10-66 10.10.18.3 Removing the Transparency Sensor (front/rear) ....................................................................... 10-66 10.10.19 Manual Feed Pickup Solenoid .......................................................................................................... 10-66 Contents 10.10.19.1 Removing the Manual Feed Unit ............................................................................................... 10-66 10.10.19.2 Removing the Manual Feed Unit Cover .................................................................................... 10-67 10.10.19.3 Removing the Manual Feed Roller ............................................................................................ 10-67 10.10.19.4 Removing the Motor Cover ....................................................................................................... 10-68 10.10.19.5 Removing the Manual Feed Pickup Solenoid ............................................................................ 10-69 10.10.20 Registration Motor ............................................................................................................................ 10-69 10.10.20.1 Removing the Manual Feed Unit ............................................................................................... 10-69 10.10.20.2 Removing the Manual Feed Unit Cover .................................................................................... 10-70 10.10.20.3 Removing the Motor Cover ....................................................................................................... 10-70 10.10.20.4 Removing the Registration Motor ............................................................................................. 10-70 10.10.21 Pre-Registration Motor ...................................................................................................................... 10-71 10.10.21.1 Removing the Manual Feed Unit ............................................................................................... 10-71 10.10.21.2 Removing the Manual Feed Unit Cover .................................................................................... 10-71 10.10.21.3 Removing the Motor Cover ....................................................................................................... 10-72 10.10.21.4 Removing the Pre-Registration Motor ....................................................................................... 10-72 10.10.22 Horizontal Registration Motor .......................................................................................................... 10-72 10.10.22.1 Removing the Fixing Unit ......................................................................................................... 10-72 10.10.22.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-72 10.10.22.3 Removing the Duplex Open/Close Guide ................................................................................. 10-73 10.10.22.4 Removing the Fixing/Feeder Assembly Back Sheet ................................................................. 10-73 10.10.22.5 Removing the Horizontal Registration Motor Support Plate ..................................................... 10-73 10.10.22.6 Removing the Horizontal Registration Motor ........................................................................... 10-74 10.10.23 Registration Sensor ........................................................................................................................... 10-74 10.10.23.1 Removing the Manual Feed Unit ............................................................................................... 10-74 10.10.23.2 Removing the Transparency Sensor Mounting Plate ................................................................ 10-75 10.10.23.3 Removing the Registration Sensor ............................................................................................ 10-75 10.10.24 Fixing/Feeder Unit ............................................................................................................................ 10-75 10.10.24.1 Removing the Fixing Unit ......................................................................................................... 10-75 10.10.24.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-75 10.10.25 Vertical Path Roller ........................................................................................................................... 10-76 10.10.25.1 Removing the Cassette ............................................................................................................... 10-76 10.10.25.2 Removing the Front Right Cover ............................................................................................... 10-76 10.10.25.3 Removing the Rear Right Cover ................................................................................................ 10-76 10.10.25.4 Removing the Pickup Vertical Path Cover ................................................................................ 10-76 10.10.25.5 Removing the Pickup Unit ......................................................................................................... 10-77 10.10.25.6 Removing the Pick-up System Sensor Mounting Plate ............................................................. 10-77 10.10.25.7 Mounting the Pick-up System Sensor Mounting Plate .............................................................. 10-77 10.10.25.8 Removing the Vertical Path Roller ............................................................................................ 10-78 10.10.26 Inside Delivery Roller ....................................................................................................................... 10-78 10.10.26.1 Removing the Inside Delivery Roller ........................................................................................ 10-78 10.10.27 Fixing/Feeder Unit Open/Closed Sensor ........................................................................................... 10-79 10.10.27.1 Removing the Upper Left Cover ............................................................................................... 10-79 10.10.27.2 Removing the Center Delivery Tray .......................................................................................... 10-79 10.10.27.3 Removing the Delivery Vertical Path Unit (Old) ...................................................................... 10-79 10.10.27.4 Removing the Delivery Vertical Path Unit (New) ..................................................................... 10-80 10.10.27.5 Removing the Fixing/Feeder Unit Open/Closed Sensor Mounting Plate .................................. 10-83 10.10.27.6 Removing the Fixing/Feeder Unit Open/Closed Sensor ............................................................ 10-84 10.10.28 Pickup Vertical Path Cover Open/Closed Sensor ............................................................................. 10-84 10.10.28.1 Removing the Cassette ............................................................................................................... 10-84 10.10.28.2 Removing the Front Right Cover ............................................................................................... 10-84 10.10.28.3 Removing the Rear Right Cover ................................................................................................ 10-84 10.10.28.4 Removing the Pickup Vertical Path Cover ................................................................................ 10-84 10.10.28.5 Removing the Pickup Unit ......................................................................................................... 10-85 10.10.28.6 Removing the Pickup Vertical Path Cover Open/Closed Sensor .............................................. 10-85 Contents 10.10.29 Fixing/Feeder Unit Open/Closed Detecting Switch ......................................................................... 10-86 10.10.29.1 Removing the Upper Left Cover ............................................................................................... 10-86 10.10.29.2 Removing the Center Delivery Tray ......................................................................................... 10-86 10.10.29.3 Removing the Delivery Vertical Path Unit (Old) ...................................................................... 10-86 10.10.29.4 Removing the Delivery Vertical Path Unit (New) .................................................................... 10-87 10.10.29.5 Removing the Fixing/Feeder Unit Open/Closed Sensor Mounting Plate ................................. 10-89 10.10.29.6 Removing the Fixing/Feeder Unit Open/Closed Detecting Switch .......................................... 10-90 10.10.30 Drawer Connector (manual feed unit) .............................................................................................. 10-90 10.10.30.1 Removing the Manual Feed Unit .............................................................................................. 10-90 10.10.30.2 Removing the Disconnecting the Drawer Connector (manual feed unit) ................................. 10-91 10.10.31 Drawer Connector (fixing/feeder unit) ............................................................................................. 10-91 10.10.31.1 Removing the Fixing Unit ......................................................................................................... 10-91 10.10.31.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-91 10.10.31.3 Removing the Drawer Connector (fixing feeder unit) .............................................................. 10-92 10.10.32 Duplex Roller 1 ................................................................................................................................. 10-92 10.10.32.1 Removing the Fixing Unit ......................................................................................................... 10-92 10.10.32.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-92 10.10.32.3 Removing the Duplex Roller 1 .................................................................................................. 10-92 10.10.33 Duplex Feed Motor ........................................................................................................................... 10-94 10.10.33.1 Removing the Fixing Unit ......................................................................................................... 10-94 10.10.33.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-95 10.10.33.3 Removing the Duplex Feed Motor ............................................................................................ 10-95 10.10.34 Duplex Registration Sensor .............................................................................................................. 10-96 10.10.34.1 Removing the Fixing Unit ......................................................................................................... 10-96 10.10.34.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-96 10.10.34.3 Removing the Fixing/Feeder Assembly Back Sheet ................................................................. 10-96 10.10.34.4 Removing the Duplex Registration Sensor ............................................................................... 10-97 10.10.35 Duplex Horizontal Registration Sensor ............................................................................................ 10-97 10.10.35.1 Removing the Fixing Unit ......................................................................................................... 10-97 10.10.35.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-98 10.10.35.3 Removing the Fixing/Feeder Assembly Back Sheet ................................................................. 10-98 10.10.35.4 Removing the Horizontal Registration Motor Support Plate .................................................... 10-98 10.10.35.5 Removing the Duplex Registration Sensor ............................................................................... 10-99 10.10.36 Duplex Pickup Sensor ....................................................................................................................... 10-99 10.10.36.1 Removing the Cleaner Fan Cover ............................................................................................. 10-99 10.10.36.2 Removing the Intermediate Transfer Unit Releasing Lever ...................................................... 10-99 10.10.36.3 Removing the Inside Cover (lower) ........................................................................................ 10-100 10.10.36.4 Removing the Cassette ............................................................................................................ 10-100 10.10.36.5 Removing the Manual Feed Unit ............................................................................................ 10-100 10.10.36.6 Removing the Front Cover ...................................................................................................... 10-100 10.10.36.7 Removing the Rear Right Cover ............................................................................................. 10-101 10.10.36.8 Removing the Pickup Vertical Path Cover .............................................................................. 10-101 10.10.36.9 Removing the Pickup Unit ...................................................................................................... 10-101 10.10.36.10 Removing the Upper Rear Cover .......................................................................................... 10-101 10.10.36.11 Removing the Lower Rear Cover .......................................................................................... 10-101 10.10.36.12 Removing the High-Voltage Unit ......................................................................................... 10-101 10.10.36.13 Removing the Controller Box Cover ..................................................................................... 10-102 10.10.36.14 Removing the DC Controller PCB Cover ............................................................................. 10-102 10.10.36.15 Opening the Main Controller Box ......................................................................................... 10-103 10.10.36.16 Removing the DC Controller Mounting ................................................................................ 10-104 10.10.36.17 Removing the Fixing Heat Discharge Fan ............................................................................ 10-104 10.10.36.18 Removing the Developing Drive Unit ................................................................................... 10-104 10.10.36.19 Removing the Lattice Connector Mounting .......................................................................... 10-105 10.10.36.20 Removing the Manual Feed Cooling Fan Duct ..................................................................... 10-105 Contents 10.10.36.21 Removing the Duplex Driver PCB ........................................................................................ 10-105 10.10.36.22 Removing the Duplex Pickup Sensor .................................................................................... 10-105 10.10.37 Duplex Registration Clutch ............................................................................................................. 10-106 10.10.37.1 Removing the Fixing Unit ....................................................................................................... 10-106 10.10.37.2 Removing the Fixing/Feeder Unit ........................................................................................... 10-107 10.10.37.3 Removing the Duplex Feeder Motor Connector ...................................................................... 10-107 10.10.37.4 Removing the Duplex Open/Close Guide ............................................................................... 10-107 10.10.37.5 Removing the Duplex Registration Clutch .............................................................................. 10-107 10.10.38 Duplex Pickup Clutch ..................................................................................................................... 10-108 10.10.38.1 Removing the Fixing Unit ....................................................................................................... 10-108 10.10.38.2 Removing the Fixing/Feeder Unit ........................................................................................... 10-109 10.10.38.3 Removing the Duplex Open/Close Guide ............................................................................... 10-109 10.10.38.4 Removing the Duplex Pickup Clutch ...................................................................................... 10-109 10.10.39 Delivery Vertical Path Unit ............................................................................................................. 10-110 10.10.39.1 Removing the Fixing Unit ....................................................................................................... 10-110 10.10.39.2 Removing the Center Delivery Tray ........................................................................................ 10-111 10.10.39.3 Removing the Upper Left Cover ............................................................................................. 10-111 10.10.39.4 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-111 10.10.39.5 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-112 10.10.40 Face-Down Delivery Roller 1 ......................................................................................................... 10-115 10.10.40.1 Removing the Upper Left Cover ............................................................................................. 10-115 10.10.40.2 Removing the Center Delivery Tray ........................................................................................ 10-115 10.10.40.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-115 10.10.40.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-116 10.10.40.5 Removing the Delivery Sensor Mounting Plate ...................................................................... 10-119 10.10.40.6 Removing the Face-Down Delivery Sensor Flag .................................................................... 10-119 10.10.40.7 Removing the Face-Down Delivery Roller 1 .......................................................................... 10-120 10.10.41 Face-Up Delivery Roller ................................................................................................................. 10-120 10.10.41.1 Removing the Fixing/Feeder Unit ........................................................................................... 10-120 10.10.41.2 Removing the Fixing/Feeder Unit Cover ................................................................................. 10-121 10.10.41.3 Removing the Inside Delivery Roller ...................................................................................... 10-121 10.10.41.4 Removing the Face-Up Delivery Roller .................................................................................. 10-122 10.10.42 Delivery Vertical Path Roller 1 ....................................................................................................... 10-123 10.10.42.1 Removing the Upper Left Cover ............................................................................................. 10-123 10.10.42.2 Removing the Center Delivery Tray ........................................................................................ 10-123 10.10.42.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-124 10.10.42.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-125 10.10.42.5 Removing the Face-Down Delivery Sensor 2 ......................................................................... 10-127 10.10.42.6 Removing the Delivery Vertical Path Roller 1 ........................................................................ 10-128 10.10.43 Delivery Vertical Path Roller 2 ....................................................................................................... 10-128 10.10.43.1 Removing the Upper Left Cover ............................................................................................. 10-128 10.10.43.2 Removing the Center Delivery Tray ........................................................................................ 10-128 10.10.43.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-129 10.10.43.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-130 10.10.43.5 Removing the Delivery Vertical Path Roller 2 ........................................................................ 10-132 10.10.44 Face-Down Delivery Motor ............................................................................................................ 10-133 10.10.44.1 Removing the Upper Left Cover ............................................................................................. 10-133 10.10.44.2 Removing the Center Delivery Tray ........................................................................................ 10-133 10.10.44.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-133 10.10.44.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-134 10.10.44.5 Removing the Face-Down Delivery Motor ............................................................................. 10-137 10.10.45 Delivery Vertical Path Motor .......................................................................................................... 10-137 10.10.45.1 Removing the Upper Left Cover ............................................................................................. 10-137 10.10.45.2 Removing the Center Delivery Tray ........................................................................................ 10-137 Contents 10.10.45.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-137 10.10.45.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-138 10.10.45.5 Removing the Delivery Vertical Path Motor ........................................................................... 10-141 10.10.46 Face-Down Delivery Sensor 1 ........................................................................................................ 10-141 10.10.46.1 Removing the Upper Left Cover ............................................................................................. 10-141 10.10.46.2 Removing the Center Delivery Tray ....................................................................................... 10-141 10.10.46.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-142 10.10.46.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-142 10.10.46.5 Removing the Face-Down Delivery Sensor 1 ......................................................................... 10-145 10.10.47 Center Delivery Tray Full sensor .................................................................................................... 10-146 10.10.47.1 Removing the Upper Left Cover ............................................................................................. 10-146 10.10.47.2 Removing the Center Delivery Tray ....................................................................................... 10-146 10.10.47.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-146 10.10.47.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-147 10.10.47.5 Removing the Center Delivery Tray Full sensor ..................................................................... 10-149 10.10.48 Face-Down Delivery Sensor 2 ........................................................................................................ 10-150 10.10.48.1 Removing the Upper Left Cover ............................................................................................. 10-150 10.10.48.2 Removing the Center Delivery Tray ....................................................................................... 10-150 10.10.48.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-150 10.10.48.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-151 10.10.48.5 Removing the Face-Down Delivery Sensor 2 ......................................................................... 10-153 10.10.49 Delivery Vertical Path Cover Open/Closed Sensor ........................................................................ 10-154 10.10.49.1 Removing the Upper Left Cover ............................................................................................. 10-154 10.10.49.2 Removing the Center Delivery Tray ....................................................................................... 10-154 10.10.49.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-154 10.10.49.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-156 10.10.49.5 Removing the Delivery Vertical Path Cover Open/Closed Sensor ......................................... 10-158 10.10.50 Delivery Path Switching Solenoid 1 ............................................................................................... 10-158 10.10.50.1 Removing the Upper Left Cover ............................................................................................. 10-158 10.10.50.2 Removing the Center Delivery Tray ....................................................................................... 10-158 10.10.50.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-159 10.10.50.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-160 10.10.50.5 Removing the Cleaner Fan Cover ........................................................................................... 10-162 10.10.50.6 Removing the Cleaner Fan ...................................................................................................... 10-162 10.10.50.7 Removing the Delivery Path Switching Solenoid 1 ................................................................ 10-162 10.10.51 Delivery Path Switching Solenoid 2 ............................................................................................... 10-163 10.10.51.1 Removing the Delivery Path Switching Solenoid 2 ................................................................ 10-163 10.10.52 Face-Down Delivery Roller 1 Drive Belt ....................................................................................... 10-163 10.10.52.1 Removing the Upper Left Cover ............................................................................................. 10-163 10.10.52.2 Removing the Center Delivery Tray ....................................................................................... 10-163 10.10.52.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-164 10.10.52.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-165 10.10.52.5 Removing the Face-Down Delivery Roller 1 Drive Belt ........................................................ 10-167 Chapter 11 Fixing System 11.1 Construction .................................................................................................................................................. 11-1 11.1.1 Specifications, Control Mechanisms, and Functions ............................................................................. 11-1 11.1.2 Major Components ................................................................................................................................. 11-1 11.1.3 Construction of the Control System ....................................................................................................... 11-3 11.2 Basic Sequence .............................................................................................................................................. 11-4 11.2.1 Sequence of Operations at Power-On .................................................................................................... 11-4 11.2.2 Sequence of Operations (printing; plain paper, for less than 180 sec) ................................................... 11-5 11.2.3 Basic Sequence of Operations (during printing; plain paper, for 180 sec or more) ............................... 11-6 Contents 11.3 Various Control Mechanisms ........................................................................................................................ 11-7 11.3.1 Controlling the Speed of the Fixing Roller ............................................................................................. 11-7 11.3.1.1 Outline ............................................................................................................................................. 11-7 11.3.1.2 Controlling the Speed According to the Type of Paper ................................................................... 11-7 11.3.1.3 Controlling the Speed According to the Quantity of Printing ......................................................... 11-8 11.3.1.4 Preventing Partial Deformation of the Roller .................................................................................. 11-8 11.3.2 Controlling the Fixing Roller Temperature ............................................................................................. 11-8 11.3.2.1 Outline ............................................................................................................................................. 11-8 11.3.2.2 At Power-On .................................................................................................................................. 11-10 11.3.2.3 In Standby ...................................................................................................................................... 11-10 11.3.2.4 During Printing .............................................................................................................................. 11-11 11.3.2.5 Between Sheets .............................................................................................................................. 11-12 11.3.2.6 Overheating in Areas Without Paper ............................................................................................. 11-13 11.3.2.7 Return for Low-Power Mode ......................................................................................................... 11-13 11.3.3 Detecting the Passage of Paper ............................................................................................................. 11-14 11.3.3.1 Detecting the Passage of Paper ...................................................................................................... 11-14 11.4 Protective Functions .................................................................................................................................... 11-15 11.4.1 Turning Off the Power Against Overheating (in response to activation of thermal switch) ................ 11-15 11.4.2 Detecting Overheating by the Thermistors ........................................................................................... 11-16 11.5 Parts Replacement Procedure ...................................................................................................................... 11-17 11.5.1 Fixing Unit ............................................................................................................................................ 11-17 11.5.1.1 Removing the Fixing Unit ............................................................................................................. 11-17 11.5.1.2 After Disassembling the Fixing Unit ............................................................................................. 11-17 11.5.2 Fixing Upper Frame .............................................................................................................................. 11-18 11.5.2.1 Removing the Fixing Unit ............................................................................................................. 11-18 11.5.2.2 Removing the Delivery Upper Guide ............................................................................................ 11-18 11.5.2.3 Removing the Fixing Upper Frame ............................................................................................... 11-19 11.5.2.4 After Disassembling the Fixing Unit ............................................................................................. 11-20 11.5.3 Fixing Roller ......................................................................................................................................... 11-21 11.5.3.1 Removing the Fixing Unit ............................................................................................................. 11-21 11.5.3.2 Removing the Delivery Upper Guide ............................................................................................ 11-21 11.5.3.3 Removing the Fixing Upper Frame ............................................................................................... 11-22 11.5.3.4 Remove the Fixing Main Heater and the Fixing Sub Heater ......................................................... 11-23 11.5.3.5 Removing the Fixing Roller .......................................................................................................... 11-24 11.5.3.6 After Disassembling the Fixing Unit ............................................................................................. 11-25 11.5.4 Pressure Roller ...................................................................................................................................... 11-26 11.5.4.1 Removing the Fixing Unit ............................................................................................................. 11-26 11.5.4.2 Removing the Delivery Upper Guide ............................................................................................ 11-26 11.5.4.3 Removing the Fixing Upper Frame ............................................................................................... 11-27 11.5.4.4 Removing the Fixing Temperature Retainer Heater ...................................................................... 11-28 11.5.4.5 Removing the Pressure Roller ....................................................................................................... 11-29 11.5.4.6 After Disassembling the Fixing Unit ............................................................................................. 11-29 11.5.5 Fixing Main Thermistor ........................................................................................................................ 11-30 11.5.5.1 Removing the Fixing Unit ............................................................................................................. 11-30 11.5.5.2 Removing the Delivery Upper Guide ............................................................................................ 11-30 11.5.5.3 Removing the Fixing Upper Frame ............................................................................................... 11-31 11.5.5.4 Removing the Fixing Main Thermistor ......................................................................................... 11-32 11.5.5.5 After Disassembling the Fixing Unit ............................................................................................. 11-33 11.5.6 Fixing Sub Thermistor .......................................................................................................................... 11-34 11.5.6.1 Removing the Fixing Unit ............................................................................................................. 11-34 11.5.6.2 Removing the Delivery Upper Guide ............................................................................................ 11-34 11.5.6.3 Removing the Fixing Upper Frame ............................................................................................... 11-35 11.5.6.4 Removing the Fixing Sub thermistor ............................................................................................. 11-36 11.5.6.5 After Disassembling the Fixing Unit ............................................................................................. 11-36 Contents 11.5.7 Fixing Thermal Switch ......................................................................................................................... 11-37 11.5.7.1 Removing the Fixing Unit ............................................................................................................. 11-37 11.5.7.2 Removing the Delivery Upper Guide ............................................................................................ 11-38 11.5.7.3 Removing the Fixing Upper Frame ............................................................................................... 11-38 11.5.7.4 Removing the Fixing Thermal Switch .......................................................................................... 11-40 11.5.7.5 After Disassembling the Fixing Unit ............................................................................................. 11-41 11.5.8 Fixing Main Heater/Fixing Sub Heater ................................................................................................. 11-42 11.5.8.1 Removing the Fixing Unit ............................................................................................................. 11-42 11.5.8.2 Removing the Delivery Upper Guide ............................................................................................ 11-42 11.5.8.3 Removing the Fixing Upper Frame ............................................................................................... 11-43 11.5.8.4 Remove the Fixing Main Heater and the Fixing Sub Heater ........................................................ 11-44 11.5.8.5 After Disassembling the Fixing Unit ............................................................................................. 11-45 11.5.9 Fixing Heat Retaining Heater ............................................................................................................... 11-45 11.5.9.1 Removing the Fixing Unit ............................................................................................................. 11-45 11.5.9.2 Removing the Delivery Upper Guide ............................................................................................ 11-46 11.5.9.3 Removing the Fixing Upper Frame ............................................................................................... 11-46 11.5.9.4 Removing the Fixing Temperature Retainer Heater ..................................................................... 11-48 11.5.9.5 After Disassembling the Fixing Unit ............................................................................................. 11-49 11.5.10 Fixing Inlet Guide ............................................................................................................................... 11-50 11.5.10.1 Removing the Fixing Unit ........................................................................................................... 11-50 11.5.10.2 Removing the Fixing Inlet Guide ................................................................................................ 11-50 11.5.10.3 After Disassembling the Fixing Unit ........................................................................................... 11-50 11.5.11 Delivery Upper Guide ......................................................................................................................... 11-51 11.5.11.1 Removing the Fixing Unit ........................................................................................................... 11-51 11.5.11.2 Removing the Delivery Upper Guide .......................................................................................... 11-51 11.5.12 Delivery Lower Guide ........................................................................................................................ 11-52 11.5.12.1 Removing the Fixing Unit ........................................................................................................... 11-52 11.5.12.2 Removing the Delivery Upper Guide .......................................................................................... 11-52 11.5.12.3 Removing the Fixing Upper Frame ............................................................................................. 11-53 11.5.12.4 Removing the Fixing Temperature Retainer Heater ................................................................... 11-54 11.5.12.5 Removing the Pressure Roller ..................................................................................................... 11-55 11.5.12.6 Remove the Delivery Lower Guide ............................................................................................. 11-55 11.5.12.7 After Disassembling the Fixing Unit ........................................................................................... 11-56 11.5.13 Fixing Inlet Sensor .............................................................................................................................. 11-57 11.5.13.1 Removing the Fixing Unit ........................................................................................................... 11-57 11.5.13.2 Removing the Delivery Upper Guide .......................................................................................... 11-58 11.5.13.3 Removing the Fixing Upper Frame ............................................................................................. 11-58 11.5.13.4 Removing the Fixing Inlet Sensor ............................................................................................... 11-60 11.5.13.5 After Disassembling the Fixing Unit ........................................................................................... 11-60 11.5.14 Fixing Delivery Sensor ....................................................................................................................... 11-61 11.5.14.1 Removing the Fixing Unit ........................................................................................................... 11-61 11.5.14.2 Removing the Delivery Upper Guide .......................................................................................... 11-61 11.5.14.3 Removing the Fixing Upper Frame ............................................................................................. 11-62 11.5.14.4 Removing the Fixing Delivery Sensor ........................................................................................ 11-63 11.5.14.5 After Disassembling the Fixing Unit ........................................................................................... 11-63 11.5.15 Fixing Motor ....................................................................................................................................... 11-64 11.5.15.1 Removing the Upper Rear Cover ................................................................................................ 11-64 11.5.15.2 Removing the Lower Rear Cover ................................................................................................ 11-64 11.5.15.3 Removing the Left Upper Rear Cover ......................................................................................... 11-64 11.5.15.4 Removing the Controller Box Cover ........................................................................................... 11-65 11.5.15.5 Removing the DC Controller PCB Cover ................................................................................... 11-65 11.5.15.6 Opening the Main Controller Box ............................................................................................... 11-65 11.5.15.7 Removing the Fixing Heat Discharge Fan .................................................................................. 11-66 11.5.15.8 Removing the High-Voltage Unit ............................................................................................... 11-66 Contents 11.5.15.9 Removing the Left Lower Rear cover ......................................................................................... 11-67 11.5.15.10 Removing the Secondary Transfer High-Voltage Unit ............................................................. 11-67 11.5.15.11 Removing the Fixing Drive Unit ............................................................................................... 11-68 11.5.15.12 Removing the Fixing Motor ...................................................................................................... 11-69 Chapter 12 Externals and Controls 12.1 Control Panel ................................................................................................................................................. 12-1 12.1.1 Outline .................................................................................................................................................... 12-1 12.1.2 LCD Processing ...................................................................................................................................... 12-1 12.1.3 LCD Contras Adjustment ....................................................................................................................... 12-1 12.1.4 Functions of the Control Panel CPU ...................................................................................................... 12-2 12.2 Counters ......................................................................................................................................................... 12-3 12.2.1 Outline .................................................................................................................................................... 12-3 12.2.2 Signal-Sided Print and 2nd Side of a Double-Sided Print ...................................................................... 12-5 12.2.3 Side of a Duplex Print (duplex model only) ........................................................................................... 12-5 12.3 Fans ................................................................................................................................................................ 12-6 12.3.1 Outline .................................................................................................................................................... 12-6 12.3.2 Sequence of Operations (fan) ................................................................................................................. 12-7 12.4 Power Supply ................................................................................................................................................. 12-8 12.4.1 Power Supply .......................................................................................................................................... 12-8 12.4.1.1 Timing of Power Supply .................................................................................................................. 12-8 12.4.1.2 Wiring to Various Accessories ........................................................................................................ 12-8 12.4.1.3 Route of Power Supply .................................................................................................................... 12-9 12.4.1.4 Power Supply Route lnside the Printer Unit .................................................................................. 12-10 12.4.2 Rated Output of DC Power Supply PCB .............................................................................................. 12-11 12.4.2.1 Rated Output of the Machine Power Suppy .................................................................................. 12-11 12.4.3 Protection Function ............................................................................................................................... 12-12 12.4.3.1 Protective Mechanisms .................................................................................................................. 12-12 12.4.4 Backup Battery ...................................................................................................................................... 12-12 12.4.4.1 Backup Power Supply .................................................................................................................... 12-12 12.4.5 Energy-Saving Function ........................................................................................................................ 12-13 12.4.5.1 Outline ........................................................................................................................................... 12-13 12.5 Parts Replacement Procedure ...................................................................................................................... 12-15 12.5.1 Fixing Drive Unit .................................................................................................................................. 12-15 12.5.1.1 Removing the Upper Rear Cover ................................................................................................... 12-15 12.5.1.2 Removing the Lower Rear Cover .................................................................................................. 12-15 12.5.1.3 Removing the Left Upper Rear Cover ........................................................................................... 12-15 12.5.1.4 Removing the Controller Box Cover ............................................................................................. 12-15 12.5.1.5 Removing the DC Controller PCB Cover ...................................................................................... 12-15 12.5.1.6 Opening the Main Controller Box ................................................................................................. 12-15 12.5.1.7 Removing the Fixing Heat Discharge Fan ..................................................................................... 12-16 12.5.1.8 Removing the High-Voltage Unit .................................................................................................. 12-17 12.5.1.9 Removing the Left Lower Rear cover ........................................................................................... 12-17 12.5.1.10 Removing the Secondary Transfer High-Voltage Unit ............................................................... 12-17 12.5.1.11 Removing the Fixing Drive Unit ................................................................................................. 12-18 12.5.2 Developing Drive Unit .......................................................................................................................... 12-18 12.5.2.1 Removing the Upper Rear Cover ................................................................................................... 12-18 12.5.2.2 Removing the Lower Rear Cover .................................................................................................. 12-19 12.5.2.3 Removing the Left Upper Rear Cover ........................................................................................... 12-19 12.5.2.4 Removing the Controller Box Cover ............................................................................................. 12-19 12.5.2.5 Removing the DC Controller PCB Cover ...................................................................................... 12-19 12.5.2.6 Opening the Main Controller Box ................................................................................................. 12-19 12.5.2.7 Removing the DC Controller Mounting ........................................................................................ 12-20 Contents 12.5.2.8 Removing the Fixing Heat Discharge Fan .................................................................................... 12-21 12.5.2.9 Removing the Machine Heat Discharge Fan ................................................................................. 12-21 12.5.2.10 Removing the Developing Drive Unit ......................................................................................... 12-21 12.5.3 High-Voltage Unit ................................................................................................................................ 12-22 12.5.3.1 Removing the Upper Rear Cover .................................................................................................. 12-22 12.5.3.2 Removing the Lower Rear Cover .................................................................................................. 12-22 12.5.3.3 Removing the High-Voltage Unit ................................................................................................. 12-22 12.5.4 Secondary Transfer High-Voltage Unit ................................................................................................ 12-23 12.5.4.1 Removing the Upper Rear Cover .................................................................................................. 12-23 12.5.4.2 Removing the Lower Rear Cover .................................................................................................. 12-23 12.5.4.3 Removing the High-Voltage Unit ................................................................................................. 12-23 12.5.4.4 Removing the Left Lower Rear cover ........................................................................................... 12-23 12.5.4.5 Removing the Secondary Transfer High-Voltage Unit ................................................................. 12-23 12.5.5 DC Power Supply Unit ......................................................................................................................... 12-24 12.5.5.1 Removing the Upper Rear Cover .................................................................................................. 12-24 12.5.5.2 Removing the Lower Rear Cover .................................................................................................. 12-24 12.5.5.3 Removing the DC Power Supply Unit .......................................................................................... 12-24 12.5.6 Control Panel ........................................................................................................................................ 12-25 12.5.6.1 Removing the Upper Left Cover (small) ....................................................................................... 12-25 12.5.6.2 Removing the Inside Cover ........................................................................................................... 12-25 12.5.6.3 Removing the Control Panel ......................................................................................................... 12-25 12.5.7 Control Panel LCD Unit ....................................................................................................................... 12-25 12.5.7.1 Removing the Upper Left Cover (small) ....................................................................................... 12-25 12.5.7.2 Removing the Inside Cover ........................................................................................................... 12-25 12.5.7.3 Removing the Control Panel ......................................................................................................... 12-25 12.5.7.4 Removing the Control Panel Back Plate ....................................................................................... 12-26 12.5.7.5 Removing the Control Panel LCD Unit ........................................................................................ 12-26 12.5.8 DC Controller PCB ............................................................................................................................... 12-26 12.5.8.1 Removing the Upper Rear Cover .................................................................................................. 12-26 12.5.8.2 Removing the Lower Rear Cover .................................................................................................. 12-26 12.5.8.3 Removing the Controller Box Cover ............................................................................................. 12-27 12.5.8.4 Removing the DC Controller PCB Cover ..................................................................................... 12-27 12.5.8.5 Removing the DC Controller PCB ................................................................................................ 12-27 12.5.8.6 When Replacing the DC Controller PCB ...................................................................................... 12-28 12.5.9 Counter Memory PCB .......................................................................................................................... 12-28 12.5.9.1 Removing the Upper Rear Cover .................................................................................................. 12-28 12.5.9.2 Removing the Lower Rear Cover .................................................................................................. 12-28 12.5.9.3 Removing the Left Upper Rear Cover ........................................................................................... 12-28 12.5.9.4 Removing the Controller Box Cover ............................................................................................. 12-28 12.5.9.5 Removing the DC Controller PCB Cover ..................................................................................... 12-28 12.5.9.6 Opening the Main Controller Box ................................................................................................. 12-29 12.5.9.7 Removing the Counter Memory PCB ........................................................................................... 12-30 12.5.10 Fuse PCB ............................................................................................................................................ 12-30 12.5.10.1 Removing the Upper Rear Cover ................................................................................................ 12-30 12.5.10.2 Removing the Lower Rear Cover ................................................................................................ 12-30 12.5.10.3 Removing the DC Power Supply Unit ........................................................................................ 12-30 12.5.10.4 Removing the Fuse PCB ............................................................................................................. 12-31 12.5.11 Leakage Breaker ................................................................................................................................. 12-31 12.5.11.1 Removing the Upper Rear Cover ................................................................................................ 12-31 12.5.11.2 Removing the Lower Rear Cover ................................................................................................ 12-31 12.5.11.3 Removing the DC Power Supply Unit ........................................................................................ 12-31 12.5.11.4 Removing the Power Supply Cooling Fan Mounting ................................................................. 12-31 12.5.11.5 Removing the Leakage Breaker .................................................................................................. 12-31 12.5.12 Duplex Driver PCB ............................................................................................................................. 12-32 Contents 12.5.12.1 Removing the Upper Rear Cover ................................................................................................. 12-32 12.5.12.2 Removing the Lower Rear Cover ................................................................................................ 12-32 12.5.12.3 Removing the Lattice Connector Mounting ................................................................................ 12-32 12.5.12.4 Removing the Duplex Driver PCB .............................................................................................. 12-33 12.5.13 Relay PCB 1 ........................................................................................................................................ 12-33 12.5.13.1 Removing the Upper Rear Cover ................................................................................................. 12-33 12.5.13.2 Removing the Lower Rear Cover ................................................................................................ 12-33 12.5.13.3 Removing the Left Upper Rear Cover ......................................................................................... 12-33 12.5.13.4 Removing the Controller Box Cover ........................................................................................... 12-33 12.5.13.5 Removing the DC Controller PCB Cover .................................................................................... 12-33 12.5.13.6 Opening the Main Controller Box ............................................................................................... 12-34 12.5.13.7 Removing the DC Controller Mounting ...................................................................................... 12-35 12.5.13.8 Removing the Relay PCB 1 ......................................................................................................... 12-35 12.5.14 Control Panel CPU PCB ..................................................................................................................... 12-35 12.5.14.1 Removing the Upper Left Cover (small) ..................................................................................... 12-35 12.5.14.2 Removing the Inside Cover ......................................................................................................... 12-35 12.5.14.3 Removing the Control Panel ........................................................................................................ 12-35 12.5.14.4 Removing the Control Panel CPU PCB ...................................................................................... 12-36 12.5.15 Control Panel Key Switch PCB .......................................................................................................... 12-36 12.5.15.1 Removing the Upper Left Cover (small) ..................................................................................... 12-36 12.5.15.2 Removing the Inside Cover ......................................................................................................... 12-36 12.5.15.3 Removing the Control Panel ........................................................................................................ 12-36 12.5.15.4 Removing the Control Panel Back Plate ...................................................................................... 12-37 12.5.15.5 Removing the Control Panel Key PCB ........................................................................................ 12-37 12.5.16 Control Panel Inverter PCB ................................................................................................................. 12-37 12.5.16.1 Removing the Upper Left Cover (small) ..................................................................................... 12-37 12.5.16.2 Removing the Inside Cover ......................................................................................................... 12-37 12.5.16.3 Removing the Control Panel ........................................................................................................ 12-37 12.5.16.4 Removing the Control Panel Back Plate ...................................................................................... 12-38 12.5.16.5 Removing the Control Panel Inverter PCB .................................................................................. 12-38 12.5.17 Environment Sensor ............................................................................................................................ 12-38 12.5.17.1 Pressure Release of the Intermediate Transfer Unit .................................................................... 12-38 12.5.17.2 Removing the Upper Right Cover ............................................................................................... 12-39 12.5.17.3 Removing the Environment Sensor ............................................................................................. 12-39 12.5.18 Manual Feed Unit Open/Closed Sensor .............................................................................................. 12-39 12.5.18.1 Removing the Upper Rear Cover ................................................................................................. 12-39 12.5.18.2 Removing the Lower Rear Cover ................................................................................................ 12-40 12.5.18.3 Removing the Left Upper Rear Cover ......................................................................................... 12-40 12.5.18.4 Removing the Controller Box Cover ........................................................................................... 12-40 12.5.18.5 Removing the DC Controller PCB Cover .................................................................................... 12-40 12.5.18.6 Opening the Main Controller Box ............................................................................................... 12-40 12.5.18.7 Removing the DC Controller Mounting ...................................................................................... 12-41 12.5.18.8 Removing the Registration Unit Open/Closed Sensor Mounting ................................................ 12-42 12.5.18.9 Removing the Manual Feed Unit Open/Closed Sensor ............................................................... 12-42 12.5.19 Front Cover Open/Closed Sensor ........................................................................................................ 12-42 12.5.19.1 Removing the Tonner Container release Lever ........................................................................... 12-42 12.5.19.2 Removing the Cleaner Fan Cover ................................................................................................ 12-42 12.5.19.3 Removing the Inside Cover ......................................................................................................... 12-43 12.5.19.4 Removing the Upper Rear Cover ................................................................................................. 12-43 12.5.19.5 Removing the Lower Rear Cover ................................................................................................ 12-43 12.5.19.6 Removing the Left Upper Rear Cover ......................................................................................... 12-43 12.5.19.7 Removing the DC Controller PCB Cover .................................................................................... 12-43 12.5.19.8 Removing the DC Controller Mounting ...................................................................................... 12-44 12.5.19.9 Removing the Front Cover Open/Closed Sensor ..................................................................... 12-44 Contents 12.5.20 Main Power Switch ............................................................................................................................. 12-44 12.5.20.1 Removing the Upper Rear Cover ................................................................................................ 12-44 12.5.20.2 Removing the Lower Rear Cover ................................................................................................ 12-44 12.5.20.3 Removing the Left Upper Rear Cover ......................................................................................... 12-44 12.5.20.4 Removing the Controller Box Cover ........................................................................................... 12-44 12.5.20.5 Removing the DC Controller PCB Cover ................................................................................... 12-45 12.5.20.6 Opening the Main Controller Box ............................................................................................... 12-45 12.5.20.7 Removing the DC Controller Mounting ...................................................................................... 12-46 12.5.20.8 Removing the Fixing Heat Discharge Fan .................................................................................. 12-46 12.5.20.9 Removing the Fixing Drive Unit ................................................................................................. 12-46 12.5.20.10 Removing the Lattice Connector Mounting .............................................................................. 12-47 12.5.20.11 Removing the High-Voltage Unit ............................................................................................. 12-47 12.5.20.12 Removing the Manual Feed Cooling Fan Duct ......................................................................... 12-47 12.5.20.13 Removing the Main Power Supply Switch ............................................................................... 12-48 12.5.21 Manual Feed Unit Open/Closed Detecting Switch ............................................................................. 12-48 12.5.21.1 Removing the Upper Rear Cover ................................................................................................ 12-48 12.5.21.2 Removing the Lower Rear Cover ................................................................................................ 12-48 12.5.21.3 Removing the Left Upper Rear Cover ......................................................................................... 12-48 12.5.21.4 Removing the Controller Box Cover ........................................................................................... 12-48 12.5.21.5 Removing the DC Controller PCB Cover ................................................................................... 12-49 12.5.21.6 Opening the Main Controller Box ............................................................................................... 12-49 12.5.21.7 Removing the DC Controller Mounting ...................................................................................... 12-50 12.5.21.8 Removing the Registration Unit Open/Closed Sensor Mounting ............................................... 12-50 12.5.21.9 Removing the Manual Feed Unit Open/Close Switch ................................................................ 12-50 12.5.22 Front Cover Open/Closed Detecting Switch ....................................................................................... 12-51 12.5.22.1 Removing the Tonner Container release Lever ........................................................................... 12-51 12.5.22.2 Removing the Cleaner Fan Cover ............................................................................................... 12-51 12.5.22.3 Removing the Inside Cover ......................................................................................................... 12-51 12.5.22.4 Removing the Upper Rear Cover ................................................................................................ 12-51 12.5.22.5 Removing the Lower Rear Cover ................................................................................................ 12-51 12.5.22.6 Removing the Left Upper Rear Cover ......................................................................................... 12-52 12.5.22.7 Removing the DC Controller PCB Cover ................................................................................... 12-52 12.5.22.8 Removing the DC Controller Mounting ...................................................................................... 12-52 12.5.22.9 Removing the Front Cover Open/Close Switch .......................................................................... 12-52 12.5.23 Cleaner Fan ......................................................................................................................................... 12-53 12.5.23.1 Removing the Cleaner Fan Cover ............................................................................................... 12-53 12.5.23.2 Removing the Cleaner Fan .......................................................................................................... 12-53 12.5.24 Manual Feed Cooling Fan ................................................................................................................... 12-53 12.5.24.1 Removing the Upper Rear Cover ................................................................................................ 12-53 12.5.24.2 Removing the Lower Rear Cover ................................................................................................ 12-53 12.5.24.3 Removing the Left Upper Rear Cover ......................................................................................... 12-54 12.5.24.4 Removing the Controller Box Cover ........................................................................................... 12-54 12.5.24.5 Removing the DC Controller PCB Cover ................................................................................... 12-54 12.5.24.6 Opening the Main Controller Box ............................................................................................... 12-54 12.5.24.7 Removing the DC Controller Mounting ...................................................................................... 12-55 12.5.24.8 Removing the Fixing Heat Discharge Fan .................................................................................. 12-56 12.5.24.9 Removing the Developing Drive Unit ......................................................................................... 12-56 12.5.24.10 Removing the Lattice Connector Mounting .............................................................................. 12-57 12.5.24.11 Removing the High-Voltage Unit ............................................................................................. 12-57 12.5.24.12 Removing the Manual Feed Cooling Fan Duct ......................................................................... 12-57 12.5.24.13 Removing the Manual Feed Cooling Fan .................................................................................. 12-57 12.5.25 Fixing Heat Discharge Fan ................................................................................................................. 12-58 12.5.25.1 Removing the Upper Rear Cover ................................................................................................ 12-58 12.5.25.2 Removing the Lower Rear Cover ................................................................................................ 12-58 Contents 12.5.25.3 Removing the Left Upper Rear Cover ......................................................................................... 12-58 12.5.25.4 Removing the Controller Box Cover ........................................................................................... 12-58 12.5.25.5 Removing the DC Controller PCB Cover .................................................................................... 12-58 12.5.25.6 Opening the Main Controller Box ............................................................................................... 12-59 12.5.25.7 Removing the Fixing Heat Discharge Fan ................................................................................... 12-60 12.5.26 Power Supply Cooing Fan ................................................................................................................... 12-60 12.5.26.1 Removing the Upper Rear Cover ................................................................................................. 12-60 12.5.26.2 Removing the Lower Rear Cover ................................................................................................ 12-60 12.5.26.3 Removing the DC Power Supply Unit ......................................................................................... 12-60 12.5.26.4 Removing the Power Supply Cooling Fan Mounting .................................................................. 12-60 12.5.26.5 Removing the Power Supply Cooing Fan .................................................................................... 12-60 12.5.27 Delivery Cooling Fan .......................................................................................................................... 12-61 12.5.27.1 Removing the Upper Rear Cover ................................................................................................. 12-61 12.5.27.2 Removing the Lower Rear Cover ................................................................................................ 12-61 12.5.27.3 Removing the High-Voltage Unit ................................................................................................ 12-61 12.5.27.4 Removing the Left Lower Rear cover ......................................................................................... 12-61 12.5.27.5 Removing the Secondary Transfer High-Voltage Unit ............................................................... 12-61 12.5.27.6 Removing the Delivery Cooling Fan ........................................................................................... 12-62 12.5.28 Machine Heat Discharge Fan .............................................................................................................. 12-62 12.5.28.1 Removing the Upper Rear Cover ................................................................................................. 12-62 12.5.28.2 Removing the Lower Rear Cover ................................................................................................ 12-62 12.5.28.3 Removing the Left Upper Rear Cover ......................................................................................... 12-63 12.5.28.4 Removing the Controller Box Cover ........................................................................................... 12-63 12.5.28.5 Removing the DC Controller PCB Cover .................................................................................... 12-63 12.5.28.6 Opening the Main Controller Box ............................................................................................... 12-63 12.5.28.7 Removing the Machine Heat Discharge Fan ............................................................................... 12-64 12.5.29 Drum Unit Drive Belt .......................................................................................................................... 12-65 12.5.29.1 Removing the Upper Rear Cover ................................................................................................. 12-65 12.5.29.2 Removing the Lower Rear Cover ................................................................................................ 12-65 12.5.29.3 Removing the Left Upper Rear Cover ......................................................................................... 12-65 12.5.29.4 Removing the Controller Box Cover ........................................................................................... 12-65 12.5.29.5 Removing the DC Controller PCB Cover .................................................................................... 12-65 12.5.29.6 Opening the Main Controller Box ............................................................................................... 12-66 12.5.29.7 Removing the DC Controller Mounting ...................................................................................... 12-67 12.5.29.8 Removing the Fixing Heat Discharge Fan ................................................................................... 12-67 12.5.29.9 Removing the Developing Drive Unit ......................................................................................... 12-67 12.5.29.10 Removing the Lattice Connector Mounting .............................................................................. 12-68 12.5.29.11 Removing the High-Voltage Unit .............................................................................................. 12-68 12.5.29.12 Removing the Manual Feed Cooling Fan Duct ......................................................................... 12-69 12.5.29.13 Removing the Drum ITB Motor Mounting ............................................................................... 12-69 12.5.29.14 Removing the Drum Drive Unit ................................................................................................ 12-70 12.5.29.15 Detaching the Drum Unit Drive Belt ......................................................................................... 12-70 Chapter 13 MEAP 13.1 Overview ........................................................................................................................................................ 13-1 13.2 MEAP Counter .............................................................................................................................................. 13-2 13.3 Construction of the MEAP Platform ............................................................................................................. 13-4 Chapter 14 Maintenance and Inspection 14.1 Periodically Replaced Parts ........................................................................................................................... 14-1 14.1.1 Periodically Replaced Parts .................................................................................................................... 14-1 14.1.2 Reader Unit/Color Image Reader-C1 ..................................................................................................... 14-1 Contents 14.1.3 Printer Unit ............................................................................................................................................. 14-1 14.2 Durables and Consumables ........................................................................................................................... 14-2 14.2.1 Outline .................................................................................................................................................... 14-2 14.2.2 Reader Unit/Color Image Reader-C1 ..................................................................................................... 14-2 14.2.3 Printer Unit ............................................................................................................................................. 14-2 14.3 Scheduled Servicing Basic Procedure ........................................................................................................... 14-4 14.3.1 Scheduled Servicing (Reader Unit) ........................................................................................................ 14-4 14.3.2 Scheduled Servicing (Printer Unit) ........................................................................................................ 14-6 Chapter 15 Standards and Adjustments 15.1 Image Adjustments ........................................................................................................................................ 15-1 15.1.1 Standards for Image Position ................................................................................................................. 15-1 15.1.2 Checking the Image Position .................................................................................................................. 15-1 15.1.3 Adjusting the Left/Right Margin (Cassette) ........................................................................................... 15-2 15.1.4 Adjusting the Left/Right Margin (Manual Feed Tray) ........................................................................... 15-3 15.1.5 Adjusting the Left/Right Margin (Side Paper Deck) .............................................................................. 15-3 15.1.6 Duplex Unit ............................................................................................................................................ 15-4 15.2 Scanning System ........................................................................................................................................... 15-5 15.2.1 After Replacing the Scanning Lamp ...................................................................................................... 15-5 15.2.2 After Replacing the Copyboard Glass .................................................................................................... 15-5 15.2.3 After Replacing the CCD Unit ............................................................................................................... 15-5 15.3 Laser Exposure System ................................................................................................................................. 15-6 15.3.1 After Replacing the Laser Unit .............................................................................................................. 15-6 15.4 Image Formation System ............................................................................................................................... 15-7 15.4.1 After Replacing the Drum Unit .............................................................................................................. 15-7 15.4.2 After Replacing the Transfer Unit .......................................................................................................... 15-7 15.4.3 After Replacing the Pattern Reading Unit .............................................................................................. 15-7 15.5 Fixing System ................................................................................................................................................ 15-8 15.5.1 After Disassembling the Fixing Unit ...................................................................................................... 15-8 15.6 Electrical Components .................................................................................................................................. 15-9 15.6.1 When Replacing the Reader Controller PCB ......................................................................................... 15-9 15.6.2 When Replacing the DC Controller PCB ............................................................................................... 15-9 15.6.3 When Replacing the Main Controller PCB (main) .............................................................................. 15-10 15.6.4 When Replacing the Main Controller PCB (sub) ................................................................................. 15-10 15.6.5 When Replacing the SRAM PCB ........................................................................................................ 15-10 15.6.6 When Replacing the HDD .................................................................................................................... 15-11 15.6.7 When Replacing the Power Supply PCB ............................................................................................. 15-11 15.7 Pickup/Feeding System ............................................................................................................................... 15-12 15.7.1 Adjusting the Horizontal Registration When Replacing the Pickup Cassette ...................................... 15-12 15.7.2 Adjusting the Horizontal Registration When Replacing the Duplex Unit ........................................... 15-13 Chapter 16 Correcting Faulty Images 16.1 Making lnitial Checks ................................................................................................................................... 16-1 16.1.1 Site Environment .................................................................................................................................... 16-1 16.1.2 Checking the Paper ................................................................................................................................. 16-1 16.1.3 Checking the Placement of Paper ........................................................................................................... 16-1 16.1.4 Checking the Durables ........................................................................................................................... 16-1 16.1.5 Checking the Periodically Replaced Parts .............................................................................................. 16-1 16.1.6 Checking the Units and Functional Blocks ............................................................................................ 16-1 16.1.7 Others ..................................................................................................................................................... 16-3 16.2 Test Print ....................................................................................................................................................... 16-4 16.2.1 Outline .................................................................................................................................................... 16-4 Contents 16.2.2 Test Print TYPE ...................................................................................................................................... 16-4 16.2.3 Selecting a Test Print TYPE ................................................................................................................... 16-4 16.2.4 Gradations (TYPE=4) ............................................................................................................................. 16-5 16.2.5 Full Halftone (TYPE=5) ......................................................................................................................... 16-5 16.2.6 Grid (TYPE=6) ....................................................................................................................................... 16-6 16.2.7 MCYBk Horizontal Stripe (TYPE=10) .................................................................................................. 16-7 16.2.8 Gradations (TYPE=12) ........................................................................................................................... 16-8 16.2.9 Full Color 16 Gradations (TYPE=14) .................................................................................................... 16-8 16.3 Troubleshooting ............................................................................................................................................. 16-9 16.3.1 Symptoms ................................................................................................................................................ 16-9 16.3.1.1 Image Fault Case Studies (A4) ........................................................................................................ 16-9 16.3.1.2 Image Fault Case Samples (A3) .................................................................................................... 16-14 16.3.2 Image Faults .......................................................................................................................................... 16-18 16.3.2.1 Blank Image ................................................................................................................................... 16-18 16.3.2.2 Solid Image .................................................................................................................................... 16-18 16.3.2.3 Light Image / Weak Density .......................................................................................................... 16-18 16.3.2.4 Foggy Image .................................................................................................................................. 16-24 16.3.2.5 Uneven Density .............................................................................................................................. 16-35 16.3.2.6 Out of Focus ................................................................................................................................... 16-40 16.3.2.7 Partially Blank/Streaked ................................................................................................................ 16-43 16.3.2.8 Smudged/Streaked ......................................................................................................................... 16-54 16.3.2.9 Ghost / Memory ............................................................................................................................. 16-60 16.3.2.10 Poor Finxing ................................................................................................................................ 16-62 16.3.2.11 Faulty Color Reproduction .......................................................................................................... 16-64 16.3.2.12 Stretching/Shrinking .................................................................................................................... 16-65 16.3.3 Faulty Feeding ....................................................................................................................................... 16-66 16.3.3.1 Double-Feed/ Multiple Feed .......................................................................................................... 16-66 16.3.3.2 Skew Feed ...................................................................................................................................... 16-66 16.3.3.3 Wrinkle .......................................................................................................................................... 16-67 16.3.3.4 Ripple/Curl ..................................................................................................................................... 16-67 16.3.3.5 Wrap ............................................................................................................................................... 16-68 16.3.4 Malfunction ........................................................................................................................................... 16-68 16.3.4.1 No Power ....................................................................................................................................... 16-68 16.3.4.2 Control Panel-Related .................................................................................................................... 16-70 16.3.4.3 Counter Malfunction ...................................................................................................................... 16-72 16.3.4.4 Malfunction/Faulty Detection ........................................................................................................ 16-72 16.3.4.5 Noise .............................................................................................................................................. 16-77 16.3.4.6 User Warning Message .................................................................................................................. 16-78 16.3.4.7 Other Defect ................................................................................................................................... 16-83 16.3.4.8 Part Breakage/Detachment ............................................................................................................ 16-88 16.3.5 Printing/scanning ................................................................................................................................... 16-88 16.3.5.1 No Output ...................................................................................................................................... 16-88 16.3.5.2 Installation Failure ......................................................................................................................... 16-91 16.3.5.3 Faulty Printing/Scanning Result .................................................................................................... 16-92 16.3.6 Network ............................................................................................................................................... 16-107 16.3.6.1 Start-Up Failure ........................................................................................................................... 16-107 16.3.6.2 Connection Problem .................................................................................................................... 16-107 16.3.7 Transmission/Fax-Related ................................................................................................................... 16-108 16.3.7.1 Transmission Problem ................................................................................................................. 16-108 16.3.7.2 Reception Problem ....................................................................................................................... 16-115 16.3.7.3 Other Operational Defect ............................................................................................................. 16-116 16.3.8 Jam (Main Unit) .................................................................................................................................. 16-116 16.3.8.1 Paper not picked up: although the paper sensor detects paper inside the cassette ....................... 16-116 16.3.8.2 0102 Jam Code ............................................................................................................................. 16-117 Contents 16.3.8.3 0105 Jam Code: Occurs with machine having mylar sheet to fixing/feeder sensor flag ............ 16-117 16.3.8.4 JAM CODE 0107 ........................................................................................................................ 16-117 16.3.8.5 JAM CODE 0108, 0207 .............................................................................................................. 16-118 16.3.8.6 JAM CODE 0207 ........................................................................................................................ 16-118 16.3.8.7 0207 Jam Code: Because of deformation of internal delivery roller ........................................... 16-118 16.3.8.8 0A06 Jam Code ........................................................................................................................... 16-119 16.3.8.9 JAM CODE 0A0A: At about 41 sec. after the power is turned ON, due to a duplexing driver PCB failure ................................................................................................................. 16-119 16.3.8.10 JAM CODE 0B00/0105 ............................................................................................................ 16-120 16.3.9 Jam (Document Feeder) ...................................................................................................................... 16-120 16.3.9.1 JAM CODE 008C: frequent occurrence recorded in jam history under service mode, although unable to reproduce during paper feeding test. ............................................................ 16-120 16.3.10 Error Code ......................................................................................................................................... 16-121 16.3.10.1 E000 Error code detail The rise in temperature in the fixing unit at time of power-on is inadequate. ........................................................................................................................ 16-121 16.3.10.2 E001 Error code detail The fixing unit is overheating. ........................................................... 16-121 16.3.10.3 E002 Error code detail The rise in temperature of the fixing unit is inadequate. .................... 16-122 16.3.10.4 E003 Error code detai The temperature of the fixing unit is abnormally low after standby. ... 16-123 16.3.10.5 E004 Error code detail The protection circuit of the fixing unit is faulty. ............................... 16-123 16.3.10.6 E004-0003 Error code Or message 'Remove the paper from the finisher trays.': after implementing countermeasure against malfunction of fixing feeder unit open/closed sensor ............. 16-124 16.3.10.7 E004-0005 Error Code: Because of faulty DC Controller PCB ................................................ 16-124 16.3.10.8 E004-0007 Error Code: Occasionally occurs first in the morning ............................................ 16-125 16.3.10.9 E004-0006/E004-0007 Error Code Descriptions ...................................................................... 16-125 16.3.10.10 E012 Error code detail The drum ITB motor is faulty. .......................................................... 16-126 16.3.10.11 E012-0001 Error code ITB motor not rotating ....................................................................... 16-126 16.3.10.12 E012-0001 Error code At about 37 sec. after the power is turned ON, due to a drum ITB motor failure ................................................................................................................. 16-126 16.3.10.13 E012-0001 Error code At about 37 sec. after the power is turned ON, due to a microswitch PCB failure ............................................................................................................... 16-127 16.3.10.14 E012-0001 Error Code: Drum ITB Motor, DC Power Supply PCB and Fuse PCB work normally ...................................................................................................................... 16-128 16.3.10.15 E012-0001 Error Code: Because Drum ITB Motor is faulty, or Fuse PCB is faulty .............. 16-128 16.3.10.16 E020-0134 Error code Recurring even after replacement of yellow drum unit ..................... 16-129 16.3.10.17 E020 Error code detail There is a fault associated with the drum/developer. ........................ 16-129 16.3.10.18 E020-xx81: generally E020-0181 Error Code ......................................................................... 16-131 16.3.10.19 E020-0081 Error code Displaying when a copy is made with the service case removed ..... 16-132 16.3.10.20 E020-0X34, E020-0X21 Error code Upon installation in a cold season ................................ 16-132 16.3.10.21 E020-04B0 Error code At about 200 to 300 sheets from installation, toner container motor (Bk) not rotating (Refer to SymptomExplanation.) .................................................... 16-132 16.3.10.22 E020-04B0 Cautions in replacing the drum unit ..................................................................... 16-133 16.3.10.23 E020-0X81 Error Code Displaying because of an open/close failure of the SALT sensor shutter .............................................................................................................................. 16-134 16.3.10.24 E020-0124 Error Code ........................................................................................................... 16-134 16.3.10.25 E020-OXB0 Error Code .......................................................................................................... 16-135 16.3.10.26 E020-xx24 Error Code ............................................................................................................ 16-135 16.3.10.27 E020-xxA0 Error Code ............................................................................................................ 16-136 16.3.10.28 E020-xxD0 Error Code ............................................................................................................ 16-136 16.3.10.29 E020-xx34 Error Code ............................................................................................................ 16-136 16.3.10.30 E020-0125 Error Code ............................................................................................................ 16-137 16.3.10.31 E020-03B0 Error Code: Overall fogging (no margin) occurred after replacement of Cyan drum unit .................................................................................................................................. 16-137 16.3.10.32 E032 Error code detail The counter of the NE controller fails to operate. ............................ 16-137 16.3.10.33 E110 Error code detail The operation of the laser scanner motor is faulty. ........................... 16-137 Contents 16.3.10.34 E110-0x10 Error Code ............................................................................................................. 16-138 16.3.10.35 E202 Error code detail A fault has occurred in detecting the No. 1 mirror home position. .. 16-139 16.3.10.36 E202-0000 Error Code ............................................................................................................. 16-139 16.3.10.37 E220 Error code detail A fault has occurred in activating the scanning lamp. ...................... 16-140 16.3.10.38 E220-0000 Error Code: Entire image sometimes becomes tinged with red ............................ 16-140 16.3.10.39 E220-0000 Error Code ............................................................................................................. 16-141 16.3.10.40 E220-0000 Error code Faulty connection in the flat cable from the CCD unit into R-CON J205 causes. ............................................................................................................... 16-141 16.3.10.41 E220-0000 Error Code: Scanning lamp did not light up after turning power ON ................... 16-142 16.3.10.42 E220-0000 Error Code when turning power ON while opening platen cover ........................ 16-142 16.3.10.43 E220-0000 Error Code: No problem with CCD unit and Reader Controller PCB .................. 16-142 16.3.10.44 E220-0000 Error Code: At power-on upon installation, because of poor contact of J204 on Reader Controller PCB, iRC3220 ........................................................................................ 16-143 16.3.10.45 E240 Error code detail The communication between the main motor controller and the DC controller is faulty. ............................................................................................................. 16-143 16.3.10.46 E243 Error code detail The control panel is faulty. ................................................................ 16-143 16.3.10.47 E302 Error code detail A fault has occurred in relation to shading correction. .................... 16-144 16.3.10.48 E315 Error code detail The image data is faulty. ................................................................... 16-144 16.3.10.49 E315-0010 Error code Only for FAX is transmitted .............................................................. 16-144 16.3.10.50 E351 Error code detail The ECO-ID PCB is faulty. ............................................................... 16-145 16.3.10.51 E351-0000 Error Code: Because of poor connection of connector on ECO-ID PCB ............. 16-145 16.3.10.52 E402 Error code detail There is a fault in the feeder motor. .................................................. 16-145 16.3.10.53 E402 Error Code ...................................................................................................................... 16-146 16.3.10.54 E404 Error code detail There is a fault in the delivery motor. ............................................... 16-146 16.3.10.55 E500 Error code detail There is a fault in finisher communication. (Finisher-N1) ............... 16-146 16.3.10.56 E500 Error code detail There is a fault in finisher communication. (Finisher-M1) ............... 16-147 16.3.10.57 E503 Error code detail There is a fault in saddle communication. ......................................... 16-147 16.3.10.58 E504 Error code detail There is a fault in stack size detection. .............................................. 16-148 16.3.10.59 E505 Error code detail There is a fault in the backup RAM. ................................................. 16-148 16.3.10.60 E512 Error code detail There is a fault in delivery. (Finisher-N1) ......................................... 16-149 16.3.10.61 E512 Error code detail There is a fault in delivery. (Finisher-M1) ....................................... 16-149 16.3.10.62 E514 Error code detail There is a fault in stack processing (clockwise direction) ................. 16-150 16.3.10.63 E530 Error code detail There is a fault in alignment.(Finisher-N1) ...................................... 16-150 16.3.10.64 E530 Error code detail There is a fault in rear alignment. (Finisher-M1) .............................. 16-151 16.3.10.65 E531 Error code detail There is a fault in stapling. (Finisher-M1) ......................................... 16-151 16.3.10.66 E531 Error code detail There is a fault in stapling. (Finisher-N1) ........................................ 16-152 16.3.10.67 E532 Error code detail There is a fault in the shift of the stapler ........................................... 16-152 16.3.10.68 E535 Error code detail There is a fault in the swing mechanism. ......................................... 16-153 16.3.10.69 E537 Error code detail There is a fault in front alignment. .................................................... 16-153 16.3.10.70 E540 Error code detail There is a fault in the ascent/descent of the tray. .............................. 16-154 16.3.10.71 E577 Error code detail There is a fault in stack processing (counterclockwise direction). .... 16-154 16.3.10.72 E580 Error code detail There is a fault in ascent/descent of the stack tray. .......................... 16-155 16.3.10.73 E584 Error code detail There is a fault in feed operation (No. 2). ......................................... 16-155 16.3.10.74 E5F0 Error code detail There is a fault in paper positioning for the saddle. .......................... 16-156 16.3.10.75 E5F1 Error code detail There is a fault in paper folding for the saddle. ............................... 16-156 16.3.10.76 E5F2 Error code detail There is a fault in the saddle guide. ................................................... 16-157 16.3.10.77 E5F3 Error code detail There is a fault in saddle alignment. ................................................ 16-157 16.3.10.78 E5F4 Error code detail There is a fault in stapling at the saddle rear. ................................... 16-158 16.3.10.79 E5F5 Error code detail There is a fault in stapling at the saddle front. ................................. 16-158 16.3.10.80 E5F6 Error code detail There is a fault in stapling by the saddle paper pushing plate. ......... 16-159 16.3.10.81 E5F8 Error code detail There is a fault in the saddle connector. ........................................... 16-160 16.3.10.82 E5F9 Error code detail There is a fault in the saddle switch. ................................................ 16-160 16.3.10.83 E601-0xdd: after performing [COPIER>ADJUST>V-CONT-Y/M/C/K] to improve faint image ............................................................................................................................... 16-161 Contents 16.3.10.84 E602-0001/E602-0002/E602-0003 Error Code: Remedy upon occurrence of error code ...... 16-162 16.3.10.85 E602 Error code detail The hard disk is faulty. ...................................................................... 16-163 16.3.10.86 E602-0001 Error code At about 5 sec. after the power is turned ON, due to a failure of the Distribution Board PCB Ass'y ........................................................................................ 16-165 16.3.10.87 E602-0001 Error code At about 5 sec. after the power is turned ON, due to a connection failure of the flat cable between the HDD unit and the main controller ............................ 16-165 16.3.10.88 E602-0202 Error Code: Recovered after performing HD-CHECK ........................................ 16-166 16.3.10.89 E602-0202 Error Code: Because of faulty SRAM Board PCB ............................................... 16-166 16.3.10.90 Progress bar on machine starting-up window is slower than usual, then E602 Error Code is displayed ......................................................................................................................... 16-166 16.3.10.91 E602-0402 Error Code: not recovered after replacement of main controller PCB ................. 16-166 16.3.10.92 E602-0x02 Error Code ............................................................................................................ 16-167 16.3.10.93 E602-0001 Error Code ............................................................................................................ 16-167 16.3.10.94 E602-0402 Error Code: At power-on upon installation, iRC3220 .......................................... 16-167 16.3.10.95 E604 Error code detail There is a shortage in image memory (SDRAM). ........................... 16-167 16.3.10.96 E604-0000 Error Code: Because of faulty expansion RAM ................................................... 16-168 16.3.10.97 E605 Error code detail The battery for image memory is faulty. ........................................... 16-168 16.3.10.98 E606 Error code detail The hard disk is faulty. ...................................................................... 16-169 16.3.10.99 E674 Error code detail The fax board is faulty. .................................................................... 16-169 16.3.10.100 E677-0002 Error Code .......................................................................................................... 16-169 16.3.10.101 E711 Error code detail There is a fault in IPC communication.(DADF-K1) ...................... 16-170 16.3.10.102 E711 Error code detail There is a fault in IPC communication. .......................................... 16-170 16.3.10.103 E712 Error code detail There is a fault in the communication between the ADF and the reader unit. ...................................................................................................................... 16-171 16.3.10.104 E713 Error code detail There is a fault in the communication between the finisher and the cassette pedestal. .......................................................................................................... 16-171 16.3.10.105 E716 Error code detail There is a fault in the communication between the cassette pedestal and the printer unit. .................................................................................................... 16-172 16.3.10.106 E716-0000 Error code Recorded only in the error history ................................................... 16-172 16.3.10.107 E717 Error code detail The communication with the NE controller is faulty. ..................... 16-172 16.3.10.108 E719 Error code detail The coin vendor is faulty. ............................................................... 16-173 16.3.10.109 E719-0011 Error code After the cable is disconnected because of a scanning fault in card reader D1 ............................................................................................................ 16-173 16.3.10.110 E719-0001 Error code When the coin vendor is disconnected, unable to be cleared .......... 16-174 16.3.10.111 E731 Error code detail There is a fault in the UFR board. .................................................. 16-174 16.3.10.112 E732 Error code detail There is a reader communication error. .......................................... 16-174 16.3.10.113 E732-9999 Error Code: Recorded in error log after performing service mode COPIER> Function> CLEAR> MN-CON ............................................................................................ 16-175 16.3.10.114 E732-0001 Error code A message 'Starting up. Please wait' keeps displaying for about 2 min. 40 sec. after the power is turned ON, and then the error code results (DC power supply unit PCB J158 output failure) ................................................................................................... 16-175 16.3.10.115 E732-0001 Error Code: After turning power ON, message "Starting up. Please wait" changes to error code indication .................................................................................................. 16-176 16.3.10.116 E732-0001 Error code A message 'Starting up. Please wait' keeps displaying for about 2 min. 40 sec. after the power is turned ON, and then the error code results ............................. 16-177 16.3.10.117 E733 Error code detail There is a printer communication error. ......................................... 16-177 16.3.10.118 E733-0001 Error code Printer communication error ........................................................... 16-178 16.3.10.119 E740 Error code detail The Ethernet board is faulty. ........................................................... 16-178 16.3.10.120 E744 Error code detail The language file is faulty. ............................................................. 16-178 16.3.10.121 E745 Error code detail The TokenRing board is faulty. ..................................................... 16-179 16.3.10.122 E747-8702 Error Code .......................................................................................................... 16-179 16.3.10.123 E747 Error code detail The image processing ASIC or the memory control/ communication ASIC is faulty. ............................................................................................................. 16-179 16.3.10.124 E747-00FF Error code Only with printing operation ......................................................... 16-180 Contents 16.3.10.125 E747-8701 Error Code ........................................................................................................... 16-180 16.3.10.126 E747-00FF Error Code .......................................................................................................... 16-180 16.3.10.127 E751-0304 Error Code ........................................................................................................... 16-181 16.3.10.128 E804 Error code detail The power supply cooling fan is faulty. .......................................... 16-181 16.3.10.129 E804-0004 Error Code ........................................................................................................... 16-181 16.3.10.130 E804-0004 Error code Displaying if the jack of the controller fan (FM7) which is fixed on the controller box ..................................................................................................... 16-182 16.3.10.131 E804-0004 due to faulty fuse PCB Error Code .................................................................... 16-182 16.3.10.132 E805 Error code detail The cleaner fan is faulty. ................................................................ 16-182 16.3.10.133 E805 Error code detail The fixing heat discharge fan is faulty. .......................................... 16-183 16.3.11 FAX # Code ...................................................................................................................................... 16-183 16.3.11.1 Åî037 ......................................................................................................................................... 16-183 16.3.12 FAX ## Code .................................................................................................................................... 16-183 16.3.12.1 ##111, ##228 FAX Error Code .................................................................................................. 16-183 16.3.12.2 ##281/##104 FAX Error Code .................................................................................................. 16-184 16.3.12.3 ##796 FAX Error Code .............................................................................................................. 16-184 16.4 Outline of Electrical Components ............................................................................................................. 16-185 16.4.1 Clutch/Solenoid ................................................................................................................................... 16-185 16.4.1.1 Reader Unit .................................................................................................................................. 16-185 16.4.1.2 Printer Unit .................................................................................................................................. 16-185 16.4.2 Motor ................................................................................................................................................... 16-186 16.4.2.1 Reader Unit .................................................................................................................................. 16-186 16.4.2.2 Printer Unit .................................................................................................................................. 16-186 16.4.3 Fan ....................................................................................................................................................... 16-188 16.4.3.1 Reader Unit .................................................................................................................................. 16-188 16.4.3.2 Printer Unit .................................................................................................................................. 16-188 16.4.4 Sensor .................................................................................................................................................. 16-189 16.4.4.1 Reader Unit .................................................................................................................................. 16-189 16.4.4.2 Printer Unit .................................................................................................................................. 16-190 16.4.5 Switch .................................................................................................................................................. 16-192 16.4.5.1 Reader Unit .................................................................................................................................. 16-192 16.4.5.2 Printer Unit .................................................................................................................................. 16-192 16.4.6 Lamps, Heaters, and Others ................................................................................................................ 16-194 16.4.6.1 Reader Unit .................................................................................................................................. 16-194 16.4.6.2 Printer Unit .................................................................................................................................. 16-194 16.4.7 PCBs .................................................................................................................................................... 16-195 16.4.7.1 Reader Unit .................................................................................................................................. 16-195 16.4.7.2 Printer Unit .................................................................................................................................. 16-196 16.4.8 Plane Pedistal ...................................................................................................................................... 16-198 16.4.8.1 Plain Pedestal-C1 ......................................................................................................................... 16-198 16.4.9 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB ............................ 16-199 16.4.9.1 Adjusting the Variable Resistors (VR), the Light-Emitting Diodes (LED), and the Check Pins by PCB .......................................................................................................................... 16-199 16.4.9.2 Main Controller PCB (main) ....................................................................................................... 16-200 16.4.9.3 Main Controller PCB (sub) .......................................................................................................... 16-201 16.4.9.4 Reader Controller PCB ................................................................................................................ 16-201 16.4.9.5 Inverter PCB ................................................................................................................................ 16-202 16.4.9.6 Differential PCB .......................................................................................................................... 16-202 Chapter 17 Self Diagnosis 17.1 Error Code Details ......................................................................................................................................... 17-1 17.1.1 Error Code Details Table ........................................................................................................................ 17-1 Contents Chapter 18 Service Mode 18.1 Outline ........................................................................................................................................................... 18-1 18.1.1 Service mode screen configuration ........................................................................................................ 18-1 18.1.2 Entering or selecting service modes ....................................................................................................... 18-2 18.1.3 Exiting service modes ............................................................................................................................ 18-3 18.1.4 Service mode backup .............................................................................................................................. 18-3 18.1.5 Initial screen ........................................................................................................................................... 18-4 18.1.6 Main/intermediate item screen ............................................................................................................... 18-4 18.1.7 Sub-item screen ...................................................................................................................................... 18-5 18.2 DISPLAY (Status Display Mode) ................................................................................................................. 18-6 18.2.1 COPIER .................................................................................................................................................. 18-6 18.2.1.1 VERSION ........................................................................................................................................ 18-6 18.2.1.2 ACC-STS ......................................................................................................................................... 18-8 18.2.1.3 ANALOG ........................................................................................................................................ 18-9 18.2.1.4 JAM ............................................................................................................................................... 18-10 18.2.1.5 ERR ............................................................................................................................................... 18-18 18.2.1.6 DENS ............................................................................................................................................. 18-20 18.2.1.7 MISC ............................................................................................................................................. 18-21 18.2.1.8 ALARM-1 ..................................................................................................................................... 18-21 18.2.1.9 ALARM-2 ..................................................................................................................................... 18-22 18.2.1.10 ENVRNT ..................................................................................................................................... 18-25 18.2.2 FEEDER ............................................................................................................................................... 18-26 18.2.2.1 FEEDSIZE ..................................................................................................................................... 18-26 18.2.3 DISPLAY Level 2 ................................................................................................................................. 18-26 18.2.3.1 DISPLAY (Status Display Mode) - Level 2 .................................................................................. 18-26 18.2.4 DISPLAY (Status Display Mode) Level 2 ........................................................................................... 18-28 18.2.4.1 COPIER ......................................................................................................................................... 18-28 18.3 I/O (I/O Display Mode) ............................................................................................................................... 18-32 18.3.1 I/O (display mode) ................................................................................................................................ 18-32 18.3.2 DC-CON ............................................................................................................................................... 18-33 18.3.3 R-CON .................................................................................................................................................. 18-42 18.3.4 FEEDER ............................................................................................................................................... 18-44 18.3.5 SORTER ............................................................................................................................................... 18-46 18.3.6 MN-CON .............................................................................................................................................. 18-63 18.4 ADJUST (Adjustment Mode) ..................................................................................................................... 18-65 18.4.1 COPIER ................................................................................................................................................ 18-65 18.4.1.1 ADJ-XY ......................................................................................................................................... 18-65 18.4.1.2 CCD ............................................................................................................................................... 18-67 18.4.1.3 IMG-REG ...................................................................................................................................... 18-70 18.4.1.4 BLANK ......................................................................................................................................... 18-71 18.4.1.5 PASCAL ........................................................................................................................................ 18-72 18.4.1.6 FEED-ADJ .................................................................................................................................... 18-72 18.4.1.7 CST-ADJ ....................................................................................................................................... 18-73 18.4.1.8 MISC ............................................................................................................................................. 18-73 18.4.2 FEEDER ............................................................................................................................................... 18-74 18.4.2.1 DOCST .......................................................................................................................................... 18-74 18.4.3 ADJUST (Adjustment Mode) Level 2 .................................................................................................. 18-76 18.4.3.1 COPIER ......................................................................................................................................... 18-76 18.5 FUNCTION (Operation/Inspection Mode) ................................................................................................. 18-82 18.5.1 COPIER ................................................................................................................................................ 18-82 18.5.1.1 INSTALL ...................................................................................................................................... 18-82 18.5.1.2 CCD ............................................................................................................................................... 18-82 18.5.1.3 LASER .......................................................................................................................................... 18-83 18.5.1.4 CST ................................................................................................................................................ 18-83 Contents 18.5.1.5 CLEANING ................................................................................................................................... 18-84 18.5.1.6 FIXING .......................................................................................................................................... 18-84 18.5.1.7 PANEL ........................................................................................................................................... 18-85 18.5.1.8 PART-CHK ................................................................................................................................... 18-85 18.5.1.9 CLEAR .......................................................................................................................................... 18-86 18.5.1.10 MISC-R ........................................................................................................................................ 18-86 18.5.1.11 MISC-P ........................................................................................................................................ 18-86 18.5.1.12 SYSTEM ...................................................................................................................................... 18-87 18.5.2 FEEDER ................................................................................................................................................ 18-88 18.5.2.1 SENS-INT ...................................................................................................................................... 18-88 18.5.3 FUNCTION (operation/inspection mode): Level 2 .............................................................................. 18-88 18.5.3.1 COPIER ......................................................................................................................................... 18-88 18.6 OPTION (Machine Settings Mode) ............................................................................................................. 18-90 18.6.1 COPIER ................................................................................................................................................. 18-90 18.6.1.1 BODY ............................................................................................................................................ 18-90 18.6.1.2 USER ............................................................................................................................................. 18-91 18.6.1.3 ACC ............................................................................................................................................... 18-91 18.6.1.4 INT-FACE ..................................................................................................................................... 18-92 18.6.2 SORTER ................................................................................................................................................ 18-94 18.6.2.1 BLNK-SW ..................................................................................................................................... 18-94 18.6.3 BOARD ................................................................................................................................................. 18-94 18.6.3.1 SURF-OFF ..................................................................................................................................... 18-94 18.6.4 OPTION (mechanical specifications setting mode): Level 2 ................................................................ 18-95 18.6.4.1 COPIER ......................................................................................................................................... 18-95 18.6.4.2 BOARD ....................................................................................................................................... 18-112 18.7 TEST (Test Print Mode) ............................................................................................................................ 18-113 18.7.1 COPIER ............................................................................................................................................... 18-113 18.7.1.1 NETWORK ................................................................................................................................. 18-113 18.8 COUNTER (Counter Mode) ...................................................................................................................... 18-115 18.8.1 COPIER ............................................................................................................................................... 18-115 18.8.1.1 Overview ...................................................................................................................................... 18-115 18.8.1.2 TOTAL ........................................................................................................................................ 18-116 18.8.1.3 PICK-UP ...................................................................................................................................... 18-118 18.8.1.4 FEEDER ...................................................................................................................................... 18-118 18.8.1.5 JAM ............................................................................................................................................. 18-119 18.8.1.6 DRBL-1 ....................................................................................................................................... 18-119 18.8.1.7 DRBL-2 ....................................................................................................................................... 18-120 Chapter 19 Upgrading 19.1 Outline ........................................................................................................................................................... 19-1 19.1.1 Construction of Firmware ....................................................................................................................... 19-1 19.1.2 Outline of the Service Support Tool ....................................................................................................... 19-2 19.1.3 Network Interface of the Machine with the SST in Use ......................................................................... 19-5 19.2 Making Preparations ...................................................................................................................................... 19-8 19.2.1 Registering the Firmware ....................................................................................................................... 19-8 19.2.2 Making Connections ............................................................................................................................. 19-11 19.3 Formatting the HDD .................................................................................................................................... 19-17 19.3.1 Formatting All Partitions ...................................................................................................................... 19-17 19.3.2 Formatting Selected Partitions .............................................................................................................. 19-18 19.3.3 Formatting the Partitions ...................................................................................................................... 19-20 19.4 Downloading System Software ................................................................................................................... 19-27 19.4.1 Downloading the System Software ....................................................................................................... 19-27 19.4.1.1 Outline ........................................................................................................................................... 19-27 Contents 19.4.1.2 Downloading Procedure ................................................................................................................ 19-28 19.4.2 Downloading the RUI, and Language Module ..................................................................................... 19-35 19.4.2.1 Outline ........................................................................................................................................... 19-35 19.4.2.2 Downloading Procedure ................................................................................................................ 19-36 19.4.3 Downloading the BOOT Software ........................................................................................................ 19-42 19.4.3.1 Outline ........................................................................................................................................... 19-42 19.4.3.2 Downloading Procedure ................................................................................................................ 19-44 19.4.4 Downloading the Dcon and Rcon Software .......................................................................................... 19-50 19.4.4.1 Outline ........................................................................................................................................... 19-50 19.4.4.2 Downloading Procedure ................................................................................................................ 19-51 19.4.5 Downloading the G3 FAX Software ..................................................................................................... 19-58 19.4.5.1 Outline ........................................................................................................................................... 19-58 19.4.5.2 Downloading Procedure ................................................................................................................ 19-59 19.5 Uploading and Downloading Backup Data ................................................................................................. 19-65 19.5.1 Outline .................................................................................................................................................. 19-65 19.5.2 Uploading Procedure ............................................................................................................................ 19-66 19.5.3 Downloading Procedure ....................................................................................................................... 19-72 Chapter 20 Service Tools 20.1 Special Tools ................................................................................................................................................. 20-1 20.2 Solvents and Oils ........................................................................................................................................... 20-2 Contents Chapter 1 Introduction Contents Contents 1.1 System Construction .......................................................................................................................................... 1-1 1.1.1 System Construction of the Pickup/Delivery Options ............................................................................... 1-1 1.1.2 System Configuration and Print/Transmission Accessories ...................................................................... 1-2 1.1.3 Functions of Printing/Transmission Accessories ....................................................................................... 1-3 1.1.4 Overview of Printing/Transmitting Accessories ........................................................................................ 1-4 1.2 Product Specifications ....................................................................................................................................... 1-5 1.2.1 Names of Parts ............................................................................................................................................ 1-5 1.2.1.1 External View ...................................................................................................................................... 1-5 1.2.1.2 Cross Section ....................................................................................................................................... 1-7 1.2.2 Using the Machine ...................................................................................................................................... 1-8 1.2.2.1 Turning On the Power ......................................................................................................................... 1-8 1.2.2.2 Points to Note When Turning Off the Main Power Switch ................................................................. 1-9 1.2.2.3 Control Panel ..................................................................................................................................... 1-11 1.2.3 User Mode Items ....................................................................................................................................... 1-12 1.2.3.1 Common Settings .............................................................................................................................. 1-12 1.2.3.2 Timer Settings ................................................................................................................................... 1-13 1.2.3.3 Adjustments and Cleaning ................................................................................................................. 1-13 1.2.3.4 Report Generation ............................................................................................................................. 1-14 1.2.3.5 System Control Settings .................................................................................................................... 1-15 1.2.3.6 Copier Specifications Settings ........................................................................................................... 1-16 1.2.3.7 Transmission/Reception Specifications Settings ............................................................................... 1-16 1.2.3.8 Box Specifications Settings ............................................................................................................... 1-17 1.2.3.9 Printer Specifications Settings ........................................................................................................... 1-18 1.2.3.10 Destinations Table Specifications Settings ..................................................................................... 1-19 1.2.4 User Maintenance ..................................................................................................................................... 1-19 1.2.4.1 Cleaning ............................................................................................................................................. 1-19 1.2.4.2 Inspection .......................................................................................................................................... 1-20 1.2.5 Safety ........................................................................................................................................................ 1-20 1.2.5.1 Safety of the Laser System ................................................................................................................ 1-20 1.2.5.2 Regulations by the Center for Devices and Radiational Heath(CDRH) ........................................... 1-21 1.2.5.3 Handling the Laser Assembly ........................................................................................................... 1-21 1.2.5.4 Safety of Toner .................................................................................................................................. 1-21 1.2.6 Product Specifications .............................................................................................................................. 1-22 1.2.6.1 Type and Functions ........................................................................................................................... 1-22 1.2.7 Function List ............................................................................................................................................. 1-23 1.2.7.1 Print Speed ......................................................................................................................................... 1-23 1.2.7.2 Print Size ........................................................................................................................................... 1-25 1.2.7.3 Others ................................................................................................................................................ 1-27 1.2.7.4 Reader Unit Specifications ................................................................................................................ 1-28 Chapter 1 1.1 System Construction 1.1.1 System Construction of the Pickup/Delivery Options 0000-4246 A system may be configured as follows: [8] [1] [7] [9] [6] [2] [14] [4] [17] [10] [11] [15] [16] *[5] [12] [15] [3] [16] [13] F-1-1 T-1-1 [1] Finisher-M1 [10] Slide Paper Deck-P1 [2] Saddle Finisher-N2 [11] Card Reader-D1 [3] Finisher-N1 [12] Plain Pedestal-C1 [4] Copy Tray-H1 [13] 2-Cassette Pedestal-X1 [5] Delivery Tray (standard) [14] Anti-Condensation Heater (100/230V) [6] NE Controller-A1 [15] Cassette Heater Kit-A1 [7] DADF-K1 [16] Cassette Heater Unit-24 [8] Copyboard Cover [17] Cassette Heater Unit-25 [9] Original Tray *The presence of any of [1] through [3] prevents installation of [4] and [5]. 1-1 Chapter 1 1.1.2 System Configuration and Print/Transmission Accessories 0006-8287 The machine may be configured as follows: [12] [9] [8A] [8B] [10] [1] [2] [3] [4] [7A] [5] [7B] [6] [11] F-1-2 [1] Super G3 Fax Board-M2 [2] Ethernet Board (standard) [3] UFR Board or Open Interface Board [4] USB Interface Board or TokeRing Board [5] Image Conversion Board-A2 [6] PS Print Server Unit-C1 [7A] PDL Expansion Kit (LIPS)-A2 (boot ROM for LIPS model: 100V model only) [7B] PDL Expansion Kit (LIPS/PS Kanji) A2 (Boot Rom for LIPS/PS Kanji model: 100V machine only) [8A] Color iR256 MB Expansion RAM (if 100V, optional) [8B] Color iR512MB Expansion RAM (if 100V, optional) [9] SEND Expansion Kit-B2/B2U (dongle for functional expansion) [10] iR Security Kit-A2P/A2U [11] USB Application Interface Board-C1 [12] Workplase Gateway 1-2 Chapter 1 1.1.3 Functions of Printing/Transmission Accessories 0006-8352 T-1-2 GDI-UFR printing -> - UFR Printer and Scanner Kit-A2 LIPS printing -> - UFR Printer and Scanner Kit-A2 - PDL Expansion Kit (LIPS)-A2 LIPS/PS kanji printing -> - UFR Printer and Scanner Kit-A2 - PDL Expansion Kit (LIPS/PS kanji)-A2 Transmitting -> - SEND Expansion Kit-B2U/B2P - Image Conversion Board-A2 Faxing -> - Super G3 FAx Board-M2 - Image Conversion Board-A2 Local printing -> - USB Interface Board-A3 - UFR Printer and Scanner Kit-A2 LIPS printing + -> transmitting - UFR Printer and Scanner Kit-A2 - PDL Expansion Kit (LIPS)-A2 - iR256MB Expansion RAM or iR512MB Expansion RAM LISP printing + faxing -> - UFR Printer and Scanner Kit-A2 - PDL Expansion Kit (LIPS)-A2 - Super G3 Fax Board-M2 - Image Conversion Board-A2 - iR256MB Expansion RAM or iR512MB Expansion RAM LIPS/PS kanji printing + -> transmitting - UFR Printer and Scanner Kit-A2 - PDL Expansion Kit (LIPS/PS Kanji)-A2 - iR512MB Expansion RAM LISP/PS kanji printing + -> faxing - UFR Printer and Scanner Kit-A2 - PDL Expansion Kit (LIPS/PS kanji)-A2 - Super G3 Fax Board-M2 - Image Conversion Board-A2 - iR512MB Expansion RAM MEAP (authentication -> iR256MB Expansion RAM -> iR512MB Expansion RAM function only) MEAP (various application operation) 1-3 Chapter 1 1.1.4 Overview of Printing/Transmitting Accessories 0006-8332 The following gives an outline of individual accessories; for details, see the descriptions found in subsequent chapters: 1) UFR Printer and Scanner Kit-A2 Adds GDI-UFR printing functions and scanning functions associated with ScanGear. 2) PDL Expansion Kit (LIPS)-A2 Adds LIPS printing functions. The Kt does not come with a PDL board, requiring a UFR board. 3) Color iR256MB Expansion RAM Required when transmitting/faxing functions are added. 4) Color iR512MB Expansion RAM Required when MEAP functions are added. 5) SEND Expansion Kit-B2P/B2U Adds transmitting functions. It requires setup work using a PC. Select B2P (for use of a PC parallel port) or B2U (for use of a PC USB port). 6) Image Conversion Board-A2 Addition of transmitting/faxing functions requires the Image Conversion Board-A2. 7) USB Interface Board-A3 Adds printing functions through local connection of PC (USB). Requires a UFR board. 8) Super G3 Fax Board-M2 Adds G3 fax functions. 9) PDL Expansion (LISP/PS kanji)-A2 Adds LIPS printing/PS kanji printing functions. This board does not come with a PDL board, requiring a UFR board. 10) USB Application Interface Board-C1 Connects a USB device for MEAP applications. It is an interface board. 11) Workplase Gateway Adds security functions for image data and server functions. 1-4 Chapter 1 1.2 Product Specifications 1.2.1 Names of Parts 1.2.1.1 External View 0000-4257 F-1-3 T-1-3 [1] Rear left cover [10] Delivery cover (2) [2] Copyboard cover [11] Lower left cover [3] Reader front cover [12] Rear left cover (lower) [4] Upper left cover (small) [13] Delivery cover (1) [5] Center delivery tray [14] Rear left cover (upper) [6] Control panel [15] Upper left cover [7] Front cover [16] Upper cover [8] Cassette 1 [17] Inside upper cover [9] Cassette 2 1-5 Chapter 1 F-1-4 T-1-4 [1] Reader right cover [8] Right cover [2] Copyboard glass [9] Front right cover [3] Reader rear cover [10] Manual feed tray [4] Upper right cover (small) [11] Manual feed unit cover [5] Upper rear cover [12] Model right cover [6] Lower rear cover [13] Upper right cover [7] Rear right cover 1-6 Chapter 1 1.2.1.2 Cross Section [1] [2] 0000-4258 [3] [4] [5] [6] [46] [7] [45] [8] [44] [43] [42] [41] [40] [9] [10] [39] [38] [37] [11] [12] [13] [14] [15] [16] [17] [18] [36] [35] [34] [19] [33] [20] [32] [31] [30] [29] [28][27][26] [25] [24] [23] [22] [21] F-1-5 T-1-5 [1] No. 3 mirror [24] Registration lower roller [2] No. 2 mirror [25] Duplex roller 3 [3] No. 1 mirror [26] Secondary transfer external roller [4] Scanning lamp [27] Secondary transfer internal roller [5] CCD unit [28] Duplex roller 2 [6] Toner container [29] Intermediate transfer belt tension roller [7] Laser unit [30] Cassette 2 [8] Primary transfer roller [31] Transfer cleaning unit [9] Registration detention unit [32] Fixing lower roller (pressure roller) [10] Manual feed pickup tray unit [33] Fixing upper roller (fixing roller) 1-7 Chapter 1 [11] Manual feed roller [34] Duplex roller 1 [12] Pre-registration roller [35] Internal delivery roller [13] Manual feed separation roller [36] Face-up delivery roller [14] Re-pick up roller [37] Delivery vertical path roll [15] Pickup vertical path roller [38] Delivery vertical path roller 2 [16] Feed roller [39] Photopositive drum [17] Pickup roller [40] Developing cylinder [18] Separation roller [41] Drum unit [19] Pickup assembly 1 [42] Charging roller [20] Pickup assembly 2 [43] Delivery vertical path roller 1 [21] Cassette 1 [44] Delivery path roll [22] Duplex roller 4 [45] Intermediate transfer belt [23] Registration upper roller [46] Face-down delivery roller 1 1.2.2 Using the Machine 1.2.2.1 Turning On the Power 0000-4259 The machine is equipped with 2 power switches: main power switch and control panel power switch. Normally, the machine is supplied with power when the main power switch is turned on (i.e., other than when it is in power save mode, low power mode, or sleep mode). F-1-6 1-8 Chapter 1 T-1-6 [1] Control panel power switch [3] Main power switch [2] Main power lamp Never turn off the main power while the progress bar is indicated. (The machine is accessing its HDD.) Otherwise, the HDD can go out of order (E602). Starting up. Please wait. F-1-7 1.2.2.2 Points to Note When Turning Off the Main Power Switch 0000-4260 Be sure to turn off the control panel power switch before turning off the main power switch. - When the Printer Is in Operation/Fax Data Is Being Sent/Received Be sure that the Execution/Memory lamp on the control panel is OFF before touching the main power switch. (Otherwise, the data being processed can be lost.) 1-9 Chapter 1 7 8 9 * 0 # Execution/Memory ID Error F-1-8 - When Downloading Is Under Way Never turn off the main power switch or the control panel power switch. (If you turn off the main power switch while downloading is under way, the machine may fail to operate.) ON /O FF F-1-9 1-10 Chapter 1 1.2.2.3 Control Panel 0000-4261 F-1-10 T-1-7 [1] Image contrast adjusting dial [10] User mode key [2] Counter check key [11] Numeric keypad [3] Power Save Key [12] Execute/Memory lamp [4] Control panel power switch [13] Error lamp [5] Touch pen holder [14] ID key [6] Clip holder [15] Clear key [7] Touch panel [16] Main power lamp [8] Reset key [17] Start key [9] Help key [18] Stop key 1-11 Chapter 1 1.2.3 User Mode Items 1.2.3.1 Common Settings 0006-0742 *Factory default. T-1-8 Mode Description initial functions *copy, fax, box, SEND use it to switch the System Status screen to the Initial screen. (*ON/OFF) use it to give priority to [device] of the System Status screen for display. (*ON/OFF) function after auto clear *return, do not return enable/disable buzzer input correct: *ON/OFF input incorrect: ON/*OFF supply alert: ON/*OFF alert: *ON/OFF job end: *ON/OFF residual original: ON/*OFF priority on text/photo upon selection of auto text, *photo color inch input enable inch input (ON/*OFF; ON if 120 V) paper type registration upon cassette auto copier, printer, box, fax, other selection registration paper type yes change power save mode *-10%/- 5%/- 0%, immediate recovery power consumption in sleep state *little, much select special tray use finisher tray for: copier, box, printer, fax, other priority on print copy: *1, 2, 3; printer: 1, *2, 3; fax/box/ other: 1, 2, *3 register standard mode for manually fed enable/disable standard mode for manually paper fed paper (ON/*OFF) 1-12 Chapter 1 Mode Description standard mode for local print paper select (*auto), print count (*1), sorter (*sort/group/stable), double-sided print (*off/on), file delete after print (*off/on), print merge (*off/on) switch language of display ON/*OFF reverse screen color ON/*OFF between-jobs shift *ON/OFF JPEG compression rate at remote scan high, *average, low gamma value at remote scan g1.0/g1.4/*g1.8/g2.2 initialize common settings *yes, no 1.2.3.2 Timer Settings 0005-9694 * factory settings. T-1-9 Mode Description set date/time if fax is installed (10-digit number) auto sleep time 10 min, *15 min, 20 min, 30 min, 40 min, 50 min, 1 hr, 90 min, 2 hr to 3 hr to 4 hr change auto clear time 0: none; 1 to 9 min (*2 min) set weekly timer 00:00 to 23:59 (1-min increments) shift to low-power consumption 10 min, *15 min, 20 min, 30 min, 40 min, 50 min, 1 hr, 90 min, mode 2 hr to 3 hr to 4 hr 1.2.3.3 Adjustments and Cleaning 0005-9696 *factory settings. T-1-10 Mode Description zoom fine adjust -1.0 to+1.0%: 0.1% intervals,*H270% center binding staple edging yes center binding position change (A3, 11x17)/B4/(A4R, LTRR) 1-13 Chapter 1 Mode Description auto gradation correction plain paper (full correction/quick correction), heavy paper (full correction/ quick correction) density correction copy/box, black-and-white transmission, color transmission; density 5 settings each cleaning inside machine yes cleaning of feeder yes 1.2.3.4 Report Generation 0000-4265 *factory settings. T-1-11 Mode Description setup>transmission transmission results report (*only if error, ON, OFF) communication control report>auto print at 100 communications (*ON/OFF), print at specified time (*ON/OFF) setup>fax fax transmission results report (*only if error, ON, OFF) fax communication control report>auto print at 40 communications (*ON/OFF), print at specified time (*ON/OFF) fax reception results report (only if error, ON, *OFF) fax box reception report (*ON, OFF) list print>transmission destinations list user data list 1-14 list print>fax user data list list print>network user data list Chapter 1 1.2.3.5 System Control Settings 0000-4266 *factory settings. T-1-12 Mode Description set system administrator info yes group ID control register ID, control count; ON/OFF set communication control fax settings, system box settings enable/disable remote UI *ON/OFF limit destinations list ID in destinations table, access No. in destinations table set device info device name, site of installation set network TCP/IP setup (IP address/DNS/PING command/SINS/LPD/RAW/IPP print (*off); HTTP (*on); IP address settings range NetWare setup AppleTalk setup SMB settings SNMB settings special port settings (*ON/OFF) spool function (ON/*OFF) start-up time settings (0 to 300 sec; *60 sec) e-mail/i-fax set transfer yes auto online/offline shift auto online shift (ON/*OFF) auto offline shift (ON/*OFF) register to LDAP server yes switch limits to functions with control *partial limits, entire limits screen setup single/standard 1-15 Chapter 1 1.2.3.6 Copier Specifications Settings 0000-4267 *factory settings. T-1-13 Mode Description set preference key 1/2 w/ function, *no settings auto sort *ON/OFF priority on image orientation ON/*OFF indicate copy wait time ON/*OFF enable auto vertical/horizontal *ON/OFF rotation change standard mode register/initialize initialize copier ecifications settings Yes, No 1.2.3.7 Transmission/Reception Specifications Settings * factory settings. T-1-14 Mode Description common setup>transmission register sending party name (100 max.) function setup register user abbreviation for FTP transmission, permit non-ASCII code (on/*off) clear error file (*ON/OFF) JPEG compression rate (high/*standard/low) process transfer error file (print always, store/print, *OFF) number of retries (0 to 5; *3) transmission function standard mode change>read mode, file contraction routine button registration>registration, name PDF (high compression) image level>text, photo mode; photo mode set initial display of transmission screen (default task button, one-touch button, *new destination) record source of transmission (*attach, do not attach) 1-16 0000-4268 Chapter 1 Mode Description sound of transmission (*add/do not add)>location of indication (inside of image/outside of image), telephone number mark (*fax/tel), communication mode (G3-G4/ *G3 only) initialize transmission function settings common setup>reproduction record double-sided (ON/*OFF) function setup cassette selection>switch A, B, C, D image resolution>image resolution (*on/off), reduction mode (*auto/fixed), fixing mode reduction rate (97%/95%/ 90%/75%), reduction direction (vertical and horizontal/ *vertical) record 2-on-1 (ON/*OFF) record reception info (attach, *do not attach) fax setup>basic registration user telephone number registration>telephone number line type selection (120, 230V: *push tone/dial, 10PPS; 100V: *20PPS/10PPS/push tone) volume control>alarm (0-8; *4), communication volume (0-8; *4) fax setup>transmission function ECM transmission (*ON/OFF) setup pause length set (*1-15 sec; *4-11 sec; 3-6 sec) auto redial (*on/off)>number of redials (100V: 1-15 (*2)/ 230V: 1-10 (*2), redial interval (2-99 min; *2), redial at transmission error (1 page and error page/all pages/off) fax setup>reception function setup ECM reception (*ON/OFF) 1.2.3.8 Box Specifications Settings 0000-4269 T-1-15 Mode Description set up/register user box box selection (0-99), box name registration , ID No. (0 to 9999999), file auto deletion (0/ 1/2/3/6/12 hr; 1/2/3/7/30 days; 3 days), reset set standard mode for reading set/register fax box register, initialize box selection (0-49), box name registration, ID No. (0 to 999999), reset 1-17 Chapter 1 1.2.3.9 Printer Specifications Settings 0000-4270 Making settings if the machine is not equipped with any accessory. * factory settings. T-1-16 Mode Description set specifications number of copies (1 to 2000: *1) double-sided (double-sided, *single sided) pickup>default paper size, default paper type, paper size replacement (*yes/no) print adjustment>super smooth (*yes/no), toner density (YMCK density 8 settings), toner saving (yes/*no) layout>bind position (longer side/shorter side), binding margin (*0), vertical position (*0), horizontal position (*0) secure print deletion time (1 hr/2/3/6/12/24) time-out (*time-out time (5 to 300 sec; 15)/no) post-RIP printing (yes/*no) sorter (no/sort/rotation sort/rotation group) transparency interleaf (*disable, use blank paper, use print paper) set reception function color mode (common settings) (*auto switchover, full-color, monochrome) gradation setup/gradation (*standard/smooth 1/smooth 2), application to graphics (*yes)/application to image (*yes) halftone selection>text (resolution/gradation/*error diffusion), graphics (resolution/gradation/*error diffusion), image (resolution/gradation/*error diffusion) compression image output (*output, error indication) initialize printer settings utility 1-18 initialize printer Chapter 1 1.2.3.10 Destinations Table Specifications Settings 0000-4271 T-1-17 Mode Description register destination yes register name of destination yes register one-touch button yes 1.2.4 User Maintenance 1.2.4.1 Cleaning 0000-4272 - Face of Copyboard, Back of Copyboard Cover Instruct the user to clean the face of the copyboard glass and the back of the copyboard cover at least once a month. Cleaning Procedure Using a cloth moistened with water or solution of mild detergent (well-wrung), clean the face of the copyboard glass [1] and the back of the copyboard cover [2]; then, dry wipe the surfaces. F-1-11 F-1-12 1-19 Chapter 1 1.2.4.2 Inspection 0000-4273 - Checking the Leakage Breaker Instruct the user to check the leakage breaker periodically (once or twice a month), and keep a record of the work. Inspection Procedure 1) Turn on the main power switch. 2) Press the test button [1] of the breaker with the tip of a ball-point pen [2] or the like. 3) Check to see that the breaker switch shits to the OFF side and the power goes OFF. F-1-13 4) Turn off the main power switch. 5) Shift the breaker switch [1] to the ON side. F-1-14 6) Turn on the main power switch. 1.2.5 Safety 1.2.5.1 Safety of the Laser System 0000-4274 Laser Light in General Laser light can prove to be very harmful to the human body, requiring full care. About the Machine Laser System The machinelaser optical system is sealed inside a protective housing and external covers, and the machine is 1-20 Chapter 1 constructed to prevent leakage of laser light outside it. As such, the light cannot escape the machine as long as the machine is used for the operations for which it is designed. 1.2.5.2 Regulations by the Center for Devices and Radiational Heath(CDRH) 0000-4275 The Center for Devices and Radiation Heath (CDRH) of the United States put into effect regulations drawn up for laser products. These regulations apply to laser products that are produced on August 1, 1976, and thereafter, and ban the sale of laser products without certification indicated by a label obtained from the organization.. 1.2.5.3 Handling the Laser Assembly 0000-4276 Points to Note When Servicing the Area Around the Laser Optical System - Do not put an object with a high reflectance (e.g., screwdriver) into the path of the laser light. - Do not wear a watch or ring during work. (They can reflect the laser light, causing damage to your eyes.) The machinelaser light is red in color, and the covers that can reflect the light are identified with a label [1]. Pay special attention whenever servicing an area behind these covers. [1] [1] [1] [1] F-1-15 1.2.5.4 Safety of Toner 0000-4277 About the MachineToner The machine toner is non-toxic, consisting of plastic and iron materials with a few amount of dye. Do not throw toner into fire. It can explode. 1-21 Chapter 1 Toner Stains 1. If your skin or clothing has come into contact with toner, remove it with dry tissue, and then wash with water. 2. Do not use warm water; otherwise, the toner will become jell-like, permanently fusing with the fibers of the cloth and resisting removal. 3. Do not bring toner into contact with vinyl material, as they can easily react. 1.2.6 Product Specifications 1.2.6.1 Type and Functions 0005-9070 Copyboard Flat-bed Body Desk-top Photosensitive medium OPC drum Exposure method Laser exposure Charging method Roller charging Development method Bk Cassette pickup method Separation retard Multifeeder pickup method Simple retard Transfer method Intermediate transfer belt Transfer method (primary by charging roller 30.6 mm dia. (4 pc.) Dry, 2-component Color Dry, 2-component transfer) Transfer method (secondary by charging roller transfer) Separation method Curvature separation (static eliminator) Drum cleaning method None Trasnsfer cleaning method Blade (equalizing operation used) Fixing method Roller fixing Delivery method Face-down, face-up Warm-up time At power-on - 6 min or less (at 20 deg C room temperature) Return from low-power mode - 30 sec (Bk mode only) Print area Maximum image guarantee area 301 x 452 mm Maximum print area 305 x 452 mm Printing resolution read resolution: 600 x 600 dpi write resolution: 9600 (equivalent) x 600 dpi 1-22 Toner level detection function Yes Drum wear detection function Yes Chapter 1 1.2.7 Function List 1.2.7.1 Print Speed 0006-3356 First Print Time T-1-18 Unit: sec A4, plain (64 g/m2 to 105 g/m2) Full-color Monochrome 12.8 (simplex model) 9.5 (simplex model) 13.1 (duplex model) 9.8 (duplex model) Printing Speed - Plain Paper Mode (64 g/m2 to 105 g/m2) T-1-19 unit: prints/min Paper size Cassette, Manual Side paper Face-down, Face-up, single- feeder, deck, single- double-sided double- sided single-sided sided B5 32 19 32 13.5 10.25 A5R 16 16 - 7.5 7 A4 32 19 32 13.5 10.25 STMT-R 16 16 - 8 8 LTR 32 19 - 13.5 10.25 B5R 16 16 - 7.5 7 LTR-R 16 16 - 7.5 7 A4R 16 16 - 7.5 7 LGL 16 14 - 6.5 5.5 B4 16 14 - 6.5 5.5 A3 16 13 - 6.5 5.5 279mm x 432mm 16 13 - 6.5 5.5 15 13 - 6.25 5.5 A5 - 16 - - - 320mm x 450mm - 13 - - - sided (11 x 17) 305mm x 457mm (12 x 18) (12.6 x 17.7) 1-23 Chapter 1 - Thick Paper Mode (more than 105 g/m2) T-1-20 unit: prints/min Paper size Cassette, Manual feeder, Side paper deck, Face-down, Face-up, single-sided single-sided single-sided double-sided double-sided B5 16 9.5 16 6.75 5.13 A5R 16 9.5 - 6.75 5.13 A4 16 9.5 16 6.75 5.13 STMT-R 16 9.5 - 6.75 5.13 LTR 16 9.5 16 6.75 5.13 B5R 11 8 - 3.75 3.5 LTR-R 11 8 - 3.75 3.5 A4R 11 8 - 3.75 3.5 LGL 9.5 7 - 3.25 2.75 B4 9.5 7 - 3.25 2.75 A3 8 6.5 - 3.25 2.75 279mm x 432mm 8 6.5 - 3.25 2.75 7.5 6.5 - 3.25 2.75 A5 - 9.5 - - - Jpn postcard - 9.5 - - - Tab paper - 9 - - - 320mm x 450mm - 9.5 - - - (11 x 17) 305mm x 457mm (12 x 18) (12.6 x 17.7) - Color Transparency Film T-1-21 unit: prints/min Paper size 1-24 Cassette, single-sided Manual feeder, single-sided B5 - - A4 6 6 LTR 6 6 LTR-R 6 6 A4R 6 6 Chapter 1 - Monochrome, transparency T-1-22 unit: prints/min Paper size Cassette, single-sided Manual feeder, single-sided B5 - - A4 7 7 LTR 7 7 LTR-R 7 7 A4R 7 7 1.2.7.2 Print Size 0006-3390 T-1-23 Cassette Manual Feed Side Paper Cassette Duplexing Tray Deck Pedestal Unit*2 <Paper Size> A5R yes yes no yes yes B5 yes yes yes yes yes B5R yes yes no yes yes A4 yes yes yes yes yes A4R yes yes no yes yes B4 yes yes no yes yes A3 yes yes no yes yes yes yes no yes yes yes yes no yes yes no yes no no no LGL yes no no yes yes LTR yes no no yes yes LTR-R yes no yes yes yes STMT-R yes no no yes yes postcard no yes no no no 279x432[mm] (11x17) 305x457[mm] (12x18) 320x450[mm] (12.6x17.7) 1-25 Chapter 1 T-1-24 Manual Side Paper Cassette Duplexing Feed Tray Deck Pedestal Unit*2 yes yes yes yes no yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes no yes no bond paper *1 no yes no no yes gloss paper*1 no yes no no no label paper*1 no yes no no no no yes no no no tracing paper *1 no yes no no no tab paper*1 no yes no no no postcard no yes no no no 2-pane postcard no yes no no no 4-pane postcard no yes no no no Cassette <Paper Type> light paper (up to 64 g/m2) plain paper (64 to 105 g/m2) heavy paper (up to 209 g/2) recycled paper transparency*1 (A4/LTR) Japanese paper*1 *1: support limited to single-sided printing. *2: support limited on iR C3200. 1-26 Chapter 1 1.2.7.3 Others 0006-3415 T-1-25 Operation Temperature range 15 to 32.5 deg C Humidity range 25 to 75% environment Atmospheric pressure range 810.6 to 1013.3 hpa (0.8 to 1.0 atm) Operating noise Power supply In operation 74 dB or less In standby 50 dB or less 100 V 120 V 230 V Power consumption maximum 1500 W or less (if equipped with cassette pedestal) In standby 100V:344W* 120V:273W* 230V:350W* *When equipped with all accessories. Ozone Dimensions Weight Maximum 0.05 ppm or less Average 0.02 ppm or less Width (W) 620 mm Depth (D) 786 mm Height (H) 1040 mm (including cassette pedestal) Total 118.5 kg (including duplex unit; excluding toner container, drum unit, cable) Printer unit 105.5 kg (including duplex unit) The descriptions are subject to change for product improvement. 1-27 Chapter 1 1.2.7.4 Reader Unit Specifications 0006-3419 T-1-26 Copyboard Fixed Original size detection Feed sensors, reading CCD; copyboard cover angle Original type Sheet, book, 3-D object (2 kg max.) Maximum original size 297 mm x 432 mm Reproduction ratio 100%, Reduce I (1:0.250), Reduce II (1:0.500), Reduce III (1:0.611), Reduce IV (1:0.707), Reduce V (1:0.816), Reduce VI (1:0.865); Enlarge I (1:1.154), Enlarge II (1:1.224), Enlarge III (1:1.414), Enlarge IV (1:2.000), Enlarge V (1:4.000); Zoom (1:0.250 to 4.000; 25% to 400%: in 1% increments) Reading resolution Main scanning direction 600 dpi Sub scanning direction 600 dpi Number of gradations Reading maximum 256 Main scanning direction 0 to 2 mm against 297 mm Sub scanning direction 0 to 2 mm against 420 mm Source of light Xenon lamp Dimensions Width (W) 585 mm Depth (D) 543 mm Height (H) 87 mm Weight 12.5 kg Option Anti-condensation heater (100/230V model only) The descriptions are subject to change for product improvement. 1-28 Chapter 2 Installation Contents Contents 2.1 Making Pre-Checks ........................................................................................................................................... 2-1 2.1.1 Selecting the Site ........................................................................................................................................ 2-1 2.1.2 Site Space ................................................................................................................................................... 2-3 2.1.3 Sequence of Installing Accessories ............................................................................................................ 2-5 2.1.4 Connecting the Power Cables ..................................................................................................................... 2-6 2.1.5 Points to Note Before Starting the Work .................................................................................................... 2-6 2.2 Unpacking and Installation ................................................................................................................................ 2-7 2.2.1 Checking the Contents ................................................................................................................................ 2-7 2.2.2 Configuring the Cassette ............................................................................................................................ 2-7 2.2.3 Connecting the Reader Unit ....................................................................................................................... 2-8 2.2.4 Removing the Fixing Members from the Printer ....................................................................................... 2-9 2.2.5 Installing the Reader Unit ......................................................................................................................... 2-10 2.2.6 Installing the Secondary Transfer Outside Roller Unit ............................................................................ 2-16 2.2.7 Connecting the Power Cord ..................................................................................................................... 2-17 2.2.8 Mounting the Transfer Cleaning Unit ...................................................................................................... 2-17 2.2.9 Fitting the Toner Container ...................................................................................................................... 2-18 2.2.10 Fitting the Drum Unit ............................................................................................................................. 2-19 2.2.11 Connecting to the Network ..................................................................................................................... 2-21 2.3 Checking the Connection to the Network ....................................................................................................... 2-22 2.3.1 Checking the Connection to the Network ................................................................................................ 2-22 2.3.2 Using PING .............................................................................................................................................. 2-22 2.3.3 Making Checks Using a Remote Host Address ....................................................................................... 2-23 2.4 Troubleshooting the Network .......................................................................................................................... 2-24 2.4.1 Troubleshooting the Network ................................................................................................................... 2-24 2.4.2 Checking the Connection of the Network Cable ...................................................................................... 2-24 2.4.3 Making Checks Using a Loopback Address ............................................................................................ 2-24 2.4.4 Making a Check Using a Local Host Address ......................................................................................... 2-24 2.5 Checking the Images/Operations ..................................................................................................................... 2-25 2.5.1 Checking the Images/Operations .............................................................................................................. 2-25 2.5.2 PASCAL Setting ...................................................................................................................................... 2-28 2.5.3 Preventing Anti-Condensation ................................................................................................................. 2-29 2.6 Relocating the Machine ................................................................................................................................... 2-30 2.6.1 Preparing for Relocation .......................................................................................................................... 2-30 2.7 Installing the Card Reader ............................................................................................................................... 2-31 2.7.1 Checking the Contents .............................................................................................................................. 2-31 2.7.2 Installation Procedure ............................................................................................................................... 2-31 2.7.3 Making Settings If Net Spot Accountant (NSA) Is Used ......................................................................... 2-33 2.8 Installing the NE Controller-A1 ...................................................................................................................... 2-34 2.8.1 Installing the NE Controller-A1 ............................................................................................................... 2-34 2.9 Installing the Original Tray ............................................................................................................................. 2-43 2.9.1 Checking the Contents .............................................................................................................................. 2-43 2.9.2 Installation Procedure ............................................................................................................................... 2-43 2.10 Installing the Key Switch Unit-A1 ................................................................................................................ 2-45 2.10.1 Checking the Contents ............................................................................................................................ 2-45 2.10.2 Installation Procedure ............................................................................................................................. 2-45 2.10.3 Making Checks After Installation .......................................................................................................... 2-47 2.11 Installing the Reader Heater .......................................................................................................................... 2-48 2.11.1 Checking the Contents ............................................................................................................................ 2-48 2.11.2 Installation Procedure ............................................................................................................................. 2-49 Contents 2.12 Installing the Cassette Heater ........................................................................................................................ 2-59 2.12.1 Checking the Contents ............................................................................................................................ 2-59 2.12.2 Installation Procedure ............................................................................................................................. 2-60 2.12.3 Installing the Cassette Heater Kit to a Copier ........................................................................................ 2-61 2.12.4 Installing the Cassette Heater Kit to a 2-Cassette Pedestal-X1 .............................................................. 2-63 2.13 Replacing the Drum Unit ............................................................................................................................... 2-64 2.13.1 Preparing for the Work ........................................................................................................................... 2-64 2.13.2 Installation Procedure ............................................................................................................................. 2-65 Chapter 2 2.1 Making Pre-Checks 2.1.1 Selecting the Site 0000-4363 Select the site of installation while keeping the following in mind; if possible, visit the user's premises before the delivery of the machine: 1. The place must provide a source of power that is as rated (±10%) and that may be used exclusively by the machine; it also must provide a terminal for grounding. 2. The place must fall within the following ranges of temperature and humidity. The site must not be near a water faucet, water boiler, humidifier, or refrigerator. Humidity (%RH) 80 75 60 40 25 20 10 0 (32) 10 (50) 15 (59) 20 (68) 27.5 30 °C (81.5)(86) (°F) Temperature F-2-1 3. The site must not be near a source of fire or subject to dust or ammonium gas. If exposed to direct rays of the sun, provide curtains. 4. The amount of ozone generated by the machine in operation is not of a level that would harm the health of individuals around it. Some, however, may find its order unpleasant, requiring good ventilation for the work place. 5. Be sure that the machine's feet will remain in contact with the floor and the machine will remain level. 6. Be sure that the machine will be at least 10 cm from all walls and there will be ample space for using the machine. 2-1 Chapter 2 100 mm min. 1110 mm 500 mm min. 500 mm min. 1225 mm 500 mm min. F-2-2 Without Options 100 mm min. 1120 mm 500 mm min. 500 mm min. 2000 mm 500 mm min. F-2-3 2-2 Chapter 2 With a Finisher-N1 and Side Paper Deck-P1 Installed 100 mm min. 1120 mm 500 mm min. 500 mm min. 2210 mm 500 mm min. F-2-4 With a Finisher-N1/Saddle Finisher-N2 and Side Paper Deck-P1 Installed 7. The site must be well ventilated. Take care so that the machine will not be installed near a vent from which air is taken into the room. 2.1.2 Site Space 0006-4577 1) Be sure the will be 10 cm or more between the machine and any wall and there will be enough space for operating the machine. 100 mm min. 1110 mm 500 mm min. 500 mm min. 1225 mm 500 mm min. F-2-5 2-3 Chapter 2 With Accessories Installed 100 mm min. 1120 mm 500 mm min. 500 mm min. 2000 mm 500 mm min. F-2-6 With a Finisher-M1, Side Paper Deck-P1, and NEW Controller-A1 Installed 100 mm min. 1120 mm 500 mm min. 500 mm min. 2-4 2210 mm 500 mm min. Chapter 2 F-2-7 With a Finisher-N1/Saddle Finisher-N2, Side Paper Deck-P1, and NE Controller-A1 Installed 200 mm min. 1110mm 500 mm min. 500 mm 1225 mm 500 mm min. F-2-8 With a PS Print Server Unit-C1 Installed 2) Be sure the room is well ventilated. Be sure also that the machine is not placed near the air vent of the room. 2.1.3 Sequence of Installing Accessories 0006-4594 Memo, If you are installing the machine and its accessories at the same item, be sure to go through the work in the following sequence: 1. Cassette Heater Kit-A1 (to the pedestal) 2. 2-Cassette Pedestal-X1, or Plain Pedestal-C1 3. Machine 4. Anti-condensation heater 5. DADF-K1, or copyboard cover 6. Cassette Heater Kit-A1 (to the machine) 7. Card Reader-D1 8. NE Controller-A1 9. Deck heater 10. Side Paper Deck-P1 11. Key Switch Unit-A1 12. Original holder 13. Copy Tray-H1 14. Finisher-M1, Finisher-N1, or Saddle Finisher-N2 2-5 Chapter 2 2.1.4 Connecting the Power Cables 0006-4602 When connecting accessories to the machine, be sure to connect the power cables as indicated: When connecting the pedestal, paper deck, finisher, ADF, anti-condensation heater, and PS print server unit. DADF-K1 Inlet included with anti-condensation heater) PS Print Server Unit-C1 Inlet Outlet1 Outlet2 Outlet3 Inlet 2-Cassette Pedestal-X1 included with PS Print Server Unit-C1) included with machine) included with pedestal) F-2-9 2.1.5 Points to Note Before Starting the Work 0000-4364 Keep the following in mind when installing the machine: 1. If the machine is brought from a cold to warm place, condensation can occur in its optical system, laser unit, or pickup/feeder unit, leading to image faults. If such is the case, leave the machine alone without unpacking for 1 hr or more before starting the work. The term condensation refers to the phenomenon that occurs on a metal surface when it is brought from a cold to warm location as the result of rapidly cooled vapor. It is seen as droplets of water on the metal surface. 2. The machine weighs about 120 kg (including the reader unit). Be sure to work in a group of 4. 2-6 Chapter 2 2.2 Unpacking Installation 2.2.1 Checking and the Contents 0006-4619 Open the shipping box, and check to make sure that none of the following is missing: F-2-10 T-2-1 [1] [2] Drum unit (Y, M, C, K) 1 pc. 1 pc. each each Toner cartridge (Y, M, C, K) 1 pc. [10] Cable clamp (round) 6 pc. [11] Cable clamp (angular) 2 pc. each [3] Transfer cleaning unit 1 pc. [12] Size plate label 2 pc. [4] Secondary transfer outside 1 pc. [13] User's Manual 1 pc. 1 pc. [14] Installation Procedure 1 pc. roller unit [5] Delivery tray (100-V model only) [6] Power cord (for wall outlet) 1 pc. [15] QR Sheet (100-V model 1 pc. only) [7] Touch pen 1 pc. [16] Service Book (100-V 1 pc. model only) [8] Grounding cord (100-V 1 pc. [17] CD-ROM (iR C3200 only) 1 pc. model only) [9] Reader controller 1 pc. communication cable 2.2.2 Configuring the Cassette all tape; then, detach the holding plate [1]. [1] 0000-4365 1) Open the shipping box, and remove the plastic sheets. - If you are installing the pedestal at the same time, be sure to follow the instructions on the sheet that comes with the pedestal. 2) Remove all tape from the machine. F-2-11 3) Slide out the upper and lower cassettes, and remove 2-7 Chapter 2 4) Push the release button of the cassette, and slide out the cassette to the front. 5) Find out the size of paper used by the user, and set the slide guide [1] of each cassette to suit the paper [1] size. [2] F-2-14 8) Put paper in the cassette, and put the cassette back into the machine. [1] STMT R LTR LTR R LGL 11X17 2.2.3 Connecting the Reader Unit F-2-12 6) Pick the levers of the side guide plate [1] and the 0000-4366 1) Remove the 2 mirror fixing screws [1] from the left side of the reader unit. (Be sure to store them away for possible future transport.) rear guide plate [2], and move them to the appropriate index. [1] [2] F-2-15 2) Connect the reader controller communication cable [1] that comes with the machine. [1] F-2-13 7) Attach the size label [2] to the cassette size plate [1]; then, fit it to the cassette. 2-8 Chapter 2 2.2.4 Removing the Fixing Members from the Printer 0006-4646 1) Slide out the fixing/feeding assembly [1] from the left side of the machine. F-2-16 3) Using 5 included round cable clamps [1], fix the reader unit power cable [2] in place; then, using another round cable clamp [1] and 2 angular cable clamps, fix the reader controller communication cable [4] in place. F-2-19 2) Shift down the fixing roller releasing lever [1] to unlock the fixing roller; then, remove the releasing spacers [2] from the front and the rear. (These members will no longer be used.) F-2-17 F-2-20 F-2-18 2-9 Chapter 2 F-2-23 F-2-21 3) Shift the fixing roller releasing lever [1] back to its 2) Remove the face cap [1]. (Save it for later.) initial position, and push in the fixing/feeding assembly. F-2-24 3) Remove the screw [1], and detach the inside cover F-2-22 [2]. (Save it for later.) 2.2.5 Installing the Reader Unit 0006-3756 If the machine comes as two separate units (printer and reader), go through the following steps: 1) Remove the 2 screws [1] from the printer unit, and detach the center delivery tray [2]. (Save all for later.) F-2-25 4) Remove the screw [1], and detach the upper right cover (small) [2]. (Save the screw for later; put away the cover.) 2-10 Chapter 2 Fit it so that the sheet [1] attached to the joint plate is under the joint [2]. F-2-26 5) Remove the face cap [1], and remove the screw [2] (1 each); then, detach the 2 small covers [3]. (Put away the cap; save the screws for later; put away the cover.) F-2-29 Wrong (The sheet is above the joint.) Place the included joint plate (front)/(rear) [1] on the front/rear joint. F-2-27 F-2-30 6) Fit the included joint [1] in the hole in the machine's top as shown. (2 locations at front and rear) (front) F-2-31 F-2-28 7) (rear) 2-11 Chapter 2 8) For both front and rear, secure the joint grounding spring [2] using the screw [1] removed from the 10) Secure the reader connection unit [1] using the 2 included screws [2]. small cover (for the front, tighten over the plate); then, secure the joint plate (front/rear) [4] using the 2 included screws [3] (1 each at front and rear). F-2-35 F-2-32 11) Then, use the included 2 screws [1] to further secure it in place. (front) F-2-36 F-2-33 12) Shift down the arm [1] of the reader connection unit by 90 deg C; then, hook it on the protrusion [2] sticking out of the machine. (rear) 9) Where the upper right cover (small) has been removed, fit the positioning pin [A] for the bottom of the reader connection unit [1]. F-2-37 F-2-34 2-12 Chapter 2 F-2-41 F-2-38 15) Unpack the reader unit. 16) Place the reader unit on the printer unit 7 to 8 cm When folding the arm, be sure that it is under the displaced to the side (temporarily). protrusion. 7 to 8cm F-2-42 F-2-39 13) Attach the inside cover using the 2 previously removed screws. 17) Fit the included supports into the 2 holes in the bottom of the reader unit; then, tighten them firmly using a screwdriver so that they are fully fitted with the joints. F-2-40 F-2-43 14) Attach the center delivery tray using the 2 previously removed screws. 2-13 Chapter 2 20) Remove the 2 screws [1], and detach the upper left cover [2]. (Save all for later.) F-2-44 18) Open the delivery cover [1]. F-2-47 21) Remove the 2 screws [1], and detach the reader left cover [2]. (Save all for later.) F-2-45 19) Remove the face cap [1], and remove the 2 screws [2]; then, detach the upper left cover (small) [3]. (Save all for later.) F-2-48 22) Hook the reader unit retainer [1] on the hole in the reader unit; then, while pushing it down from above, secure it in place using the 2 included screws [2]. F-2-46 F-2-49 2-14 Chapter 2 25) Attach the reader left cover using the 2 previously removed screws. F-2-50 F-2-53 23) Bend and remove the 2 claws [1] found on the top of the removed upper left cover; then, attach them 26) Remove the 2 mirror fixing screws [1] from the in place using the 2 previously removed screws. left side of the reader unit. (Store away the removed (Put away the claws.) mirror fixing screws for later, i.e., for possible relocation of the machine.) F-2-51 24) Attach the upper left cover (small) using the 2 previously removed screws. F-2-54 27) Lift the reader unit slightly, and push into the tip of the positioning pin [1] into the hole [2] in the reader unit. F-2-52 F-2-55 2-15 Chapter 2 28) When the positioning pin [1] is fully in place, secure it using the stepped screw [2]. 2.2.6 Installing Secondary the Transfer Outside Roller Unit 0006-4664 Do not touch the roller area of the secondary transfer outside roller. 1) Open the package, and open the cardboard used to F-2-56 29) Secure the wire [2] in place using the included RS tightening stepped screw [1]. protect the secondary transfer outside roller unit. 2) Slide out the machine's fixing/feeding unit. 3) Picking the tabs at both ends of the secondary transfer outside roller [1], place the roller in the secondary transfer unit [2] inside the fixing/feeding unit; then, push on both ends so that it fits in place. (Be sure to force the roller until a click is heard.) F-2-57 F-2-59 30) Using the screw [1] removed from the upper right cover (small) and the included screw [2], secure the reader connection unit cover [3] in place. F-2-60 F-2-58 2-16 4) Close the fixing/feeding unit. Chapter 2 2.2.7 Connecting the Power Cord 2.2.8 0006-4669 Mounting the Transfer Cleaning Unit 0000-4367 - When Using a Pedestal 1) Open the front cover. 1) Fix the power cord that comes with the machine in 2) Turn the intermediate transfer unit releasing lever place to the pedestal side using the included cable [1] in the direction of the arrow. clamp (small) [2]; then, connect one end to the socket. F-2-63 F-2-61 3) Remove the waste toner container [1]. 2) Remove the screw [1] from under the power cord slot on the pedestal side; then, fit the other end [A] (hook-shaped) of the included grounding wire [2] to the pedestal. Grounding Members - grounding terminal of power outlet - iron rod buried 75 cm or more in ground - terminal wired to specification F-2-64 4)Remove the screw [1], and remove the dummy transfer cleaning unit. Be sure to store away the removed transfer cleaning unit. You will need it when executing the following service mode (for freeing the machine from F-2-62 condensation as needed by the site of installation): COPIER>FUNCTION> INSTALL>DRY-RT. 2-17 Chapter 2 2.2.9 Fitting the Toner Container 0000-4368 Each toner container has its specific position according to color (viewing from the control panel and starting at the left, Y, M, C, and Bk). Do not force the wrong container into place. F-2-65 1) Take out the toner container (Y) from the packing box. 5) 2) Take out the toner container (Y) from the packing bag; then, leave it alone for a while until it becomes Do not touch the tip of the transfer cleaning unit blade. The area is coated with lubricant. used to the ambient temperature. 3) Turn the fixing lever [1] of the toner container (Y) 90° clockwise. Take out the included transfer cleaning unit from the bag, and remove the packing material (cardboard). 6) Using the included binding screw [1], mount the transfer cleaning unit [2]. (Be sure to match the protrusion on the top of the waste toner feedscrew case with the groove in the base of the transfer cleaning unit.) F-2-67 4) Holding the toner container (Y) [1] with both hands, move it several times as if to rotate it. F-2-66 7) Fit the waste toner container. 8) Shift back the intermediate transfer unit releasing lever back to its initial position. F-2-68 2-18 Chapter 2 5) Push it all the way in the direction of the arrow indicated on the top edge. F-2-71 F-2-69 4) Remove the anti-interference sheet [1]. 6) Shift the fixing lever of the toner container (Y) back to its initial position (by turning it counterclockwise by 90°). 7) Fit the rest of the toner containers (M, C, Bk) in the same way. 2.2.10 Fitting the Drum Unit 0000-4369 1) Take out the drum unit (Y) from the packing box. 2) Take out the drum unit (H) [1] from the packing bag; then, take out the drying agent (silica gel). F-2-70 F-2-72 5) Turn the intermediate transfer unit releasing lever [1] in the direction of the arrow. F-2-73 3) Do not remove the protective cover. It serves as a rail. Pull out the pressure releasing hook [1] at the front and the rear. 2-19 Chapter 2 6) Turn the open/close lever [2] of the cartridge cover [1] clockwise by 90° to open the cartridge cover. F-2-76 F-2-74 9) 7) Match the groove [1] found behind the machine's cartridge cover and the protrusion [2] found on the bottom of the protective cover; then, secure them in place. When pulling out the sealing tape, be sure to hold the drum cartridge with your hand so that the cartridge will not slip off. Pull out the sealing tape [1]. F-2-75 8) F-2-77 1. Push the drum cartridge in the direction of the arrow [1] indicated on its top edge. 2. Store away the protective cover after fitting the drum cartridge. 10) Fit the M, C, and Bk drum cartridges in the same way. 11) Close the cartridge cover, and turn the open/close lever clockwise to set it in place. 12) Shift the intermediate transfer unit releasing lever While supporting the protective cover [2] with you hand, push in the cartridge (Y) [3], thereby setting it in place (Y, M, C, and Bk starting from left). 2-20 back to its initial position. 13) Close the front cover. Chapter 2 2.2.11 Connecting to the Network 0000-4371 Perform the following only if the model is equipped with printer functions. 1) Turn off the control panel power switch. 2) Turn off the main power switch. 3) Connect the network cable to the machine, and turn on the main power switch. 4) Inform the user's system administrator that the installation work is over, and ask him/her to set up the machine for use on the user's network. 5) When network settings have been made, turn off the control power switch, and then turn off and then on the main power switch. 2-21 Chapter 2 2.3 Checking the Connection to the Network 2.3.1 Checking the Connection to the Network 0000-8240 Perform the following work only if the machine is equipped with printer functions: If the user's network is in a TCP/IP environment, use the PING function to make sure that the Ethernet PCB has been installed properly and all network settings have been made properly. If the user's network is in an IPX/SPX or AppleTalk environment, this check is not needed. 2.3.2 Using PING 0000-4373 Go through the following steps only if the machine is connected to a network: If the user's network environment is based on TCP/IP, use the PING function to see that the Ethernet PCB has been correctly mounted and the network settings have been correctly made. If the user's network environment is based on IPX/SPX or AppleTalk, on the other hand, you need not make a PING-based check. 1) Make the following selections in service mode: COPIER>TEST>NETWORK>PING. 2) Enter the IP address using the keypad on the control panel, and press the OK key. 3) Press the Start key. - If the PING check is successful, the machine will indicate 'OK'; otherwise, it will indicate 'NG'. Result(OK/NG) <READY > < 1/1 > <NETWORK> PING 0. 0. 0. IP address input +/- F-2-78 2-22 0 OK Chapter 2 2.3.3 Making Checks Using a Remote Host Address 0000-4374 You can execute PING using a remote host address, thereby checking the connection to the network. The term "remote address" refers to the IP address of a PC terminal connected to and operating in a TCP/IP network environment to which the machine belongs. 1) Inform the system administrator that you will be checking the connection to the network using PING. 2) Check with the system administrator to find out the remote host address. 3) Enter the remote host address you obtained in PING. 4) If the indication is 'OK", the machine is correctly connected to the network. 5) If the indication is 'NG", the machine is not correctly connected to the network. Go through the following troubleshooting steps: 2-23 Chapter 2 2.4 Troubleshooting the Network 2.4.1 Troubleshooting the Network 0000-4375 Go through the following steps only if the machine is connected to the network: If the connection to the network is not correct, you may suspect the following: a. poor connection between the network and the Ethernet PCB b. wrong TCP/IP setting on the machine c. faulty Ethernet PCB or poorly mounted PCB d. faulty user network 2.4.2 Checking the Connection of the Network Cable 0000-4376 1) Check to see if the network cable is correctly connected to the Ethernet PCB. - If the connector is normal, make a check using the PING function and a loopback address or a local host address. - if not correct, try a check once again using a remote host address. 2.4.3 Making Checks Using a Loopback Address 0000-8237 A loopback address returns before it reaches the network PCB; therefore, executing PING using a loopback address will enable you to find out whether the TCP/IP settings of the machine are correct. 1) Enter the loopback address (127.0.0.1) to PING. - if the machine indicates 'NG', check the TCP/IP settings of the machine once again, and then execute PING once again. - if the machine indicates 'OK', check the local host address. 2.4.4 Making a Check Using a Local Host Address 0000-8238 The local host address is the IP address of the machine; therefore, executing PING using the local host address, which returns after it has reached the network PCB, enables you to find out if the network PCB is good or not. 1) Enter the IP address of the machine to PING. - if the machine indicates 'NG', make the following checks/corrections, and execute PING once again. a. faulty IP address of the machine: check with the system administrator to find out if the IP address (and its settings) assigned to the machine is correct. b. poor connection of the network PC: check the connectors associated with the network PCB. c. faulty network PCB: replace the network PCB. - if the machine indicates 'OK', suspect a fault in the user's network environment. Report to the system administrator, ask for corrective action. 2-24 Chapter 2 2.5 Checking the Images/Operations 2.5.1 Checking the Images/Operations 0000-4379 Be sure to put back the service book cover; turning on the machine's main power without doing so will cause a fault associated with error code E020. (The protrusion [A] of the service book cover will push the segment identified as [B] in the figure when the front cover is closed, thus opening/closing the shutter assembly of the pattern reader unit.) F-2-79 Place a test sheet on the copyboard glass, and select the cassette 1/2 as the source of paper; then, make copies, and check the images. (If a 2-cassette pedestal is used, try cassette 3/4 to check images.) - Check to be sure there is no abnormal noise. - Check to be sure that the images are free of faults at all default reproduction ratios. - Check to make sure that as many copies as are specified are made without a problem. - Check to make sure that the margin (L2) to the front of the copies made with each of the cassettes as the source of paper is 2.0 ±1.5 mm; otherwise, make the following adjustments: 1) Slide out the manual feed unit and the cassette 1/2; then, open the pickup vertical path cover. (In the case of a 2-cassette pedestal, cassette 3/4.) 2) Remove the 2 screws [1], and detach the right front cover [2]. (Do the same also for a 2-cassette pedestal.) 2-25 Chapter 2 F-2-80 - Making Adjustments for Cassette 1 Insert a screwdriver through the hole in the right front stay, and loosen the screw [1] to adjust the position of the adjusting plate [2]. (Do the same for cassette 3/4.) F-2-81 If the adjusting plate is moved to the right, L2 image the margin to the front of the paper will decrease. F-2-82 - Making Adjustments for Cassette 2 3) Remove the grip [1] on the front right. 2-26 Chapter 2 F-2-83 4) Insert a screwdriver through the hole in the right front stay, and loosen the screw [1] to adjust the position of the adjusting plate [2]. F-2-84 If the adjusting plate is moved to the right, L2 image the margin to the front of the paper will decrease. F-2-85 - Check to make sure that the margin (L1) along the leading edge of paper picked from each of the cassettes is 2.5 ±1.5 mm; otherwise, make the following adjustments: 1) Make the following selections in service mode: COPIER>ADJUST>FEED-ADJ>REGIST. 2-27 Chapter 2 2) Change the setting to make adjustments. (A change by '1' will cause a shift of 0.1 mm; a higher value will move the image toward the leading edge of the paper.) L1 Image An increase in the value of REGIST will move the image toward the leading edge of the paper. F-2-86 - Adjusting the Image Area (non-image width) 1) Make the following selections in service mode: COPIER>ADJUST>BLANK>BLANK_T/L/B/R. 2) Change the settings to make adjustments. (An increase by '24' will increase the non-image width by about 1 mm; the setting may be between 0 and 1000.) - If a line is found in the output image, go through the following: 1) Make the following selections in service mode: COPIER>CCD>SH-PS-ST. 2) Press the OK key so that the indication on the screen will change to 'ACTIVE' indicating that the machine is executing automatic adjustment of shading position. - If 'OK' is indicated on the screen, 3) See that auto adjustment has ended. - If 'NG' is indicated on the screen, 3) Make the following selections in service mode: COPIER>ADJUST>ADJ-XY>ADJ-S. 4) Change the setting to adjust the shading position. 2.5.2 PASCAL Setting 1) Make the following selections in service mode: COPIER>OPTION>BODY>PASCAL. 2) Check to make sure that the setting is '1'. 3) Press the Reset key several times to end service mode. 4) Make the following selections in user mode: adjust/clean>auto gradation correction. 5) Select the appropriate type of paper, and press [full correction]. 6) Place the test print 1 output on the copyboard glass, and have the machine read it. 7) Press [test print 2] to generate test print 2. 8) Place the test print 2 output on the copyboard glass, and have the machine read it. 9) Press [test print 3] to generate test print 3. 10) Place the test print 3 output on the copyboard glass, and have the machine read it. When all work is done, turn the adjuster on the bottom of the pedestal to secure the machine in place. 2-28 0000-4380 Chapter 2 2.5.3 Preventing Anti-Condensation 0006-4719 If condensation is expected at the site of installation, enable or disable the sleep mechanism on a monthly basis to prevent it. Service Mode (Category 2) COPIER>OPTIONAL>BODY>SLPOFF01 to 12 Setting 0: enable sleep mode 1: disable sleep mode (prevent condensation) 2-29 Chapter 2 2.6 Relocating the Machine 2.6.1 Preparing for Relocation 0000-4381 If the machine must be relocated after installation, be sure to perform the following work before relocation: Do not use the machine's grips when moving it over a step while it is on a pedestal; otherwise, the machine and the pedestal may separate. Be sure to hold the pedestal. 1) Fix the scanner in place using the scanner fixing screw [1] removed and stored at time of installation. F-2-87 2) Be sure to put about 10 sheets of paper [1] over the copyboard glass. [1] F-2-88 2-30 Chapter 2 2.7 Installing the Card Reader 2.7.1 Checking the Contents 0000-8498 Open the shipping box, and check to make sure none of the following is missing. F-2-89 [1] Card Reader-D1................. 1 unit [2] Pan-head screw (small)......... 1 pc. [3] Binding screw (M4)............. 4 pc. 2.7.2 Installation Procedure 0000-8502 1) Remove the face cap [1] and 2 screw [2]; then, detach the upper left cover (small) [3]. F-2-90 2) Remove the 3 screws [1] from behind the upper left cover (small), and detach the inside cover [2]; then, attach it as shown (by changing its orientation). 2-31 Chapter 2 F-2-91 F-2-92 3) When attaching, be sure that a card may be inserted with the label on the face side. Using the 4 included binding screws [1], mount the card reader [2] to the inside cover. F-2-93 2-32 Chapter 2 4) Secure the grounding wire [1] in place using the included pan-head screw (small) [2]; then, connect the connector [3] of the card reader to the machine's connector. F-2-94 5) Attach the upper left cover (small) using the previously removed screw. 6) Turn on the main power switch, and make the following selections in service mode: COPIER>FUNCTION>INSTALL>CARD. Then, enter any number (from 1 to 2000) to serve as the number to identify the first card used by the user. 7) Turn off and then on the main power switch. 2.7.3 Making Settings If Net Spot Accountant (NSA) Is Used 0000-8503 1) Check to make sure that IDs (from ID00000001 through ID00001000; i.e., if '1' is entered in COPIER>FUNCTION>INSTALL>CARD in service mode) have been prepareed in user mode (system control settings>group ID control>count control). 2) Set up the following in user mode (system control settings>network settings>TCP/IP settings>IP address): 'IP address', 'gateway address', 'subnet mask'. 3) If you fail to set up 'system control group' and 'system control ID No.', you will not be able to execute 'register card to device' when setting up NSA. Enter any number for 'system control group' and 'system control ID No.' in user mode (under 'system administrator info'). 4) Turn off and then on the machine. 2-33 Chapter 2 2.8 Installing the NE Controller-A1 2.8.1 Installing the NE Controller-A1 0000-8506 Keep the following in mind when installing the controller to its host machine: 1. Be sure that the work complies with the laws and regulations of the country of installation. 2. Be sure that its host machine has properly been installed before starting the work. 3. Be sure to disconnect its host machine's power plug before starting the work. 4. Be sure to identify the screws by type (length, diameter) and location. 5. Be sure to prepare the appropriate settings data on a PC at the service station. 1) Remove the 2 screws [2], and detach the upper cover [1]. [1] [2] [2] F-2-95 2) Connect the connector [3] of the power supply unit to the connector [4] as shown. [4] [3] F-2-96 3) Remove the 6 screws [5], and detach the face plate [3] of the host machine's upper rear cover. 2-34 Chapter 2 F-2-97 4) Connect the cable [7] to the connector (J1511) [8] of the host machine's power distribution PCB. F-2-98 5) Secure the controller to the host machine's rear cover using the 4 included screws. [8] [8] F-2-99 2-35 Chapter 2 6) Remove the slack from the cable connecting to the host machine; as necessary, bundle any stray segment of the cables as shown and secure it in place with a harness band [9]. [9] F-2-100 7) Shift bit 4 of the DIP switch (SW2) [10] on the PCB to ON (so that the mode used to communicate with the host machine will be IPC). 1 2 3 4 5 6 7 8 [10] LED1 LED2 LED3 2 6 1 1 BAT1 SW3 SW2 LED5 LED6 LED4 1 SW4 2 IC6 CN4 SW1 CN3 CN2 F-2-101 8) If IC6 [11] is found on the PCB, shift bit 7 of the DIP switch (SW2) [12] to ON; otherwise, shift bit 7 of the DIP switch (SW2) [16] to OFF. If IC6 [11] is not found, you need not mount it newly. If you must mount or replace a ROM (IC6) [11] for upgrading the controller, be sure to shift bit 7 of the DIP switch (SW2) [12] to ON. 2-36 1 2 3 4 5 6 7 8 Chapter 2 [12] LED1 LED2 LED3 2 6 1 1 BAT1 LED5 LED6 LED4 1 SW3 SW2 SW4 2 IC6 CN4 [11] SW1 CN3 CN2 F-2-102 9) Set the bits of the DIP switch (SW3) [13] as indicated. LED1 LED2 LED3 2 1 2 3 4 5 6 7 8 [13] 6 BAT1 1 1 SW3 SW2 LED5 LED6 LED4 1 SW4 2 IC6 CN4 SW1 CN3 CN2 F-2-103 T-2-2 Notation Setting SW3-1 SW3-2 Description SW3-1 SW3-2 OFF OFF Description sets the signal transmission level of the modem to -16 dBm. See right ON OFF sets the signal transmission level of the modem to -14 dBm. OFF ON sets the signal transmission level of the modem to -12 dBm. ON ON ets the signal transmission level of the modem to -10 dBm. 2-37 Chapter 2 Notation Setting SW3-3 OFF sets it to OFF at all times. SW3-4 ON sets the line setting to tone pulse. OFF sets the line setting to dial pulse. ON sets the dial pulse speed to 20 pps. OFF sets the dial pulse speed to 10 pps. - not used SW3-5 SW3-6 Description 10) Connect the power plug of the power supply unit, and check to make sure that LED1 [14] (orange) on the PCB goes ON. [14] LED1 LED2 LED3 2 6 BAT1 1 SW2 LED5 LED6 LED4 1 1 SW3 SW4 2 IC6 CN4 SW1 CN3 CN2 F-2-104 11) Initialize the RAM. Set the bits of the DIP switch (SW2) [15] on the PCB as indicated in the table; then, press the push switch (SW4) [16] so that LED5 [17] (red) goes ON. 1 2 3 4 5 6 7 8 [15] [17] LED1 LED2 LED3 2 6 BAT1 1 1 SW3 SW2 LED5 LED6 LED4 [16] IC6 SW1 CN3 CN2 F-2-105 2-38 1 SW4 2 CN4 Chapter 2 T-2-3 SW2 bits Setting SW2-1 OFF SW2-2 OFF SW2-3 ON SW2-4 ON SW2-5 OFF SW2-6 OFF SW2-7 See step 8). SW2-8 OFF 12) When LED5 [17] (red) has gone ON, set the bits of the DIP switch (SW2) [15] on the PCB as indicated in the table, and press the push switch (SW4) [16] so that LED5 [17] (red) goes OFF, indicating the end of RAM initialization. 1 2 3 4 5 6 7 8 [15] [17] LED1 LED2 LED3 2 6 1 1 BAT1 SW3 SW2 LED5 LED6 LED4 1 SW4 [16] IC6 2 CN4 SW1 CN3 CN2 F-2-106 T-2-4 SW2 bits Setting SW2-1 OFF SW2-2 OFF SW2-3 OFF SW2-4 ON 2-39 Chapter 2 SW2 bits Setting SW2-5 OFF SW2-6 ON SW2-7 See step 8). SW2-8 OFF 13) Shift bit 6 of the DIP switch (SW2) [18] on the PCB to OFF. LED1 LED2 LED3 2 1 2 3 4 5 6 7 8 [18] 6 BAT1 1 1 1 SW3 SW2 LED5 LED6 LED4 SW4 2 IC6 CN4 SW1 CN3 CN2 F-2-107 14) Connect the telephone line to the controller. If the connection is to the controller alone, connect the modular jack cable to the connector (LINE) [19]. If the controller's extension function is to be used, connect the existing telephone or fax to the connector (TEL) [2)] and then connect the telephone line to the connector (LINE) [19]. LED1 LED2 LED3 2 6 BAT1 1 SW2 LED5 LED6 LED4 1 SW3 2 IC6 CN4 SW1 CN3 CN2 [20] [19] F-2-108 2-40 1 SW4 Chapter 2 15) Ring the service station for initial settings of the controller. (Upon arrival, LED 4 [21] (red) will start to flash.) LED1 LED2 LED3 2 6 BAT1 1 SW2 LED5 LED6 LED4 1 1 SW3 SW4 2 IC6 CN4 SW1 [21] CN3 CN2 F-2-109 16) Ring the service station, and find out if initial settings have been made. If the setup has failed, initialize the RAM once again (steps 11) through 13)) to start over. Be sure to check with the service station once again to make sure that the controller settings are correct. 17) Check to make sure that the controller may be used to call up the PC at the service station. Press the push switch (SW4) [16] on the PCB so that LED6 [22] (red) goes ON. The LED goes OFF when the transmission ends successfully; otherwise, it will start to flash. When the push switch (SW4) [16] is pressed while LED6 [22] is flashing, a transmission will be initiated once again. If the push switch (SW1) [23] is pressed while LED6 [22] is flashing, the ongoing transmission will be cancelled. LED1 LED2 LED3 2 6 BAT1 1 SW2 LED5 LED6 LED4 [22] 1 1 SW3 SW4 [16] 2 IC6 SW1 CN4 [23] CN3 CN2 F-2-110 18) Check to make sure that the communication with its host machine is normal. Connect the host machine's power plug, and turn on the power switch; then, check to make sure that LED2 [24] (orange) starts to flash. [24] LED1 LED2 LED3 2 6 BAT1 1 SW2 LED5 LED6 LED4 1 SW3 1 SW4 2 IC6 CN4 SW1 CN3 CN2 F-2-111 2-41 Chapter 2 19) Press the host machine's Start key, and check that LED3 [25] (pink) flashes each time paper is delivered. [25] LED1 LED2 LED3 2 6 BAT1 1 SW2 LED5 LED6 LED4 1 1 SW3 SW4 2 IC6 CN4 SW1 CN3 CN2 F-2-112 20) Attach the switch settings label [26] on the top cover, and record the switch settings. 21) Secure the upper cover [1] using 2 screws [2]. When doing so, check to make sure that the power unit cable is secured to the cable guide inside the controller and is not trapped by the upper cover [1]. [2] [26] [1] [2] F-2-113 2-42 Chapter 2 2.9 Installing the Original Tray 2.9.1 Checking the Contents 0000-8545 Open the shiping box, and check to make sure that none of the fllowing is missing: F-2-114 [1] Original base........ 1 pc. [2] Stepped screw (M4)... 2 pc. [3] Washer............... 2 pc. 2.9.2 Installation Procedure 0000-8546 1) Fit the 2 included washers [1] and 2 stepped screws [2] to the upper right cover. F-2-115 2-43 Chapter 2 2) Separate the original tray into top and lower parts, and hook the cut-off [2] of the reinforcing plate of the original tray (upper) [1] on the stepped screw [3] previously fitted. F-2-116 3) Fit it to the original tray (lower) [1] together with the original tray (upper). F-2-117 2-44 Chapter 2 2.10 Installing the Key Switch Unit-A1 2.10.1 Checking the Contents 0000-8548 Open the shipping box, and check to make sure that none of the following is missing: F-2-118 [1] Key switch unit .............. 1 pc. [2] Control key .................. 1 pc. [3] Binding screw (M4)............ 1 pc. 2.10.2 Installation Procedure 0000-8550 1) Remove the 2 screws [1], and detach the host machine's center delivery tray [2]. F-2-119 2-45 Chapter 2 2) Cut out the excess [1] of the upper right cover. F-2-120 3) Slide out the manual feed tray; then, remove tha screw [1], and detach the middle right cover. F-2-121 4) Remove the 4 screws [1], and detach the upper right cover [2]. F-2-122 2-46 Chapter 2 5) Fit the plate of the key switch unit [1] into the cut-off of the upper right stay; then, secure it in place using the included binding screw [2]. F-2-123 6) Connect the connector [1]. F-2-124 7) Attach the upper right cover using the 2 previously removed screws. 8) Attach the printer upper right cover using the 2 right screws. 2.10.3 Making Checks After Installation 0006-0710 1) Start service mode. 2) Make the following selections in service mode, and enter - COPIER>FUNCTION>INSTALL>KEY. 3) Turn OFF and then ON the host machine. 2-47 Chapter 2 2.11 Installing the Reader Heater 2.11.1 Checking the Contents 0000-8554 Be sure to turn off the host machine before starting the work and observe the points to note indicated on the next page. Open the shipping box, and check none of the following is missing: F-2-125 T-2-5 [1] Reader heater ... 1 pc. [6] Wire saddle ... 2 pc. [2] Fuse PCB unit ... 1 pc. [7] Gounding cord (100v ... 1 pc. ... 1 pc. model only) [3] RS tightening screw ... 5 pc. (M4x8) [4] Power cable (for wall Power cable (for copier outlet) 2-48 Power supply label (100v model only) ... 1 pc. ... 1 pc. outlet) [5] [8] Chapter 2 2.11.2 Installation Procedure 0000-8557 Before starting the work, be sure to perform the follwing: 1. Turn off the control panel power switch. 2. Turn off the main power switch. 3. Disconnect the power cable (for wall outlet). ON /O FF [1] OFF [2] OFF [3] Pull out. F-2-126 1) Remove the copyboard cover. (If an ADF is used, you need not remove it.) 2) Release the 2 cable clamps [1] to free the reader power cable. [1] F-2-127 2-49 Chapter 2 3) Desconnect the reader controller communication cable. 4) Remove the 7 screws [1], and detach the reader unit rear cover [2]. (Save it for later.) F-2-128 5) Remove the 2 screws [1], and detach the face plate. (Save it for later.) F-2-129 6) Using the 2 included screws [1], mount the fuse PCB unit [2]. F-2-130 2-50 Chapter 2 7) Connect the harness [1] of the fuse PCB unit to the connector [2] of the interface PCB. F-2-131 8) When removing the copyboard glass, take care not to touch the glass face and the white plate found on the back of it. (Dirt can cause black lined in the images.) If soiled, clean it with lint-free paper moistened with alcohol. F-2-132 2-51 Chapter 2 F-2-133 Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. F-2-134 9) When moving the No.1 mirror base, be sure to hold it by the bend [A] of the cut-out in the mirror stay shown in the figure. F-2-135 2-52 Chapter 2 F-2-136 Move the No.1 mirror base [1] fully to the right. F-2-137 When shifting the mirror unit, be sure not to touch the mirror unit. Otherwise, clean it with lint-free papaer moistened with aocohol. 2-53 Chapter 2 10) Mount the Reader heater where indicated in the figure. When doing so, be sure that the harness guide of the heater is above the harness of the fuse PCB. [2] [1] F-2-138 11) Using 2 included screws [1], secure the longer segment (silver-coloured) of the Reader heater [2]. F-2-139 12) Holding it where indicated [A], shift the No.1 mirror base to the left. F-2-140 2-54 Chapter 2 13) Fit the harness guide [1], i.e., fit it in the hole in the base plate, and shift it to the right to secure; then, fit the harness band [2]. F-2-141 14) Secure the shorter segment (black) of the Reader heater [1] using 2 included screws [2]. (To do so, insert a screwdriver through the hole in the lens cover.) F-2-142 15) Connect the connector [1] of the Reader heater to the connector [2] of the fuse PCB unit. F-2-143 2-55 Chapter 2 16) Put the No.1 mirror base to its initial position (left edge). 17) Attach the reader unit rear cover. 18) When removing the copyboard glass, be sure not to touch the glass face or the white plate found on its back. (Dirt can cause black lines in the images.) If soiled, clean it with lint-freee paper moistened with alcohol. F-2-144 Attach the copyboard glass. F-2-145 2-56 Chapter 2 19) Secure the reader controller communication cable and the reader power supply cable back to their initial positions. 20) Connect the power cable. - If a pedestal (2-cassette pedestal or plain pedestal) is connected to the host machine, remove the 2 face stickers [1] from the upper rear cover. [1] F-2-146 Connect the power cable (for wall outlet) [1] and the inlet terminal and the outlet terminal (topmost of the 3) of the pedestal; then, secure it in place using the 2 included wire saddles. F-2-147 2-57 Chapter 2 - If no pedestal (2-cassette pedestal or plain pedestal) is connected to the host machine, connect the power cable (for wall outlet) [1] to the inlet terminal. F-2-148 - Only if 100v Model 21) Remove the screw [1] found under the inlet terminal, and connect the included gounding wire [1] (i.e., if no pedestal is connected). F-2-149 22) Attach the included power supply label [1] to the reader unit rear cover. F-2-150 2-58 Chapter 2 2.12 Installing the Cassette Heater 2.12.1 Checking the Contents 0006-0711 To install the heater kit, you must obtain a separately available Cassette Heater Unit-24. Before starting the work, be sure to turn off the host machine; for installation, keep in mind the points to note indicated on the next page. Open the shipping box, and check to make sure that none of the following is missing: Cassette Heater Kit-A1 F-2-151 T-2-6 [1] Heater PCB unit.....1 pc. [2] RS tightening screw (M4).....2 pc. Cassette Heater Unit-24 F-2-152 T-2-7 [1] Heater unit.....1 pc. [2] Binding screw (M4).....1 pc. 2-59 Chapter 2 2.12.2 Installation Procedure 0006-0718 Before staritng the work, be sure to perform the following on the host machine in the order indicated: 1. Turn off the control panel power switch. 2. Turn off the main power switch. 3. Disconnect the power cable (for power outlet). ON /O FF [1] OFF [2] OFF [3] Pull out. F-2-153 MEMO: The Cassette Heater Kit-A1 is designed for installation to either a copying machine or a 2-cassette pedestal using the same installation procedure. The following steps (images) are based on installation to a 2-cassette pedestal. 2-60 Chapter 2 2.12.3 Installing the Cassette Heater Kit to a Copier 0006-0719 1) Pull out both cases of the copier. 2) Insert a screwdriver from the front of the copier, and remove the 2 screws [2] to detach the heater PCB unit cover [1] attached to the rear side plate of the copier. F-2-154 3) MEMO: When detaching the heater unit PCB cover, slide it upward while pulling the stop [1] mounted to the cover toward the front. F-2-155 4) Before installing the heater PCB unit, be sure to turn off the host machine. Using the 2 included RS tightening screws [1], mount the heater PCB unit [2], and connect the 2 connectors [3]. 2-61 Chapter 2 F-2-156 5) Connect the included connector of the heater unit with the connector [2] of the heater PCB unit. F-2-157 6) When mounting the heater unit, be sure to securely fit the 3 protrusions, and check to make sure there is no gap. Fit the 3 protrusions [2] of the heater unit [1] into the slits in the base plate; match the holes, and secure it to the cassette heater unit using the included binding screw [3]. 2-62 Chapter 2 F-2-158 F-2-159 7) Mount the heater PCB unit cover using the previously removed screw. 2.12.4 Installing the Cassette Heater Kit to a 2-Cassette Pedestal-X1 0006-0720 1) Slide out both cassettes from the cassette pedestal. Hereafter, go through the same steps used for the installation to a copier. 2-63 Chapter 2 2.13 Replacing the Drum Unit 2.13.1 Preparing for the Work 0006-0723 1) Take out the drum unit (Y) from its shipping box; then, take out the drum unit (Y) [1] from its packing bag, and also take out the drying agent [2]. F-2-160 2) Do not remove the protective cover. It serves as a rail for installation. Pull out the releasing hook [1] at the front and the rear. F-2-161 2-64 Chapter 2 3) Remove the interference protective sheet [1]. F-2-162 2.13.2 Installation Procedure 0006-0728 Before starting the work, be sure to perform the following on the host machine in the order indicated: 1. Turn of the control panel power switch. 2. Turn off the main power switch. 3. Pull out the power cable (for wall outlet). ON /O FF [1] OFF [2] OFF [3] Pull out. F-2-163 2-65 Chapter 2 1) Open the copier's front cover, and turn the intermediate transfer unit releasing lever [1] in the direction of the arrow. F-2-164 2) Turn the open/closed lever of the drum unit cover [1] counterclockwise by 90 deg to open the drum unit cover. F-2-165 3) Match the dent [1] found in the back of the drum unit cover and the protrusion [2] on the bottom face of the protective cover, and secure it in place. F-2-166 4) 2-66 Chapter 2 1. Push it in the direction of the arrow [1] indicated on the top edge of the drum unit. 2. After setting the drum unit in place, be sure to store away the protective cover. Holding the protective cover [2] level, push in the drum unit (Y) [3] to set; the units are Y, M, C, and Bk, starting from the left. F-2-167 5) When pulling out the sealing tape, be sure to hold the drum unit in place so that the drum unit will not slide out. Pull out the sealing tape [1]. F-2-168 6) Set the drum units for other colors (M, C, Bk) in the same way. 7) Close the drum unit cover, and shift the open/close lever back to its initial position. 8) Shift the intermediate transfer unit releasing lever back to its initial position. 9) Close the front cover. 2-67 Chapter 2 2-68 Chapter 3 Basic Operation Contents Contents 3.1 Construction ...................................................................................................................................................... 3-1 3.1.1 Functional Construction ............................................................................................................................. 3-1 3.1.2 Arrangement of Major PCBs ...................................................................................................................... 3-2 3.2 Basic Sequence .................................................................................................................................................. 3-5 3.2.1 Basic Sequence of Operations at Power-On ............................................................................................... 3-5 3.2.2 Basic Sequence of Operations .................................................................................................................... 3-7 Chapter 3 3.1 Construction 3.1.1 Functional Construction 0000-4278 The machine can broadly be divided into the following functional blocks: Original exposure system Reader control system [7] [1] General control system Main controller [2] [3] [8] [4] Printer control system DC controller [5] [6] Image formation system [9] [10] [11] [12] [13] 2-cassette pedestal (option) Pickup/ feeder system Side paper deck (option) [14] [15] F-3-1 T-3-1 [1] HDD [9] Secondary transfer [2] Option boards [10] Pickup control [3] Photosensitive drum (Y) [11] Duplexing feed [4] Photosensitive drum (M) [12] Cassette 1 [5] Photosensitive drum (C) [13] Cassette 2 [6] Photosensitive drum (Bk) [14] Cassette 3 [7] Delivery system [15] Cassette 4 [8] Fixing system 3-1 Chapter 3 3.1.2 Arrangement of Major PCBs The machine's 0006-8366 major PCBs are wired as indicated in the following diagram: Reader unit [2] J601 [1] [3] J303 J102 J103 J204 J205 J203 J307 J206 [4] Printer unit [5] J511 [6] [7] J607 J608 J115 J1301 J114 J1209 [9] J1303 [8] [10] J1501,J1502 J1508,J1509 J102 J105 J131 J100 [13] J814 J75,J92 [14] [15] [16] [17] [18] [19] [11] J95 J90 [12] J441 J64 J50,J59 J60,J74 J54 J69 J58 [20] J3 [21] J5 J158 J155 J53 J153 J154 [22] [23] flat cable. PCB-to-PCB connector. F-3-2 T-3-2 3-2 [1] Inverter PCB [13] High-voltage unit [2] Reader controller PCB [14] HV1 PCB [3] Interface PCB [15] HV1-SUB PCB [4] CCD/AP PCB [16] HV2 PCB [5] Control panel CPU PCB [17] HV2-SUBY PCB [6] BD detection PCB [18] HV4 PCB [7] Laser driver PCB [19] HV3 PCB [8] DC controller PCB [20] Fuse PCB Chapter 3 [9] Main controller PCB (sub) [21] Heater control PCB [10] Main controller PCB (main) [22] DC power supply PCB (1) [11] Drive PCB [23] DC power supply PCB (2) [12] Duplex driver PCB The symbol <=> in the diagram indicates major wiring connections, and does NOT indicate the direction of signals. The major PCBs within the machine's main controller are connected as follows: J1400 [13] J1301 [4] [5] J1202 [6] J1201 J1203 [1] J1342 [2] [7] J1318 J1204 [3] J1207 J1213 J1210 [8] [9] J1205 [10] J1206 [11] J1513 J1507 [12] Flat cable/signal. J1303 PCB-to-PCB connector. F-3-3 3-3 Chapter 3 T-3-3 [1] Main controller PCB (sub) [8] Ethernet board [2] SRMA PCB [9] UFR board or Open I/F [3] HDD [10] USB interface board or TokenRing board [4] Main controller PCB (main) [11] Image conversion board [5] Image memory (SDRAM-: 512 MB, standard) [12] Power distribution PCB [6] Image memory (SDRAM: 512 MB, expansion) [13] Differential PCB [7] Boot ROM (Fiash ROM) The symbol <=> used in the diagram indicates connection between major PCBs, and does NOT indicate the direction of signals. 3-4 Chapter 3 3.2 Basic Sequence 3.2.1 Basic Sequence of Operations at Power-On 0000-4280 T-3-4 Period Description WMUP (warm-up) From when the main power switch is turned on until the surface temperature of the fixing roller reaches 90 deg C. SSTBY (scanner standby) From when shading correction ends until the Start key is turned on or the main power switch is turned off. WMUPR (warm-up From when the surface temperature of the fixing roller reaches 90 deg C until it rotation) reaches 190 deg C (i.e., the drive system has started up and, in addition, bias adjustment and image stabilization correction control are under way). PSTBY (printer standby) From WMUPR ends until the Start key is enabled. 3-5 Chapter 3 Main power switch ON Standby Reader unit WMUP SSTBY 30 sec Size detection/shading correction Original lamp (LA1) Scanner motor (M1) Printer unit Home position search Main power switch ON Starts here if, when the main power is turned ON, the surface temperature of the fixing roller is 90˚C or more Standby (at this time, the surface temperature of the fixing roller must have reached 190˚C) WMUP WMUPR PSTBY 360 sec Fixing main heater (H1) Fixing sub heater (H2) 90˚C *1 *1 Fixing heat retention heater (H3) In the case of a new cartridge, rotates for 30 sec; otherwise, rotates for 0.3 sec Development motor Drum ITB motor (M1) Fixing motor (M24) Rotates idly for 300 sec after the drum ITB motor stops Auto adjustment *1: The main heater or the sub heater is used for temperature control according to The following control is executed the difference in the readings between the according to the surface temperature of the fixing roller when the main main thermistor (TH1) and the sub power is turned ON: thermistor (TH2). • if less than 100˚C, • if 100˚C or higher (control at 190˚C) [1] discharge current control [1] discharge current control [2] ATVC control [2] ATVC control [3] ATR control [3] image position control [4] SALT-Dmax control [5] image position correction [6] SALT-Dhalf control F-3-4 3-6 3.2.2 Basic Sequence of Operations 0000-4281 a. Full-Color full-color, A4, 2 copies continuous, 100%, cassette 1 T-3-5 Period Description SSTBY From when shading ends until the Start key is turned ON or the main power is turned OFF. SREADY While shading correction is under way after a press on the Start key. SCFW SCRV While an originals is being read (scanner forward). While the scanner is returning to the home position after the original is read (scanner in reverse). PSTBY (print standby) While the machine is ready to review a print request signal. PINTR (printer initial rotation) From when a print request signal is received until the image leading signal is sent. PRINT Until all toner is transferred to paper. LSTR (last rotation) From when printing ends until all drive stops. Chapter 3 Start key ON Reader unit SSTBY SREADY SCFW SCRV Scanning lamp (LA1) Scanner motor (M1) Printer unit Image formation Start key ON ready timing PSTBY PINTR Used to stabilize rotation (Bk: 2.5 sec Y/M/C: 3.5 sec) PRINT LSTR PSTBY Laser scanner motor (M2 to M5)(Y,M,C,Bk) ITOP signal Laser ON Toner container motor (M20 to 23)(Y,M,C,Bk) Developing motor (M12 to 15)(Y,M,C,Bk) Developing bias Primary charging roller Drum ITB motor (M1) Cassette 1 pickup motor (M6) Cassette 1 pickup solenoid (SL3) Pre-registration motor (M9) Registration motor (M8) Acceleration, half-speed, constant speed control (to match transfer timing and process speed) Fixing motor (M24) Fixing main heater (H1) Fixing sub heater (H2) Fixing heat retention motor (H3) *1 *1 *1 *1 *1: The machine executes temperature control using the main heater or the sub heater according to the difference in the readings of the main thermistor (TH1) and the sub thermistor (TH2). (control at 190˚C) F-3-5 b. Monochrome monochrome, A4, 2 copies continuous, 100%, cassette 1 T-3-6 Period Description SSTBY While an original is being read. SREADY While shading correction is under way after a press on the Star key. SCFW 3-8 While an original is being read. Chapter 3 Period Description SCRV While the scanner is returning to the home position after an original has been read. PSTBY (print standby) While the machine is ready to receive a print request signal. PSINTR (printer initial rotation) From when a print request signal is received until when the image leading signal is received. PRINT Unit all toner is transferred to paper. LSTR (last rotation) From when printing ends until al drive stops. Start key ON Reader unit SREADY SSTBY SCFW SCRV Scanning lamp (LA1) Scanner motor (M1) Printer unit Image formation Start key ON ready timing PSTBY PINTR Used to stabilize rotation (2.5 sec) PRINT LSTR PSTBY Laser scanner motor (Bk) (M5) ITOP signal Laser ON Toner container motor (Bk) (M23) Development motor (Bk) (M15) Developing bias Primary charging roller Drum ITB motor (M1) Cassette 1 pickup motor (M6) Cassette 1 pickup solenoid (SL3) Pre-registration motor (M9) Registration motor (M8) Acceleration, half-speed, and constant speed control (to match transfer timing and process speed) Fixing motor (M24) Fixing main heater (H1) Fixing sub heater (H2) Fixing heat retention heater (H3) *1 *1 *1 *1 *1: The machine uses the main heater or the sub heater for temperature control according to the difference in the readings of the main thermistor (TH1) and the sub thermistor (TH2). (control at 190˚C) F-3-6 3-9 Chapter 3 3-10 Chapter 4 Basic Operations (As a Printer) Contents Contents 4.1 Construction ...................................................................................................................................................... 4-1 4.1.1 Functional Construction ............................................................................................................................. 4-1 4.2 Construction of the Electrical Circuitry ............................................................................................................ 4-2 4.2.1 Arrangement of Major PCBs ...................................................................................................................... 4-2 4.2.2 DC Controller PCB .................................................................................................................................... 4-4 4.3 Basic Sequence .................................................................................................................................................. 4-5 4.3.1 Basic Sequence of Operations at Power-On ............................................................................................... 4-5 4.3.2 Basic Sequence of Operations .................................................................................................................... 4-7 Chapter 4 4.1 Construction 4.1.1 Functional Construction 0000-4447 The machine can roughly be divided into the following functional blocks: Original exposure system Reader control system [7] [1] General control system Main controller [2] [3] [4] Printer control system DC controller [5] [6] Image formation system [8] [9] [10] [11] [12] Pickup/ feeder system [13] [14] 2-cassette pedestal (option) Side paper deck (option) [15] [16] F-4-1 T-4-1 [1] HDD [9] Feeding system [2] Option boards [10] Transfer system [3] Photosensitive drum (Y) [11] Pickup control [4] Photosensitive drum (M) [12] Duplex/feeder [5] Photosensitive drum (C) [13] Cassette 1 [6] Photosensitive drum (Bk) [14] Cassette 2 [7] Delivery system [15] Cassette 3 [8] Fixing system [16] Cassette 4 4-1 Chapter 4 4.2 Construction of the Electrical Circuitry 4.2.1 Arrangement of Major PCBs 0006-8375 The machine's major PCBs are wired as follows: Printer unit [1] J511 [2] [3] J607 J608 J115 J1301 J114 J1209 [5] J1303 [4] [6] J1501,J1502 J1508,J1509 J102 J105 J131 J100 [9] J814 J75,J92 [10] [11] [12] [13] [14] [15] [7] J64 J95 J90 [8] J441 J50,J59 J60,J74 J69 J58 J54 J3 [17] [16] J5 J158 J155 J53 J153 J154 [18] [19] flat cable. PCB-to-PCB connector. F-4-2 T-4-2 4-2 [1] Control panel CPU PCB [11] HV1-SUB PCB [2] BD detection PCB [12] HV2 PCB [3] Laser driver PCB [13] HV2-SBU PCB [4] DC controller PCB [14] HV4 PCB [5] Main controller PCB (sub) [15] HV3 PCB Chapter 4 [6] Main controller PCB (main) [16] Fuse PCB [7] Drum ITB motor [17] Heater control PCB [8] Duplex driver PCB [18] DC power supply PCB (1) [9] High-voltage unit [19] DC power supply PCB (2) [10] HV1 PCB The arrow used in the diagram indicates connection of PCBs, and does NOT indicate the direction of signals. The major PCBs of the machine's main controller are connected as follows: [13] J1400 J1301 [1] J1202 [5] [4] J1201 J1203 [6] J1342 [2] [7] J1318 J1204 [3] J1207 [9] J1205 J1213 J1206 J1210 [8] [10] [11] J1513 J1507 [12] F-4-3 T-4-3 [1] Main controller PCB (sub) [8] Ethernet board [2] SRAM PCB [9] UFR board or Open interface board [3] HDD [10] USB interface board, TokenRing board, or USB application interface board [4] Main controller PCB (main) 4-3 Chapter 4 [5] 512-MB expansion RAM [11] Image conversion board or USB application interface board [6] 256/512MB expansion RAM [12] Power distribution PCB [7] Boot ROM [13] Differential PCB The arrow used in the diagram indicates connection of PCBs, and does NOT indicate the direction of signals. 4.2.2 DC Controller PCB 0000-4449 The following is a functional diagram of the DC controller PCB: Converts control signals sent to D/A converter (3.3V→ 5V) Retains various data (parameters for image formation; margin, color displacement, laser adjustment value, etc.) Converts signals from CPU into analog signals Laser activation control IC1019 ATR sensor control signal (0 to 12V) • SALT sensor control signal • pattern reader unit control signal(0 to 5V) Retains settings data; e.g., service mode (SRAM) Stores start-up program (Boot ROM) Bk C BAT IC1018 IC1016 M IC1 IC30 IC24 IC12 Controls loads IC25 IC27 IC49 IC15 CPU IC14 Interfaces with external devices Stores firmware (Flash ROM) Converts signals from CPU to analog signals (0 to 12V) 24 VDC 15 VDC 5 VDC 3.3 VDC J100 F-4-4 4-4 Y IC1017 IC48 IC43 IC42 IC41 IC40 Control signals to HVT Chapter 4 4.3 Basic Sequence 4.3.1 Basic Sequence of Operations at Power-On 0000-4450 T-4-4 Period Description WMUP (warm-up) While the drive system is at rest and, in addition, until the surface temperature of the fixing roller reaches 90 deg C. WMUPR (warm-up rotation) After the drive system starts up and, in addition, bias adjustment is under way. PSTBY (printer standby) While the machine is ready for a copy/print request signal. 4-5 Chapter 4 Main power switch ON Standby Reader unit WMUP SSTBY 30 sec Size detection/shading correction Original lamp (LA1) Scanner motor (M1) Printer unit Home position search Main power switch ON Starts here if, when the main power is turned ON, the surface temperature of the fixing roller is 90˚C or more Standby (at this time, the surface temperature of the fixing roller must have reached 190˚C) WMUP WMUPR PSTBY 360 sec Fixing main heater (H1) Fixing sub heater (H2) 90˚C *1 *1 Fixing heat retention heater (H3) In the case of a new cartridge, rotates for 30 sec; otherwise, rotates for 0.3 sec Development motor Drum ITB motor (M1) Fixing motor (M24) Rotates idly for 300 sec after the drum ITB motor stops Auto adjustment *1: The main heater or the sub heater is used for temperature control according to The following control is executed the difference in the readings between the according to the surface temperature of the fixing roller when the main main thermistor (TH1) and the sub power is turned ON: thermistor (TH2). • if less than 100˚C, • if 100˚C or higher (control at 190˚C) [1] discharge current control [1] discharge current control [2] ATVC control [2] ATVC control [3] ATR control [3] image position control [4] SALT-Dmax control [5] image position correction [6] SALT-Dhalf control F-4-5 4-6 Chapter 4 4.3.2 Basic Sequence of Operations 0000-4451 a. Full-Color full-color, A4, 2 copies continuous, 100%, cassette 1 T-4-5 Period Description PSTBY (print standby) While the machine is ready to accept a copy/print request signal. PINTR (printer initial rotation) From when a print request signal is received until an image signal is sent. PRINT Until all toner is transferred to paper and the paper is delivered. LSTR From when paper is delivered until all drive stops. Printer unit Start key Image formation ON ready timing PSTBY PINTR Used to stabilize rotation (Bk: 2.5 sec; Y/M/C: 3.5 sec) PRINT LSTR PSTBY Laser scanner motor (M2 to M5) (Y,M,C,Bk) ITOP signal Laser ON Toner container motor (M20 to 23) (Y,M,C,Bk) Developing motor (M12 to 15) (Y,M,C,Bk) Developing bias Primary charging roller Drum ITB motor (M1) Cassette 1 pickup motor (M6) Cassette 1 pickup solenoid (SL3) Pre-registration motor (M9) Registration motor (M8) Acceleration, half-speed, constant speed control (to match transfer timing and process speed) Fixing motor (M24) Fixing main heater (H1) Fixing sub heater (H2) *1 *1 *1 *1 Fixing heat retention heater (H3) *1: The machine executes temperature control using the main heater or the sub heater according to the difference in the readings of temperature between the main thermistor (TH1) and the sub thermistor (TH2). (controlled to 190˚C) F-4-6 4-7 Chapter 4 b. Monochrome monochrome, A4, 2 copies continuous, 100%, cassette 1 T-4-6 Period Description PSTBY (print standby) While the machine is ready to receive a copy/print request signal. PINTR (printer initial rotation) From when a print request signal is received until the image signal is sent. PRINT Until all toner is transferred to the paper and the paper is delivered. LSTR Printer unit From when paper is delivered until all drive stops. Start key Image formation ready timing ON PSTBY PINTR Used to stabilize rotation (2.5 sec) PRINT LSTR PSTBY Laser scanner motor (Bk) (M5) ITOP signal Laser activation Toner container motor (Bk) (M23) Development motor (Bk) (M15) Developing basis Primary charging roller Drum ITB motor (M1) Cassette pickup motor (M6) Cassette pickup solenoid (SL3) Pre-registration motor (M9) Registration motor (M8) Acceleration, half-speed, constant speed control (to match transfer timing and process speed) Fixing motor (M24) Fixing main heater (H1) Fixing sub heater (H2) *1 *1 *1 *1 Fixing heat retention motor (H3) *1: The machine uses the main heater or the sub heater for temperature control according to the difference in the readings of temperature between the main thermistor (TH1) and the sub thermistor (TH2). (controlled to 90˚C) F-4-7 4-8 Chapter 5 Main Controller Contents Contents 5.1 Construction ...................................................................................................................................................... 5-1 5.1.1 Outline ........................................................................................................................................................ 5-1 5.1.2 Functional Construction ............................................................................................................................. 5-2 5.2 Construction of the Electrical Circuitry ............................................................................................................ 5-3 5.2.1 Outline ........................................................................................................................................................ 5-3 5.2.2 Main Controller PCB .................................................................................................................................. 5-3 5.2.3 SRAM board ............................................................................................................................................... 5-4 5.2.4 HDD ........................................................................................................................................................... 5-4 5.2.5 Composition of the System Software ......................................................................................................... 5-5 5.3 Start-Up Sequence ............................................................................................................................................. 5-7 5.3.1 Outline ........................................................................................................................................................ 5-7 5.3.2 Startup Sequence ........................................................................................................................................ 5-7 5.4 Actions when HDD Error .................................................................................................................................. 5-9 5.4.1 E602 in Detail ............................................................................................................................................. 5-9 5.5 Image Processing ............................................................................................................................................. 5-14 5.5.1 Flow of Images ......................................................................................................................................... 5-14 5.5.2 Construction of the Image Processing Module ........................................................................................ 5-15 5.5.3 Reader Input Image Processing ................................................................................................................ 5-16 5.5.4 Compression/Decompression and Edit Processing Black ........................................................................ 5-17 5.5.5 Printer Output Image Processing .............................................................................................................. 5-18 5.6 Flow of Image Data ......................................................................................................................................... 5-19 5.6.1 Flow of Image Data for Copier Functions ................................................................................................ 5-19 5.6.2 Flow of Image Data for Box Functions .................................................................................................... 5-20 5.6.3 Flow of Image data for SEND function ................................................................................................... 5-21 5.6.4 Flow of Image Data for Fax Transmission Functions .............................................................................. 5-22 5.6.5 Flow of Image Data for Fax Reception Functions ................................................................................... 5-23 5.6.6 Flow of Image Data for PDL Functions ................................................................................................... 5-24 5.7 Parts Replacement Procedure .......................................................................................................................... 5-25 5.7.1 Main Controller PCB (main) .................................................................................................................... 5-25 5.7.1.1 Removing the Upper Rear Cover ...................................................................................................... 5-25 5.7.1.2 Removing the Left Upper Rear Cover ............................................................................................... 5-25 5.7.1.3 Removing the DC Controller PCB Cover ......................................................................................... 5-25 5.7.1.4 Removing the Controller Box Cover ................................................................................................. 5-25 5.7.1.5 Removing the HDD ........................................................................................................................... 5-26 5.7.1.6 Removing the Hard Disk Mounting Plates ........................................................................................ 5-26 5.7.1.7 Removing the Ethernet Board ........................................................................................................... 5-26 5.7.1.8 Removing the UFR Board ................................................................................................................. 5-27 5.7.1.9 Removing the SRAM PCB ................................................................................................................ 5-27 5.7.1.10 Removing the Main Controller PCB (sub) ...................................................................................... 5-27 5.7.1.11 Removing the Main Controller PCB (main) ................................................................................... 5-28 5.7.1.12 When Replacing the Main Controller PCB (main) ......................................................................... 5-28 5.7.2 Main Controller PCB (sub) ...................................................................................................................... 5-28 5.7.2.1 Removing the Upper Rear Cover ...................................................................................................... 5-28 5.7.2.2 Removing the Left Upper Rear Cover ............................................................................................... 5-28 5.7.2.3 Removing the Controller Box Cover ................................................................................................. 5-28 5.7.2.4 Removing the HDD ........................................................................................................................... 5-29 5.7.2.5 Removing the Hard Disk Mounting Plates ........................................................................................ 5-29 5.7.2.6 Removing the SRAM PCB ................................................................................................................ 5-30 5.7.2.7 Removing the Main Controller PCB (sub) ........................................................................................ 5-30 Contents 5.7.2.8 When Replacing the Main Controller PCB (sub) .............................................................................. 5-30 5.7.3 SRAM PCB .............................................................................................................................................. 5-31 5.7.3.1 Removing the Upper Rear Cover ....................................................................................................... 5-31 5.7.3.2 Removing the Controller Box Cover ................................................................................................. 5-31 5.7.3.3 Removing the HDD ........................................................................................................................... 5-31 5.7.3.4 Removing the SRAM PCB ................................................................................................................ 5-31 5.7.3.5 When Replacing the SRAM PCB ...................................................................................................... 5-31 5.7.4 UFR Board ................................................................................................................................................ 5-32 5.7.4.1 Removing the Upper Rear Cover ....................................................................................................... 5-32 5.7.4.2 Removing the Left Upper Rear Cover ............................................................................................... 5-32 5.7.4.3 Removing the Controller Box Cover ................................................................................................. 5-32 5.7.4.4 Removing the UFR Board ................................................................................................................. 5-32 5.7.5 Ethernet Board .......................................................................................................................................... 5-33 5.7.5.1 Removing the Upper Rear Cover ....................................................................................................... 5-33 5.7.5.2 Removing the Left Upper Rear Cover ............................................................................................... 5-33 5.7.5.3 Removing the Controller Box Cover ................................................................................................. 5-33 5.7.5.4 Removing the Ethernet Board ............................................................................................................ 5-33 5.7.6 Differential PCB ....................................................................................................................................... 5-34 5.7.6.1 Removing the Upper Rear Cover ....................................................................................................... 5-34 5.7.6.2 Removing the Left Upper Rear Cover ............................................................................................... 5-34 5.7.6.3 Removing the Controller Box Cover ................................................................................................. 5-34 5.7.6.4 Removing the Differential PCB ......................................................................................................... 5-34 5.7.7 Power Distribution PCB ........................................................................................................................... 5-35 5.7.7.1 Removing the Upper Rear Cover ....................................................................................................... 5-35 5.7.7.2 Removing the Power Distribution PCB ............................................................................................. 5-35 5.7.8 HDD .......................................................................................................................................................... 5-35 5.7.8.1 Removing the Upper Rear Cover ....................................................................................................... 5-35 5.7.8.2 Removing the Controller Box Cover ................................................................................................. 5-35 5.7.8.3 Removing the HDD ........................................................................................................................... 5-35 5.7.8.4 When Replacing the HDD ................................................................................................................. 5-36 5.7.9 Controller Fan ........................................................................................................................................... 5-37 5.7.9.1 Removing the Upper Rear Cover ....................................................................................................... 5-37 5.7.9.2 Removing the Controller Box Cover ................................................................................................. 5-37 5.7.9.3 Removing the Controller Fan ............................................................................................................ 5-37 Chapter 5 5.1 Construction 5.1.1 Outline 0006-8424 The major specifications, control mechanisms, and functions of the main controller are as follows: Main controller PCB (main) Image memory (256 MB, expanded) (512 MB, standard) J1202 J1201 Flash ROM (for boot program) IC1003 LSI LSI IC1012 IC1015 IC1018 Ethernet board connector slot (for support of 10BASE-T/100BASE-Tx) J1203 J1204 UFR board or open I/F board connection PCI slot J1207 IC1029 J1205 TokenRing board or USB interface board connection PCI slot J1206 IDE hard disk (40 GB; f or support of ultra TA/66) connector Image conversion board connection PCI slot PCI slot for connection of USB application interface board F-5-1 Main Controller PCB (sub) IC10 IC15 F-5-2 5-1 Chapter 5 5.1.2 Functional Construction 0000-4282 The machine may be broadly divided into the following functional blocks (main controller indicated with shading): Retention of service mode settings/ HDD control information Image memory (SDRAM) Reader input image processing Reader unit SRAM board Main controller PCB (main) Main controller PCB (sub) DC controller PCB Boot ROM HDD Printer unit • system control • memory control • printer output image processing F-5-3 5-2 Accessory boards Chapter 5 5.2 Construction of the Electrical Circuitry 5.2.1 Outline 0000-4283 The major mechanisms of the main controller PCB are controlled by the CPU on the main controller PCB. To save on physical space, the machineís main controller PCB is divided into two: main and sub. The sub PCB serves to process input images coming from the reader unit, while the main PCB serves to control jobs, output images going to the printer, and memory. 5.2.2 Main Controller PCB 0000-4284 Main Controller PCB (main) T-5-1 IC No. Description IC1012 CPU: system control network controller PCI bus controller serial communications controller ROM/RAM controller IC1015 image input/output and image processing IC1003, 1018 image processing control of output image data to printer unit IC1029 HDD control Image memory (SDRAM) temporarily stores image data Boot ROM (Flash ROM) storage of boot program Main Controller PCB (sub) T-5-2 IC No. Description IC10 image processing control of input image data from reader unit IC15 input/output processing 5-3 Chapter 5 5.2.3 SRAM board 0006-4436 T-5-3 Description control information on image data stored on the HDD service mode settings data 5.2.4 HDD 0006-4439 The hard disk is divided into 9 partitions (blocks for storage of specific type of data), with each partition possessing its own functions: T-5-4 Partition Description DOSDEV stores multipurpose data FSTDEV stores image data DOSDEV2 stores thumbnail display data (image data) FSPTDEV stores image data DOSDEV3 temporarily stores multipurpose file (e.g., PDL spool) PDLDEV stores PDL-related files (e.g., font, stored firmware, ICC Profile, PDL color correction information file) 5-4 DOSDEV4 stores user data (address book, transfer settings) BOOTDEV stores system software DOSDEV5 for future use Chapter 5 DOSDEV FSTDEV HDD DOSDEV2 FSTPDEV DOSDEV3 PDLDEV DOSDEV4 BOOTDEV DOSDEV5 F-5-4 5.2.5 Composition of the System Software 0006-4453 The following shows the construction of the machine's system software: T-5-5 System software Description Location SYSTEM system module (controls system HDD(BOOTDEV) Remarks as a whole) Language language module (controls LCD HDD(BOOTDEV) indication) RUI language module (controls HDD(BOOTDEV) remote UI) BOOT starts up the machine BootROM DIMM G3FAX controls G3FAX G3FAX board DIMM Dcon controls the DC controller DC controller PCB soldered in place Rcon controls the reader controller reader controller PCB soldered in place 5-5 Chapter 5 RCON Reader controller PCB DC controller PCB DCON G3Fax board G3FAX HDD BOOT SYSTEM Language RUI BOOTDEV BOOTDEV F-5-5 5-6 Main controller PCB Chapter 5 5.3 Start-Up Sequence 5.3.1 Outline 0000-4285 The system control software used to control the machine is stored on the HDD. At time of startup, the CPU on the controller PCB follows the boot program to read the system software from the HDD to the Image Memory (SDRAM) on the controller PCB. While the CPU reads the system software from the HDD to the Image Memory (SDRAM), the control panel shows the following screen, and the startup sequence under way is indicated by the progress bar on the screen. Starting up. Please wait. Progress bar F-5-6 Never turn off the main power while the progress bar is indicated. The HDD is being accessed during the period, and turning off the power can cause a fault (E602) on the HDD. 5.3.2 Startup Sequence 0000-4286 <Boot ROM Area> - Self Diagnosis Program When the main power is turned on, the CPU on the main controller PCB executes the start-up sequence. In the course of the sequence, the state of the image memory (SDRAM) and the HDD is checked, and an error code will be indicated if a fault is detected. - Boot Program When the self diagnosis program ends normally, the CPI on the main controller PCB starts up the boot program. When the program is run, the system software is read from the HDD and is written to the system area of the image memory (SDRAM). <Image Memory (SDRAM) Area> A set of instructions is executed by the system software written in the boot program, initializing various settings (e.g., I/F settings of the main controller). 5-7 Chapter 5 When all the foregoing ends normally, the machine becomes ready to accept jobs. (The operation screen will appear on the control panel, and the LED on the Start key changes from red to green.) - Self Diagnosis Program Is Under Way Image memory System area SDRAM Image area CPU HDD Self diagnos is program Boot program BootROM Main controller PCB (main) :Access to the program at time of execution F-5-7 - Boot Program Is Under Way Image memory System area SDRAM Image area Systems software CPU Self diagnos is program Boot program BootROM Main controller PCB (main) : access to program at time of execution : flow of system program F-5-8 5-8 HDD Chapter 5 5.4 Actions when HDD Error 5.4.1 E602 in Detail 0006-4492 In the even that the machine suffers a fault associated with E602-xxyy, different actions are required depending on the detail code: If the machine indicates E602-xxyy, be sure to turn it off and then on once (so that it will execute automatic recovery sequence). T-5-6 xx Partition yy Description 00 HDD as a 01 The machine cannot recognize the HDD. The machine whole cannot find BOOTDEV at time of start-up. Action: Turn off the main power. Check the 2 types of cable (power, IDE) coming from the HDD; then, turn the power back on. At this time, check to see that the HDD is rotating and it is supplied with power. F 02 NG D The machine cannot find the system software of the main controller (main) CPU in BOOTDEV. 06 The machine cannot find the system software for the main controller (sub) CPU in BOOTDEV. 07 The machine cannot find an appropriate ICCProfile file in BOOTDEV/PDLDEV. Action: B 03 NG F When data is being read from BOOTDEV, the machine detects a read error sector. Action: H NG E NG F 5-9 Chapter 5 T-5-7 xx Partition yy Description 01 DOSDEV 01 The machine suffers a read error at time of start-up. 02 FSTDEV 03 DOSDEV2 04 FSTPDEV 05 DOSDEV3 06 PDLDEV 07 DOSDEV4 08 BOOTDEV 09 DOSDEV5 FF not Action: A NG B NG F - if xxyy = 0701, 0702 Action: Ask the user to collect address book data, transfer settings, and user mode data using RUI before starting the work. identified A NG C NG F - xxyy = 0801, FF01 Action: A 02 NG E NG F There is a file system error. Action: B NG F - xxyy = 0702 Action: Ask the user to collect address book data, transfer settings, and user mode data using RUI before starting the work. C NG F - if xxyy = 0802, FF02 Action: B 03 NG F There is an HDD contact fault or an OS system error. Action: Turn off the main power. Check the 2 types of cable (power, IDE) coming from the HDD; then, turn the power back on. At that time, check to see that the HDD rotates and it is supplied with power. E 5-10 NG F NG D Chapter 5 xx Partition yy Description 11,21 The HDD has poor contact. Action: Turn off the main power. Check the 2 types of cable (power, IDE) coming from the HDD; then, turn the power back on. At that time, check to see that the HDD rotates and it is supplied with power. F 13,25 NG D There is a read error. Action: A NG G NG F - if xxyy= 0713, 0725 Action: A NG C NG F - if xxyy = 0813, 0825 Action: A 10,12,14,2 NG E NG F There is a system error or a packet data error. 2,23,24 Action: B NG F A: 1) Set '0' to the following: COPIER>FUNCTION>SYSTEM>CHK-TYPE. 2) Execute the following: COPIER>FUNCTION>SYSTEM>HD-CHECK*. (Make these selections, and press the OK key.) 3) Turn off and then on the main power. B: 1) By referring to the table "HDD Format," fill 'CHK-TYPE' under the following: COPIER>FUNCTION>SYSTEM>CHK-TYPE. 2) Execute the following: COPIER>FUNCTION>SYSTEM>HD-CLEAR. (Make these selections, and press the OK key.) 3) Turn off and then on the main power. C: 1) ** Start up in normal mode (i.e., turn on the main power while holding down the 1 and 7 keys); then, make the following selections, and press the OK key: COPIER>FUNCTION>SYSTEM>DOWNLOAD. 2) Execute DOSDEV4 (formatting) using the SST. 3) Turn off and then on the main power. 5-11 Chapter 5 D: 1) Replace the main controller (main) board. 2) Mount the image memory (SDRAM) and the boot ROM (removed from the previous board) to the new board. E: 1) ** Start up in save mode (i.e., turn on the main power while holding down the 2 and 8 keys.) 2) Execute HDD formatting using the SST (ALL); then, download the system software (SYSTEM, LANG, RUI). 3) Turn off and then on the main power. F: 1) ** Replace the HDD, and start up in safe mode (i.e., turn on the main power while holding down on the 2 and 8 keys). 2) Using the SST, format the HDD (ALL) and download the system software (SYSTEM, LANG, RUI). 3) Turn off and then on the main power. G: 1) Set '1' to the following: COPIER>FUNCTION>SYSTEM>CHK-TYPE. 2) Execute the following: COPIER>FUNCTION>SYSTEM>HD-CLEAR. (Make these selections, and press the OK key.) 3) Turn off and then on the main power. H: 1) Turn off the main power, and turn on the main power while pressing the 1 and 9 keys. (In response, the machine will automatically start its recovery program*, and the control panel will turn completely black.) 2) When the screen has turned white, turn off and then on the main power. If the recovery program fails to start in response, go to E. * It will take about 30 to 50 min. ** As necessary, ask the user to make a backup of the address book, transfer, and user mode data using the RUI. T-5-8 - HDD Format Partition CHK- Data items that will be lost TYPE 1 all relating to images (e.g., reservations, Box, Fax); mode memory, routine task button DOSDEV3 2 PDL spool PDLDEV 3 PDL-related file (e.g., font, registration form, DOSDEV FSTDEV DOSDEV2 FSTPDEV ICCProfile) 5-12 Chapter 5 - HDD Format Partition CHK- Data items that will be lost TYPE 4 user data (address book data, transfer settings, system software) DOSDEV5 5 - unselected 0 - DOSDEV4 BOOTDEV 5-13 Chapter 5 5.5 Image Processing 5.5.1 Flow of Images 0000-4288 The following diagram shows the flow of images in relation to the machine's various functions: Other iR machine Original A Copy A Print output • SEND • FAX • PullScan • E-Mail Scan A Image data BOX • SEND • FAX • PDL Print PC F-5-9 5-14 Chapter 5 5.5.2 Construction of the Image Processing Module 0000-4292 The machine's major image processing is undertaken by the main controller; the construction of the modules involved in image processing is as follows: Image memory (SDRAM) Reader input image processing block Processes the image data read by the reader unit. Reader unit DC controller PCB IC10 Main controller PCB (sub) C,M IC1003 IC1015 Y,Bk IC1018 IC1012 Main controller PCB (main) HDD Printer output image processing block Processes image data from IC1015 for output to the printer. Printer unit • JPEG conversion • enlargement/reduction, rotation • color space conversion • binary processing • resolution conversion • CPU • communications control • memory access control F-5-10 5-15 Chapter 5 5.5.3 Reader Input Image Processing 0000-4293 The image data read by the reader unit (RGB data) is processed by the main controller PCB (sub). Reader unit RGB Processing that takes the place of conventional input masking; executes color correction for the CCD's RGB filters. 24 Main controller PCB (sub) RG phase correction Black text identification Input γ correction Input direct mapping ACS identification Applicable to monochrome mode; hereafter, Bk signals only. • Edge emphases • Smoothing Image signal generation • See-through prevention (BE) • Bk generation (monochrome mode) 4 • Framing • Blanking • Frame erasing RGB IC1015 Main controller PCB (main) F-5-11 5-16 Chapter 5 5.5.4 Compression/Decompression and Edit Processing Black 0000-4294 The machine uses IC1015 to undertake compression/decompression and edit processing. Reader unit 24 RGB Main controller PCB (sub) RGB 24 4 Image area signal IC1015 PDL input JPEG compression Resolution conversion Enlargement/reduction Main controller PCB (main) SDRAM JPEG decompression PC Rotation IC1012 Color conversion Binary processing For fax transmission JPEG compression JPEG decompression IC1003 IC1018 C,M Y,Bk HDD F-5-12 5-17 Chapter 5 5.5.5 Printer Output Image Processing 0000-4295 In this block, the machine processes image data coming from IC1015 for output to the printer. Reader unit 24 RGB Main controller PCB (sub) RGB If ACS identifies the original as being black-and-white, the Bk signal is generated here (if color, passed through). 4 Image area signal 24 IC1015 RGB 24 IC1003 • Background removal (AE) • Bk generation In the case of color mode, the Bk signal is generated here. 4 Image area signal IC1018 RGB-to-CMY conversion Output direct mapping For the text area, UCR processing CMYK • F value adjustment • Color balance correction Output λ correction The LUT for correction is generated using PASCAL. Optimum screen selection Smoothing C,M • Framing • Blanking To DC controller PCB Y,Bk Main controller PCB (main) F-5-13 5-18 Chapter 5 5.6 Flow of Image Data 5.6.1 Flow of Image Data for Copier Functions 0000-4296 The following shows the flow of image data when copier functions are used: Reader unit RGB 24 Main controller PCB (sub) RGB image area signal 24 Main controller PCB (main) DC controller PCB JPEG compression Magnification Rotation JPEG decompression Color conversion SDRAM HDD F-5-14 5-19 Chapter 5 5.6.2 Flow of Image Data for Box Functions The following shows the flow of image data when Box functions are used: Reader unit RGB 24 Main controller PCB (sub) RGB 24 image area signal Main controller PCB (main) DC controller PCB JPEG decompression JPEG compression Decompression conversion Rotation SDRAM HDD F-5-15 5-20 0000-4297 Chapter 5 5.6.3 Flow of Image data for SEND function 0000-4298 The following shows the flow of image data for SEND functions: Reader unit RGB 24 Main controller PCB (sub) RGB 24 image area signal Main controller PCB (main) JPEG decompression for B/Wimage Binary processing MMR compression Resolution conversion Rotation JPEG compression HDD SDRAM Image conversion board Ethernet board F-5-16 5-21 Chapter 5 5.6.4 Flow of Image Data for Fax Transmission Functions The following is the flow of image data for fax transmission functions: Reader unit RGB 24 Main controller PCB (sub) image area signal RGB Main controller PCB (main) JPEG compression Resolution conversion JPEG decompression Rotation MMR compression Binary processing HDD SDRAM Image conversion board Fax board F-5-17 5-22 0000-4299 Chapter 5 5.6.5 Flow of Image Data for Fax Reception Functions 0000-4300 The following is the flow of image data for fax reception functions: DC controller PCB Main controller PCB (main) Resolution conversion Rotation HDD SDRAM Image conversion board Fax board F-5-18 5-23 Chapter 5 5.6.6 Flow of Image Data for PDL Functions 0000-4301 The following is the flow of image data for PDL functions: Reader unit Printer unit Main controller PCB (main) SDRAM IC1015 JPEG decompression IC1003 IC1018 IC1012 DC controller PCB Main controller PCB (sub) JPEG compression RGB HDD UFR board CMYK PS Printer Server Unit-C1 LIPS data Printer output image processing block LIPS RGB CMYK Display list data RGB Option interface board GDI-UFR PS data PS F-5-19 5-24 PC Chapter 5 5.7 Parts Procedure Replacement [1] 5.7.1 Main Controller PCB (main) 5.7.1.1 Removing the Upper Rear Cover 0000-4303 1) Remove the upper rear cover. F-5-21 5.7.1.2 Removing the Left Upper Rear Cover 0000-4308 1) Removing the left rear upper cover. 5.7.1.3 Removing the Controller PCB Cover 5.7.1.4 Removing the Controller Box Cover DC 0000-4309 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 0000-4310 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-5-20 When Attaching the DC Controller PCB Cover F-5-22 When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. 5-25 Chapter 5 5.7.1.5 Removing the HDD 0000-4311 5.7.1.7 Removing the Ethernet Board 0000-4313 1) Remove the 2 screws [1], and detach the Ethernet Points to Note When Removing the HDD board [2] together with its mounting plate. When removing the HDD, be sure to take full care against damage by static discharge. Moreover, do not subject the HDD to impact. 1) Remove the 4 screws [1] and the flat cable [2], and disconnect the connector [3]; then, detach the HDD [4]. F-5-25 2) Removing the 2 screws [1], and detach the Ethernet board [3] from the mounting plate [2]. F-5-23 5.7.1.6 Removing the Hard Disk Mounting Plates 0000-4312 1) Remove the 2 screws [1], and detach the 2 hard disk mounting plates [2]. F-5-26 F-5-24 5-26 Chapter 5 5.7.1.8 Removing the UFR Board 0000-4314 1) Remove the 2 screws [1], and detach the UFR board [2] together with its mounting plate. F-5-29 5.7.1.10 Removing the Main F-5-27 Controller PCB (sub) 2) Remove the 2 screws [1], and detach the UFR board [3] from its mounting plate [2]. 0000-4316 1) Disconnect all connectors from the PCB, and remove the flat cable [1]. F-5-30 2) Remove the 7 screws [1], and remove the main F-5-28 controller PCB (sub) [2]. 5.7.1.9 Removing the SRAM PCB 0000-4315 1) Remove the 2 screws [1], and detach the SRAM PCB [2]. F-5-31 5-27 Chapter 5 5.7.1.11 Removing the Main Controller PCB (main) 0000-4317 1) Remove the 2 flat cables [1] used for connection to the DC controller PCB. F-5-34 F-5-32 2) Disconnect the connectors of the PCB; then, remove the 10 screws [1], and detach the main controller PCB (main) [2]. F-5-35 5.7.2 Main Controller PCB (sub) 5.7.2.1 Removing the Upper Rear Cover 0000-4321 1) Remove the upper rear cover. 5.7.2.2 Removing the Left Upper Rear Cover 1) Removing the left rear upper cover. F-5-33 5.7.2.3 5.7.1.12 When Replacing the Main Controller PCB (main) 0000-4322 0000-4318 Removing the Controller Box Cover 0000-4323 Be sure to use the image memory (SDRAM) [1] PCB 1) Disconnect the connector J1512 [1] from the power and the boot ROM [2] from the old PCB on the new distribution PCB, and free the harness from the main controller PCB (main). wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. 5-28 Chapter 5 5.7.2.5 Removing the Hard Disk Mounting Plates 0000-4325 1) Remove the 2 screws [1], and detach the 2 hard disk mounting plates [2]. F-5-38 F-5-36 5.7.2.4 Removing the HDD 0000-4324 Points to Note When Removing the HDD When removing the HDD, be sure to take full care against damage by static discharge. Moreover, do not subject the HDD to impact. 1) Remove the 4 screws [1] and the flat cable [2], and disconnect the connector [3]; then, detach the HDD [4]. F-5-37 5-29 Chapter 5 5.7.2.6 Removing the SRAM PCB 0000-4326 1) Remove the 2 screws [1], and detach the SRAM PCB [2]. F-5-41 5.7.2.8 When Replacing the Main Controller PCB (sub) F-5-39 0000-4329 Be sure to use the SRAM PCB [1] from the old PCB on the new main controller PCB (sub) [2]. 5.7.2.7 Removing the Main Controller PCB (sub) 0000-4327 1) Disconnect all connectors from the PCB, and remove the flat cable [1]. F-5-42 F-5-40 2) Remove the 7 screws [1], and remove the main controller PCB (sub) [2]. 5-30 Chapter 5 5.7.3 SRAM PCB 5.7.3.1 Removing the Upper Rear Cover 0000-4331 1) Remove the upper rear cover. 5.7.3.2 Removing the Controller Box Cover 0000-4332 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and F-5-44 detach the main controller cover [4]. 5.7.3.4 Removing the SRAM PCB 0000-4334 1) Remove the 2 screws [1], and detach the SRAM PCB [2]. F-5-45 F-5-43 5.7.3.3 Removing the HDD 0000-4333 5.7.3.5 When Replacing the SRAM PCB 0000-4335 Points to Note When Removing the HDD When removing the HDD, be sure to take full care When the SRAM PCB is replaced, all data in its against damage by static discharge. Moreover, do not memory will be lost (file-related, user mode-related, subject the HDD to impact. service mode-related, history-related files). There will be no error operation, and initialization will take place 1) Remove the 4 screws [1] and the flat cable [2], and automatically. disconnect the connector [3]; then, detach the HDD If you pull out the SRAM PCB from machine B and [4]. mount it to machine A, the PCB will be initialized and be rendered useless for machine A or B. Take full care. 5-31 Chapter 5 1) When you turn on the power after replacing the SRAM PCB, the machine will execute automatic initialization and will indicate a message on its panel to the effect that you are to turn off and then on the power switch found on its right side. Follow the message and turn off and then on the machine. 2) Using service mode, initialize the RAM. COPIER>FUNCTION>CLEAR>MN-CON Before starting the work, be sure to inform the user that all image data stored in the Box will be lost and obtain his/her consent. F-5-46 5.7.4 UFR Board 5.7.4.4 Removing the UFR 5.7.4.1 Removing the Upper Rear Cover 0000-4338 0000-4341 1) Remove the 2 screws [1], and detach the UFR board 1) Remove the upper rear cover. 5.7.4.2 Board [2] together with its mounting plate. Removing the Left Upper Rear Cover 0000-4339 1) Removing the left rear upper cover. 5.7.4.3 Removing the Controller Box Cover 0000-4340 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and F-5-47 detach the main controller cover [4]. 2) Remove the 2 screws [1], and detach the UFR board [3] from its mounting plate [2]. 5-32 Chapter 5 F-5-48 5.7.5 Ethernet Board 5.7.5.1 Removing the Upper Rear Cover F-5-49 0000-4343 5.7.5.4 Removing the Ethernet 1) Remove the upper rear cover. Board 5.7.5.2 Removing the Left Upper Rear Cover 0000-4346 1) Remove the 2 screws [1], and detach the Ethernet 0000-4344 board [2] together with its mounting plate. 1) Removing the left rear upper cover. 5.7.5.3 Removing the Controller Box Cover 0000-4345 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-5-50 2) Removing the 2 screws [1], and detach the Ethernet board [3] from the mounting plate [2]. 5-33 Chapter 5 F-5-51 5.7.6 Differential PCB F-5-52 5.7.6.1 Removing the Upper Rear Cover 0000-4348 1) Remove the upper rear cover. 5.7.6.2 5.7.6.4 Removing Differential PCB 0000-4351 1) Remove the flat cable [1]. Removing the Left Upper Rear Cover the 0000-4349 1) Removing the left rear upper cover. 5.7.6.3 Removing the Controller Box Cover 0000-4350 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-5-53 2) Remove the 3 screws [1], and detach the differential PCB [2]. 5-34 Chapter 5 5.7.8 HDD 5.7.8.1 Removing the Upper Rear Cover 0000-4357 1) Remove the upper rear cover. 5.7.8.2 Removing the Controller Box Cover 0000-4358 1) Disconnect the connector J1512 [1] from the power F-5-54 distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and 5.7.7 Power Distribution PCB detach the main controller cover [4]. 5.7.7.1 Removing the Upper Rear Cover 0000-4353 1) Remove the upper rear cover. 5.7.7.2 Removing the Power Distribution PCB 0000-4354 1) Disconnect the connectors from the PCB, and remove the 4 screws [1] to detach the power distribution PCB [2]. F-5-56 5.7.8.3 Removing the HDD 0000-4359 Points to Note When Removing the HDD When removing the HDD, be sure to take full care F-5-55 against damage by static discharge. Moreover, do not subject the HDD to impact. 1) Remove the 4 screws [1] and the flat cable [2], and disconnect the connector [3]; then, detach the HDD [4]. 5-35 Chapter 5 control settings>group ID control>count control; then, check to see that IDs from 00000001 through 00001000 have been prepared. Make the following selections: user mode>system control settings>network settings>TCP/IP settings>IP address; then, set up 'IP address' 'gateway address' and 'subnet mask' Make the following selections: user mode>system administrator setup; then, fill in 'system control group ID' and 'system control ID No.' thereafter, turn off and then on the machine. If you leave out 'system control group ID' and F-5-57 'system control ID No.' the service engineer will not be able to 'register card to device' as part of setup 5.7.8.4 When Replacing the HDD work for NSA. 0000-4360 If NetSpot Accountant (NSA) Is Not Used 3) With the machine in standby state, download the card ID to be used from NSA. 4) When the card data has been downloaded from 1) Formatting the HDD While holding down the 2 and 8 keys on the control NSA, check to see that the ID data has correctly panel, turn on the power to start up. Using the HD been downloaded on the screen brought up by formatting function of the SST, format all making the following selections: user mode>system control settings>group ID control partitions. (Only the downloaded ID data must be indicated.) 2) Downloading the Software Using the SST, download the various software 5) Make copies using a user card registered with NSA, (system, language, RUI). The machine will take and check to see that statistical operations are made about 10 min to start up after downloading. for the device in question. If NetSpot Accountant (NSA) Is Used Together with a Card Reader The card ID used by the NSA resides on the HDD. If you have replaced the HDD, therefore, you will have to newly download the card data from NSA to enable the statistical operations of NSA. After going through steps 1) and 2) above, perform the following: 1) Set the following in service mode: Make the following selections: COPIER>FUNCTION>INSTALL>CARD; then, enter the number of the first card, and press [OK]. (For instance, if cards No. 1 through No. 1000 are used for group control, enter '1') 2) Turn off and then on the machine; when the machine has started up, perform the following in user mode: Make the following selections: user mode>system 5-36 Chapter 5 5.7.9 Controller Fan 5.7.9.3 Removing Controller Fan 5.7.9.1 Removing the Upper Rear Cover the 0000-4302 1) Disconnect the connector [1], and remove the 4 0000-8501 screws [2]; then, detach the controller fan [3]. 1) Remove the upper rear cover. 5.7.9.2 Removing the Controller Box Cover 0000-8192 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-5-59 F-5-58 5-37 Chapter 5 5-38 Chapter 6 Original Exposure System Contents Contents 6.1 Construction ...................................................................................................................................................... 6-1 6.1.1 Specifications, Control Mechanisms, and Functions ................................................................................. 6-1 6.1.2 Major Components ..................................................................................................................................... 6-1 6.1.3 Construction of the Control System ........................................................................................................... 6-4 6.1.4 Reader Controller PCB ............................................................................................................................... 6-4 6.2 Basic Sequence .................................................................................................................................................. 6-5 6.2.1 Basic Sequence of Operations at Power-On ............................................................................................... 6-5 6.2.2 Basic Sequence of Operations in Response to a Press on the Start Key (book mode, 1 original) ............. 6-6 6.3 Various Control Mechanisms ............................................................................................................................ 6-7 6.3.1 Controlling the Scanner Drive System ....................................................................................................... 6-7 6.3.1.1 Outline ................................................................................................................................................. 6-7 6.3.1.2 Controlling the Scanner Motor ............................................................................................................ 6-8 6.3.2 Enlargement/Reduction ............................................................................................................................... 6-9 6.3.2.1 Changing the Reproduction Ratio ....................................................................................................... 6-9 6.3.2.2 Changing the Reproduction Ratio in Main Scanning Direction .......................................................... 6-9 6.3.2.3 Changing the Reproduction Ratio in Sub Scanning Direction ............................................................ 6-9 6.3.3 Controlling the Scanning Lamp .................................................................................................................. 6-9 6.3.3.1 Outline ................................................................................................................................................. 6-9 6.3.3.2 Scanning Lamp .................................................................................................................................. 6-10 6.3.3.3 Turning On/Off the Lamp ................................................................................................................. 6-10 6.3.3.4 Checking for an Error ........................................................................................................................ 6-10 6.3.4 Detecting the Size of Originals ................................................................................................................. 6-10 6.3.4.1 Outline ............................................................................................................................................... 6-10 6.3.4.2 Points of Detection (original size) ..................................................................................................... 6-11 6.3.4.3 Outline of Detection Operations ........................................................................................................ 6-11 6.4 Parts Replacement Procedure .......................................................................................................................... 6-14 6.4.1 Copyboard Glass ....................................................................................................................................... 6-14 6.4.1.1 Removing the Copyboard Glass ........................................................................................................ 6-14 6.4.1.2 After Replacing the Copyboard Glass ............................................................................................... 6-14 6.4.2 Exposure Lamp ......................................................................................................................................... 6-15 6.4.2.1 Removing the Copyboard Glass ........................................................................................................ 6-15 6.4.2.2 Removing the Reader Left Cover/Reader Right Cover/Reader Front Cover .................................... 6-15 6.4.2.3 Removing the CCD Unit Cover ........................................................................................................ 6-15 6.4.2.4 Removing the Scanning Lamp .......................................................................................................... 6-16 6.4.3 Reader Controller PCB ............................................................................................................................. 6-17 6.4.3.1 Removing the Copyboard Glass ........................................................................................................ 6-17 6.4.3.2 Removing the CCD Unit Cover ........................................................................................................ 6-17 6.4.3.3 Removing the Original Size Detection Unit ...................................................................................... 6-18 6.4.3.4 Removing the Reader Controller PCB .............................................................................................. 6-18 6.4.3.5 When Replacing the Reader Controller PCB .................................................................................... 6-18 6.4.4 Interface PCB ............................................................................................................................................ 6-19 6.4.4.1 Removing the Copyboard Glass ........................................................................................................ 6-19 6.4.4.2 Removing the Reader Rear Cover ..................................................................................................... 6-20 6.4.4.3 Removing the Interface PCB ............................................................................................................. 6-20 6.4.5 Inverter PCB ............................................................................................................................................. 6-21 6.4.5.1 Removing the Copyboard Glass ........................................................................................................ 6-21 6.4.5.2 Removing the CCD Unit Cover ........................................................................................................ 6-22 6.4.5.3 Removing the Inverter PCB .............................................................................................................. 6-22 6.4.6 CCD Unit .................................................................................................................................................. 6-22 Contents 6.4.6.1 Removing the Copyboard Glass ........................................................................................................ 6-22 6.4.6.2 Removing the CCD Unit Cover ......................................................................................................... 6-23 6.4.6.3 Removing the Original Size Detection Unit ...................................................................................... 6-23 6.4.6.4 Removing the CCD Unit .................................................................................................................... 6-24 6.4.6.5 After Replacing the CCD Unit ........................................................................................................... 6-24 6.4.7 Fuse PCB (option) ..................................................................................................................................... 6-24 6.4.7.1 Removing the Reader Rear Cover ..................................................................................................... 6-24 6.4.7.2 Removing the Copyboard Cover Open/Closed Sensor Mounting ..................................................... 6-24 6.4.7.3 Removing the Fuse PCB Unit (option; 100/230v model only) ......................................................... 6-25 6.4.8 Scanner Motor ........................................................................................................................................... 6-25 6.4.8.1 Removing the Copyboard Glass ........................................................................................................ 6-25 6.4.8.2 Removing the Reader Rear Cover ..................................................................................................... 6-26 6.4.8.3 Removing the Interface PCB ............................................................................................................. 6-26 6.4.8.4 Removing the Scanner Motor ............................................................................................................ 6-27 6.4.8.5 Mounting the Scanner Motor ............................................................................................................. 6-27 6.4.9 Original Cover Sensor ............................................................................................................................... 6-28 6.4.9.1 Removing the Reader Rear Cover ..................................................................................................... 6-28 6.4.9.2 Removing the Copyboard Cover Open/Closed Sensor Mounting ..................................................... 6-28 6.4.9.3 Removing the Copyboard Cover Open/Closed Sensor Cover ........................................................... 6-29 6.4.9.4 Removing the Copyboard Cover Open/Closed Sensor ..................................................................... 6-29 6.4.10 Scanner HP Sensor .................................................................................................................................. 6-29 6.4.10.1 Removing the Reader Rear Cover ................................................................................................... 6-29 6.4.10.2 Removing the Copyboard Cover Open/Closed Sensor Mounting ................................................... 6-29 6.4.10.3 Removing the Mirror Base Home Position Sensor .......................................................................... 6-30 6.4.11 Original Sensor ........................................................................................................................................ 6-30 6.4.11.1 Removing the Copyboard Glass ...................................................................................................... 6-30 6.4.11.2 Removing the CCD Unit Cover ....................................................................................................... 6-31 6.4.11.3 Removing the Original Size Detection Unit .................................................................................... 6-31 6.4.11.4 Removing the Original Size Sensor ................................................................................................. 6-31 6.4.12 Reader Heater (option) ............................................................................................................................ 6-31 6.4.12.1 Removing the Copyboard Glass ...................................................................................................... 6-31 6.4.12.2 Removing the Reader Rear Cover ................................................................................................... 6-32 6.4.12.3 Removing the Fuse PCB Unit .......................................................................................................... 6-33 6.4.12.4 Removing the Reader Heater (option; 100/230V model only) ........................................................ 6-33 Chapter 6 6.1 Construction 6.1.1 Specifications, Control Mechanisms, and Functions 0006-0654 The major specifications, control mechanisms, and functions of the original exposure system are as follows: T-6-1 Item Description Scanning lamp Xenon lamp Original scanning in book mode: by moving the scanner in ADF mode: by moving the scanner Reading resolution 600 dpi (main scanning) x 600 dpi (sub scanning) Scanner position detection by scanner HP sensor (PS2) Lens lens array (single focus, fixed) Enlargement/reduction (zoom) in copyboard cover mode: 100% in ADF mode: 100% in main scanning direction, image processing in the controller unit in sub scanning direction, image processing in the controller unit Scanner drive control No. 1/No. 2 mirror mount (control by a pulse motor M1) Scanning lamp [1] activation control by an inverter circuit Activation control [2] detection of error Original size identification [1] in book mode, sub scanning direction: by reflection type sensor main scanning direction: by CCD [2] in ADF mode: by ADF 6.1.2 Major Components 0000-4383 The major components of the original exposure system are as f follows: T-6-2 Component Notation Description Scanning lamp LA1 xenon lamp (intensity of 35,000 lx) Scanner motor M1 2-phase pulse motor (pulse control) Scanner HP sensor PS2 photointerrupter (scanner home position detection) 6-1 Chapter 6 Component Notation Copyboard cover open/ Description PS1 photointerrupter (copyboard cover state (open/closed) closed sensor detection; identifies as being "Closed"when the copyboard is brought down to 30 deg or lower) Mirror --- No. 1/No. 2/No. 3 mirror Scanner motor Scanner HP sensor Reader controller PCB CCD unit Interface PCB Copyboard cover open/closed sensor Fuse PCB Inverter PCB Anti-condensation heater Available as option only for 100/230V model Original size sensor (Inch) Original size sensor (AB, Inch) Scanning lamp (LA1) F-6-1 Shading position Start position Original size detection position Home position sensor detection position Image leading edge Vertical size plate White plate Original No. 2 mirror Scanning lamp No. 1 mirror base No. 3 mirror No. 1 mirror No. 2 mirror base F-6-2 6-2 Copyboard glass (w/ integrated white plate) Lens CCD Chapter 6 Scanner motor (M1) Light-blocking plate Scanning lamp (LA1) Scanner HP sensor (PS2) (forward) (reverse) No. 1 mirror base No. 2 mirror base F-6-3 Scanner motor (M1) Light-blocking plate Scanning lamp (LA1) Scanner HP sensor (SR2) (forward) (reverse) No. 1 mirror base No. 2 mirror base F-6-4 6-3 Chapter 6 6.1.3 Construction of the Control System 0000-4384 The control system of the original exposure system is constructed as follows: Scanner motor (M1) Scanner motor drive control Reader controller PCB To printer (main controller) Interface PCB CCD unit J 03 306 J3 08 02 J3 J2 05 04 07 J3 J2 3 J 05 03 J3 2 2 J J 10 06 J2 To DF J6 J6 01 02 Copyboard cover open/closed sensor Scanning lamp activation control Scanner HP sensor Inverter PCB Scanning lamp (LA1) F-6-5 6.1.4 Reader Controller PCB 0000-4385 The construction of the functions of the reader controller PCB is as follows: Image processing (shading correction) Storage of start-up program (boot ROM) Scanner motor Storage of firmware (flash ROM) Printer unit DF Not used DC24V DC15V DC5V DC3.3V J203 J202 J210 IC5 (CPU) IC16 J201 IC7 IC14 J204 J206 Inverter PCB J205 J207 IC3 Original size sensor J208 Original size sensor Backup of service mode settings (EEP ROM) CCD unit F-6-6 6-4 Chapter 6 6.2 Basic Sequence 6.2.1 Basic Sequence of Operations at Power-On ON (to stabilize lamp intensity) Main power switch ON 0000-4386 CCD output gain adjustment (for color original) CCD output gain adjustment (for black-and-white original) SREADY STBY Scanner HP sensor (PS2) Scanning lamp (LA1) Scanner motor(M1) Reverse Forward Forward Shading position Original size detection position F-6-7 Original size HP sensor HP Start position Shading position Image leading edge Original size detection position 1. (The main power switch is turned on.) The scanner is moved to the shading position. 2. The scanner is moved to the scanner size detection position. : No. 1 mirror base position F-6-8 6-5 Chapter 6 6.2.2 Basic Sequence of Operations in Response to a Press on the Start Key (book mode, 1 original) 0000-4387 Shading correction (for 1st sheet) Start key ON STBY SREADY SCFW Shading correction (for 2nd sheet) SCRW STBY Scanner HP sensor (PS2) Scanning lamp (LA1) Scanner motor(M1) Reverse Reverse Forward Original size Start position detection position Shading position Start position Shading position HP Original size detection position F-6-9 HP sensor HP Start Shading position position 1. (The Start key is pressed.) The scanner moves to the shading position. 2. After shading correction, the scanner moves to the start position. 3. The scanner scans the original. 4. The scanner moves to the shading position. 5. After shading correction, the scanner moves to the start position. 6. The scanner moves to the start position. 7. The scanner moves to the original size detection position. : No. 1 mirror base position F-6-10 6-6 Image Original size Image trailing Stop leading detection edge position edge position Chapter 6 6.3 Various Control Mechanisms 6.3.1 Controlling the Scanner Drive System 6.3.1.1 Outline 0000-4388 The following shows the parts associated with the scanner drive system: [1] Reader controller PCB Interface PCB [2] Scanner motor (M1) [3] Light-blocking plate Scanning lamp (LA1) (forward) Copyboard cover open/closed sensor (PS1) (reverse) Scanner HP sensor (PS2) No. 1 mirror base No. 2 mirror base F-6-11 1. Scanner Motor (M1) Drive Signal turns on/off the motor, and controls the direction/speed of its rotation. 2. Scanner HP Detection Signal indicates that the No. 1 mirror base is in the home position. 3. Copyboard Cover Detection Signal identifies the state (open/closed) of the copyboard cover. 6-7 Chapter 6 6.3.1.2 Controlling the Scanner Motor 0000-4389 The following shows the construction of the control system of the scanner motor; the motor driver operates in response to signals from the CPU to turn on/off the scanner motor or to control the direction/speed of its rotation. Reader controller PCB Interface PCB Scanner motor +24V/15V J202 J308 A [1] CPU Motor driver A* B B* J306 3 1 4 5 2 6 M1 [1] Scanner motor control signal F-6-12 a. Moving the Scanner in Reverse for Image Scanning After scanning an image, the movement of the No. 1 mirror base to the shading position is controlled at a speed twice as high as it is moved to scan an image regardless of the color mode. b. Moving the Scanner Forward for Image Scanning To scan an image, the movement of the No. 1 mirror base unit is controlled by the following motor control mechanism: Start position Image leading edge Acceleration Image trailing edge Stop Constant speed Deceleration Travel speed [1] [2] [3] [4] Travel distance [1] Acceleration area: accelerates to a speed suited to black-and-white/SEND mode or full-color mode [2] Approach speed area: allows a margin of acceleration (approach run) to ensure stable speed [3] Reading image area: reads images at specific speed (if black-and-white/SEND mode, twice as fast as in full-color mode) [4] Deceleration area: decelerates after the image trailing edge for a stop F-6-13 MEMO: The scanner is moved at the following speed to suit the selected mode: - in full-color copy mode, 117 mm/sec. - in black-and-white copy/black-and-white SEND mode, 234 mm/sec - full-color SEND mode, 234 mm/sec (300 dpi or less); 117 mm/sec (more than 300 dpi) 6-8 Chapter 6 6.3.2 Enlargement/Reduction 6.3.2.1 Changing the Reproduction Ratio 0000-4390 1. in copyboard cover mode, 100% 2. in ADF mode, 100% MEMO: - The speed of scanning is 234 mm/sec in black-and-white copy or black-and-white SEND mode (reduction by 50%); to make up for the difference, the reading speed of the CCD is doubled, ultimately resulting in a 100% reproduction ratio. - The same is true of a resolution of 300 dpi or less in full-color SEND mode. 6.3.2.2 Changing the Reproduction Ratio in Main Scanning Direction 0000-4391 In copyboard cover mode and ADF mode, reading in main scanning direction is at 100% at all times, and the reproduction ratio is changed through data processing in the main controller. 6.3.2.3 Changing the Reproduction Ratio in Sub Scanning Direction 0000-4392 In copyboard cover mode and ADF mode, reading in sub scanning direction is at 100% at all times, and the reproduction ratio is changed through data processing in the main controller. 6.3.3 Controlling the Scanning Lamp 6.3.3.1 Outline 0000-4393 The items of control related to the scanning lamp and the construction of its control system are as follows: 1) turning on/off the lamp 2) checking for a fault Inverter PCB Xenon lamp LA1 Activation control circuit J601 J206 GND 1 9 GND 2 8 GND 3 7 GND 4 6 LAMP-ON 5 5 24V 6 4 24V 7 3 8 Sync signal 2 24V 9 1 Reader controller PCB CPU F-6-14 6-9 Chapter 6 6.3.3.2 Scanning Lamp 0000-4394 The machine's scanning lamp is a xenon lamp made up of a glass tube in which xenon gas is sealed. On the outside of the tube are 2 terminals laid in parallel in axial direction, while the inner side of the tube is coated with fluorescent material. When a high frequency, high voltage is applied to the terminals, the gas starts to discharge, thus causing the fluorescent material to emit light. Electrode Electrode Fluorescent material Open interval Glass tube Electrode Electrode F-6-15 6.3.3.3 Turning On/Off the Lamp 0000-4395 The scanning lamp is turned on/off by the drive signal (LAMP_ON) sent by the CPU on the reader controller PCB. When the signal is sent, the inverter PCB generates high-frequency, high voltage in the activation control circuit using the drive voltage (+24 V) supplied by the reader controller PCB for the activation of the xenon lamp. 6.3.3.4 Checking for an Error 0000-4396 At time of initial activation (e.g., shading correction), the lamp is checked for a fault (low intensity, activation failure; i.e., activation error caused by lack of intensity). E220 (lamp activation error at power-on) Indicates a fault in the inverter PCB, reader controller PCB, or scanning 6.3.4 Detecting the Size of Originals 6.3.4.1 Outline 0000-4397 The machine identifies the size of originals with reference to the combinations of the outputs of reflection type sensors and the intensities of the CCD measured at specific points. - in main scanning direction, of CCD (for AB, 4 points; for Inch, 2 points) - in sub scanning direction, of reflection type photosensor (for AB, 1 point; for Inch, 2 points) The machine identifies the size of an original using the following steps: 1. Search for External Light (main scanning direction only) With the scanning lamp OFF, the level of the CCD at each point of detection is measured. 2. Detection of the Sensor Output Level The scanning lamp is turned on, and the CCD level at each point of detecting in main scanning direction is measured. In addition, the LED of the reflection type photosensor in sub scanning direction is turned on to measure the output of the sensor. 6-10 Chapter 6 The combination of these outputs is used to identify the size of the original. For specific operation, see the pages that follow. 6.3.4.2 Points of Detection (original size) 0000-4398 For main scanning direction, the No. 1 mirror base is moved to the following positions to measure the intensity of light at each point of detection. For sub scanning direction, the outputs of the sensors mounted at the following points are used. AB-configuration Inch-configuration Original Original sensor 1 sensor 2 Original sensor 1 Original detection position1 Original detection position2 Original detection position3 B5 Original detection position4 B5R A4R Original detection position 1 B4 A3 A4 LTRR Original detection position 2 LTR CCD original detection position LGL 279.4×431.8mm (11"×17") CCD original detection position F-6-16 6.3.4.3 Outline of Detection Operations 0000-4399 a. Book Mode, 1 Original, Copyboard Cover Closed T-6-3 1. The machine is in a standby state. Xenon lamp No. 1 mirror at original detection position base: Original sensor Copyboard cover Reader unit Original detection position 1 Original detection position 2 Original detection position 3 Original detection position 4 Copyboard glass xenon lamp: OFF original sensor: Original detection positio 2. The copyboard cover is opened. No. 1 mirror at original detection point base: (external light) xenon lamp: OFF original OFF sensor: 6-11 Chapter 6 3. The copyboard cover is closed. - If the external light is blocked, the machine assumes the presence of an original; outside the Original (A4R) (external light) area, where light is detected, the machine assumes that there is no original. (search for external light) At this point in time, B5, B4, A4, and A3 are excluded. - When the copyboard cover is brought to 30 deg, the copyboard cover sensor identifies the condition to be "cover closed," thus causing the machine to start original size detection. - After a search for external light, the machine 30˚ turns on the xenon lamp (for main scanning direction), and checks the reflected light by the CCD at 4 points. For sub scanning direction, the machine efers to the outputs of original sensors. 4. The copyboard cover is fully down. - The machine monitors the outputs of the sensors for 5 sec after the copyboard cover sensor has identified a "closed" state. -If there is no change in the level, the machine assumes the presence of an original at the sensor. The machine uses the combination of the outputs (changes) at 5 points. 5. The machine is in a standby sate (waiting for a press on the Start key). No. 1 mirror at original detection position base: xenon lamp: OFF original OFF sensor: 6-12 Chapter 6 AB-configuration Original size A3 B4 A4R A4 B5 B5R None Inch-configuration CCD detection position Original 1 sensor 1 2 3 4 Original CCD detection Original Original position size 1 2 sensor 1 sensor 2 11" X 17" LGL LTRR LTR None :change absent : change present F-6-17 6-13 Chapter 6 6.4 Parts Procedure Replacement 6.4.1 Copyboard Glass 6.4.1.1 Removing the Copyboard Glass 0000-4400 1) Open the ADF or the copyboard cover. F-6-19 2) 3) Remove the 2 screws [1], and detach the right glass Points to Note When Removing the Copyboard retainer [2]; then, detach the copyboard glass [3]. Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind it. (The presence of dirt will cause lines in the images.) If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. F-6-20 6.4.1.2 After Replacing the Copyboard Glass 0000-4401 Enter the value indicated on the copyboard glass (F01301-04) using the following service mode items: COPIER>ADJUST>CCD>W-PLT-X/Y/Z Use it to enter data for the standard white plate. 820686679349 F-6-21 F-6-18 6-14 Chapter 6 6.4.2 Exposure Lamp 6.4.2.1 Removing the Copyboard Glass 0000-8280 1) Open the ADF or the copyboard cover. 2) F-6-23 Points to Note When Removing the Copyboard Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind it. 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. (The presence of dirt will cause lines in the images.) If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. F-6-24 6.4.2.2 Removing the Reader Left Cover/Reader Right Cover/Reader Front Cover 0000-4424 1) Remove the reader left cover, reader right cover, and reader front cover. 6.4.2.3 Removing the CCD Unit Cover 0000-4425 1) Remove the 8 screws [1], and detach the CCD unit F-6-22 cover [2]. 6-15 Chapter 6 3) Slide the No. 1 mirror base [1] until it matches against the cut-off in the frame; then, remove the 3 screws [2], and remove the scanning lamp [3]. F-6-25 6.4.2.4 Removing the Scanning Lamp 0000-4426 F-6-28 1) Peel the sheet [1] (1 each at front and rear) of the reader frame. Points to Note When Attaching the Scanning Lamp To mount the scanning lamp, route the harness [1] of the lamp unit through the white guide [2] of the No. 2 mirror base and then the black harness guide [3]; thereafter, connect the connector [4] to the inverter PCB. F-6-26 2) Disconnect the connector [1] from the inverter PCB, and free the harness [3] from the edge saddle [2] of the frame. F-6-29 F-6-27 6-16 Chapter 6 6.4.3 Reader Controller PCB 6.4.3.1 Removing the Copyboard Glass 0000-8290 1) Open the ADF or the copyboard cover. 2) F-6-31 Points to Note When Removing the Copyboard Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind it. 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. (The presence of dirt will cause lines in the images.) If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. F-6-32 6.4.3.2 Removing the CCD Unit Cover 0000-8292 1) Remove the 8 screws [1], and detach the CCD unit cover [2]. F-6-30 F-6-33 6-17 Chapter 6 6.4.3.3 Removing the Original Size Detection Unit J203 0000-8293 J202 J210 IC5 (CPU) IC16 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the original size detection J201 J206 J205 IC7 IC14 ON J204 OFF SW1 1 2J208 J207 IC3 F-6-36 unit [3]. T-6-4 SW-1 SW-2 AB OFF OFF A ON OFF A/INCH OFF ON AB/INCH ON ON - Using the SST, download the latest firmware. F-6-34 - Enter the values indicated on the service label in service mode (refer to the following list). 6.4.3.4 Removing the Reader Controller PCB COPIER>ADJUST>ADJ-XY>ADJ-X 0000-4432 1) Remove the 5 flat cables [1], disconnect the Use it to adjust the scanner leading edge position. COPIER>ADJUST>ADJ-XY>ADJ-Y connector [2], and remove the 4 screws [3]; then, Use it to adjust the CCD read start cell position. detach the reader controller PCB [4]. COPIER>ADJUST>ADJ-XY>ADJ-S Use it to enter an adjustment value for the scanner shading measurement point. COPIER>ADJUST>CCD>W-PLT-X Use it to enter white level data for the standard while plate. COPIER>ADJUST>CCD>W-PLT-Y Use it to enter white level data for the standard white plate. COPIER>ADJUST>CCD>W-PLT-Z Use it to enter white level data for the standard while plate. F-6-35 COPIER>ADJUST>CCD>CLF-R-RG Use it to enter a color displacement correction value 6.4.3.5 When Replacing the Reader Controller PCB for sub scanning direction. 0000-4433 - Set the DIP switch on the reader controller PCB to the same settings as the initial PCB. COPIER>ADJUST>CCD>CLF-R-GB Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>CL-R-RG Use it to enter a color displacement correction value for sub scanning direction. 6-18 Chapter 6 COPIER>ADJUST>CCD>CL-R-GB Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>BW-R-RG Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>BW-R-GB Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>CCDU-RG Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>CCDU-GB Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>FCCDU-RG Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>FCCDU-GB Use it to enter a color displacement correction value F-6-37 for sub scanning direction. 6.4.4 Interface PCB 6.4.4.1 Removing the Copyboard Glass 0006-0814 1) Open the ADF or the copyboard cover. 2) F-6-38 Points to Note When Removing the Copyboard Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind it. (The presence of dirt will cause lines in the images.) If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. 6-19 Chapter 6 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. F-6-41 6.4.4.3 Removing the Interface F-6-39 PCB 0000-4403 6.4.4.2 Removing the Reader Rear Cover 0000-4402 1) Remove the 2 cable clamps [1] to free the reader power cable. Points to Note Before Removing the Interface PCB Without detaching the motor unit, mark its position of the rear side plate using a scriber [A]. [1] F-6-40 2) Disconnect the reader controller communications F-6-42 cable. 3) Remove the 7 screws [1], and detach the reader rear cover [2]. 1) Remove the 2 RS tightening screws and 4 binding screws [2]; then, detach the I/F PCB cover [3]. 6-20 Chapter 6 6.4.5 Inverter PCB 6.4.5.1 Removing the Copyboard Glass 0000-8287 1) Open the ADF or the copyboard cover. 2) Points to Note When Removing the Copyboard F-6-43 Glass When removing the copyboard glass, take care not to 2) Remove the 2 screws [1], and disconnect the 2 connectors [2]; then, detach the connector base [3]. touch the surface of the glass or the white plate behind it. (The presence of dirt will cause lines in the images.) If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. F-6-44 3) Disconnect the 4 connectors [1] and the 2 flat cables [2], and remove the 5 screws [3] then, detach the interface PCB unit [4]. F-6-46 F-6-45 6-21 Chapter 6 6.4.5.3 Removing the Inverter PCB 0000-4431 3) Disconnect the connector [1], and remove the flat cable; then, remove the screw [3], and detach the inverter PCB [4]. F-6-47 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. F-6-50 6.4.6 CCD Unit 6.4.6.1 Removing the Copyboard Glass 0000-8284 1) Open the ADF or the copyboard cover. 2) F-6-48 6.4.5.2 Removing the CCD Unit Cover Points to Note When Removing the Copyboard 0000-8288 1) Remove the 8 screws [1], and detach the CCD unit Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind cover [2]. it. (The presence of dirt will cause lines in the images.) If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. F-6-49 6-22 Chapter 6 F-6-53 6.4.6.2 Removing the CCD Unit Cover 0000-8285 1) Remove the 8 screws [1], and detach the CCD unit cover [2]. F-6-51 F-6-54 6.4.6.3 Removing the Original F-6-52 Size Detection Unit 0000-8286 1) Disconnect the connector [1], and remove the 4 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. screws [2]; then, detach the original size detection unit [3]. 6-23 Chapter 6 6.4.7 Fuse PCB (option) 6.4.7.1 Removing the Reader Rear Cover 0000-4411 1) Remove the 2 cable clamps [1] to free the reader power cable. F-6-55 [1] 6.4.6.4 Removing the CCD Unit 0000-4429 4) Remove the 2 flat cables [1] of the reader controller F-6-57 PCB, 2 screws [2], and leaf spring [3]; then, detach the CCD unit [4]. 2) Disconnect the reader controller communications cable. 3) Remove the 7 screws [1], and detach the reader rear cover [2]. F-6-56 6.4.6.5 After Replacing the CCD Unit When you have replaced the CCD unit, enter the values (for color displacement correction in sub scanning direction) indicated on the label attached to the unit in service mode: COPIER>ADJUST>CCD>CCDU-RG/GB Use it to enter the image position correction value (dependent on the CCD unit). 6-24 F-6-58 0000-4430 6.4.7.2 Removing Copyboard Cover the Open/ Closed Sensor Mounting 0000-4412 1) Remove the 2 screws [1], and detach the sensor base [2]. Chapter 6 (The presence of dirt will cause lines in the images.) If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. F-6-59 6.4.7.3 Removing the Fuse PCB Unit (option; 100/230v model only) 0000-4413 1) Disconnect the 2 connectors [1], ad remove the 2 screws [2]; then, remove the fuse PCB unit [3]. F-6-61 F-6-60 6.4.8 Scanner Motor 6.4.8.1 Removing the Copyboard Glass 0006-7342 F-6-62 1) Open the ADF or the copyboard cover. 2) 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. Points to Note When Removing the Copyboard Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind it. 6-25 Chapter 6 6.4.8.3 Removing the Interface PCB 0000-4420 Points to Note Before Removing the Interface PCB Without detaching the motor unit, mark its position of the rear side plate using a scriber [A]. F-6-63 6.4.8.2 Removing the Reader Rear Cover 0000-4419 1) Remove the 2 cable clamps [1] to free the reader power cable. F-6-66 1) Remove the 2 RS tightening screws and 4 binding [1] screws [2]; then, detach the I/F PCB cover [3]. F-6-64 2) Disconnect the reader controller communications cable. 3) Remove the 7 screws [1], and detach the reader rear cover [2]. F-6-67 2) Remove the 2 screws [1], and disconnect the 2 connectors [2]; then, detach the connector base [3]. F-6-65 6-26 Chapter 6 2) Remove the 3 screws [1], and detach the scanner motor [2]. F-6-68 F-6-71 3) Disconnect the 4 connectors [1] and the 2 flat cables [2], and remove the 5 screws [3] then, detach 6.4.8.5 Mounting the Scanner the interface PCB unit [4]. Motor 0000-4422 1) Fit the scanner motor from the machine's rear, and attach the belt [1] on the pulley [2] of the motor unit through the space (front side) vacated by the copyboard glass. F-6-69 6.4.8.4 Removing the Scanner Motor 0000-4421 1) Remove the 5 screws [1], and detach the DF base F-6-72 [2]. 2) With the belt on the pulley, pull the motor unit [1] as far as the marking [A] you have drawn with a scriber; then, secure it in place with 3 screws [2]. F-6-70 6-27 Chapter 6 F-6-73 F-6-75 6.4.9.2 Removing Copyboard Points to Note After Mounting the Scanner Motor When you have mounted the motor, either move the mirror or make a test print (so as to be sure that the motor belt is correctly placed). Cover base [2]. 0000-4404 1) Remove the 2 cable clamps [1] to free the reader power cable. F-6-76 F-6-74 2) Disconnect the reader controller communications cable. 3) Remove the 7 screws [1], and detach the reader rear cover [2]. 6-28 0006-7327 1) Remove the 2 screws [1], and detach the sensor 6.4.9.1 Removing the Reader [1] Open/ Closed Sensor Mounting 6.4.9 Original Cover Sensor Rear Cover the Chapter 6 6.4.9.3 Removing Copyboard Cover the Open/ Closed Sensor Cover 0000-4406 1) Disconnect the connector [1], and remove the [1] screws [2]; then, detach the sensor cover [3]. F-6-79 2) Disconnect the reader controller communications cable. 3) Remove the 7 screws [1], and detach the reader rear cover [2]. F-6-77 6.4.9.4 Removing Copyboard Cover the Open/ Closed Sensor 0000-4407 1) Remove the copyboard cover open/closed sensor [1]. F-6-80 6.4.10.2 Copyboard Removing Cover the Open/ Closed Sensor Mounting 0000-4409 1) Remove the 2 screws [1], and detach the sensor base [2]. F-6-78 6.4.10 Scanner HP Sensor 6.4.10.1 Removing the Reader Rear Cover 0000-4408 1) Remove the 2 cable clamps [1] to free the reader power cable. F-6-81 6-29 Chapter 6 6.4.10.3 Removing the Mirror Base Home Position Sensor 0000-4410 1) Disconnect the connector [1], and detach the mirror base home position sensor [2]. F-6-82 6.4.11 Original Sensor 6.4.11.1 Removing the Copyboard Glass 0000-8281 F-6-83 1) Open the ADF or the copyboard cover. 2) Points to Note When Removing the Copyboard Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind it. (The presence of dirt will cause lines in the images.) F-6-84 If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. 6-30 Chapter 6 F-6-85 F-6-87 6.4.11.2 Removing the CCD Unit Cover 6.4.11.4 Removing the Original 0000-8282 1) Remove the 8 screws [1], and detach the CCD unit Size Sensor 1) While freeing the claw at the edge, detach the cover [2]. original size sensor [1]. F-6-88 F-6-86 6.4.12 Reader Heater (option) 6.4.11.3 Removing the Original Size Detection Unit 0000-4427 1) Disconnect the connector [1], and remove the 4 6.4.12.1 Removing the Copyboard Glass screws [2]; then, detach the original size detection unit [3]. 0000-4428 0000-8933 1) Open the ADF or the copyboard cover. 2) Points to Note When Removing the Copyboard Glass When removing the copyboard glass, take care not to touch the surface of the glass or the white plate behind it. (The presence of dirt will cause lines in the images.) 6-31 Chapter 6 If dirt is found, be sure to remove it using lint-free paper moistened with alcohol. F-6-91 6.4.12.2 Removing the Reader Rear Cover 0000-4415 1) Remove the 2 cable clamps [1] to free the reader power cable. F-6-89 [1] F-6-92 2) Disconnect the reader controller communications cable. 3) Remove the 7 screws [1], and detach the reader rear cover [2]. F-6-90 3) Remove the 2 screws [1], and detach the right glass retainer [2]; then, detach the copyboard glass [3]. F-6-93 6-32 Chapter 6 6.4.12.3 Removing the Fuse PCB Unit 0000-4416 1) Remove the fuse PCB unit. 6.4.12.4 Removing the Reader Heater (option; 100/230V model only) 0000-4417 1) Move the No. 1 mirror base [1] into the direction of the arrow. F-6-96 2) Remove the 3 screws used to secure the Reader heater [1] in place, and remove the harness band [3]. F-6-94 When moving the mirror base, be sure to hold the cutup [A] on the mirror stay. F-6-97 3) Shift the mirror base to the farthest right, and free the harness guide [1] at one location; then, while shifting it to the left, detach the harness guide, and detach the Reader heater [2]. F-6-95 F-6-98 6-33 Chapter 6 6-34 Chapter 7 Image Processing System Contents Contents 7.1 Outline ............................................................................................................................................................... 7-1 7.1.1 Specifications, Control Mechanisms, and Functions ................................................................................. 7-1 7.1.2 Functional Construction of the PCBs ......................................................................................................... 7-1 7.2 Analog Image Processing .................................................................................................................................. 7-2 7.2.1 Outline ........................................................................................................................................................ 7-2 7.2.2 CCD Drive .................................................................................................................................................. 7-3 7.2.3 CCD Output Gain Correction and Offset Correction ................................................................................. 7-3 7.2.4 A/D Conversion of CCD Putput ................................................................................................................. 7-3 7.3 Digital Image Processing ................................................................................................................................... 7-4 7.3.1 Outline ........................................................................................................................................................ 7-4 7.3.2 Shading Correction ..................................................................................................................................... 7-4 Chapter 7 7.1 Outline 7.1.1 Specifications, Control Mechanisms, and Functions 0000-4434 The machine's image processing system has the following specifications and functions: T-7-1 1) CCD (image sensor) number of lines:3 (RGB, 1 line each) number of pixels:7350 size of pixel:9.3X9.3 um 2) Shading Correction shading adjustment: executed in service mode shading correction: executed for each copy 7.1.2 Functional Construction of the PCBs Analog image processing block 0000-4435 Digital image processing block CCD Reader controller PCB Analog image processing A/D conversion Shading processing Controller block CCD/AP PCB F-7-1 The PCBs of the image processing system have the following functions: T-7-2 1) CCD/P PCB: CCD drive, analog image processing, A/D conversion 2) Reader Controller PCB: shading correction 7-1 Chapter 7 7.2 Analog Image Processing 7.2.1 Outline 0000-4436 The machine uses the CCD/AP PCB to perform analog image processing for each RGB line; the major operations involved are as follows: T-7-3 1 ) 2 ) 3 ) CCD drive CCD output gain correction, offset correction CCD output A/D conversion CCD (RGB, 1 line each) J101 J204 A12V A5V Odd-numbered Even-numbered pixel pixels Analog image signal Analog image processing CCD drive control Even-numbered pixel A/D • gain correction Odd-numbered conversion pixel • offset correction Gain correction data Digital image signal 10 J102 CCD/AP PCB F-7-2 7-2 J204 CCD control signal J205 Reader controller PCB Chapter 7 7.2.2 CCD Drive 0000-4437 The CCD sensor used in the machine is a 3-line (RGB, 1 line each) linear image sensor consisting of photocells of 7350 pixels. The signals photo-converted by the light-receiving block are sent out as analog signals of 2 channels (even-numbered pixels EVEN and odd-numbered pixels ODD). Output buffer Odd-numbered data Shift register Gate Light-receiving block (photodiode) 6 5 4 3 2 1 Gate Even-numbered data shift register Output buffer F-7-3 CCD Block Diagram 7.2.3 CCD Output Gain Correction and Offset Correction 0000-4438 The analog video signals from the CCD are modified so that the rate of its amplitude is of a specific level (gain correction); it is also modified so that its output voltage in the absence of incident light is a specific level (offset correction). 7.2.4 A/D Conversion of CCD Putput 0000-4439 The odd-numbered and even-numbered analog video signals after correction are further converted into 10-bit digital signals corresponding to the levels of the pixel voltages by the A/D converter. 7-3 Chapter 7 7.3 Digital Image Processing 7.3.1 Outline 0006-0674 The machine uses the reader controller PCB for digital image processing; the major operations involved are as follows: 1. Shading Correction Reader controller PCB J101 J204 Gain correction data EEP-ROM CPU Target value SRAM CCD/AP PCB J102 J205 Digital image signal 10 J203 Shading correction Digital image signal 8 F-7-4 7.3.2 Shading Correction 0006-0678 The output of the CCD is not necessarily uniform even when the density of the original is even for the following factors: 1. variation in sensitivity among pixels of the CCD 2. difference in transmission between the middle and the edge of the lens 3. difference in the intensity of light between the middle and the edges of the scanning lamp 4. deterioration of the scanning lamp The machine executes shading correction so as to even out the discrepancies in CCD output. Shading correction may be shading adjustment, in which a target value is determined in service mode, or shading correction, in which a target value is determined for each scan of the original. Shading Adjustment In shading adjustment, the density of the standard white plate is measured, and the result is stored in memory as density data; the data is then computed to obtain the target value for shading correction. Shading Correction Shading correction is executed for each scan of the original. The density of the standard white plate is measured, and the shading correction circuit compares the result against the target value stored in memory in advance; the result of comparison is then used as the shading correction value to make up for the discrepancies among CCD pixels occurring at time of scans, thus ensuring uniform image density. 7-4 Chapter 7 Characteristics after correction CCD output Characteristics before correction Target value Measurement taken White Density of original Standard white plate F-7-5 7-5 Chapter 7 7-6 Chapter 8 Laser Exposure Contents Contents 8.1 Construction ...................................................................................................................................................... 8-1 8.1.1 Specifications, Control Mechanisms, and Functions ................................................................................. 8-1 8.1.2 Major Components ..................................................................................................................................... 8-2 8.1.3 Construction of the Control System ........................................................................................................... 8-3 8.2 Basic Sequence .................................................................................................................................................. 8-4 8.2.1 Basic Sequence of Operations .................................................................................................................... 8-4 8.3 Various Control ................................................................................................................................................. 8-5 8.3.1 Controlling the Laser Activation Timing .................................................................................................... 8-5 8.3.1.1 Turning On/Off the Laser .................................................................................................................... 8-5 8.3.1.2 BD Signal ............................................................................................................................................ 8-7 8.3.1.3 Controlling Synchronization in Main Scanning Direction .................................................................. 8-8 8.3.1.4 Controlling Synchronization in Sub Scanning Direction .................................................................... 8-8 8.3.2 Controlling the Intensity of Laser Light ..................................................................................................... 8-9 8.3.2.1 APC Control ........................................................................................................................................ 8-9 8.3.2.2 PWM Control ...................................................................................................................................... 8-9 8.3.3 Controlling the Laser Scanner Motor ....................................................................................................... 8-10 8.3.3.1 Controlling the Laser Scanner Motor ................................................................................................ 8-10 8.3.4 Controlling the Laser Shutter .................................................................................................................... 8-10 8.3.4.1 Controlling the Laser Shutter ............................................................................................................ 8-10 8.3.5 Correcting Image Displacement ................................................................................................................ 8-11 8.3.5.1 Outline ............................................................................................................................................... 8-11 8.3.5.2 Timing of Color Displacement Detection/Correction ....................................................................... 8-12 8.3.5.3 Detecting/Correcting Color Displacement in Sub Scanning Direction ............................................. 8-13 8.3.5.4 Detecting/Correcting the Angle in Main Scanning Direction ........................................................... 8-14 8.3.5.5 Detecting/Correcting Color Displacement in Main Scanning Direction ........................................... 8-16 8.3.5.6 Detecting/Correcting Changes in the Reproduction Ratio in Main Scanning Direction ................... 8-17 8.4 Parts Replacement Procedure .......................................................................................................................... 8-19 8.4.1 Laser Unit .................................................................................................................................................. 8-19 8.4.1.1 Removing the Center Delivery Tray ................................................................................................. 8-19 8.4.1.2 Removing the Laser Unit ................................................................................................................... 8-19 8.4.1.3 After Replacing the Laser Unit .......................................................................................................... 8-20 Chapter 8 8.1 Construction 8.1.1 Specifications, Control Mechanisms, and Functions 0000-4452 T-8-1 Laser light Wave length 780 nm (infrared) Output 5 mW Number of laser beams 2 T-8-2 Scanner motor Type of motor DC brush-less Number of revolutions 23000 rpm (approx.) Type of bearing Oil T-8-3 Polygon mirror Number of facets 4 facets (f20) T-8-4 Control mechanisms Sync control main scanning direction sub scanning direction Light intensity APC control PWM control Color displacement correction reproduction ratio in main scanning direction displacement in main scanning direction Others scanner motor control laser shutter control laser ON/OFF control 8-1 Chapter 8 8.1.2 Major Components 0000-4453 T-8-5 Name Description Laser driver generates laser light. Polygon mirror scans the laser beam in main scanning direction. guide mirror directs laser light in the direction of the drum. Corrective lens corrects displacement of laser light coming from the guide mirror in main scanning direction. displacement correction moves the corrective lens to correct displacement in main motor scanning direction. BD detection PCB detects laser light as a BD signal. BD mirror reflects the laser light in the direction of the BD detection PCB. Guide mirror Polygon mirror Laser driver Corrective lens (front) Displacement correction motor (rear) Photosensitive drum F-8-1 8-2 Chapter 8 BD detection PCB BD mirror F-8-2 8.1.3 Construction of the Control System 0000-4454 The laser exposure system is controlled mainly by the DC controller PCB. Laser scanner motor control ON/OFF control Main scanning direction correction control APC control J114(Y)/J116(M)/ J118(C)/J120(Bk) J115 IC for control PWMIC J113 J117 J117 Main scanning direction sync control J1216 PWM signal Image data PWM control DC controller PCB Main controller PCB J129 Laser shutter control Manual feed unit Fixing feeder unit Front cover F-8-3 8-3 Chapter 8 8.2 Basic Sequence 8.2.1 Basic Sequence of Operations 0000-4455 The laser scanner motor starts to rotate when the Start key is pressed (or the print request signal is issued). When its rotation has stabilized, the printer unit becomes ready for formation of images, causing the printer side to generate the sync signal (PTOP). The machine uses the signal to generate the sub scanning direction signals (Y-TOP, M-TOP, C-TOP, K-TOP) for individual colors, and turns on the lasers of the corresponding colors. Print request signal (Start key ON) Image formation enable timing PSTBY Polygon motor (Y,M,C,Bk) PINTR PRINT Used to stabilize rotation(3.5sec) PTOP signal Y-TOP signal Laser Y ON M-TOP signal Laser M ON C-TOP signal Laser C ON Bk-TOP signal Laser Bk ON F-8-4 8-4 LSTR PSTBY Chapter 8 8.3 Various Control 8.3.1 Controlling the Laser Activation Timing 8.3.1.1 Turning On/Off the Laser 0000-4456 The laser light is turned on/off in keeping with combinations of control signals (TRL0/1/2) from the DC controller PCB. T-8-6 CTR CTR CTR L2 L1 L0 0 0 0 0 0 1 Status of laser A Status of laser B OFF OFF OFF APC control (bias current applied) 0 1 0 APC control OIFF (bias current applied) 0 1 1 1 1 1 0 0 1 1 1 0 1 0 1 OFF OFF (bias current applied) (bias current applied) ON ON (for factory adjustment) (for factory adjustment) OFF ON (bias current applied) (for factory adjustment) ON OFF (for factory adjustment) (bias current applied) ON ON (for image formation) (for image formation) 8-5 Y-CRL-0 Y-CRL-1 Y-CRL-2 Chapter 8 J114 for M: J116 for C: J118 for Bk: J120 DC controller PCB F-8-5 Print request signal (Start key ON) PSTBY Image formation enable timing PRINT PINTR Polygon motor (Y, M, C, Bk) PTOP signal Y-TOP signal Laser ON For laser A BD detection, APC control ON For laser B BD detection, APC control ON Image equivalent of 1 line F-8-6 8-6 Image equivalent of 1 line Chapter 8 8.3.1.2 BD Signal 0000-4457 - The machine is equipped with a laser unit that can generate 2 channels of laser light (A and B). - These 2 channels of laser light are based on separate BD signals. BD signal J115 A/B separation BD for laser A BD for laser B DC controller PCB F-8-7 8-7 Chapter 8 8.3.1.3 Controlling Synchronization in Main Scanning Direction 0000-4458 The control of synchronization in main scanning direction is based on the BD signal. Clock signals/ sync signals based on the BD signal are generated. BD detection signal BD detection PCB J115 DC controller PCB PWMIC A The BD signal is separated into 2 channels for laser A and laser B. A/B separation B FIFO Image signal for laser A Image signal for laser B Video signals are generated in keeping with the sync signals. F-8-8 8.3.1.4 Controlling Synchronization in Sub Scanning Direction 0000-4459 - The synchronization in sub scanning direction is controlled with reference to the PTOP signal (image formation start signal). - When the mechanism becomes ready for image formation, the PTOP signal (image formation start signal) is generated, turning on the individual lasers based on the signal. 8-8 Chapter 8 Print request signal (Start key ON) Image formation enable timing PSTBY Laser scanner motor (Y,M,C,Bk) PINTR PRINT LSTR PSTBY Used to stabilize rotation (3.5sec) PTOP signal Y-TOP signal Laser Y ON M-TOP signal Laser M ON C-TOP signal Laser C signal Bk-TOP signal Laser Bk ON F-8-9 8.3.2 Controlling the Intensity of Laser Light 8.3.2.1 APC Control 0000-4460 The machine uses the photodiode mounted on the laser driver PCB to monitor the intensify of laser light so as to ensure that it remains at a specific level. 8.3.2.2 PWM Control 0000-4461 - A single pixel is divided into 32, and a 16-level activation pattern is selected to suit the image data in question. Pixels Lowest intensity 1 2 3 4 5 6 7 26 27 28 29 30 31 32 1 2 3 4 5 6 7 26 27 28 29 30 31 32 ON 1 2 3 4 5 6 7 26 27 28 29 30 31 32 16 levels of intensity ON 1 2 3 4 5 6 7 26 27 28 29 30 31 32 ON 1 2 3 4 5 6 7 26 27 28 29 30 31 32 ON 1 2 3 4 5 6 7 26 27 28 29 30 31 32 ON Highest intensity 1 2 3 4 5 6 7 26 27 28 29 30 31 32 ON F-8-10 8-9 Chapter 8 8.3.3 Controlling the Laser Scanner Motor 8.3.3.1 Controlling the Laser Scanner Motor 0000-4462 The machine uses the acceleration/deceleration signal to control the speed of rotation of the laser scanner motor so that the BD signal from individual laser units will be of the same phase as the reference signal (if the BD signal is behind the reference signal, accelerate; if ahead, decelerates). Deceleration signal Acceleration signal BD signal J117 J115 IC for control Reference signal DC controller PCB F-8-11 8.3.4 Controlling the Laser Shutter 8.3.4.1 Controlling the Laser Shutter 0000-4463 The laser light is turned off whenever a cover (indicated) that can let laser light to escape is opened: - front cover - manual feed unit - fixing feeder unit If any of the covers (units) is opened, the operation voltage applied to the latest driver is turned off and, in addition, the laser control signal/image signal is also turned off. 8-10 Chapter 8 Front cover switch Manual feed unit open/closed switch Image signal DC power supply unit Control signal DC5V Fixing feeder unit open/closed switch Front cover open/closed sensor PWMIC Control IC Manual feed unit open/closed sensor J129 PS23 Fixing feeder unit open/closed sensor J127 PS28 DC controller PCB PS5 F-8-12 8.3.5 Correcting Image Displacement 8.3.5.1 Outline 0000-4464 The following factors can displace images of individual colors: - displacement of the photosensitive drum caused by replacement of the drum unit/toner container ->displacement in sub scanning direction - displacement of laser path caused by replacement of laser unit ->displacement/angle in main scanning direction - displacement in laser path length caused by changes in temperature inside machine ->variation in magnification To correct the discrepancies in images, the machine executes corrective control for image position; it detects displacement in color by forming a pattern of a specific color on the transfer belt and reading it against the correct position. 8-11 Chapter 8 Detecting displacement in color • Forms an image position correction pattern on the transfer belt (direct transfer). • Reads the individual pattern (of different colors) using the pattern reader photo sensors. • Identifies displacement in color with reference to the pattern signals in the DC controller. Displacement in sub scanning direction corrects the write start position in sub scanning direction. Displacement in main scanning direction corrects the start position in main scanning direction. Angle in main scanning direction corrects the laser path inside the laser unit. Discrepancy in reproduction ratio in main scanning direction corrects image data generation timing in main scanning direction F-8-13 LED Photosensor Bk C M Reader for individual color patterns Y Bk C M Y F-8-14 8.3.5.2 Timing of Color Displacement Detection/Correction 0000-4465 The machine detects/corrects color displacement at the following timing: - during warm-up after the main power switch is turned on - during warm-up after jam clear - during warm-up after return from sleep - during warm-up after replacement of the drum unit (not when the toner container is replaced) - during warm-up when low-power mode is turned on after opening/closing of the cover while the machine is in low- 8-12 Chapter 8 power mode - 2 hr after the machine has been left alone in standby state - during quick correction (auto gradation correction) - after sheet-to-sheet auto correction when 300 sheets (small-size, equivalent in single-sided) have been fed continuously - during last rotation auto correction at time of counter increments occurring after intermittent jobs of 300 pages (small-size, equivalent of single-sided) - in response to changes in the environment - when replacing the toner cartridge 8.3.5.3 Detecting/Correcting Color Displacement in Sub Scanning Direction 0000-4466 The Y pattern is used as the reference. The machine identifies the degree of color displacement in sub scanning direction with reference to the timing at which other color patterns are checked after a check on the Y pattern. If the timing is not correct, the machine corrects the laser write start timing in sub scanning direction. For C For Bk rear For C For Bk Correct position Too early front F-8-15 Displacement in sub scanning direction F-8-16 8-13 Chapter 8 8.3.5.4 Detecting/Correcting the Angle in Main Scanning Direction 0000-4467 The Bk pattern is used as the reference. The machine identifies the angle in main scanning direction with reference to front/rear discrepancies of individual colors. rear Displacement front F-8-17 Angle F-8-18 If the machine detects any angle, it turns on the main scanning direction angle correction motor located inside the laser unit. 8-14 Chapter 8 Main scanning direction correction motor Main scanning direction angle correction lens F-8-19 8-15 Chapter 8 8.3.5.5 Detecting/Correcting Color Displacement in Main Scanning Direction 0000-4468 The Bk pattern is used as the reference. The machine compares the length of the center line of the Bk image position correction pattern (front) and the length of the center line of the image position correction pattern (front) of individual colors, and identifies the difference between the two as the degree of color displacement in main scanning direction. When the machine detects color displacement, it corrects the timing at which the laser is started in main scanning direction. Displacement in main scanning direction F-8-20 Bk C M Y F-8-21 8-16 Chapter 8 8.3.5.6 Detecting/Correcting Changes in the Reproduction Ratio in Main Scanning Direction 0000-4469 The Bk pattern is used as the reference. The machine copies the center line of the Bk image correction pattern (rear) and the center line of the individual image position correction patterns (rear), and identifies the difference between the two as the change in the reproduction ratio in main scanning direction. When the machine detects any change, it corrects the timing at which the video signals are transferred to the laser unit. (rear) Bk C M Y F-8-22 8-17 Chapter 8 Change in reproduction ratio in main scanning direction PWMIC Video signal for laser A Video signal for laser B The machine changes the frequency of the image clock to change the reproduction ratio in main scanning direction. F-8-23 8-18 Frequency control block DC controller PCB Chapter 8 8.4 Parts Procedure Replacement 8.4.1 Laser Unit 8.4.1.1 Removing the Center Delivery Tray 0000-4289 1) Remove the 2 screws [1], and detach the center F-8-26 delivery tray [2]. 3) Remove the face cap [1] and the screw [2]; then, while lifting the rear reader unit [3] slightly, detach the upper inside cover [4]. F-8-24 8.4.1.2 Removing the Laser Unit F-8-27 0000-4471 1) Remove the 2 screws [1], and detach the reader ink unit cover [2]. 4) Shift the arm [1] of the reader link unit 90 deg to support the reader unit. F-8-25 F-8-28 2) Remove the stepped screw [1], and detach the positioning pin [2] from the reader link unit. 5) Disconnect the 8 connectors [1], and detach the harness guide [2]. 8-19 Chapter 8 F-8-31 F-8-29 6) Remove the 2 screws [1], and detach the cover [2] of the laser driver PCB. (The cover for Y has a MEMO: different shape, but may be removed in the same When mounting the laser unit, tighten the screws in way.) diagonal sequence for proper balance. 8.4.1.3 After Replacing the Laser Unit 0000-4291 If you have replaced the laser unit, execute the following service mode: COPIER>FUNCTION>LASER>L-ADJ-0 Use it to execute automatic adjustment of laser intensity. F-8-30 7) Disconnect the connector[1], and remove the 4 screws [2];then, detach the laser unit [3]. 8-20 Chapter 9 Image Formation Contents Contents 9.1 Construction ...................................................................................................................................................... 9-1 9.1.1 Specifications, Control Mechanisms, and Functions ................................................................................. 9-1 9.1.2 Major Components of the Image Formation System ................................................................................. 9-3 9.1.3 Charging Specifications ............................................................................................................................. 9-4 9.2 Image Formation Process .................................................................................................................................. 9-6 9.2.1 Image Formation Process (general) ............................................................................................................ 9-6 9.2.2 Image Formation Process (image formation) ............................................................................................. 9-7 9.2.3 Image Formation Process (transfer) ........................................................................................................... 9-7 9.3 Basic Sequence .................................................................................................................................................. 9-8 9.3.1 At Power-On (1) ......................................................................................................................................... 9-8 9.3.2 At Power-On (2) ......................................................................................................................................... 9-8 9.3.3 During Copying/Printing Operations (normal speed) ................................................................................ 9-9 9.3.4 Making Copies/Prints (half speed) ........................................................................................................... 9-10 9.3.5 After Replacing the Drum Unit (D-UNIT) ............................................................................................... 9-10 9.3.6 Printing Originals Containing a Color Page ............................................................................................. 9-11 9.3.7 Driving and Controlling the Image Formation System and the High-Voltage System ............................ 9-11 9.4 Image Stabilization Control ............................................................................................................................. 9-13 9.4.1 Outline of Image Quality Control ............................................................................................................ 9-13 9.4.2 Automatic Image Stabilization Control .................................................................................................... 9-13 9.4.3 ATR Control ............................................................................................................................................. 9-17 9.4.4 Discharge Current Level Control ............................................................................................................. 9-17 9.4.5 ATVC Control (transfer bias level correction) ......................................................................................... 9-18 9.4.6 PASCAL Control (image gradation) ........................................................................................................ 9-18 9.4.7 SALT-Dmax Control (development characteristics correction) .............................................................. 9-19 9.4.8 SALT-Dhalf Control (development characteristics correction) ............................................................... 9-20 9.4.9 Auto Gradation Control ............................................................................................................................ 9-22 9.5 Drum Unit ........................................................................................................................................................ 9-24 9.5.1 Outline of the Drum Unit ......................................................................................................................... 9-24 9.5.1.1 Outline of the Drum Unit .................................................................................................................. 9-24 9.5.1.2 Controlling the Drive of the Drum Unit (D-UNIT) ........................................................................... 9-25 9.5.2 Developing Assembly .............................................................................................................................. 9-26 9.5.2.1 Construction of the Developing Assembly ........................................................................................ 9-26 9.5.2.2 Controlling the Developing Bias ....................................................................................................... 9-27 9.5.3 Auxiliary Brush ........................................................................................................................................ 9-29 9.5.3.1 Construction of the Auxiliary Brush ................................................................................................. 9-29 9.5.3.2 Controlling the Auxiliary Bias .......................................................................................................... 9-30 9.5.4 Charging Mechanism ............................................................................................................................... 9-34 9.5.4.1 Construction of the Charging Mechanism ......................................................................................... 9-34 9.5.4.2 Controlling the Charging Bias ........................................................................................................... 9-35 9.6 Toner Container ............................................................................................................................................... 9-37 9.6.1 Outline of the Toner Container ................................................................................................................ 9-37 9.6.2 Controlling the Toner Container Drive .................................................................................................... 9-37 9.6.3 Checking the Level of Toner .................................................................................................................... 9-38 9.6.4 Controlling the Supply of Toner .............................................................................................................. 9-39 9.7 Transfer Unit ................................................................................................................................................... 9-40 9.7.1 Outline of the Transfer Unit ..................................................................................................................... 9-40 9.7.1.1 Outline of the Transfer Unit .............................................................................................................. 9-40 9.7.1.2 Controlling the Drive of the Transfer Unit ........................................................................................ 9-40 9.7.2 Controlling the Transfer Bias ................................................................................................................... 9-42 Contents 9.7.2.1 Controlling the Transfer Bias ............................................................................................................ 9-42 9.7.3 Cleaning .................................................................................................................................................... 9-44 9.7.3.1 Intermediate Transfer Belt (ITB) ....................................................................................................... 9-44 9.7.3.2 Secondary External Roller ................................................................................................................. 9-45 9.7.3.3 Collecting Waste Toner ..................................................................................................................... 9-45 9.7.4 Separation Mechanism .............................................................................................................................. 9-46 9.7.4.1 Separation .......................................................................................................................................... 9-46 9.8 Parts Replacement Procedure .......................................................................................................................... 9-48 9.8.1 Drum ITB Motor ....................................................................................................................................... 9-48 9.8.1.1 Slide Out the Drum Unit .................................................................................................................... 9-48 9.8.1.2 Removing the Upper Rear Cover ....................................................................................................... 9-48 9.8.1.3 Removing the Lower Rear Cover ...................................................................................................... 9-48 9.8.1.4 Removing the Controller Box Cover ................................................................................................. 9-48 9.8.1.5 Removing the DC Controller PCB Cover .......................................................................................... 9-48 9.8.1.6 Removing the Left Upper Rear Cover ............................................................................................... 9-48 9.8.1.7 Opening the Main Controller Box ..................................................................................................... 9-49 9.8.1.8 Removing the DC Controller Mounting ............................................................................................ 9-50 9.8.1.9 Removing the Fixing Heat Discharge Fan ......................................................................................... 9-50 9.8.1.10 Removing the Machine Heat Discharge Fan ................................................................................... 9-50 9.8.1.11 Removing the Developing Drive Unit ............................................................................................. 9-51 9.8.1.12 Removing the Lattice Connector Mounting .................................................................................... 9-51 9.8.1.13 Removing the High-Voltage Unit .................................................................................................... 9-52 9.8.1.14 Removing the Manual Feed Cooling Fan Duct ............................................................................... 9-52 9.8.1.15 Removing the Drum ITB Motor Mounting ..................................................................................... 9-52 9.8.1.16 Removing the Drum ITB Motor ...................................................................................................... 9-53 9.8.2 Drum Drive Unit ....................................................................................................................................... 9-53 9.8.2.1 Slide Out the Drum Unit .................................................................................................................... 9-53 9.8.2.2 Removing the Upper Rear Cover ....................................................................................................... 9-53 9.8.2.3 Removing the Lower Rear Cover ...................................................................................................... 9-53 9.8.2.4 Removing the Controller Box Cover ................................................................................................. 9-53 9.8.2.5 Removing the DC Controller PCB Cover .......................................................................................... 9-54 9.8.2.6 Removing the Left Upper Rear Cover ............................................................................................... 9-54 9.8.2.7 Opening the Main Controller Box ..................................................................................................... 9-54 9.8.2.8 Removing the DC Controller Mounting ............................................................................................ 9-55 9.8.2.9 Removing the Fixing Heat Discharge Fan ......................................................................................... 9-56 9.8.2.10 Removing the Machine Heat Discharge Fan ................................................................................... 9-56 9.8.2.11 Removing the Developing Drive Unit ............................................................................................. 9-56 9.8.2.12 Removing the Lattice Controller Base ............................................................................................. 9-57 9.8.2.13 Removing the High-Voltage Unit .................................................................................................... 9-57 9.8.2.14 Removing the Drum ITB Motor Mounting Base ............................................................................. 9-58 9.8.2.15 Removing the Drum Drive Unit ...................................................................................................... 9-58 9.8.3 Drive Roller .............................................................................................................................................. 9-59 9.8.3.1 Pressure Release of the Intermediate Transfer Unit .......................................................................... 9-59 9.8.3.2 Removing the Intermediate Transfer Unit ......................................................................................... 9-59 9.8.3.3 Removing the Intermediate Transfer Belt ......................................................................................... 9-60 9.8.3.4 Removing the Drive Roller ................................................................................................................ 9-62 9.8.4 Developing Motor (Bk) ............................................................................................................................ 9-63 9.8.4.1 Removing the Upper Rear Cover ....................................................................................................... 9-63 9.8.4.2 Removing the Lower Rear Cover ...................................................................................................... 9-63 9.8.4.3 Removing the Left Upper Rear Cover ............................................................................................... 9-63 9.8.4.4 Removing the Controller Box Cover ................................................................................................. 9-63 9.8.4.5 Removing the DC Controller PCB Cover .......................................................................................... 9-63 9.8.4.6 Opening the Main Controller Box ..................................................................................................... 9-64 9.8.4.7 Removing the DC Controller Mounting ............................................................................................ 9-65 Contents 9.8.4.8 Removing the Developing Motor (Bk) .............................................................................................. 9-65 9.8.5 Developing Motor (Y/M/C) ..................................................................................................................... 9-65 9.8.5.1 Removing the Upper Rear Cover ...................................................................................................... 9-65 9.8.5.2 Removing the Lower Rear Cover ...................................................................................................... 9-65 9.8.5.3 Removing the Left Upper Rear Cover ............................................................................................... 9-65 9.8.5.4 Removing the Controller Box Cover ................................................................................................. 9-65 9.8.5.5 Removing the DC Controller PCB Cover ......................................................................................... 9-66 9.8.5.6 Opening the Main Controller Box ..................................................................................................... 9-66 9.8.5.7 Removing the DC Controller Mounting ............................................................................................ 9-67 9.8.5.8 Removing the Developing Motor (Y/M/C) ....................................................................................... 9-67 9.8.6 Secondary Transfer Unit .......................................................................................................................... 9-68 9.8.6.1 Removing the Fixing Unit ................................................................................................................. 9-68 9.8.6.2 Removing the Duplex Open/Close Guide ......................................................................................... 9-68 9.8.6.3 Removing the Secondary Transfer Unit ............................................................................................ 9-68 9.8.7 Intermediate Transfer Unit ....................................................................................................................... 9-69 9.8.7.1 Pressure Release of the Intermediate Transfer Unit .......................................................................... 9-69 9.8.7.2 Removing the Intermediate Transfer Unit ......................................................................................... 9-69 9.8.8 Transfer Cleaning Unit ............................................................................................................................. 9-69 9.8.8.1 Removing the Waste Toner Container .............................................................................................. 9-69 9.8.8.2 Removing the Transfer Cleaning Unit .............................................................................................. 9-70 9.8.9 Intermediate Transfer Belt ........................................................................................................................ 9-70 9.8.9.1 Pressure Release of the Intermediate Transfer Unit .......................................................................... 9-70 9.8.9.2 Removing the Intermediate Transfer Unit ......................................................................................... 9-70 9.8.9.3 Removing the Intermediate Transfer Belt ......................................................................................... 9-71 9.8.10 Primary Transfer Roller .......................................................................................................................... 9-73 9.8.10.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-73 9.8.10.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-73 9.8.10.3 Removing the Intermediate Transfer Belt ....................................................................................... 9-74 9.8.10.4 Removing the Primary Transfer Roller ........................................................................................... 9-76 9.8.11 Secondary Transfer External Roller ....................................................................................................... 9-77 9.8.11.1 Removing the Fixing Unit ............................................................................................................... 9-77 9.8.11.2 Removing the Secondary Transfer External Roller ......................................................................... 9-77 9.8.12 Secondary Transfer Internal Roller ........................................................................................................ 9-78 9.8.12.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-78 9.8.12.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-78 9.8.12.3 Removing the Intermediate Transfer Belt ....................................................................................... 9-79 9.8.12.4 Removing the Secondary Transfer Internal Roller .......................................................................... 9-81 9.8.13 Toner Container Drive Unit ................................................................................................................... 9-82 9.8.13.1 Removing the Waste Toner Container ............................................................................................ 9-82 9.8.13.2 Removing the Upper Rear Cover .................................................................................................... 9-82 9.8.13.3 Removing the Lower Rear Cover .................................................................................................... 9-82 9.8.13.4 Removing the Left Upper Rear Cover ............................................................................................. 9-82 9.8.13.5 Removing the Controller Box Cover ............................................................................................... 9-82 9.8.13.6 Removing the DC Controller PCB Cover ....................................................................................... 9-83 9.8.13.7 Opening the Main Controller Box ................................................................................................... 9-83 9.8.13.8 Removing the DC Controller Mounting .......................................................................................... 9-84 9.8.13.9 Removing the Toner Container Drive Unit ..................................................................................... 9-84 9.8.14 Waste Toner Detection PCB .................................................................................................................. 9-85 9.8.14.1 Removing the Waste Toner Container ............................................................................................ 9-85 9.8.14.2 Removing the Front Cover .............................................................................................................. 9-85 9.8.14.3 Removing the Intermediate Transfer Unit Releasing Lever ............................................................ 9-85 9.8.14.4 Removing the Cleaner Fan Cover ................................................................................................... 9-86 9.8.14.5 Removing the Inside Cover (lower) ................................................................................................ 9-86 9.8.14.6 Removing the Waste Toner Detection PCB .................................................................................... 9-86 Contents 9.8.15 Feedscrew Rotation Sensor ..................................................................................................................... 9-86 9.8.15.1 Removing the Waste Toner Container ............................................................................................. 9-86 9.8.15.2 Removing the Upper Rear Cover ..................................................................................................... 9-87 9.8.15.3 Removing the Lower Rear Cover .................................................................................................... 9-87 9.8.15.4 Removing the Left Upper Rear Cover ............................................................................................. 9-87 9.8.15.5 Removing the Controller Box Cover ............................................................................................... 9-87 9.8.15.6 Removing the DC Controller PCB Cover ........................................................................................ 9-87 9.8.15.7 Opening the Main Controller Box ................................................................................................... 9-88 9.8.15.8 Removing the DC Controller Mounting .......................................................................................... 9-89 9.8.15.9 Removing the Toner Container Drive Unit ..................................................................................... 9-89 9.8.15.10 Removing the Toner Container Drive Assembly Upper Plate ...................................................... 9-89 9.8.15.11 Removing the Feedscrew Rotation Sensor .................................................................................... 9-90 9.8.16 Tone Container Motor ............................................................................................................................ 9-90 9.8.16.1 Removing the Waste Toner Container ............................................................................................. 9-90 9.8.16.2 Removing the Upper Rear Cover ..................................................................................................... 9-91 9.8.16.3 Removing the Lower Rear Cover .................................................................................................... 9-91 9.8.16.4 Removing the Left Upper Rear Cover ............................................................................................. 9-91 9.8.16.5 Removing the Controller Box Cover ............................................................................................... 9-91 9.8.16.6 Removing the DC Controller PCB Cover ........................................................................................ 9-91 9.8.16.7 Opening the Main Controller Box ................................................................................................... 9-92 9.8.16.8 Removing the DC Controller Mounting .......................................................................................... 9-93 9.8.16.9 Removing the Toner Container Drive Unit ..................................................................................... 9-93 9.8.16.10 Removing the Toner Container Drive Assembly Upper Plate ...................................................... 9-93 9.8.16.11 Removing the Toner Container Motor ........................................................................................... 9-94 9.8.17 Waste Toner Feedscrew Case ................................................................................................................. 9-94 9.8.17.1 Removing the Waste Toner Container ............................................................................................. 9-94 9.8.17.2 Removing the Transfer Cleaning Unit ............................................................................................. 9-95 9.8.17.3 Removing the Waste Toner Feedscrew Case .................................................................................. 9-95 9.8.18 Pattern Reader Unit ................................................................................................................................. 9-95 9.8.18.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-95 9.8.18.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-96 9.8.18.3 Removing the Upper Right Cover ................................................................................................... 9-96 9.8.18.4 Removing the Pattern Reader Unit .................................................................................................. 9-96 9.8.19 Auto Registration Sensor PCB ............................................................................................................... 9-97 9.8.19.1 Pressure Release of the Intermediate Transfer Unit ........................................................................ 9-97 9.8.19.2 Removing the Intermediate Transfer Unit ....................................................................................... 9-98 9.8.19.3 Removing the Upper Right Cover ................................................................................................... 9-98 9.8.19.4 Removing the Pattern Reader Unit .................................................................................................. 9-98 9.8.19.5 Removing the Auto Registration Sensor PCB ................................................................................. 9-99 9.8.20 SALT Sensor ........................................................................................................................................ 9-100 9.8.20.1 Pressure Release of the Intermediate Transfer Unit ...................................................................... 9-100 9.8.20.2 Removing the Intermediate Transfer Unit ..................................................................................... 9-101 9.8.20.3 Removing the Upper Right Cover ................................................................................................. 9-101 9.8.20.4 Removing the Pattern Reader Unit ................................................................................................ 9-101 9.8.20.5 Removing the SALT Sensor .......................................................................................................... 9-103 Contents Chapter 9 9.1 Construction 9.1.1 Specifications, Control Mechanisms, and Functions 0000-4473 T-9-1 Photosensitive drum Drum unit Type of drum OPC Diameter of drum 30.6 mm (D-UNIT) Cleaning mechanism Cleaner-less The residual toner after transfer is charged for collection by the developing assembly. Process speed 130 mm/sec (plain paper) 65 mm/sec (thick paper, special paper, transparency) T-9-2 Developing assembly Diameter of developing cylinder 16 mm Method of development dry, 2-component Toner non-magnetic, negative (S toner) Detection of toner inside ATR sensor (magnetic sensor) developing assembly Starter held by drum unit T-9-3 Primary charging assembly Method of charging roller, contact charging Diameter of charging roller 14 mm Cleaning mechanism cleaning sheet, in contact (reciprocating movement of 5 mm; cycle of 1.5 sec) 9-1 Chapter 9 T-9-4 Auxiliary brush Type of brush fur brush Intrusion of brush 1.3 mm (upstream) 1.3 mm (downstream) T-9-5 Others Items of control by internal memory color of toner inside drum unit cumulative number of prints cumulative number of video counts data on life of drum unit data on toner supply control T-9-6 Toner container Detection of toner level in reference to number of rotations made by toner feedscrew Toner volume Y: 490 g M: 470 g C: 470 g Bk: 530 g T-9-7 Others Items of control by internal memory color of toner inside toner container data on life of toner container T-9-8 Inter-mediate Intermediae transfer belt (ITB) seamless transfer unit Drive for belt through gears from drum ITB motor Feeding speed 130 mm/sec (plain paper) 65 mm/sec (thick paper, special paper, transparency) Cleaning mechanism 9-2 cleaning blade Chapter 9 T-9-9 Image stabili- Descharge current level control to prevent image faults caused by zation mechanism changes in environment ATVC control to ensure good transfer ATR control to correct toner density (about) PASCAL control to correct image gradation characteristics SALT-Dmax control to correct development density (maximum density) characteristics SALT-Dhalf control to correct development density (gradation) characteristics 9.1.2 Major Components of the Image Formation System 0000-4474 Toner container (Bk) Developing cylinder D-UNIT(Bk) Developing assembly Primary charging roller Intermediate transfer belt Auxiliary brushes Photosensitive drum D-UNIT(Y) D-UNIT(M) D-UNIT(C) Intermediate transfer unit Primary transfer rollers Secondary transfer internal roller F-9-1 9-3 Chapter 9 9.1.3 Charging Specifications 0000-4475 Drum unit (high voltage) T-9-10 Photosensitive drum charging Method of primary charging roller contact AC component rating specifications range 1300 to 2000 Vp-p (standard: 1500 Vp-p) DC component rating specifications range -300 to -700 V (standard: -450 V) AC component voltage correction factor environment sensor DC component voltage correction factor environment sensor, SALT sensor T-9-11 Auxiliary charging Method of charging fur brush (upstream, downstream) Upstream auxiliary brush AC component rating 200 Vp-p specifications range Upstream auxiliary brush DC component rating +200 to +300 V (standard: +250 V) specifications range Downstream brush DC component rating -700 to -800 V (standard: -750 V) specifications range Voltage correction factor environment sensor T-9-12 Developing bias AC component standard value 1800 Vp-p (fixed) DC component rating specifications range -150 to -550 V (standard: -300 V) Voltage correction factor environment sensor, SALT sensor Transfer unit specifications (high-voltage) T-9-13 Primary transfer 9-4 Method of transfer Roller transfer Object of transfer Transfer belt (ITB) DC component rating use range 0 to +1200 V Chapter 9 Primary transfer Voltage control factor environment sensor, print mode* T-9-14 Secondary transfer Method of transfer roller Object of transfer paper (transfer media) DC component rating use range -2500 to +7000 V Voltage correction factor paper type, environment sensor reading, print mode* *Full color or monochrome mode. Developing cylinder Primary charging roller 0V 0V -300V -450V 1800Vp-p 1500Vp-p Downstream auxiliary brush 0V -750V Secondary transfer external roller Primary transfer roller Upstream auxiliary brush +2000V +250V +400V 0V 0V 200Vp-p 0V Full color, Plain paper, Normal temperature/humidify F-9-2 9-5 Chapter 9 9.2 Image Formation Process 9.2.1 Image Formation Process (general) 0000-4476 T-9-15 Functional block STEP Description Electrostatic latent image formation 1, 2 forms an electrostatic latent image on the block photosensitive drum. Development block 3 deposits toner over the electrostatic latent image, thereby turning it into a visible image. Transfer block 4, 5, 6 moves the toner image to the ITB or paper. Intermediate transfer belt (ITB) cleaning 7 collects residual toner from the ITB. 8, 9, 10 collects residual toner from the block Photosensitive drum cleaning block photosensitive drum. Photosensitive drum 2.Laser beam exposure 1.Charging 10.Toner collection 9.Charging roller cleaning 3.Development M Y C 8.Auxiliary charging 4.Primary transfer 4.Primary transfer 4.Primary transfer 7.ITB cleaning ITB Delivery Fixing 6.Separation 5.Secondary transfer F-9-3 9-6 Pickup Bk 4.Primary transfer Chapter 9 9.2.2 Image Formation Process (image formation) 0000-4477 Toner not charged to a negative potential by the downstream brush Photosensitive drum cleaning block [6] Colled to the developing assembly. - [5] Charging to a negative potential by friction against the cleaning sheet. + + - - - - - - - - [1] Development - - - - [4] Charging to a negative potential by the downstream auxiliary brush.*2 - - + + + Development block - + - - - - [3] Charging to a positive potential by the upstream auxiliary brush.*1 + - - - - - - Transfer residual toner*3 [2] Primary transfer Primary transfer block *1: reducing negative charges on toner (removal of charges) *2: evening out charge to a specific level *3: toner left behind from secondary transfer (mix of positive and negative charges) F-9-4 9.2.3 Image Formation Process (transfer) 0000-4478 [1] Moving the toner from the photosensitive drum to the ITB [3] Scraping off the toner by the cleaning blade Y ITB cleaning block M C Bk Primary transfer block Transfer residual toner* Waste tone container Paper Secondary transfer [2] Moving the toner image block from the ITB to paper * Toner left behind from secondary transfer. F-9-5 9-7 Chapter 9 9.3 Basic Sequence 9.3.1 At Power-On (1) 0000-4479 If the main power switch is turned on while the surface temperature of the fixing roller is less than 100°C (e.g., first time in the morning or after a long period of no use), Characteristics - the same control timing is used for the Y, M, C, and Bk drum units. - the machine takes about 300 to 360 sec before it enters PSTBY. - the machine executes image stabilization control in the following order while it is warming up: discharge current level control ATVC control ATR control SALT-Dmax control image position control SALT-Dhalf control Main power switch ON WMUPR CNTR Approx. 120sec Approx. 120sec PSTBY Drum/ITB motor (M1) Exposure (Y) Charging (DC) bias (Y) Charging (AC) bias (Y) Development motor (Y) Image stabilization control (for details, see appropriate sections) Developing (DC) bias (Y) Developing (AC) bias (Y) Scraping off toner by auxiliary brush Upstream auxiliary (DC) bias (Y) Upstream auxiliary (AC) bias (Y) Scraping off toner by auxiliary brush Downstream auxiliary (DC) bias (Y) Primary transfer bias (Y) Cleaning by secondary transfer roller Secondary transfer bias • Start-up sequence of the drum unit (Y; with surface temperature of fixing roller at 100 or more). F-9-6 9.3.2 At Power-On (2) 0000-4480 If the main power switch is turned on while the surface temperature of the fixing roller is 100°C or more (i.e., after it returns from jam recovery*, after it has been forced off and then on, or after its front cover has been opened and then closed while an imaged is made). Characteristics - the same control timing is used for the Y, M, C, and Bk drum units. - the machine takes about 80 sec before it enters PSTBY. - the machine executes image stabilization in the following order while it is warming up: discharge current level control ATVC control 9-8 Chapter 9 image position correction *If the surface temperature of the fixing roller is less than 100°C after jam recovery, the machine uses the sequence it uses at power-on (1). Main power switch ON WMUPR PSTBY CNTR Approx. 50sec Approx. 30sec Drum/ITB motor (M1) Exposure (Y) Charging (DC) bias (Y) Charging (AC) bias (Y) Development motor (Y) Image stabilization control (for details, see appropriate sections) Developing (DC) bias (Y) Developing (AC) bias (Y) Scraping off toner by auxiliary brush Upstream auxiliary (DC) bias (Y) Upstream auxiliary (AC) bias (Y) Scraping off toner by auxiliary brush Downstream auxiliary (DC) bias (Y) Primary transfer bias (Y) Cleaning by secondary transfer roller Secondary transfer bias • Start-up sequence of the drum unit (Y; with surface temperature of fixing roller at 100˚C or more). F-9-7 9.3.3 During Copying/Printing Operations (normal speed) 0000-4481 Full color, Plain paper, A4, 2 copies/prints, Y drum unit Characteristics - in response to a press on the Start key, the intermediate transfer belt (ITB) stars to rotate. - the sequence of operations for drum units after exposure starts with a delay of 0.7 sec each - the ITB continues to rotate after delivery of paper from the fixing unit (for post-imaging control) Start key ON PSTBY PINTR 5sec PRINT LSTR 4sec 12sec PSTBY Drum/ITB motor (M1) Exposure (Y) Charging (DC) bias (Y) Charging (AC) bias (Y) Development motor (Y) Developing (DC) bias (Y) Developing (AC) bias (Y) Scraping off toner by auxiliary brush Upstream auxiliary (DC) bias (Y) Upstream auxiliary (AC) bias (Y) Scraping off toner by auxiliary brush Downstream auxiliary (DC) bias (Y) Primary transfer bias (Y) Cleaning by secondary transfer roller Secondary transfer bias • Y Drum Unit Sequence of Image Formation (plain paper) F-9-8 9-9 Chapter 9 When Making Y/M/C Monochrome Copies/Prints If not for Bk (i.e., for Y, M, C), a high voltage is applied for the 4 colors as for full-color output when making monochrome copies/prints. (Exposure is not executed for colors other than those in question.) When Making Bk Monochrome Copies/Prints When making Bk monochrome copies/prints, no high voltage is applied for Y or M, and the developing motors for these colors are not driven. 9.3.4 Making Copies/Prints (half speed) 0000-4482 Full color, Thick paper/Special paper/Transparency, A4, 2 copies/prints, Y drum unit Characteristics - in response to a press on the Start key, the photosensitive drum and the intermediate transfer belt (ITB) start to rotate - the sequence of operations of the drum units after exposure starts with a delay of 1.5 sec - the photosensitive drum and the ITB continue to rotate after paper has been discharged from the fixing unit (for post-imaging control) Start key ON PSTBY PINTR 15sec PRINT LSTR 7sec PSTBY 25sec Drum/ITB motor (M1) Exposure (Y) Charging (DC) bias (Y) Charging (AC) bias (Y) Development motor (Y) Developing (DC) bias (Y) Developing (AC) bias (Y) Scraping off toner by auxiliary brush Upstream auxiliary (DC) bias (Y) Upstream auxiliary (AC) bias (Y) Scraping off toner by auxiliary brush Downstream auxiliary (DC) bias (Y) Primary transfer bias (Y) Cleaning by secondary transfer roller Secondary transfer bias • Y Drum Formation Sequence (thick paper/special paper/transparency) F-9-9 9.3.5 After Replacing the Drum Unit (D-UNIT) 0000-4483 When a new drum unit (D-UNIT) has been installed, Characteristics - when a drum unit is fitted and the machine's front cover is closed, the developing cylinder starts to rotate. - so that the developing cylinder may be coated evenly with developer, the cylinder is rotated for 30 sec at the beginning - if the drum unit is not new, this sequence is not executed; the sequence used at power-on (1) or (2) is executed - about 150 sec after the drum unit has been fitted, image stabilization control is executed in the following order discharge current level control ATVC control ATR control 9-10 Chapter 9 SALT-Dmax control image position correctionSALT-Dhalf control New drum unit fitted, and front cover closed WMUPR Approx. 30sec CNTR Approx. 120sec Approx. 120sec PSTBY Drum/ITB motor (M1) Exposure (Y) Charging (DC) bias (Y) Charging (AC) bias (Y) Image stabilization control (for details, see appropriate sections) Development motor (Y) Developing (DC) bias (Y) Developing (AC) bias (Y) Scraping off toner by auxiliary brush Upstream auxiliary (DC) bias (Y) Upstream auxiliary (AC) bias (Y) Scraping off toner by auxiliary brush Downstream auxiliary (DC) bias (Y) Primary transfer bias (Y) Cleaning by secondary transfer roller Secondary transfer bias • Y Drum Unit Initialization Sequence F-9-10 9.3.6 Printing Originals Containing a Color Page 0000-4484 When making copies/prints of originals containing a color page, the machine uses the following sequence to avoid a drop in productivity: T-9-16 color original: monochrome original: full-color mode sequence for 3rd and subsequent copies/prints after color page, fullcolor mode sequence for 4th and subsequent copies/prints after color page, monochrome sequence MEMO: A switch-over from full-color mode to monochrome mode requires a sequence in which the high voltage of YMC must be lowered. By reducing the use of such a sequence, the machine avoids an appreciable drop in productivity. 9.3.7 Driving and Controlling the Image Formation System and the High-Voltage System 0000-4485 Drive Control The image formation system is driven by the toner container motor, developing motor, and drum ITB motor through gears. (For details, see the appropriate sections.) 9-11 Chapter 9 DC controller PCB Toner container motor drive signal J126 M20 M21 M22 M23 Developing motor drive signal J110 Toner drive motor M12 M13 M14 M15 Drum/ITB motor drive signal J105 M1 Developing motor ITB Drum/ITB motor F-9-11 High-Voltage Control The high-voltage unit is used to supply high voltage to each of the blocks in the image formation system. (For details, see the appropriate sections.) Y M C Developing cylinder Bk Primary charging roller Photosensitive drum Downstream auxiliary brush Upstream auxiliary brush Secondary transfer external roller HV1 (1 each for YMCBk) HV4 HV2 (1 for YM; 1 for CBk) Secondary transfer high-voltage unit High-voltage unit HV: high-voltage PCB F-9-12 9-12 HV3 Chapter 9 9.4 Image Stabilization Control 9.4.1 Outline of Image Quality Control 0000-4486 Changes in temperature/humidity or passage of time can cause the machine to produce images of varying quality. To ensure that the quality of images remain stable, the levels of voltage outputs and volumes of toner supply are corrected: T-9-17 So that the machine's image reproduction remains stable, the following control mechanisms are used: ATR Control to suit changes in toner density/toner consumption Discharge Current Level Control to prevent faulty images in a high humidity environment (correction of charging AC bias) ATVC Control to ensure good transfer (correction of transfer bias level) PASCAL Control/SALT Control to suit changes in image density and gradation (correction of charging/developing/transfer bias; correction of image correction table) 9.4.2 Automatic Image Stabilization Control 0000-4487 T-9-18 Operation Discharge ATVC ATR SALT- Image SALT- Estimated current control control Dmax position Dhalf duration control correction control (sec) YES NO about 80 *6 YES YES level control Power-on/ jam - if fixing roller surface temperature >= 100 deg C YES YES NO NO recovery - if fixing roller surface temperature < 100 deg C YES YES YES YES about 240 *7 9-13 Chapter 9 T-9-19 New if the number of rotations made by the toner feedscrew has reached the threshold and, toner in addition, the reading of the ATR sensor is lower than a specific value *8 container YES YES YES YES YES NO replacem about 190 ent if the number of rotations of the toner feedscrew has reached a specific value (100%) *8 NO NO NO NO NO NO YES YES about 20 T-9-20 Drum YES YES YES YES unit about 280 *7 replacem ent T-9-21 Cover *1 opened/ - if fixing roller surface temperature>=100 deg C *2 NO NO NO NO NO NO YES YES about 20 closed - if fixing roller surface temperature < 100 deg C YES YES YES YES about 240 *7 T-9-22 Number - cumulative output (number of pages) is 100 or more and less than 200 (LSTR) *3 of pages YES YES YES NO *10 (YES: 300 NO pages *9 ) about 30 (50) - cumulative output (number of pages) is 100 or more and less than 200 (INTR) *3 YES YES NO NO NO NO about 15 - cumulative output (number of pages) reaching 200 pages or more *3 YES YES YES NO (YES: 400 NO pages *9 ) about 30 (50) - cumulative output (number of pages) reaching 500 pages or more (LSTR) *3 YES YES YES YES (YES) NO about 50 (70) 9-14 Chapter 9 T-9-23 Left alone in YES YES NO YES YES YES about STBY for 2 hr 120 *3 /Rapid change in environment T-9-24 Return from low - cover is not opened and closed during low power mode NO NO NO NO NO NO about 30 *4 NO about 80 *6 power mode state - cover is opened and closed during low power mode YES YES NO NO YES T-9-25 Return from - STBY + power save mode lasts 1.9 hr or more before starting sleep mode YES YES YES YES YES YES about 240 *7 sleep state - STBY + power save mode lasts less than 1.9 hr before starting sleep mode *5 YES YES (YES) (YES) YES (YES) about 80 *6 (about 240 *7 ) *1The term "over"refers to all covers. *2 If the cover is opened and then closed again before the machine will be standby state(fixing roller surface temperature >=100 deg C), the sequence used for 'cover opened/closed'(i.e., fixing roller surface temperature <100 deg C) is executed. *3See the description or the service mode item in question. *4The duration refers to the period of time for the fixing roller surface temperature to reach a level ready to start a job. *5The condition depends on the fixing roller surface temperature upon return from sleep mode. *6time that includes about 30 sec of various operations taking place before image stabilization control starts. *7time that includes about 120 sec of various operations taking place before image stabilization control starts. *8the toner container is identified as having reached the end of its life. *9if the counter reading for image position correction is 300 or higher, image position correction is executed together with other image stabilization control mechanisms. *10the counters used in relation to a specific number of pages are of the following 3 types: - used to set up discharge current level control, ATVC control, ATR control - used to set up discharge current level control, ATVC control, ATR control, SALT-Dmax control - used to correct image position *The control mechanism executed after processing a specific number of pages is executed at the following timing of operation: 9-15 Chapter 9 Cumulative output is 100 pages or more and less 1st page 2nd page than 200 pages 99th page 105th page next job *1 Continuous jobs Control executed during post rotation of last sheet of job in excess of 100 pages Cumulative output is 200 pages or more 199th page 200th page 201st page 400th page Pickup stopped once; then, control executed between sheets every 200 pages *2 Control executed also during initial rotation of next job *2 401st page Pickup stopped once; then, control executed between sheets every 200 pages *2 *1 : job next to the one ending in excess of 100 pages. *2 : counter reading returns to '0' when control is executed. : timing at which control is executed. F-9-13 COPIER>OPTION>BODY>INTROT-1 Use it to change the intervals between sessions of execution of image stabilization control (adjustment set-1) for initial/last rotation in terms of the number of pages. Default (at shipment/upon RAM initialization): 100 COPIER>OPTION>BODY>INTROT-2 Use it to change the intervals between execution sessions of image stabilization control (adjustment set-2) for initial/last rotation in terms of the number of pages. Default (at shipment/upon RAM initialization): 500 COPIER>OPTION>BODY>PPR-1 Use it to change the intervals of execution sessions (adjustment set-1) for image stabilization control between sheets in terms of the number of pages. Default (at shipment/upon RAM initialization): 200 COPIER>OPTION>BODY>INTROT-T Use it to change the intervals of execution sessions for image stabilization control for standby. Default (at shipment/upon RAM initialization): 2 COPIER>OPTION>BODY>ADJ-LVL Use it to change the execution mode settings for image stabilization control for a specific number of pages. Default (at shipment/upon RAM initialization): 0 9-16 Chapter 9 9.4.3 ATR Control 0000-4488 The machine executes ATR control to maintain a specific image density, which otherwise would change as more and more toner is used. The machine measures the concentration of toner and adjusts its supply. Forms a sample image (every specific number of pages) Measures the concentration of toner inside the developing assembly at all items (ATR sensor) Measures the density of the sample image (SALT sensor) Computes the change in density from 2 sets of measurements (data) Verifies the volume of toner to supply Determines the volume of toner to be supplied ATR control F-9-14 Bk C M Y SALT sensor F-9-15 9.4.4 Discharge Current Level Control 0000-4489 - The machine controls the level of discharge current so as to ensure the optimum level in keeping with changes in temperature/humidify. (The term "discharge current"refers to the current that occurs between the primary charging roller and the photosensitive drum.) The current is controlled to a level that enables prevention of faulty images in a high humidity environment and, at the same time, permits collection of toner remaining from transfer to the developing assembly. Operation 1. An AC bias is applied to the primary charging assembly; the level of current occurring at the time is measured by the high-voltage PCB (HV1-SUB) and is sent to the CPU on the DC controller PCB as feedback. 2. The roller is charged using the AC charging bias corrected by the CPU. - If thick paper, special paper, or transparency is used, the frequency of the AC bias applied to the primary charging roller is halved. 9-17 9.4.5 ATVC Control (transfer bias level correction) 0000-4490 The ATVC control mechanism is used to determine the optimum level of transfer voltage for transfer of images from the photosensitive drum to the ITB, and from the ITB to paper. The level of transfer voltage is corrected in relation to changes in temperature/humidity, deterioration of rollers, and types of paper. Description of Control 1. A reference voltage is applied to the transfer roller, and the level of current that occurs in response is checked by the high-voltage PCB and communicated to the CPU on the DC controller PCB as feedback. 2. The machine executes transfer using a transfer voltage which is the result of correction by the CPU. T-9-26 Item Description Primary Applies a reference voltage to the primary charging roller. transfer Uses the high-voltage PCB (HV-2) to check the level of current, and the result is fed back to the CPU for determination of the optimum level. Secondary Applies a reference voltage to the secondary transfer external roller. transfer Uses the high-voltage PCB (HV-3) to check the level of current, and the result is fed back to the CPU for determination of the optimum level. 9.4.6 PASCAL Control (image gradation) 0000-4491 The PASCAL control mechanism is used to stabilize gradation characteristics of images on paper. It makes up for the changes in gradation occurring in response to changes in temperature/humidity or as the machine is used over time. - PASCAL Control for Half-Speed The mechanism is used to correct the changes in the gradation characteristics that otherwise would occur when thick paper, special paper, or transparency is used. The test print used for the mechanism is the same as the test print used for plain paper. Description of Control Start-up V Prints out the test pattern stored in the main controller (3 types). V Uses the scanner to read the test print (previously printed out) set in the reader. V Prepares the image correction table A (data processing). V End Timing of Control Chapter 9 - Service Person Interaction The mechanism is executed when 'full correction'is executed while auto gradation correction is under way in user mode. MEMO; Differences Among 3 Test Patterns - Test Print 1 It shows 64 gradations expressed by means of error diffusion processing, which is not subject to moire and, therefore, used in text/photo/map, print photo, and text mode. - Test Print 2 It shows 64 gradations expressed by means of screening with a low number of lines, which is suitable for the expression of gradation and, therefore, is used for print film photo mode and when priority is placed on PDL. - Test Print 3 It shows 64 gradations expressed by means of screening with a high number of lines, which is suitable for the achievement of a high resolution and is, therefore, used when priority is placed on PDL resolution. Test Print F-9-16 9.4.7 SALT-Dmax Control (development characteristics correction) 0000-4492 This mechanism is used to stabilize the maximum resolution on the intermediate transfer belt (ITB). It is used to make up for changes in the maximum density (Dmax), changes in response to deterioration in developer or the drum, changes in temperature/humidity, or changes occurring as the machine is used over time. Description of Control Start-up V Measures the light reflected by the surface of the ITB (background measurement). V Forms a sample patch of the maximum solid density stored in the DC controller. 9-19 Chapter 9 V Uses the SALT sensor to take the reading. V Converts density (performs computation using the measurement taken). V Determines the charging DC bias, developing DC bias, and primary charging current level. V End Timing of Control - Service Person InteractionThe mechanism is executed when 'full correction' or 'quick correction' of auto gradation correction is under way in user mode. Bk C M Y SALT sensor F-9-17 9.4.8 SALT-Dhalf Control (development characteristics correction) 0000-4493 The SALT-Dhalf control mechanism is used to stabilize the gradation of images on the ITB. It makes up for the changes in gradation characteristics that occur in response to the deterioration in developer or photopositive drum, changes in temperature/humidity, and changes that occur as the machine is used over time. Gradation Density Control for Half Speed The control mechanism is used to make up for the changes in the gradation in images when thick paper, special paper, or transparency is used. When the mechanism is enabled in service mode, it is activated when auto control is executed. The time it takes is about double the time taken when plain paper is used. Description of Control Start-up* V Measures the light reflected by the surface of the ITB (background measurement). V Forms a sample patch of a gradation pattern stored in the main controller on the ITB. V Uses the SALT sensor to take a reading. 9-20 Chapter 9 V Performs density conversion (performs computation using the measurement taken). V Prepares an image correction table B/C (data processing). V End - Non-AutomaticThe mechanism is executed when 'full correction'or 'quick correction' is under way in user mode. COPIER>OPTION>BODY>CAL-SW Use it to change the conditions that initiate automatic control. default: 0 (disable gradation density control for half speed) Bk C M Y SALT sensor F-9-18 9-21 Chapter 9 9.4.9 Auto Gradation Control 0000-4494 Outline The auto gradation control mechanism is used to correct image gradation by correcting the laser output so as to obtain ideal gradation characteristics. Image density Actual gradation characteristics 1.45 Ideal characteristics 0 255 Relationship between laser output and image density F-9-19 T-9-27 Full Correction: The machine knows the actual gradation characteristics based on the 64gradation density data collected from the scanner. Quick Correction: The machine knows the actual gradation characteristics based on the 9gradation density data. User Mode The machine uses 2 types of auto gradation correction mechanisms, combining the best mechanisms to suit individual requirements. T-9-28 Description 9-22 Full correction Quick correction Start up Start up | | v v SALT-Dmax control SALT-Dmax control (determines developing DC, (determines developing DC, charging DC, primary current charging DC, and primary levels) transfer levels) | | v | Chapter 9 Full correction Quick correction PASCAL control | (prepares image correction | table A) | | | v v Image position correction Image position correction | | v v SALT-Dhalf control SALT-Dhalf control (prepares image correction (prepares image correction table B) table C) | | v v End End T-9-29 Image correction Image correction table A Table prepared by the result of table for use at time including the contents of the table A to of image formation the result of compari-son between image correction tables B and C T-9-30 Characteristics A test print must be printed and The machine does not use (print) a test read by the machine. print. 9-23 Chapter 9 9.5 Drum Unit 9.5.1 Outline of the Drum Unit 9.5.1.1 Outline of the Drum Unit 0000-4495 The drum unit consists of the developing assembly, photosensitive drum, auxiliary brush, and charging mechanism. As many as 4 units are used (Y, M, C, Bk), and all of them have the same construction. Developing cylinder Primary charging roller Cleaning sheet Developing assembly Downstream auxiliary brush Upstream auxiliary brush ATR sensor Developing blade Photosensitive drum F-9-20 9-24 Chapter 9 9.5.1.2 Controlling the Drive of the Drum Unit (D-UNIT) 0000-4496 T-9-31 Parts Source of drive Remarks Developing cylinder Developing motor (M2 driven through gears through M15) Toner stirring screw Developing motor (M2 driven through gears through M15) Charging roller Linked to photosensitive drum Photosensitive drum Drum ITB motor (M1) driven through gears Auxiliary brush, cleaning Drum ITB motor (M1) (reciprocating movement in sheet drum axial direction) Development motor drive signal ITB drum motor drive signal DC controller PCB Developing motor (pulse) M Drum ITB motor (DC) Developing cylinder M Cleaning sheet Primary changing roller Auxiliary brushes ATR sensor Toner stirring screw Photosensitive drum F-9-21 9-25 Chapter 9 9.5.2 Developing Assembly 9.5.2.1 Construction of the Developing Assembly 0000-4497 Outline and Uses 1. turning latent static image into visible image (development) 2. collecting residual toner from photosensitive drum - eliminates the need for a cleaning mechanism for the photosensitive drum T-9-32 Component Developing cylinder - deposits toner on the photosensitive drum. - collects toner from the photosensitive drum coming from upstream Developing blade - serves to coat the developing cylinder with a uniform layer of developerserves to coat the developing cylinder with a uniform layer of developer Toner stirring screw - stirs the toner and the developer inside the developing assembly (thus, charging the toner to a negative potential). ATR sensor - detects the amount (concentration of toner) inside the developing assembly. Developing cylinder Developing assembly Toner stirring screw ATR sensor Developing blade F-9-22 9-26 9.5.2.2 Controlling the Developing Bias 0000-4498 1) AC Component fixed; used to increase the density of output images. 2) DC Component output suited to the reading of the environment sensor/SALT sensor; changes the median voltage of the AC bias to adjust the image density a-1. Route of the Developing Bias DC power supply unit High-voltage unit J91 HV2-SUB J85 J87 J71 J73 J75 J72 J71 J86 J76 J82 HV1-SUB HV2 J77 J72 J81 J79 J71 J72 J71 J72 HV1(Y) HV1(M) HV1(C) HV1(Bk) J70 J70 J70 J70 AC/DC bias for developing cylinder : +24V : -1kV F-9-23 Chapter 9 a-2. Route of the Developing Cylinder Control Signal Environment sensor SALT sensor DC controller PCB J131-A J109 DEV_AC_CTRLT_Y,M DEV_DC_CTRL_Y,M DEV_MODE_Y,M J131-B DEV_CLK-A DEV_CLK-B DEV_CLK-C DEV_AC_CTRLT_C,K DEV_DC_CTRL_C,K DEV_MODE_C,K J88 High-voltage unit HV2-SUB J87 DEV_CLK-A DEV_CLK-B DEV_CLK-C J97 J76 J98 HV1-SUB J73 DEV_AC_CLK1_Y DEV_AC_CLK2_Y J75 _Y DEV_VIN _M _M J77 _M DEV_VIN _C _C J79 _C DEV_VIN _K _K DEV_DC_CTRL_K DEV_VIN J72 J72 J72 J72 HV1(Y) HV1(M) HV1(C) HV1(Bk) J70 J70 J70 J70 : control signal. F-9-24 9-28 Chapter 9 9.5.3 Auxiliary Brush 9.5.3.1 Construction of the Auxiliary Brush 0000-4499 Outline and Uses 1. removes charges from the photosensitive drum; charges residual toner 2. controls the polarity of residual toner - thereby preventing adhesion of toner to the primary charging roller - thereby eliminating the need for a cleaning mechanism for the photosensitive drum T-9-33 Component Upstream auxiliary - removes charge from the photosensitive drum. (in preparation for the brush next image formation session, the latent static image from the previous session is removed) - charges the residual toner to a positive potential. (to increase the effects of charging by the downstream brush as part of the upcoming operation) Downstream - charges the photosensitive drum to a negative potential. auxiliary brush - charges the residual toner to a negative potential. (to facilitate collection by the developing assembly) Downstream auxiliary brush Upstream auxiliary brush F-9-25 9-29 Chapter 9 9.5.3.2 Controlling the Auxiliary Bias 0000-4500 T-9-34 AC Component: level of output suited to the reading of the environment sensor. (upstream auxiliary brush) DC Component: level of output suited to the reading of the environment sensor. (upstream/downstream auxiliary brush) b-1. Route of the Upstream Auxiliary Brush Bias DC power supply unit High-voltage unit J91 HV2-SUB J85 J87 J86 J76 HV1-SUB J74 J78 J94 J94 J82 HV4(Y,M) HV4(C,Bk) HV2 J93 J93 J81 DC bias for upstream auxiliary brush J71 J71 J71 J71 HV1(Y) HV1(M) HV1(C) HV1(Bk) J70 J70 J70 J70 DC bias for upstream auxiliary brush : +24V : -1kV F-9-26 9-30 Chapter 9 b-2. Route of the Upstream Auxiliary Brush Bias Control Signal Environment sensor DC controller PCB J131-A J131-B SUB_UP_DC_CTRL_K.C SUB_UP_AC_CTRL_K.C SUB_UP_DC_CTRL_Y.M SUB_UP_AC_CTRL_Y.M High-voltage unit J97 J98 HV1-SUB J74 J78 SUB_UP_DC_CTRL_K.C SUB_UP_AC_CTRL_K.C SUB_UP_DC_CTRL_Y.M SUB_UP_AC_CTRL_Y.M J94 J94 HV4(Y,M) HV4(C,Bk) J93 J93 J71 J71 J71 J71 HV1(Y) HV1(M) HV1(C) HV1(Bk) J70 J70 J70 J70 : control signal. F-9-27 9-31 Chapter 9 c-1. Route of the Downstream Auxiliary Brush Bias DC power supply unit High-voltage unit J91 HV2-SUB J85 J87 J71 J73 J75 J72 J71 J86 J76 J82 HV1-SUB HV2 J77 J72 J81 J79 J71 J72 J71 J72 HV1(Y) HV1(M) HV1(C) HV1(K) J70 J70 J70 J70 DC bias for downstream auxiliary brush : +24V : -1kV F-9-28 9-32 Chapter 9 c-2. Route for the Downstream Auxiliary Brush Bias Control Signal Environment sensor DC controller PCB J131-A J131-B SUB_LO_DC_CTRL_Y,M High-voltage unit SUB_LO_DC_CTRL_C,K J97 J73 SUB_LO_CTRL_Y J98 HV1-SUB J75 SUB_LO_CTRL_M J77 SUB_LO_CTRL_C J79 SUB_LO_CTRL_K J72 J72 J72 J72 HV1(Y) HV1(M) HV1(C) HV1(Bk) J70 J70 J70 J70 : control signal. F-9-29 9-33 Chapter 9 9.5.4 Charging Mechanism 9.5.4.1 Construction of the Charging Mechanism 0000-4501 Outline and Uses 1. charging the photosensitive drum 2. controlling the polarity of residual toner by the cleaning sheet T-9-35 thus preventing the adhesion of toner to the primary changing roller thus eliminating the need for a cleaning mechanism for the photosensitive drum Component Primary charging roller 1. in preparation for the next image formation session, the photosensitive drum is evenly charged to a negative potential. 2. returns the toner changed to a negative potential to the photosensitive drum (for collection in the developing assembly). Primary charging roller cleaning charges residual toner to a negative potential by sheet friction (thereby returning the toner to the photosensitive drum). Charging roller F-9-30 9-34 Cleaning sheet Chapter 9 9.5.4.2 Controlling the Charging Bias 0000-4502 T-9-36 AC level of output suited to discharge current control Component: DC level of output suited to the reading of the environment sensor/SALT Component: sensor d-1. Route of the Primary Charging Bias DC power supply unit High-voltage unit J91 HV2-SUB J85 J87 J71 J73 J75 J72 J71 J86 J76 J82 HV1-SUB HV2 J77 J72 J81 J79 J71 J72 J71 J72 HV1(Y) HV1(M) HV1(C) HV1(Bk) J70 J70 J70 J70 AC/DC bias for primary charging roller : +24V : -1kV F-9-31 9-35 Chapter 9 d-2. Route for the Primary Charging Bias Control Signal Environment sensor SALT sensor DC controller PCB J131-A J109 CHRG_DC_CTRL _Y,M CHRG_AC_CTRL _Y,M J131-B CHRG_DC_CTRL _C,K CHRG_AC_CTRL _C,K CH_CLK High-voltage unit J88 HV2-SUB J87 CHRG_AC_CLK J97 J98 J76 HV1-SUB J73 CHRG_DC_CTRL _Y CHRG_AC_CTRL _Y_SND J75 _M CHRG_AC _CLK _M_SND J77 _C CHRG_AC _CLK _C_SND J79 _K CHRG_AC _CLK _K_SND CHRG_AC _CLK J72 J72 J72 J72 HV1(Y) HV1(M) HV1(C) HV1(Bk) J70 J70 J70 J70 : control signal. F-9-32 9-36 Chapter 9 9.6 Toner Container 9.6.1 Outline of the Toner Container 0000-4503 The toner container consists of toner, stirring blade, and toner feedscrew; as many as 4 containers are used (Y, M, C, Bk), and all of them are of the same construction. Stirring blade Toner Toner feedscrew (supplies toner from the container to the developing assembly) F-9-33 9.6.2 Controlling the Toner Container Drive 0000-4504 T-9-37 Part Source of drive Remarks Stirring blade Toner container motor (M20 to 23) driven through gars Toner feedscrew Toner container motor (M20 to 23) driven through gears DC controller PCB Toner container motor drive signal M20 M21 M22 M23 Toner stirring blade Y M C Bk Toner feedscrew F-9-34 9-37 9.6.3 Checking the Level of Toner 0000-4505 The machine checks the level of toner using the following sensors: T-9-38 Developing assembly ATR sensor magnetic sensor Description checks the concentration of toner inside the developing assembly. relies on the fact that a change in the ratio between carrier (magnetic) and toner (non-magnetic) changes the force of magnetism. detects changes to identify the level of toner. SALT Sensor photo sensor Description checks the sample toner formed on the intermediate transfer belt (ITB) at such times as programmed. checks the density of the toner image after development. Toner Toner feedscrew rotation sensor container photosensor Description checks the number of revolutions made by the toner feedscrew. the amount of toner supplied to the developing assembly made by a single rotation of the feedscrew is constant, enabling the computation of the level of remaining toner with reference to the number of revolutions. Chapter 9 DC controller PCB J124 J126 ATR_CTRL_Y,M ATR_SIG_Y,M J125 J129 ATR_CTRL_Y,M ATR_SIG_Y,M T-CRG_PULSE_Y,M,C,K PATCH_P PATCH_S Feedscrew rotation sensor Y M C Bk SALT sensor ATR sensor : control signal. F-9-35 9.6.4 Controlling the Supply of Toner 0000-4506 1. Developing Assembly If the ATR sensor identifies a shortage of toner inside the developing assembly, the machine starts control of toner supply from the toner container to the developing assembly. DC controller PCB J124 J126 Toner container (Y) M20 Toner feedscrew Developing assembly Y drum unit ATR sensor F-9-36 9-39 9.7 Transfer Unit 9.7.1 Outline of the Transfer Unit 9.7.1.1 Outline of the Transfer Unit 0000-4507 The transfer unit consists of 2 units: intermediate transfer unit and secondary transfer unit: Intermediate Transfer Unit intermediate transfer belt (ITB) primary transfer roller (1 pc. each for Y, M, C, and Bk) ITB cleaning blade secondary transfer internal roller Secondary Transfer Unit secondary transfer external roller static eliminator feed guide Intermediate transfer unit ITB cleaning blade Waste toner feedscrew Secondary transfer internal roller ITB Primary transfer roller Feed guide Transfer lower front guide Attraction plate Static eliminator Secondary transfer external roller Secondary transfer unit F-9-37 9.7.1.2 Controlling the Drive of the Transfer Unit 0000-4508 T-9-39 Part Source of drive Drive roller Drum ITB motor (M1) Intermediate transfer belt Linked to drive roller (ITB) Primary transfer roller Linked to ITB Remarks Chapter 9 Part Source of drive Secondary transfer internal Linked to ITB Remarks roller Secondary transfer external Secondary transfer internal roller driven through gears roller Tension roller Linked to ITB Waste toner feedscrew Tension roller driven through gears DC controller PCB J105 Drum ITB motor drive signal Drum ITB motor Tension roller M1 Primary transfer roller Secondary transfer external roller Drive roller Waste toner feedscrew ITB Secondary transfer internal roller F-9-38 9-41 Chapter 9 9.7.2 Controlling the Transfer Bias 9.7.2.1 Controlling the Transfer Bias 0000-4509 1. Primary Transfer Bias output in keeping with the reading of the environment sensor, color mode, ATVC control 2. Secondary Transfer Bias output in keeping with the type of paper, reading of the environment sensor, color mode (full-color/monochrome), ATVC control e. Route of the Primary Transfer Bias/Bias Control Signal Environment sensor DC controller PCB DC power supply unit J109 1_TR_CTRL_Y,M,C,K High-voltage unit J88 J91 HV2-SUB J89 TR1_CTRL_Y,M,C,K J80 HV2 J83 DC bias for primary transfer Primary transfer roller : +24V : +1kV : control signal F-9-39 9-42 Chapter 9 f. Route of the Secondary Transfer Bias/Bias Control Signal Environment sensor DC controller PCB DC power supply unit J109 2TR_SEL 2TR_CTRL_P,N High-voltage unit J88 J91 HV2-SUB J90 Secondary transfer high-voltage unit NCTL PCTL PSEN J95 HV3 T801 Secondary transfer external roller DC bias for secondary transfer : +24V : +1kV : control signal. F-9-40 9-43 9.7.3 Cleaning 9.7.3.1 Intermediate Transfer Belt (ITB) 0000-4510 The machine uses a cleaning blade to clean the intermediate transfer belt (ITB). T-9-40 Cleaning belt: remains in contact with the ITB at all times, and used to scrape off toner from the ITB. Scoop-up sheet: used to prevent fall of toner. Cleaning blade ITB Waste toner feedscrew Scoop-up sheet F-9-41 Chapter 9 9.7.3.2 Secondary External Roller 0000-4511 The secondary transfer external roller is cleaned electrostatically. Description of Control A bias is applied to the secondary transfer external roller alternately using the polarity used for image formation and the polarity opposite it for longer than the time it takes the roller to make a single rotation, thereby returning the toner remaining on the roller to the ITB. Timing of Control 1. when a copy/print job ends. 2. after recovery from a jam. 3. when a sample image (or test pattern) is formed as part of image stabilization control. 9.7.3.3 Collecting Waste Toner 0000-4512 The machine uses the following mechanism to collect waste toner. Waste Toner The waste toner is scraped off by the cleaning blade, and is moved to the waste toner box by the waste toner feedscrew. Waste Toner Box Full Detection The waste toner sensor consists of a LED (light-emitting) and a phototransistor (light-receiving) to find out when the waste toner box becomes full. Tension roller Waste toner sensor (light-emitting) DC controller PCB J127 +5V GND Waste toner sensor (light-receiving) +3.3V WASTE_TONER_FULL GND F-9-42 9-45 Chapter 9 9.7.4 Separation Mechanism 9.7.4.1 Separation 0000-4513 The machine uses the following mechanism to separate paper: T-9-41 1. Separation - Curvature (mechanical) - Static Eliminator (static electricity) It is grounded to lower the potential occurring on the back of paper, thus facilitating the separation of paper from the ITB. T-9-42 2. Separate Auxiliary Mechanism - Feed Guide It is used to prevent increases in the potential occurring on the back of paper because of friction used when it is moved to the fixing assembly. It is used to prevent image faults caused by contact with the attraction plate. - Attraction Plate It is grounded, and is used to draw paper. 9-46 Chapter 9 The eccentric arrangement of the 2 rollers causes the paper to separate by taking advantage of the rigidity of paper (curvature separation). ITB Paper Feed guide Attraction plate Secondary transfer external roller Feed guide Attraction plate Static eliminator F-9-43 9-47 Chapter 9 9.8 Parts Procedure Replacement 9.8.1.5 Removing the DC Controller PCB Cover 0000-4618 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 9.8.1 Drum ITB Motor 9.8.1.1 Slide Out the Drum Unit 0000-4614 1) Open the front cover, and slide out the drum unit to the front. 9.8.1.2 Removing the Upper Rear Cover 0006-7770 1) Remove the upper rear cover. 9.8.1.3 Removing the Lower Rear Cover 0000-4616 F-9-45 1) Remove the lower rear cover. 9.8.1.4 Removing the Controller Box Cover 0000-4617 When Attaching the DC Controller PCB Cover 1) Disconnect the connector J1512 [1] from the power When attaching the cover, take care so that the cut-off distribution PCB, and free the harness from the will not come into contact with the latch of the flat wire saddle [2]; then, remove the 6 screws [3], and cable. Otherwise, the flat cable can come loose. detach the main controller cover [4]. [1] F-9-46 9.8.1.6 Removing the Left Upper Rear Cover 1) Removing the left rear upper cover. F-9-44 9-48 0000-4619 Chapter 9 9.8.1.7 Opening the Controller Box Main 3) Free the controller box from the hook [A/B] at the 0000-4620 top of the main controller box. 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-9-50 4) Engage the hook [1] found on the right side of the F-9-47 main controller box on the stay [2] of the machine, and open it. 2) Remove the 9 screws [1] of the main controller box. F-9-48 F-9-51 F-9-49 9-49 Chapter 9 9.8.1.8 Removing the DC Controller Mounting 0000-4621 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-9-54 2) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the heat exhaust fan unit [3]. F-9-52 9.8.1.9 Removing the Fixing Heat Discharge Fan 0000-4622 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-9-55 F-9-53 9.8.1.10 Removing the Machine Heat Discharge Fan 0000-4623 1) Remove the screw [1], and detach the fan duct [2]. 9-50 Chapter 9 9.8.1.11 Removing Developing Drive Unit the 0000-4624 1) Disconnect the connector [2] of the developing motor [1], and free the harness [3] from the cable clamp [4]. F-9-58 9.8.1.12 Removing the Lattice Connector Mounting 0000-4625 1) Remove the 2 screws [1], and disconnect all F-9-56 connectors; then, detach the lattice connector Mounting [2]. 2) Remove the 2 screws [1], and detach the main controller base [2]. F-9-57 F-9-59 3) Remove the 7 screws [1], and detach the developing drive assembly [2]. 9-51 Chapter 9 9.8.1.13 Removing the HighVoltage Unit 0000-4626 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-9-62 9.8.1.15 Removing the Drum ITB Motor Mounting F-9-60 0000-4628 Points to Note When Removing the Drum ITB Motor Mounting 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. To remove, put your hand into the inside where you have slid out the manual feed unit; then, while holding down the swing plate [1] found to the rear of the drum drive unit, remove from the machine's rear side plate. The drum drive unit is hooked on the protrusion from the rear side plate; lift it slightly to detach. F-9-61 9.8.1.14 Removing the Manual Feed Cooling Fan Duct 0000-4627 F-9-63 1) Slide out the manual fee unit; then, disconnect the connector [1] and remove the 2 screws [2] to detach the manual feed cooling fan duct [3]. 1) Free the DC harness [1] found at the front of the drum ITB motor base from the cable clamp [2]. 9-52 Chapter 9 F-9-66 F-9-64 2) Disconnect the 2 connectors [1], and remove the 3 9.8.2 Drum Drive Unit screws [2]; then, detach the drum ITB motor base [3]. 9.8.2.1 Slide Out the Drum Unit 0006-7762 1) Open the front cover, and slide out the drum unit to the front. 9.8.2.2 Removing the Upper Rear Cover 0006-7769 1) Remove the upper rear cover. 9.8.2.3 Removing the Lower Rear Cover 0000-4632 1) Remove the lower rear cover. F-9-65 9.8.2.4 0000-4633 1) Disconnect the connector J1512 [1] from the power 0000-4629 1) Remove the 4 screws [1], and detach the drum ITB motor [2]. the Controller Box Cover 9.8.1.16 Removing the Drum ITB Motor Removing distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. 9-53 Chapter 9 [1] F-9-69 9.8.2.6 Removing the Left Upper Rear Cover F-9-67 9.8.2.5 Removing the Controller PCB Cover 0000-4635 1) Removing the left rear upper cover. DC 9.8.2.7 0000-4634 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. Opening the Controller Box Main 0000-4636 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-9-70 F-9-68 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. 9-54 2) Remove the 9 screws [1] of the main controller box. Chapter 9 F-9-71 F-9-74 9.8.2.8 Removing the Controller Mounting DC 0000-4637 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-9-72 3) Free the controller box from the hook [A/B] at the top of the main controller box. F-9-75 F-9-73 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. 9-55 Chapter 9 9.8.2.9 Removing the Fixing Heat Discharge Fan 0000-4638 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-9-78 9.8.2.11 Removing Developing Drive Unit the 0000-4640 1) Disconnect the connector [2] of the developing F-9-76 motor [1], and free the harness [3] from the cable 9.8.2.10 Removing clamp [4]. the Machine Heat Discharge Fan 0000-4639 1) Remove the screw [1], and detach the fan duct [2]. F-9-79 2) Remove the 2 screws [1], and detach the main F-9-77 2) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the heat exhaust fan unit [3]. 9-56 controller base [2]. Chapter 9 F-9-80 F-9-82 3) Remove the 7 screws [1], and detach the developing drive assembly [2]. 9.8.2.13 Removing the HighVoltage Unit 0000-4642 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-9-81 9.8.2.12 Removing the Lattice Controller Base 0000-4641 1) Remove the 2 screws [1], and disconnect all F-9-83 connectors; then, detach the lattice connector Mounting [2]. 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. 9-57 Chapter 9 F-9-84 F-9-86 9.8.2.14 Removing the Drum ITB Motor Mounting Base 2) Disconnect the 2 connectors [1], and remove the 3 0000-4644 screws [2]; then, detach the drum ITB motor base [3]. Points to Note When Removing the Drum ITB Motor Mounting To remove, put your hand into the inside where you have slid out the manual feed unit; then, while holding down the swing plate [1] found to the rear of the drum drive unit, remove from the machine's rear side plate. The drum drive unit is hooked on the protrusion from the rear side plate; lift it slightly to detach. F-9-87 9.8.2.15 Removing the Drum Drive Unit 0000-8360 1) Disconnect the 6 connectors [1], and remove the 7 screws [2]: then, take out the drum drive unit [3]. F-9-85 1) Free the DC harness [1] found at the front of the drum ITB motor base from the cable clamp [2]. 9-58 Chapter 9 F-9-90 9.8.3.2 Removing Intermediate Transfer Unit the 0000-4527 1) While picking the tabs at the front and the rear, F-9-88 slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. 9.8.3 Drive Roller 9.8.3.1 Pressure Release of the Intermediate Transfer Unit 0000-4524 1) Open the front cover, and turn the intermediate transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right cover [2]. F-9-91 F-9-89 4) Release the escape lever [1]. F-9-92 9-59 Chapter 9 9.8.3.3 Removing Intermediate Transfer Belt the 4) Remove the 4 screws [1] at the rear, and pull out the 0000-4528 link plate (rear) [2]. 1) Remove the 4 screws [1], and detach the belt cover [2]. F-9-96 5) Fit the boss [1] on the frame at the rear into the F-9-93 recess [A] in the middle right cover so that the unit is upright. 2) Remove the screw [1], and detach the varistor [2]. F-9-94 F-9-97 3) Remove the screw [1], and detach the transfer guide 6) Be sure that the rear link plate [1] is on the opposite of the middle right cover so that the intermediate plate [2]. transfer unit will not fall down. F-9-95 F-9-98 9-60 Chapter 9 7) Remove the 4 screws at the rear [1], and pull out the marking on its surface is to the rear. link plate (front) [2]; then, rotate it 180 deg. [1] F-9-101 2) When fitting the belt, place the unit in a low position so that the belt may be fitted from above F-9-99 and straight down. When you have pulled out the belt, keep it upright or place it on paper to avoid damage. After bending the transfer frame, pull out the transfer belt [1] upward. F-9-102 3) Check to make sure that the edge [A] of the belt does not ride over the rib [B] of the tension roller. [1] [2] F-9-100 [2] Check to make sure that the secondary transfer [A] [2] [A] F-9-103 internal roller is free of soiling. If dirt is found, clean it with alcohol. Points to Note When Attaching the Intermediate Transfer Belt 1) Attach the intermediate transfer belt so that the 9-61 Chapter 9 9.8.3.4 Removing the Drive Roller 0000-4529 1) 1) The spring found at the front is under pressure; thus, starting at the front can cause the spring to snap out. Be sure to start at the rear. 2) When removing the gear, be sure to take care not to lose the parallel pin. At the rear, remove the following: E-ring [1], washer [2], bearing [3], E-ring [4], gear [5], parallel pin [6], F-9-105 gear butting spacer [7], bearing [8], and 2 E-rings [9]. 3) Remove the bearing [1] found at the rear, and free the drive roller [2] from the cut-off [A] of the frame found at the front. F-9-104 F-9-106 2) At the front, remove the following: E-ring [1], washer [2], bearing [3], E-ring [4], washer [5], spring [6], washer [7], bearing [8], grounding plate [9]. Points to Note When Attaching When attaching the washer, spring, and washer at the front, be sure to fit the E-ring after forcing down the spring together with the washer until the E-ring groove [A] of the drive roller shaft is in view. 9-62 Chapter 9 F-9-107 F-9-108 9.8.4 Developing Motor (Bk) 9.8.4.5 the Controller PCB Cover 9.8.4.1 Removing the Upper Rear Cover Removing 0006-7766 DC 0000-4577 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 1) Remove the upper rear cover. 9.8.4.2 Removing the Lower Rear Cover 0006-7773 1) Remove the lower rear cover. 9.8.4.3 Removing the Left Upper Rear Cover 0000-4575 1) Removing the left rear upper cover. 9.8.4.4 Removing the Controller Box Cover 0000-4576 F-9-109 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. 9-63 Chapter 9 [1] F-9-110 F-9-113 3) Free the controller box from the hook [A/B] at the 9.8.4.6 Opening the Controller Box top of the main controller box. Main 0000-4578 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-9-114 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, F-9-111 and open it. 2) Remove the 9 screws [1] of the main controller box. F-9-115 F-9-112 9-64 Chapter 9 9.8.4.7 Removing the 9.8.5 Developing Motor (Y/M/C) DC Controller Mounting 0000-4579 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. 9.8.5.1 Removing the Upper Rear Cover 0006-7767 1) Remove the upper rear cover. 9.8.5.2 Removing the Lower Rear Cover 0006-7772 1) Remove the lower rear cover. 9.8.5.3 Removing the Left Upper Rear Cover 0006-7716 1) Removing the left rear upper cover. 9.8.5.4 Removing the Controller Box Cover F-9-116 0000-4568 1) Disconnect the connector J1512 [1] from the power 9.8.4.8 Removing Developing Motor (Bk) distribution PCB, and free the harness from the the wire saddle [2]; then, remove the 6 screws [3], and 0000-4580 detach the main controller cover [4]. 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the developer motor (Bk) [3]. F-9-117 F-9-118 9-65 Chapter 9 9.8.5.5 Removing the Controller PCB Cover 9.8.5.6 DC 0000-4569 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. Opening the Controller Box Main 0006-7725 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-9-121 F-9-119 2) Remove the 9 screws [1] of the main controller box. When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-9-122 F-9-120 F-9-123 9-66 Chapter 9 3) Free the controller box from the hook [A/B] at the top of the main controller box. F-9-126 F-9-124 9.8.5.8 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, Removing the Developing Motor (Y/M/C) 0000-4572 1) Remove the 2 screws [1], and detach the main and open it. controller base [2]. F-9-127 F-9-125 9.8.5.7 Removing the Controller Mounting 2) Remove the 2 screws [1], and disconnect the DC connector [2]; then, detach the developer motor [3] 0006-7744 (starting at the right, Y, M, and C in sequence). 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-9-128 9-67 Chapter 9 9.8.6 Secondary Transfer Unit 9.8.6.1 Removing the Fixing Unit 0000-4667 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-9-131 When removing the secondary transfer unit, be sure to take care not to lose the tension spring [1] found behind it. F-9-129 9.8.6.2 Removing the Duplex Open/Close Guide 0000-4669 1) Remove the duplex open/close guide [1]. F-9-132 2) Hold the grips at the front and the rear, and slide the front side to the right to pull out the secondary transfer unit [1]. F-9-130 9.8.6.3 Removing the Secondary Transfer Unit 0000-4670 1) Remove the screw [1] at the front, and detach the secondary transfer unit retainer [2]. F-9-133 9-68 Chapter 9 9.8.7 Intermediate Transfer Unit 9.8.7.1 Pressure Release of the Intermediate Transfer Unit 0000-4514 1) Open the front cover, and turn the intermediate transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right cover [2]. F-9-136 F-9-134 F-9-137 4) Release the escape lever [1]. 9.8.8 Transfer Cleaning Unit 9.8.8.1 Removing the Waste Toner Container 0000-4646 1) Open the front cover, and turn the intermediate transfer unit releasing lever [1] to detach the waste toner container [2]. F-9-135 9.8.7.2 Removing the Intermediate Transfer Unit 0000-4517 1) While picking the tabs at the front and the rear, slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. F-9-138 9-69 Chapter 9 F-9-139 F-9-141 9.8.8.2 Removing the Transfer Cleaning Unit 4) Release the escape lever [1]. 0000-4647 1) Remove the screw [1], and detach the transfer cleaning unit [2]. F-9-142 9.8.9.2 F-9-140 Removing Intermediate Transfer Unit 9.8.9 Intermediate Transfer Belt the 0000-4521 1) While picking the tabs at the front and the rear, slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. 9.8.9.1 Pressure Release of the Intermediate Transfer Unit 0000-4518 1) Open the front cover, and turn the intermediate transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right cover [2]. F-9-143 9-70 Chapter 9 3) Remove the screw [1], and detach the transfer guide plate [2]. F-9-144 9.8.9.3 Removing Intermediate Transfer Belt F-9-147 the 0000-4522 1) Remove the 4 screws [1], and detach the belt cover [2]. 4) Remove the 4 screws [1] at the rear, and pull out the link plate (rear) [2]. F-9-148 F-9-145 2) Remove the screw [1], and detach the varistor [2]. 5) Fit the boss [1] on the frame at the rear into the recess [A] in the middle right cover so that the unit is upright. F-9-146 F-9-149 9-71 Chapter 9 6) Be sure that the rear link plate [1] is on the opposite of the middle right cover so that the intermediate transfer unit will not fall down. F-9-152 F-9-150 7) Remove the 4 screws at the rear [1], and pull out the link plate (front) [2]; then, rotate it 180 deg. Check to make sure that the secondary transfer internal roller is free of soiling. If dirt is found, clean it with alcohol. Points to Note When Attaching the Intermediate Transfer Belt 1) Attach the intermediate transfer belt so that the marking on its surface is to the rear. [1] F-9-151 When you have pulled out the belt, keep it upright or place it on paper to avoid damage. F-9-153 After bending the transfer frame, pull out the transfer belt [1] upward. 2) When fitting the belt, place the unit in a low position so that the belt may be fitted from above and straight down. 9-72 Chapter 9 F-9-154 F-9-156 3) Check to make sure that the edge [A] of the belt does not ride over the rib [B] of the tension roller. [1] 4) Release the escape lever [1]. [2] [2] [A] [2] [A] F-9-155 F-9-157 9.8.10 Primary Transfer Roller 9.8.10.2 Removing Intermediate Transfer Unit 9.8.10.1 Pressure Release of the Intermediate Transfer Unit the 0000-4651 1) While picking the tabs at the front and the rear, 0000-4648 1) Open the front cover, and turn the intermediate slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right cover [2]. F-9-158 9-73 Chapter 9 3) Remove the screw [1], and detach the transfer guide plate [2]. F-9-159 9.8.10.3 Removing Intermediate Transfer Belt F-9-162 the 0000-4652 1) Remove the 4 screws [1], and detach the belt cover [2]. 4) Remove the 4 screws [1] at the rear, and pull out the link plate (rear) [2]. F-9-163 F-9-160 2) Remove the screw [1], and detach the varistor [2]. 5) Fit the boss [1] on the frame at the rear into the recess [A] in the middle right cover so that the unit is upright. F-9-161 F-9-164 9-74 Chapter 9 6) Be sure that the rear link plate [1] is on the opposite of the middle right cover so that the intermediate transfer unit will not fall down. F-9-167 F-9-165 7) Remove the 4 screws at the rear [1], and pull out the link plate (front) [2]; then, rotate it 180 deg. Check to make sure that the secondary transfer internal roller is free of soiling. If dirt is found, clean it with alcohol. Points to Note When Attaching the Intermediate Transfer Belt 1) Attach the intermediate transfer belt so that the marking on its surface is to the rear. [1] F-9-166 When you have pulled out the belt, keep it upright or place it on paper to avoid damage. F-9-168 After bending the transfer frame, pull out the transfer belt [1] upward. 2) When fitting the belt, place the unit in a low position so that the belt may be fitted from above and straight down. 9-75 Chapter 9 F-9-169 3) Check to make sure that the edge [A] of the belt does not ride over the rib [B] of the tension roller. [1] [2] F-9-171 [2] [A] [2] [A] Points to Note When Mounting the Primary Transfer Roller F-9-170 1) Bend over the edge of the sheet [1] at the front, and fit the edge [2] of the roller and then fit its rear side. 9.8.10.4 Removing the Primary Transfer Roller 0000-4653 1) Bend over the edge of the sheet [1] at the rear; while picking the edge [3] of the primary transfer roller[2], detach it upward. F-9-172 2) Check to make sure that the edge of the sheet [1] is on the inner side of the rib [2]. 9-76 Chapter 9 Take care not to touch the surface of the secondary transfer external roller. Holding the tabs [1] at both ends, remove the secondary transfer roller [2]. F-9-173 9.8.11 Secondary Transfer External Roller F-9-175 9.8.11.1 Removing the Fixing Unit 0000-4661 1) If the white spacer [2] of the secondary transfer 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. roller [1] becomes soiled with toner or the like, the roller can fail to rotate, causing lines. Be sure to see to it that the spacer moves. F-9-174 9.8.11.2 Removing the F-9-176 Secondary Transfer External Roller 1) 0000-4663 2) When mounting the roller [1], be sure that the edge of the leaf spring [2] found at the rear and used for electrical continuity is not bent over. 9-77 Chapter 9 cover [2]. F-9-177 F-9-179 3) Be sure that the spring [1] is securely fitted to the back of the tab used to remove/attach the roller. 4) Release the escape lever [1]. Pay attention to the orientation of the spring, as different types are used between front and rear. F-9-180 9.8.12.2 Removing Intermediate Transfer Unit F-9-178 the 0000-4657 1) While picking the tabs at the front and the rear, slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. 9.8.12 Secondary Transfer Internal Roller 9.8.12.1 Pressure Release of the Intermediate Transfer Unit 0000-4654 1) Open the front cover, and turn the intermediate transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right 9-78 F-9-181 Chapter 9 3) Remove the screw [1], and detach the transfer guide plate [2]. F-9-182 9.8.12.3 Removing Intermediate Transfer Belt F-9-185 the 0000-4658 1) Remove the 4 screws [1], and detach the belt cover [2]. 4) Remove the 4 screws [1] at the rear, and pull out the link plate (rear) [2]. F-9-186 F-9-183 2) Remove the screw [1], and detach the varistor [2]. 5) Fit the boss [1] on the frame at the rear into the recess [A] in the middle right cover so that the unit is upright. F-9-184 F-9-187 9-79 Chapter 9 6) Be sure that the rear link plate [1] is on the opposite of the middle right cover so that the intermediate transfer unit will not fall down. Check to make sure that the secondary transfer internal roller is free of soiling. If dirt is found, clean it with alcohol. Points to Note When Attaching the Intermediate Transfer Belt 1) Attach the intermediate transfer belt so that the F-9-188 marking on its surface is to the rear. [1] 7) Remove the 4 screws at the rear [1], and pull out the link plate (front) [2]; then, rotate it 180 deg. F-9-191 2) When fitting the belt, place the unit in a low position so that the belt may be fitted from above and straight down. F-9-189 When you have pulled out the belt, keep it upright or place it on paper to avoid damage. After bending the transfer frame, pull out the transfer belt [1] upward. F-9-192 3) Check to make sure that the edge [A] of the belt does not ride over the rib [B] of the tension roller. F-9-190 9-80 Chapter 9 [1] [2] [2] [A] [2] [A] F-9-193 9.8.12.4 Removing the Secondary Transfer Internal Roller F-9-195 0000-4659 1) Extend the belt frame, and fit the link plate at both front and rear. 4) Remove the E-ring [1] and the bushing [2] at the front; then, remove the secondary transfer internal 2) Remove the 2 screws [1], and remove the roller [3]. positioning block [2] at the rear. F-9-196 F-9-194 3) Remove the E-ring [1], gear [2], and bushing [3]. Points to Note When Attacing the Secondary Transfer Internal Roller When Attaching the bushing at the front, be sure to fit the bushing [2] while avoiding the spring [1] found on the inner side of the frame. 9-81 Chapter 9 F-9-199 F-9-197 9.8.13.2 Removing the Upper Rear Cover 0000-4582 9.8.13 Toner Container Drive Unit 1) Remove the upper rear cover. 9.8.13.1 Removing the Waste 9.8.13.3 Removing the Lower Toner Container 0006-0801 1) Open the front cover, and turn the intermediate Rear Cover 0000-4583 1) Remove the lower rear cover. transfer unit releasing lever [1] to detach the waste 9.8.13.4 Removing the Left toner container [2]. Upper Rear Cover 0000-4584 1) Removing the left rear upper cover. 9.8.13.5 Removing the Controller Box Cover 0000-4585 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-9-198 9-82 Chapter 9 [1] F-9-202 9.8.13.7 Opening the Main Controller Box F-9-200 0000-4587 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 9.8.13.6 Removing the DC Controller PCB Cover 0000-4586 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-9-203 2) Remove the 9 screws [1] of the main controller box. F-9-201 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. F-9-204 9-83 Chapter 9 9.8.13.8 Removing the DC Controller Mounting 0000-4588 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-9-205 3) Free the controller box from the hook [A/B] at the top of the main controller box. F-9-208 9.8.13.9 Removing the Toner Container Drive Unit 0000-4589 1) Disconnect the connector from the relay PCB 1, and feed the harness of the developer motor from F-9-206 the cable clamp; then, remove the 4 screws [1], and detach the relay PCB 1 together with its base [2]. 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. F-9-209 2) Disconnect the 2 connectors [1], and remove the 3 screws [2]; then, detach the toner container drive unit [3]. F-9-207 9-84 Chapter 9 9.8.14.2 Removing the Front Cover 0000-4560 1) Remove the screw [1] and the 2 hinge pins [2]; then, detach the front cover. F-9-210 9.8.14 Waste Toner Detection PCB F-9-213 9.8.14.1 Removing the Waste Toner Container 9.8.14.3 0000-4559 1) Open the front cover, and turn the intermediate transfer unit releasing lever [1] to detach the waste Removing the Intermediate Transfer Unit Releasing Lever 0000-4561 1) Remove the screw [1], and detach the intermediate toner container [2]. transfer unit releasing lever [2]. F-9-211 F-9-214 F-9-212 9-85 Chapter 9 9.8.14.4 Removing the Cleaner Fan Cover 0006-8837 1) Open the front cover. 2) Remove the screw [1], and detach the cleaner fan cover [2]. F-9-217 2) Detach the waste toner detection PCB [1] from the cover, and disconnect the connector [2] for replacement. F-9-215 9.8.14.5 Removing the Inside Cover (lower) 0000-4563 1) Disconnect the connector [1], and remove the 5 screws [2]; then, detach the inside cover (lower) [3]. F-9-218 9.8.15 Feedscrew Rotation Sensor 9.8.15.1 Removing the Waste Toner Container 0006-0802 1) Open the front cover, and turn the intermediate F-9-216 transfer unit releasing lever [1] to detach the waste toner container [2]. 9.8.14.6 Removing the Waste Toner Detection PCB 0000-4564 1) Remove the 2 screws [1] found behind the fixing/ feeder unit; then, detach the waste toner detection PCB cover [2]. 9-86 Chapter 9 F-9-219 F-9-221 9.8.15.6 Removing the DC Controller PCB Cover 0000-4607 1) Remove the 8 screws [1], and detach the DC F-9-220 controller PCB cover [2]. 9.8.15.2 Removing the Upper Rear Cover 0000-4603 1) Remove the upper rear cover. 9.8.15.3 Removing the Lower Rear Cover 0000-4604 1) Remove the lower rear cover. 9.8.15.4 Removing the Left Upper Rear Cover 0000-4605 1) Removing the left rear upper cover. 9.8.15.5 Removing F-9-222 the Controller Box Cover 0000-4606 1) Disconnect the connector J1512 [1] from the power When Attaching the DC Controller PCB Cover distribution PCB, and free the harness from the When attaching the cover, take care so that the cut-off wire saddle [2]; then, remove the 6 screws [3], and will not come into contact with the latch of the flat detach the main controller cover [4]. cable. Otherwise, the flat cable can come loose. 9-87 Chapter 9 [1] F-9-223 F-9-226 3) Free the controller box from the hook [A/B] at the top of the main controller box. 9.8.15.7 Opening the Main Controller Box 0000-4608 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-9-227 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, F-9-224 and open it. 2) Remove the 9 screws [1] of the main controller box. F-9-228 F-9-225 9-88 Chapter 9 9.8.15.8 Removing the DC Controller Mounting 0000-4609 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-9-231 9.8.15.10 Removing the Toner Container Drive Assembly Upper Plate F-9-229 1) Remove the screw [1], 2 E-rings [2], and 2 bushings [3]; then, free the harness from the edge saddle [4]; 9.8.15.9 Removing the Toner Container Drive Unit 0000-4611 then, free the harness [5] of the toner container 0000-4610 1) Disconnect the connector from the relay PCB 1, motor from the cord clamp [6] to detach the toner container drive assembly top plate [7]. and feed the harness of the developer motor from the cable clamp; then, remove the 4 screws [1], and detach the relay PCB 1 together with its base [2]. F-9-230 F-9-232 2) Disconnect the 2 connectors [1], and remove the 3 screws [2]; then, detach the toner container drive unit [3]. Points to Note When Attaching the Toner Container Drive Assembly Upper Plate 9-89 Chapter 9 When mounting the top plate, check to be sure to fit the edge of the idler gear [1] after matching it against the hole [2] in the top plate and the hole [3] in the bottom plate. 9.8.15.11 Removing the Feedscrew Rotation Sensor 0000-4612 1) Disconnect the connector [1], and remove the feedscrew rotation sensor [2]. F-9-233 F-9-236 9.8.16 Tone Container Motor 9.8.16.1 Removing the Waste Toner Container 0006-0803 1) Open the front cover, and turn the intermediate transfer unit releasing lever [1] to detach the waste toner container [2]. F-9-234 F-9-237 F-9-235 9-90 Chapter 9 F-9-238 9.8.16.2 Removing the Upper Rear Cover 0000-4591 1) Remove the upper rear cover. 9.8.16.3 Removing the Lower Rear Cover F-9-239 0000-4592 9.8.16.6 Removing the DC 1) Remove the lower rear cover. Controller PCB Cover 9.8.16.4 Removing the Left Upper Rear Cover 0000-4595 1) Remove the 8 screws [1], and detach the DC 0000-4593 controller PCB cover [2]. 1) Removing the left rear upper cover. 9.8.16.5 Removing the Controller Box Cover 0000-4594 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-9-240 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. 9-91 Chapter 9 [1] F-9-241 F-9-244 3) Free the controller box from the hook [A/B] at the top of the main controller box. 9.8.16.7 Opening the Main Controller Box 0000-4596 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-9-245 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, F-9-242 and open it. 2) Remove the 9 screws [1] of the main controller box. F-9-246 F-9-243 9-92 Chapter 9 9.8.16.8 Removing the DC Controller Mounting 0000-4597 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-9-249 9.8.16.10 Removing the Toner Container Drive Assembly Upper Plate F-9-247 1) Remove the screw [1], 2 E-rings [2], and 2 bushings [3]; then, free the harness from the edge saddle [4]; 9.8.16.9 Removing the Toner Container Drive Unit 0000-4599 then, free the harness [5] of the toner container 0000-4598 1) Disconnect the connector from the relay PCB 1, motor from the cord clamp [6] to detach the toner container drive assembly top plate [7]. and feed the harness of the developer motor from the cable clamp; then, remove the 4 screws [1], and detach the relay PCB 1 together with its base [2]. F-9-248 F-9-250 2) Disconnect the 2 connectors [1], and remove the 3 screws [2]; then, detach the toner container drive unit [3]. Points to Note When Attaching the Toner Container Drive Assembly Upper Plate 9-93 Chapter 9 When mounting the top plate, check to be sure to fit the edge of the idler gear [1] after matching it against the hole [2] in the top plate and the hole [3] in the bottom plate. 9.8.16.11 Removing the Toner Container Motor 0000-4600 1) Remove the gear [2] that is engaged with the gear [1] found at the tip of the toner container motor. F-9-251 F-9-254 2) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the toner container motor [3]. F-9-252 F-9-255 9.8.17 Waste Toner Feedscrew Case 9.8.17.1 Removing the Waste Toner Container 0000-4556 1) Open the front cover, and turn the intermediate F-9-253 transfer unit releasing lever [1] to detach the waste toner container [2]. 9-94 Chapter 9 Points to Note When Removing the Waste Toner Feedscrew Case Remove the waste toner feedscrew only when a jam has occurred and the sheet [1] attached to the feedscrew has become damaged or bent (rendered useless). F-9-256 F-9-259 1) Turn the intermediate transfer unit releasing lever [1] slightly counterclockwise, and remove the screw [2]; then, remove the waste toner feedscrew F-9-257 case[3]. 9.8.17.2 Removing the Transfer Cleaning Unit 0000-4557 1) Remove the screw [1], and detach the transfer cleaning unit [2]. F-9-260 9.8.18 Pattern Reader Unit F-9-258 9.8.18.1 Pressure Release of the Intermediate Transfer Unit 9.8.17.3 Removing the Waste Toner Feedscrew Case 0000-4530 1) Open the front cover, and turn the intermediate 0000-4558 transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 9-95 Chapter 9 3) Remove the screw [1], and detach the middle right cover [2]. F-9-264 9.8.18.3 Removing the Upper F-9-261 Right Cover 0000-4533 1) Remove the 4 screws [1], and detach the upper right 4) Release the escape lever [1]. cover [2]. F-9-262 F-9-265 9.8.18.2 Removing the Intermediate Transfer Unit 0000-4532 1) While picking the tabs at the front and the rear, slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. 9.8.18.4 Removing the Pattern Reader Unit 0000-4534 1) Disconnect the 2 connectors [1], and remove the screw [2]; then, free the plate [4] from the hook of the upper right stay [3], and detach the pattern reader unit [5]. F-9-263 9-96 Chapter 9 F-9-268 3) Connect the connector [1]; then, while pulling the escape lever [2] toward the front, hook the plate [3] on the left/right claw [4], and secure it in place with F-9-266 a screw [5] over the screw hole. Point to Note When Attaching the Pattern Reader Unit <Mounting to the Machine> 1) Match the boss [1] with the rail [2]. F-9-269 9.8.19 Auto Registration Sensor PCB 9.8.19.1 Pressure Release of the Intermediate Transfer Unit F-9-267 2) While pushing the cleaning member [1] to the right, fit it in while taking care so that it will not hit the slide rail [2] of the intermediate transfer unit on the side of the machine's side plate. 0000-4546 1) Open the front cover, and turn the intermediate transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right cover [2]. 9-97 Chapter 9 F-9-273 F-9-270 9.8.19.3 Removing the Upper 4) Release the escape lever [1]. Right Cover 0000-4550 1) Remove the 4 screws [1], and detach the upper right cover [2]. F-9-271 9.8.19.2 Removing the Intermediate Transfer Unit F-9-274 0000-4549 1) While picking the tabs at the front and the rear, slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. 9.8.19.4 Removing the Pattern Reader Unit 0000-4551 1) Disconnect the 2 connectors [1], and remove the screw [2]; then, free the plate [4] from the hook of the upper right stay [3], and detach the pattern reader unit [5]. F-9-272 9-98 Chapter 9 F-9-277 3) Connect the connector [1]; then, while pulling the escape lever [2] toward the front, hook the plate [3] on the left/right claw [4], and secure it in place with F-9-275 a screw [5] over the screw hole. Point to Note When Attaching the Pattern Reader Unit <Mounting to the Machine> 1) Match the boss [1] with the rail [2]. F-9-278 9.8.19.5 Removing the Auto Registration Sensor PCB 0000-4553 1) Remove the 3 screws [1], and detach the plate found to the rear of the pattern reader unit [2]. F-9-276 2) While pushing the cleaning member [1] to the right, fit it in while taking care so that it will not hit the slide rail [2] of the intermediate transfer unit on the side of the machine's side plate. 9-99 Chapter 9 F-9-281 F-9-279 2) Remove the 2 screws [1], and disconnect the 2 connectors [2]; then, remove the auto registration sensor PCB (front) [3]. MEMO: The auto registration sensor PCB (rear) is also removed in the same way. 9.8.20 SALT Sensor 9.8.20.1 Pressure Release of the Intermediate Transfer Unit 0000-4536 1) Open the front cover, and turn the intermediate transfer unit releasing lever to unlock it. 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right cover [2]. F-9-280 F-9-282 Points to Note When Attaching the Auto Registration Sensor PCB When Attaching the plate [1], be sure that its edge is farther on the inner side than the cleaning member [2]. 9-100 4) Release the escape lever [1]. Chapter 9 9.8.20.3 Removing the Upper Right Cover 0000-4540 1) Remove the 4 screws [1], and detach the upper right cover [2]. F-9-283 9.8.20.2 Removing the Intermediate Transfer Unit 0000-4539 1) While picking the tabs at the front and the rear, F-9-286 slide out the intermediate transfer unit [1]; then, detach it by holding it by the indicated area [2]. 9.8.20.4 Removing the Pattern Reader Unit 0000-4541 1) Disconnect the 2 connectors [1], and remove the screw [2]; then, free the plate [4] from the hook of the upper right stay [3], and detach the pattern reader unit [5]. F-9-284 F-9-287 F-9-285 9-101 Chapter 9 Point to Note When Attaching the Pattern Reader Unit <Mounting to the Machine> 1) Match the boss [1] with the rail [2]. F-9-290 F-9-288 2) While pushing the cleaning member [1] to the right, fit it in while taking care so that it will not hit the slide rail [2] of the intermediate transfer unit on the side of the machine's side plate. F-9-289 3) Connect the connector [1]; then, while pulling the escape lever [2] toward the front, hook the plate [3] on the left/right claw [4], and secure it in place with a screw [5] over the screw hole. 9-102 Chapter 9 9.8.20.5 Removing the SALT Sensor 0000-4543 1) Remove the 3 screws [1], and detach the plate from the rear of the pattern reader unit [2]. F-9-293 F-9-291 2) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the SALT sensor [3]. F-9-292 Points to Note When Attaching the Plate When Attaching the plate [1], be sure to position it so that it is farther on the inner side than the cleaning member [2]. 9-103 Chapter 9 9-104 Chapter 10 Pickup/ Feeding System Contents Contents 10.1 Construction .................................................................................................................................................. 10-1 10.1.1 Specifications, Control Mechanisms, and Functions ............................................................................. 10-1 10.1.2 Arrangement of he Units ........................................................................................................................ 10-2 10.1.3 Arrangement of Rollers .......................................................................................................................... 10-3 10.1.4 Diagram of the Paper Paths .................................................................................................................... 10-4 10.1.5 Arrangement of Sensors ......................................................................................................................... 10-5 10.1.6 Arrangement of the Clutches and Solenoids .......................................................................................... 10-6 10.1.7 Route of Dive ......................................................................................................................................... 10-7 10.2 Basic Sequence .............................................................................................................................................. 10-8 10.2.1 Basic Sequence of Operations at Power-On ........................................................................................... 10-8 10.2.2 Basic Sequence of Operations in Response to a Press on the Start Key ................................................ 10-8 10.3 Detecting Jams .............................................................................................................................................. 10-9 10.3.1 Delay Jams ............................................................................................................................................. 10-9 10.3.1.1 Delay Jam in the Cassette Pickup Assembly ................................................................................... 10-9 10.3.1.2 Delay Jam Outside the Cassette Pickup Assembly ......................................................................... 10-9 10.3.2 Stationary Jams ..................................................................................................................................... 10-10 10.3.2.1 Stationary Jams .............................................................................................................................. 10-10 10.3.2.2 Stationary Jams at Power-On ........................................................................................................ 10-11 10.4 Cassette ........................................................................................................................................................ 10-12 10.4.1 Identifying the Paper Size .................................................................................................................... 10-12 10.4.2 Detecting the Level of Paper ................................................................................................................ 10-14 10.5 Cassette Pick-Up Unit ................................................................................................................................. 10-16 10.5.1 Outline .................................................................................................................................................. 10-16 10.5.2 Basci Sequence of Operations .............................................................................................................. 10-17 10.6 Manual Feed Pickup Unit ............................................................................................................................ 10-18 10.6.1 Outline .................................................................................................................................................. 10-18 10.6.2 Basic Sequence of Operations .............................................................................................................. 10-19 10.6.3 Identifying the Size of Paper ................................................................................................................ 10-20 10.6.4 Detecting the Presence/Absence of Paper ............................................................................................ 10-21 10.6.5 Detecting the Last paper ....................................................................................................................... 10-22 10.7 Registration Unit ......................................................................................................................................... 10-23 10.7.1 Outline .................................................................................................................................................. 10-23 10.8 Duplex Feeding Unit ................................................................................................................................... 10-25 10.8.1 Outline .................................................................................................................................................. 10-25 10.8.2 Controling Horizontal Registration ...................................................................................................... 10-26 10.8.3 Face-Down Delivery, A4, 5 Sheets in Circulation ............................................................................... 10-27 10.8.4 Face-Down Delivery, A3, 3 Sheets in Cirucilation .............................................................................. 10-29 10.9 Delivery ....................................................................................................................................................... 10-32 10.9.1 Delivery ................................................................................................................................................ 10-32 10.9.2 Movement in the Direction of Face-Down Delivery ............................................................................ 10-33 10.9.3 Movement in the Direction of Face-Up Delivery ................................................................................ 10-34 10.9.4 Movement for CenterTray delivery ...................................................................................................... 10-34 10.9.5 Moement for Copy Tray Dievyer ......................................................................................................... 10-35 10.10 Parts Replacement Procedure .................................................................................................................... 10-36 10.10.1 Cassette Pickup Unit .......................................................................................................................... 10-36 10.10.1.1 Removing the Cassette ................................................................................................................ 10-36 10.10.1.2 Removing the Front Right Cover ................................................................................................ 10-36 10.10.1.3 Removing the Rear Right Cover ................................................................................................. 10-36 10.10.1.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-36 Contents 10.10.1.5 Removing the Pickup Unit ........................................................................................................... 10-37 10.10.2 Cassette Size Detection Unit .............................................................................................................. 10-37 10.10.2.1 Removing the Cassette ................................................................................................................. 10-37 10.10.2.2 Removing the Cassette Size Detection Unit ................................................................................ 10-37 10.10.3 Pickup Roller ...................................................................................................................................... 10-38 10.10.3.1 Removing the Cassette ................................................................................................................. 10-38 10.10.3.2 Removing the Pickup Roller ........................................................................................................ 10-38 10.10.4 Feed Roller .......................................................................................................................................... 10-38 10.10.4.1 Removing the Cassette ................................................................................................................. 10-38 10.10.4.2 Removing the Feeding Roller ...................................................................................................... 10-38 10.10.5 Separation Roller ................................................................................................................................ 10-38 10.10.5.1 Removing the Cassette ................................................................................................................. 10-38 10.10.5.2 Removing the Separation Roller .................................................................................................. 10-39 10.10.6 Cassette Pickup Motor ........................................................................................................................ 10-39 10.10.6.1 Removing the Upper Rear Cover ................................................................................................. 10-39 10.10.6.2 Removing the Lower Rear Cover ................................................................................................ 10-39 10.10.6.3 Removing the Left Upper Rear Cover ......................................................................................... 10-39 10.10.6.4 Removing the DC Power Supply Unit ......................................................................................... 10-39 10.10.6.5 Removing the Controller Box Cover ........................................................................................... 10-39 10.10.6.6 Removing the DC Controller PCB Cover .................................................................................... 10-39 10.10.6.7 Removing the Fixing Heat Discharge Fan ................................................................................... 10-40 10.10.6.8 Removing the Developing Drive Unit ......................................................................................... 10-40 10.10.6.9 Removing the Lattice Controller Base ......................................................................................... 10-41 10.10.6.10 Removing the High-Voltage Unit .............................................................................................. 10-41 10.10.6.11 Removing the Manual Feed Cooling Fan Duct ......................................................................... 10-41 10.10.6.12 Removing the Rear Right Cover ................................................................................................ 10-42 10.10.6.13 Removing the Cassette Pickup Motor ....................................................................................... 10-42 10.10.7 Cassette Retry Paper Sensor ............................................................................................................... 10-43 10.10.7.1 Removing the Cassette ................................................................................................................. 10-43 10.10.7.2 Removing the Front Right Cover ................................................................................................. 10-43 10.10.7.3 Removing the Rear Right Cover .................................................................................................. 10-43 10.10.7.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-43 10.10.7.5 Removing the Pickup Unit ........................................................................................................... 10-44 10.10.7.6 Removing the Pick-up System Sensor Mounting Plate ............................................................... 10-44 10.10.7.7 Removing the Cassette Retry Paper Sensor ................................................................................. 10-44 10.10.7.8 Mounting the Pick-up System Sensor Mounting Plate ................................................................ 10-44 10.10.8 Cassette Paper Sensor ......................................................................................................................... 10-45 10.10.8.1 Removing the Cassette ................................................................................................................. 10-45 10.10.8.2 Removing the Front Right Cover ................................................................................................. 10-45 10.10.8.3 Removing the Rear Right Cover .................................................................................................. 10-45 10.10.8.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-46 10.10.8.5 Removing the Pickup Unit ........................................................................................................... 10-46 10.10.8.6 Removing the Pick-up System Sensor Mounting Plate ............................................................... 10-46 10.10.8.7 Removing the Cassette Paper Sensor ........................................................................................... 10-47 10.10.8.8 Mounting the Pick-up System Sensor Mounting Plate ................................................................ 10-47 10.10.9 Cassette Paper Level Sensor (A/B) ..................................................................................................... 10-48 10.10.9.1 Removing the Cassette ................................................................................................................. 10-48 10.10.9.2 Removing the Front Right Cover ................................................................................................. 10-48 10.10.9.3 Removing the Rear Right Cover .................................................................................................. 10-48 10.10.9.4 Removing the Pickup Vertical Path Cover .................................................................................. 10-48 10.10.9.5 Removing the Pickup Unit ........................................................................................................... 10-48 10.10.9.6 Removing the Pick-up System Sensor Mounting Plate ............................................................... 10-49 10.10.9.7 Removing the Cassette Paper Level Sensor (A/B) ...................................................................... 10-49 10.10.9.8 Mounting the Pick-up System Sensor Mounting Plate ................................................................ 10-49 Contents 10.10.10 Slide Resistor .................................................................................................................................... 10-50 10.10.10.1 Removing the Manual Feed Unit .............................................................................................. 10-50 10.10.10.2 Removing the Manual Feed Tray Unit ...................................................................................... 10-50 10.10.10.3 Removing the Manual Feed Tray Upper Cover/Lower Cover .................................................. 10-51 10.10.10.4 Removing the Slide Resistor ..................................................................................................... 10-52 10.10.11 Cassette Pickup Solenoid ................................................................................................................. 10-52 10.10.11.1 Removing the Cassette .............................................................................................................. 10-52 10.10.11.2 Removing the Front Right Cover .............................................................................................. 10-52 10.10.11.3 Removing the Rear Right Cover ............................................................................................... 10-52 10.10.11.4 Removing the Pickup Vertical Path Cover ................................................................................ 10-53 10.10.11.5 Removing the Pickup Unit ........................................................................................................ 10-53 10.10.11.6 Removing the Cassette Pickup Solenoid ................................................................................... 10-53 10.10.12 Manual Feed Tray Unit .................................................................................................................... 10-53 10.10.12.1 Removing the Manual Feed Unit Cover .................................................................................... 10-53 10.10.12.2 Removing the Manual Feed Tray Unit ...................................................................................... 10-54 10.10.13 Manual Feed Unit ............................................................................................................................. 10-54 10.10.13.1 Removing the Manual Feed Unit .............................................................................................. 10-54 10.10.14 Manual Feed Roller .......................................................................................................................... 10-55 10.10.14.1 Removing the Manual Feed Unit .............................................................................................. 10-55 10.10.14.2 Removing the Manual Feed Unit Cover .................................................................................... 10-55 10.10.14.3 Removing the Manual Feed Roller ............................................................................................ 10-56 10.10.15 Manual Feed Separation Roller ........................................................................................................ 10-57 10.10.15.1 Removing the Manual Feed Unit .............................................................................................. 10-57 10.10.15.2 Removing the Manual Feed Unit Cover .................................................................................... 10-57 10.10.15.3 Removing the Motor Cover ....................................................................................................... 10-58 10.10.15.4 Removing the Manual Feed Roller ............................................................................................ 10-58 10.10.15.5 Removing the Manual Feed Separation Roller ......................................................................... 10-59 10.10.16 Manual Feed Last Paper Sensor ....................................................................................................... 10-60 10.10.16.1 Removing the Manual Feed Unit .............................................................................................. 10-60 10.10.16.2 Removing the Manual Feed Tray Unit ...................................................................................... 10-61 10.10.16.3 Removing the Manual Feed Tray Upper Cover/Lower Cover .................................................. 10-61 10.10.16.4 Removing the Manual Feed Last Paper Sensor ......................................................................... 10-62 10.10.17 Manual Feed Sensor ......................................................................................................................... 10-62 10.10.17.1 Removing the Manual Feed Unit .............................................................................................. 10-62 10.10.17.2 Removing the Manual Feed Unit Cover .................................................................................... 10-62 10.10.17.3 Removing the Manual Feed Roller ............................................................................................ 10-63 10.10.17.4 Removing the Motor Cover ....................................................................................................... 10-64 10.10.17.5 Removing the Manual Feed sensor ........................................................................................... 10-64 10.10.18 Transparency Sensor (Front/Rear) ................................................................................................... 10-66 10.10.18.1 Removing the Manual Feed Unit .............................................................................................. 10-66 10.10.18.2 Removing the Transparency Sensor Mounting Plate ................................................................ 10-66 10.10.18.3 Removing the Transparency Sensor (front/rear) ....................................................................... 10-66 10.10.19 Manual Feed Pickup Solenoid .......................................................................................................... 10-66 10.10.19.1 Removing the Manual Feed Unit .............................................................................................. 10-66 10.10.19.2 Removing the Manual Feed Unit Cover .................................................................................... 10-67 10.10.19.3 Removing the Manual Feed Roller ............................................................................................ 10-67 10.10.19.4 Removing the Motor Cover ....................................................................................................... 10-68 10.10.19.5 Removing the Manual Feed Pickup Solenoid ........................................................................... 10-69 10.10.20 Registration Motor ........................................................................................................................... 10-69 10.10.20.1 Removing the Manual Feed Unit .............................................................................................. 10-69 10.10.20.2 Removing the Manual Feed Unit Cover .................................................................................... 10-70 10.10.20.3 Removing the Motor Cover ....................................................................................................... 10-70 10.10.20.4 Removing the Registration Motor ............................................................................................. 10-70 10.10.21 Pre-Registration Motor ..................................................................................................................... 10-71 Contents 10.10.21.1 Removing the Manual Feed Unit ............................................................................................... 10-71 10.10.21.2 Removing the Manual Feed Unit Cover .................................................................................... 10-71 10.10.21.3 Removing the Motor Cover ....................................................................................................... 10-72 10.10.21.4 Removing the Pre-Registration Motor ....................................................................................... 10-72 10.10.22 Horizontal Registration Motor .......................................................................................................... 10-72 10.10.22.1 Removing the Fixing Unit ......................................................................................................... 10-72 10.10.22.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-72 10.10.22.3 Removing the Duplex Open/Close Guide ................................................................................. 10-73 10.10.22.4 Removing the Fixing/Feeder Assembly Back Sheet ................................................................. 10-73 10.10.22.5 Removing the Horizontal Registration Motor Support Plate ..................................................... 10-73 10.10.22.6 Removing the Horizontal Registration Motor ........................................................................... 10-74 10.10.23 Registration Sensor ........................................................................................................................... 10-74 10.10.23.1 Removing the Manual Feed Unit ............................................................................................... 10-74 10.10.23.2 Removing the Transparency Sensor Mounting Plate ................................................................ 10-75 10.10.23.3 Removing the Registration Sensor ............................................................................................ 10-75 10.10.24 Fixing/Feeder Unit ............................................................................................................................ 10-75 10.10.24.1 Removing the Fixing Unit ......................................................................................................... 10-75 10.10.24.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-75 10.10.25 Vertical Path Roller .......................................................................................................................... 10-76 10.10.25.1 Removing the Cassette ............................................................................................................... 10-76 10.10.25.2 Removing the Front Right Cover ............................................................................................... 10-76 10.10.25.3 Removing the Rear Right Cover ................................................................................................ 10-76 10.10.25.4 Removing the Pickup Vertical Path Cover ................................................................................ 10-76 10.10.25.5 Removing the Pickup Unit ......................................................................................................... 10-77 10.10.25.6 Removing the Pick-up System Sensor Mounting Plate ............................................................. 10-77 10.10.25.7 Mounting the Pick-up System Sensor Mounting Plate .............................................................. 10-77 10.10.25.8 Removing the Vertical Path Roller ............................................................................................ 10-78 10.10.26 Inside Delivery Roller ....................................................................................................................... 10-78 10.10.26.1 Removing the Inside Delivery Roller ........................................................................................ 10-78 10.10.27 Fixing/Feeder Unit Open/Closed Sensor .......................................................................................... 10-79 10.10.27.1 Removing the Upper Left Cover ............................................................................................... 10-79 10.10.27.2 Removing the Center Delivery Tray .......................................................................................... 10-79 10.10.27.3 Removing the Delivery Vertical Path Unit (Old) ...................................................................... 10-79 10.10.27.4 Removing the Delivery Vertical Path Unit (New) ..................................................................... 10-80 10.10.27.5 Removing the Fixing/Feeder Unit Open/Closed Sensor Mounting Plate .................................. 10-83 10.10.27.6 Removing the Fixing/Feeder Unit Open/Closed Sensor ............................................................ 10-84 10.10.28 Pickup Vertical Path Cover Open/Closed Sensor ............................................................................. 10-84 10.10.28.1 Removing the Cassette ............................................................................................................... 10-84 10.10.28.2 Removing the Front Right Cover ............................................................................................... 10-84 10.10.28.3 Removing the Rear Right Cover ................................................................................................ 10-84 10.10.28.4 Removing the Pickup Vertical Path Cover ................................................................................ 10-84 10.10.28.5 Removing the Pickup Unit ......................................................................................................... 10-85 10.10.28.6 Removing the Pickup Vertical Path Cover Open/Closed Sensor .............................................. 10-85 10.10.29 Fixing/Feeder Unit Open/Closed Detecting Switch ......................................................................... 10-86 10.10.29.1 Removing the Upper Left Cover ............................................................................................... 10-86 10.10.29.2 Removing the Center Delivery Tray .......................................................................................... 10-86 10.10.29.3 Removing the Delivery Vertical Path Unit (Old) ...................................................................... 10-86 10.10.29.4 Removing the Delivery Vertical Path Unit (New) ..................................................................... 10-87 10.10.29.5 Removing the Fixing/Feeder Unit Open/Closed Sensor Mounting Plate .................................. 10-89 10.10.29.6 Removing the Fixing/Feeder Unit Open/Closed Detecting Switch ........................................... 10-90 10.10.30 Drawer Connector (manual feed unit) .............................................................................................. 10-90 10.10.30.1 Removing the Manual Feed Unit ............................................................................................... 10-90 10.10.30.2 Removing the Disconnecting the Drawer Connector (manual feed unit) .................................. 10-91 10.10.31 Drawer Connector (fixing/feeder unit) ............................................................................................. 10-91 Contents 10.10.31.1 Removing the Fixing Unit ......................................................................................................... 10-91 10.10.31.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-91 10.10.31.3 Removing the Drawer Connector (fixing feeder unit) .............................................................. 10-92 10.10.32 Duplex Roller 1 ................................................................................................................................ 10-92 10.10.32.1 Removing the Fixing Unit ......................................................................................................... 10-92 10.10.32.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-92 10.10.32.3 Removing the Duplex Roller 1 .................................................................................................. 10-92 10.10.33 Duplex Feed Motor .......................................................................................................................... 10-94 10.10.33.1 Removing the Fixing Unit ......................................................................................................... 10-94 10.10.33.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-95 10.10.33.3 Removing the Duplex Feed Motor ............................................................................................ 10-95 10.10.34 Duplex Registration Sensor .............................................................................................................. 10-96 10.10.34.1 Removing the Fixing Unit ......................................................................................................... 10-96 10.10.34.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-96 10.10.34.3 Removing the Fixing/Feeder Assembly Back Sheet ................................................................. 10-96 10.10.34.4 Removing the Duplex Registration Sensor ............................................................................... 10-97 10.10.35 Duplex Horizontal Registration Sensor ............................................................................................ 10-97 10.10.35.1 Removing the Fixing Unit ......................................................................................................... 10-97 10.10.35.2 Removing the Fixing/Feeder Unit ............................................................................................. 10-98 10.10.35.3 Removing the Fixing/Feeder Assembly Back Sheet ................................................................. 10-98 10.10.35.4 Removing the Horizontal Registration Motor Support Plate .................................................... 10-98 10.10.35.5 Removing the Duplex Registration Sensor ............................................................................... 10-99 10.10.36 Duplex Pickup Sensor ...................................................................................................................... 10-99 10.10.36.1 Removing the Cleaner Fan Cover ............................................................................................. 10-99 10.10.36.2 Removing the Intermediate Transfer Unit Releasing Lever ...................................................... 10-99 10.10.36.3 Removing the Inside Cover (lower) ........................................................................................ 10-100 10.10.36.4 Removing the Cassette ............................................................................................................ 10-100 10.10.36.5 Removing the Manual Feed Unit ............................................................................................ 10-100 10.10.36.6 Removing the Front Cover ...................................................................................................... 10-100 10.10.36.7 Removing the Rear Right Cover ............................................................................................. 10-101 10.10.36.8 Removing the Pickup Vertical Path Cover .............................................................................. 10-101 10.10.36.9 Removing the Pickup Unit ...................................................................................................... 10-101 10.10.36.10 Removing the Upper Rear Cover .......................................................................................... 10-101 10.10.36.11 Removing the Lower Rear Cover .......................................................................................... 10-101 10.10.36.12 Removing the High-Voltage Unit ......................................................................................... 10-101 10.10.36.13 Removing the Controller Box Cover ..................................................................................... 10-102 10.10.36.14 Removing the DC Controller PCB Cover ............................................................................. 10-102 10.10.36.15 Opening the Main Controller Box ......................................................................................... 10-103 10.10.36.16 Removing the DC Controller Mounting ................................................................................ 10-104 10.10.36.17 Removing the Fixing Heat Discharge Fan ............................................................................ 10-104 10.10.36.18 Removing the Developing Drive Unit ................................................................................... 10-104 10.10.36.19 Removing the Lattice Connector Mounting .......................................................................... 10-105 10.10.36.20 Removing the Manual Feed Cooling Fan Duct ..................................................................... 10-105 10.10.36.21 Removing the Duplex Driver PCB ........................................................................................ 10-105 10.10.36.22 Removing the Duplex Pickup Sensor .................................................................................... 10-105 10.10.37 Duplex Registration Clutch ............................................................................................................ 10-106 10.10.37.1 Removing the Fixing Unit ....................................................................................................... 10-106 10.10.37.2 Removing the Fixing/Feeder Unit ........................................................................................... 10-107 10.10.37.3 Removing the Duplex Feeder Motor Connector ..................................................................... 10-107 10.10.37.4 Removing the Duplex Open/Close Guide ............................................................................... 10-107 10.10.37.5 Removing the Duplex Registration Clutch .............................................................................. 10-107 10.10.38 Duplex Pickup Clutch .................................................................................................................... 10-108 10.10.38.1 Removing the Fixing Unit ....................................................................................................... 10-108 10.10.38.2 Removing the Fixing/Feeder Unit ........................................................................................... 10-109 Contents 10.10.38.3 Removing the Duplex Open/Close Guide ............................................................................... 10-109 10.10.38.4 Removing the Duplex Pickup Clutch ...................................................................................... 10-109 10.10.39 Delivery Vertical Path Unit ............................................................................................................ 10-110 10.10.39.1 Removing the Fixing Unit ....................................................................................................... 10-110 10.10.39.2 Removing the Center Delivery Tray ........................................................................................ 10-111 10.10.39.3 Removing the Upper Left Cover ............................................................................................. 10-111 10.10.39.4 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-111 10.10.39.5 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-112 10.10.40 Face-Down Delivery Roller 1 ......................................................................................................... 10-115 10.10.40.1 Removing the Upper Left Cover ............................................................................................. 10-115 10.10.40.2 Removing the Center Delivery Tray ........................................................................................ 10-115 10.10.40.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-115 10.10.40.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-116 10.10.40.5 Removing the Delivery Sensor Mounting Plate ...................................................................... 10-119 10.10.40.6 Removing the Face-Down Delivery Sensor Flag .................................................................... 10-119 10.10.40.7 Removing the Face-Down Delivery Roller 1 .......................................................................... 10-120 10.10.41 Face-Up Delivery Roller ................................................................................................................. 10-120 10.10.41.1 Removing the Fixing/Feeder Unit ........................................................................................... 10-120 10.10.41.2 Removing the Fixing/Feeder Unit Cover ................................................................................. 10-121 10.10.41.3 Removing the Inside Delivery Roller ...................................................................................... 10-121 10.10.41.4 Removing the Face-Up Delivery Roller .................................................................................. 10-122 10.10.42 Delivery Vertical Path Roller 1 ...................................................................................................... 10-123 10.10.42.1 Removing the Upper Left Cover ............................................................................................. 10-123 10.10.42.2 Removing the Center Delivery Tray ........................................................................................ 10-123 10.10.42.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-124 10.10.42.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-125 10.10.42.5 Removing the Face-Down Delivery Sensor 2 ......................................................................... 10-127 10.10.42.6 Removing the Delivery Vertical Path Roller 1 ........................................................................ 10-128 10.10.43 Delivery Vertical Path Roller 2 ...................................................................................................... 10-128 10.10.43.1 Removing the Upper Left Cover ............................................................................................. 10-128 10.10.43.2 Removing the Center Delivery Tray ........................................................................................ 10-128 10.10.43.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-129 10.10.43.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-130 10.10.43.5 Removing the Delivery Vertical Path Roller 2 ........................................................................ 10-132 10.10.44 Face-Down Delivery Motor ............................................................................................................ 10-133 10.10.44.1 Removing the Upper Left Cover ............................................................................................. 10-133 10.10.44.2 Removing the Center Delivery Tray ........................................................................................ 10-133 10.10.44.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-133 10.10.44.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-134 10.10.44.5 Removing the Face-Down Delivery Motor ............................................................................. 10-137 10.10.45 Delivery Vertical Path Motor ......................................................................................................... 10-137 10.10.45.1 Removing the Upper Left Cover ............................................................................................. 10-137 10.10.45.2 Removing the Center Delivery Tray ........................................................................................ 10-137 10.10.45.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-137 10.10.45.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-138 10.10.45.5 Removing the Delivery Vertical Path Motor ........................................................................... 10-141 10.10.46 Face-Down Delivery Sensor 1 ........................................................................................................ 10-141 10.10.46.1 Removing the Upper Left Cover ............................................................................................. 10-141 10.10.46.2 Removing the Center Delivery Tray ........................................................................................ 10-141 10.10.46.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-142 10.10.46.4 Removing the Delivery Vertical Path Unit (New) ................................................................... 10-142 10.10.46.5 Removing the Face-Down Delivery Sensor 1 ......................................................................... 10-145 10.10.47 Center Delivery Tray Full sensor ................................................................................................... 10-146 10.10.47.1 Removing the Upper Left Cover ............................................................................................. 10-146 Contents 10.10.47.2 Removing the Center Delivery Tray ....................................................................................... 10-146 10.10.47.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-146 10.10.47.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-147 10.10.47.5 Removing the Center Delivery Tray Full sensor ..................................................................... 10-149 10.10.48 Face-Down Delivery Sensor 2 ....................................................................................................... 10-150 10.10.48.1 Removing the Upper Left Cover ............................................................................................. 10-150 10.10.48.2 Removing the Center Delivery Tray ....................................................................................... 10-150 10.10.48.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-150 10.10.48.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-151 10.10.48.5 Removing the Face-Down Delivery Sensor 2 ......................................................................... 10-153 10.10.49 Delivery Vertical Path Cover Open/Closed Sensor ....................................................................... 10-154 10.10.49.1 Removing the Upper Left Cover ............................................................................................. 10-154 10.10.49.2 Removing the Center Delivery Tray ....................................................................................... 10-154 10.10.49.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-154 10.10.49.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-156 10.10.49.5 Removing the Delivery Vertical Path Cover Open/Closed Sensor ......................................... 10-158 10.10.50 Delivery Path Switching Solenoid 1 .............................................................................................. 10-158 10.10.50.1 Removing the Upper Left Cover ............................................................................................. 10-158 10.10.50.2 Removing the Center Delivery Tray ....................................................................................... 10-158 10.10.50.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-159 10.10.50.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-160 10.10.50.5 Removing the Cleaner Fan Cover ........................................................................................... 10-162 10.10.50.6 Removing the Cleaner Fan ...................................................................................................... 10-162 10.10.50.7 Removing the Delivery Path Switching Solenoid 1 ................................................................ 10-162 10.10.51 Delivery Path Switching Solenoid 2 .............................................................................................. 10-163 10.10.51.1 Removing the Delivery Path Switching Solenoid 2 ................................................................ 10-163 10.10.52 Face-Down Delivery Roller 1 Drive Belt ....................................................................................... 10-163 10.10.52.1 Removing the Upper Left Cover ............................................................................................. 10-163 10.10.52.2 Removing the Center Delivery Tray ....................................................................................... 10-163 10.10.52.3 Removing the Delivery Vertical Path Unit (Old) .................................................................... 10-164 10.10.52.4 Removing the Delivery Vertical Path Unit (New) .................................................................. 10-165 10.10.52.5 Removing the Face-Down Delivery Roller 1 Drive Belt ........................................................ 10-167 Contents Chapter 10 10.1 Construction 10.1.1 Specifications, Control Mechanisms, and Functions 0005-9871 The major specifications, control mechanisms, and functions of the pickup feeder system are as follows: T-10-1 Item Description Method of paper Front loading accommodation Method of pickup Separation retard Paper feed reference Center Size of paper Cassette 1/2 550 sheets (80 g/m2) Manual feed tray 100 sheets (80 g/m2) accommodation Size of paper Cassette 1/2 A3, A4, A4R, B4, B5, B5R, A5R, 12x18, 11x17, LGL, LTR, LTRR, STMTR Manual feed tray 98 to 320 mm (main scanning direction) 148 to 457.2 mm (sub scanning direction) Type of paper Plain , Heavy, transparency 64 g/m2 to 209 g/m2 (from cassette) 64 g/m2 to 253 g/m2 (from manual feeder) Paper size switching Duplex print Cassette 1/2 by user Manual feed tray by user Through path 10-1 Chapter 10 10.1.2 Arrangement of he Units 0000-4672 [1] [8] [7] [2] [6] [3] [4] F-10-1 T-10-2 10-2 [1] Delivery assembly [5] Pickup unit [2] Fixing unit [6] Registration unit [3] Duplex unit [7] Manual feed unit [4] Secondary transfer unit [8] Intermediate transfer unit [5] Chapter 10 10.1.3 Arrangement of Rollers [2] 0000-4673 [1] [3] [4] [23] [22] [21] [20] [7] [5] [19] [18] [17] [6] [16] [8] [9] [10] [11] [12] [13] [15] [14] F-10-2 T-10-3 [1] Face-down delivery roller 1 [13] Pickup roller [2] Face-down delivery roller 2 [14] Separation roller [3] Delivery vertical path roller 1 [15] Feed roller [4] Delivery vertical path roller 2 [16] Pickup vertical path roller [5] Face-up delivery roller [17] Re-pickup roller [6] Internal delivery roller [18] Manual feed separation roller [7] Fixing roller (fixing upper roller) [19] Manual feed roller [8] Pressure roller (fixing lower roller) [20] Pre-registration roller [9] Duplex roller 1 [21] Lower registration roller [10] Duplex roller 2 [22] Upper registration roller [11] Duplex roller 3 [23] Secondary transfer roller [12] Duplex roller 4 10-3 Chapter 10 10.1.4 Diagram of the Paper Paths 0000-4674 Face-down delivery (center delivery tray) Face-down delivery (copy tray) Pickup from manual feeder Face-up delivery (side delivery tray) Pickup from cassette 1 Pickup from cassette 2 Pickup from cassette 3 Pickup from cassette 4 F-10-3 10-4 Pickup from paper deck Chapter 10 10.1.5 Arrangement of Sensors [1] 0000-4675 [23] [24] [25] [26] [22] [21] [2] [3] [20] [4] [19] [5] [18] [6] [7] [17] [8] [16] [9] [10] [11] [12] [13] [14] [15] F-10-4 T-10-4 [1] Center delivery tray full sensor (PS8) [14] Cassette 2 paper level sensor (A; PS20) [2] Face-down delivery sensor 1 (PS12) [15] Cassette 2 paper sensor (PS19) [3] Face-down delivery sensor 2 (PS6) [16] Cassette 2 retry paper sensor (PS17) [4] Delivery vertical path cover open/closed sensor (PS13) [17] Caste 1 paper sensor (PS7) [5] Fixing feeder unit open/closed sensor (PS5) [18] Cassette 1 retry paper sensor (PS16) [6] Fixing delivery sensor (PS25) 19] Pickup vertical path cover open/closed sensor (PS11) [7] Fixing inlet sensor (PS27) [20] Manual feed last paper sensor (PS9) [8] Duplex registration sensor (PS21) [21] Manual fed unit open/closed sensor (PS28) [9] Duplex horizontal registration sensor (PS22) [22] Manual feed paper sensor (PS10) [10] Duplex pick sensor (PS24) [23] Front cover open/closed sensor (PS23) [11] Cassette 1 paper level sensor (B; PS15) [24] Transparency sensor (front; OHP1) [12] Cassette 1 paper level sensor (A; PS14) [25] Transparency sensor (rear; OHP2) [13] Cassette 2 paper level sensor (B; PS18) [26] Registration sensor (PS26) 10-5 Chapter 10 10.1.6 Arrangement of the Clutches and Solenoids 0000-4676 [1] [7] SL SL SL [2] [6] CL CL SL [5] [3] SL [4] F-10-5 T-10-5 [1] Delivery path switching solenoid 1 (SL2) [5] Cassette 1 pickup solenoid (SL3) [2] Delivery path switching solenoid 2 (SL5) [6] Duplex pickup solenoid (CL2) [3] Duplex registration clutch (CL1) [7] manual feed pickup solenoid (SL1) [4] Cassette 2 pickup solenoid (SL4) 10-6 Chapter 10 10.1.7 Route of Dive 0000-4677 M11 M1 M10 M8 M9 SL1 M24 M6 CL1 SL3 M7 CL2 M26 SL4 F-10-6 T-10-6 CL1 duplex registration clutch M10 delivery vertical path motor CL2 duplex pickup clutch M11 face-down delivery motor M1 drum ITB motor M24 fixing motor M6 cassette 1 pickup motor M26 duplex feeder motor M7 caste 2 pickup motor SL1 manual feed pickup solenoid M8 registration motor SL3 caste 1 pickup solenoid M9 pre-registration motor SL4 cassette 2 pickup solenoid 10-7 Chapter 10 10.2 Basic Sequence 10.2.1 Basic Sequence of Operations at Power-On 0000-4678 Main power switch ON Printer unit WMUP WMUPR PSTBY 360 sec (approx.) Drum ITB motor (M1) Cassette 1 pickup motor (M6) Cassette 2 pickup motor (M7) Registration motor (M8) Pre-registration motor (M9) Delivery vertical path motor (M10) *1 *1 *1 *1 *1 Face-down delivery motor (M11) *1 Fixing motor (M24) Duplex feeder motor (M26) *1 *1: rotates for about 4.0 sec; a stationary jam will be identified if the sensor goes ON during the period. F-10-7 10.2.2 Basic Sequence of Operations in Response to a Press on the Start Key 0000-4679 Print start PRINT 2.76sec (approx.) 1.3sec (approx.) Cassette pickup solenoid (SL3) Cassette 1 pickup motor (M6) Cassette retry paper sensor (PS16) Registration sensor (PS26) Pre-registration sensor (M9) Registration motor (M8) F-10-8 10-8 LSTR Chapter 10 10.3 Detecting Jams 10.3.1 Delay Jams 10.3.1.1 Delay Jam in the Cassette Pickup Assembly 0000-4680 The leading edge of paper is not at the sensor within a specific period of time (for feeding) after the motor has gone ON. Start key ON or print start INTR / [1] Pickup motor PRINT [1] Jam check Normal Sensor N Error [1]: specific feed time. F-10-9 T-10-7 Source Motor Sensor Cassette 1 Pickup motor (M6) Cassette 1 retry paper sensor (PS16) Cassette 2 Pickup motor (M7) Cassette 2 retry paper sensor (PS17) 10.3.1.2 Delay Jam Outside the Cassette Pickup Assembly 0000-4681 A delay jam occurring outside the cassette pickup assembly is identified at the following timing: The period of time during which paper is moved form the sensor N-1 to the delay jam sensor N in question is controlled, and a delay jam will be identified if the delay jam sensor N in question does not go ON within a specific period of time after the sensor N-1 has gone ON. Start key ON or PRINT setting accepted INTR / [1] PRINT [1] Sensor N-1 Jam check Sensor N Normal Error [1]: specific period of feed. F-10-10 10-9 Chapter 10 T-10-8 Sensor Registration sensor (PS26) Fixing delivery sensor (PS25) Face-down delivery sensor 1 (PS12) Face-down delivery sensor 2 (PS6) Duplex registration sensor (PS21) Duplex pickup sensor (PS24) 10.3.2 Stationary Jams 10.3.2.1 Stationary Jams 0000-4682 A stationary jam will be identified if the sensor N does not go OFF within a specific period of tie after the sensor N has gone ON. Start key ON or print start INTR L+A / PRINT L+A Jam check Sensor N Normal Error (L = paper length feed distance; A = specific feed distance) F-10-11 T-10-9 Sensor Cassette 1 retry paper sensor (PS16) Caste 2 retry paper sensor (PS17) Registration sensor (PS26) Fixing delivery sensor (PS25) Face-down delivery sensor 1 (PS12) Face-down deliver y sensor 2 (PS6) Duplex registration sensor (PS21) Duplex pickup sensor (PS24) 10-10 Chapter 10 10.3.2.2 Stationary Jams at Power-On 0000-4683 The machine checks the absence of paper over the following sensors before it starts initial multiple rotations at power-on: T-10-10 Sensor Caste 1 retry paper sensor (PS16) Cassette 2 retry paper sensor (PS17) Registration sensor (PS26) Fixing delivery sensor (PS25) Face-down delivery sensor 1 (PS12) Face-down delivery sensor 2 (PS6) Duplex registration sensor (PS21) Duplex pickup sensor (PS24) Fixing inlet sensor (PS27) 10-11 Chapter 10 10.4 Cassette 10.4.1 Identifying the Paper Size 0000-4684 The machine identifies the size of paper into the cassette with reference to the slide guide (15 settings) of the cassette. The 4-in-a-row actuator designed for the identification of the cassette size found on the machine side goes ON/OFF according to the position of the slide guide, permitting the machine to identify 15 settings. In the absence of a cassette, all 4 actuators will go OFF. Paper size slide guide Cassette size detecting switch Size detecting actuator Cassette open Cassette closed Cassette F-10-12 T-10-11 4-in-a-row actuator Rear 10-12 Paper size Bit3 1 STMT R ON 2 LTR 3 LTR R Front Bit2 Bit1 ON ON ON Bit0 Chapter 10 4-in-a-row actuator Rear Paper size Bit3 Front Bit2 Bit1 ON Bit0 4 LGL ON 5 11X17*1 6 A5 R ON 7 A4 ON 8 A4 R 9 A3 ON 10 B5 ON ON 11 B5 R ON ON ON 12 B4 ON ON ON ON 13 12X18*2 ON ON ON 14 U1 ON ON 15 U2 16 no cassette ON ON ON ON ON ON ON ON ON ON: actuator pressed (i.e... '0'in reference to a check in I/O mode). *1:279 x 431.8[mm] *2:305 x 457[mm] 10-13 Chapter 10 10.4.2 Detecting the Level of Paper 0000-4685 The level of paper inside the cassette is detected using the following three sensors: [2] [3] [1] [4] [5] [6] [7] [9] [8] F-10-13 T-10-12 [1] Flag [6] Paper level sensor flag [2] Cassette paper sensor [7] Lifter gear [3] Gear [8] Tray [4] Cassette paper level sensor (A) [9] Paper [5] Cassette paper level sensor (B) 10-14 Chapter 10 View from the Front of the Machine If the cassette is full of paper Cassette paper Cassette paper level sensor (B) level sensor (A) Paper OFF OFF If the cassette is half full of paper Cassette paper Cassette paper level sensor (B) level sensor (A) Paper OFF ON If the cassette has little paper Cassette paper Cassette paper level sensor (B) level sensor (A) Paper ON ON Cassette paper sensor Flag Paper tray If the cassette has no paper F-10-14 T-10-13 Paper level sensor (A) Paper level sensor (B) Paper sensor Level of paper off off off 100% to 50% of capacity ON off off about 50% to about 50 sheets ON ON off About 50 sheets or less --- --- ON No paper Indication on control panel 10-15 Chapter 10 10.5 Cassette Pick-Up Unit 10.5.1 Outline 0005-9837 The paper inside the cassette is held up by the lifter plate, and the pickup roller is borught down to the paper for pickup. The feed roller and the srpaton roller are used to make sure that no more than a single sheet of paper is moved to the feeing assembly; the pickup vertical path roller/pre-registration roller is then used to move the paper a fara as the kegistatoin roller (upper, lower). The pickup vertical path roller and the pre-registration roller are each driven by the pickup 1 motor and the preregistration motor, respectively. [4] [5] [3] [2] [6] [1] [7] [8] [9] [10] [11] F-10-15 T-10-14 [1] Vertical path guide [7] Holding plate [2] Caste retray paper sensor [8] Lifter plate [3] Pickup vertical path roller [9] Retard guide [4] Feed roller (roller B) [10] Separation ton roller (roller C) [5] Pickup roller (roller A) [11] Retard spring [6] Cassette paper sensor 10-16 Chapter 10 10.5.2 Basci Sequence of Operations 0005-9838 Print start PRINT LSTR 2.76sec (approx.) 1.3sec (approx.) Cassette pickup solenoid (SL3) Cassette 1 pickup motor (M6) Cassette retry paper sensor (PS16) Registration sensor (PS26) Pre-registration sensor (M9) Registration motor (M8) F-10-16 10-17 Chapter 10 10.6 Manual Feed Pickup Unit 10.6.1 Outline 0000-4688 The paper in the manual feed pickup unit is forced against the pickup feeder roller as the lifter moves up, an a single sheet of paper is separed and moved ahead by the work of the pickup feeder roller and the separation roller. [1] [2] [4] [3] [5] [9] [8] [6] [7] F-10-17 T-10-15 [1] Paper tray [6] Manual feeder separation roller [2] Side guide plate [7] Registration multi frame [3] Paper flag [8] Last paper pick roll [4] Manual feed feeder roller [9] Lifter [5] Pickup guide plate 10-18 Chapter 10 Torque limter Torque delay mehcainsm Manual feeder pickup feed roller DC drive direct link Separation roller holder Manual feeder separation roller F-10-18 Torque delay mechanism in operation Initial condition Torque limiter in operation Manual feed feeder roller Paper Tortion spring Damper core Spring pin Separation roller shaft Separation roller Torque delay mechanism Separation roller shaft direction of rotation direction of rotation F-10-19 10.6.2 Basic Sequence of Operations 0000-4689 Print start PRINT LSTR 1.9 sec (approx.) Manual feed pickup Solenoid (SL1) Pre-registration motor (M9) Registration sensor (PS26) Registration motor (M8) F-10-20 10-19 Chapter 10 10.6.3 Identifying the Size of Paper 0000-4690 The machine checks the widht of paper in reference to the level of output ffrom the variable resistor operating in conjunction with the movemetn of the side guide epatle. The side guide plate on the manual feed tray is set by the user when he/she deposit paper. Variable resistor Manual feed tray Slide guide (rear) Slide guide (front) F-10-21 10-20 Chapter 10 10.6.4 Detecting the Presence/Absence of Paper 0000-4691 When paper is placed, its weight pushes down the paper detecting flag, thus enabling the manual feed paper sensor (PS10) to detect the presence of paper. Paper detecting flag Paper Manual feed paper sensor (PS10) Paper Manual feed paper Paper detecting sensor (PS10) flag F-10-22 10-21 Chapter 10 10.6.5 Detecting the Last paper 0000-4692 When the last paper pickup roll rotates, the slit in the roll cuses the output of the last paper sensor (PS9) to beocme wave-form pusles. The last paper roll rotates only when the last paper is picked up; otherwise, it remains still. The machine will identify the paper to be the last paper if it detects 4 or more output pules form the lat paper sensor. Last paper Manual feed last paper sensor (PS9) Last paper detecting roll Last paper If 4 or more output pulses are detected, the paper is identified as being the last. Manual feed lsat paper sensor (PS9) Last paper detecting roll F-10-23 10-22 Chapter 10 10.7 Registration Unit 10.7.1 Outline 0000-4693 The upper registraont roller an the lower registration roller are dreiven by the registration motor (M8), and are used to make user aht the paper an the image on the intermediate transfer rbelt mach at a specific position. The upper guide locking arm latches in place when the unit is fitted to the machine. When fitted to the machine Upper registration roller Lower registration roller Area of upper guide to be locked in place Machine rail Upper guide locking arm Upper guide preasure spring Mobile rail When the multi upper guide is shifted up Registration Nip Released The shape of the cam causes the registration upper roller to move up by 1.5 mm during rotation, releasing the nip where paper moves. Registration multi upper guide Area of upper guide to be locked in place Upper guide locking arm open (unlocked) Machine rail Upper guide pressure spring Mobile rail F-10-24 10-23 Chapter 10 Registration motor (M8) Pre-registration motor (M9) Manual feed pickup solenoid Manual feed control gear Upper registration roller Lower registration roller Pre-registration roller F-10-25 10-24 Duplex roller shaft Manual feed roller shaft Chapter 10 10.8 Duplex Feeding Unit 10.8.1 Outline 0000-4694 The duplex nit is drivn by the duplex motor (M26), and is sued when making double-sided prints. [1] [2] [3] [7] [8] [4] [5] [6] [9] [10] [11] [12] [13] [14] [15] F-10-26 T-10-16 [1] Reversing sheet [9] Delivery cooling duct [2] Reversing rollre [10] Arching assembly [3] Reversing sheet [11] Duplex roller 2 [4] Face-up delivery roller [12] Duplex horizontal registration sensor (PS22) [5] Cross path flapper [13] Duplex roller 3 [6] Duple roller 1 [14] Duplex roller 4 [7] FU/FD swtycing flapper [15] Re-pickup roller [8] Internal delivery roller 10-25 Chapter 10 10.8.2 Controling Horizontal Registration 0000-4695 When in duplexing mode, the machine executes horizontal registration detection for paper coming from the duplex feed assembly to see if there is any discrepancy in main scanning direction (front-rear direction), thus adjusting the point of laser exposure. T-10-17 Detecting of paper duplex horizontal registration sensor (PS22) position: Timing of detection: starts a specifi peirrod of time after pasage over the duplex registraont neosr (PS21) Dive horizontal registration motor (M25) Identifiaotin of with refenced to the pulse form the horizontal registration position: motor Horizontal registration motor (M25) Duplex horizontal registration sensor (PS22) Paper Home position Detection start position 10 mm (approx.) F-10-27 10-26 Paper Chapter 10 10.8.3 Face-Down Delivery, A4, 5 Sheets in Circulation 0000-4696 The number on a white backgoudn and the nbuer on a black background indicated the 1s side and the 2nd side, respse3ctively. 1 point of reversal 2 1 duplex pre-registration 2 (1) (3) (2) 2 1 check on horizontal registration (4) 2 3 3 1 in wait for re-pickup 4 1 2 1 2 (6) with 2 sheets inside duplex unit (5) (7) 10-27 Chapter 10 1 4 3 2 (8) 1 2 1 1 2 5 4 3 2 4 3 3 4 5 5 (10) thereafter, repeats (7) through (10) (9) 3 2 1 4 5 (12) 10-28 (11) Chapter 10 5 4 3 2 1 4 3 2 1 5 (14) (13) 10.8.4 Face-Down Delivery, A3, 3 Sheets in Cirucilation 0000-4697 The nbuemr on a white background and the nbuemr on a black backgrdoun indicated the 1st side and he 2nd side, respectively. 1 point of reversal 1 duplex pre-registration 1 (1) (2) (3) 10-29 Chapter 10 1 check on horizontal registration (4) 2 point of reversal 2 1 1 in wait for 1 2 re-pickup (5) (6) 1 3 2 (8) thereafter, repeats (6) through (8) 10-30 non-contact reversal (7) Chapter 10 3 2 1 2 1 3 (9) (10) 10-31 Chapter 10 10.9 Delivery 10.9.1 Delivery 0000-4698 The machine uses any of the following 3 types of delivery (paper apths): face-deown delivery (center delivery tray) face-down delivery (copy tray) face-up device r(side delivery tray) Face-down delivery (center delivery tray) Face-down delivery (copy tray) Face-up delivery (side delivery tray) F-10-28 10-32 Chapter 10 10.9.2 Movement in the Direction of Face-Down Delivery 0000-4699 After moving thtough the fixing unit, the paper moves along the FU/FD switching flapper now facing downawar; it then pushes down the plastic sheet to move to the vertical path diecoint for face-down delivery. Plastic sheet FU/FD switching flapper F-10-29 10-33 Chapter 10 10.9.3 Movement in the Direction of Face-Up Delivery 0000-4700 After moving through he fixing unit, the paper moves uder the FU/FD swtichign flapper, which has been shfited up by the delivery path switching solenoid (SL2); at this time the cross path flapper is also siwtched over by the work of the delivery path switching solenoid 2 (SL5), thus guding the paper into the direction of face-up delivery. FU/FD switching flapper Face-up delivery (side delivery tray) Cross path flapper F-10-30 10.9.4 Movement for CenterTray delivery 0000-4701 The paper moves while pushing down the plastic sheet, and then moves ahead for center tray delivery. Center tray delivery Paper Plastic sheet F-10-31 10-34 Chapter 10 10.9.5 Moement for Copy Tray Dievyer 0000-4702 The paper meos while pushign down the plastic sheet, and then moves ahead in the direction of the centra tray. Immeiately after the trailig edge of the paper moves past the palstc film the momevement stops, at which time the movmeent rverses so that the paper moves along the plastic sheet in the direction of the copy tray. Paper Copy tray delivery Plastic sheet Paper Copy tray delivery Paper movement reverse Plastic sheet F-10-32 10-35 Chapter 10 10.10 Parts Procedure Replacement cover [2]. 10.10.1 Cassette Pickup Unit 10.10.1.1 Removing the Cassette 0000-4704 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. F-10-34 1) Slide out the cassette. 10.10.1.4 Removing the Pickup Vertical Path Cover 10.10.1.2 Removing the Front Right Cover 0006-8859 1) Slide out the manual feed unit, and open the pickup vertical path cover. 1) Remove the screw [2] to detach the pickup vertical path lower cover [1]; then, detach the pickup vertical path cover [3]. 2) Remove the 2 screws [1], and detach the machine's front right cover [2]. F-10-35 F-10-33 10.10.1.3 Removing the Rear Right Cover 0006-8860 The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. 1) Remove the 2 screws [1], and detach the rear right 10-36 0000-4707 Chapter 10 10.10.1.5 Removing the Pickup Unit 0000-4708 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the pickup unit [3]. F-10-37 2) Disconnect the connector [1], and push the protrusion [A] from the left to release the lock; F-10-36 then, detach the cassette size detection unit [2] for the machine's front. 10.10.2 Cassette Size Detection Unit 10.10.2.1 Removing the Cassette 0000-4778 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. F-10-38 1) Slide out the cassette. 10.10.2.2 Removing the Cassette Size Detection Unit 0000-4779 1) Remove the 4 screws [1], and detach the machine's lower left cover [2]. MEMO: When attaching the cassette size detection unit, try pushing the 4 protrusions into the holes of the machine's stay. 10-37 Chapter 10 10.10.3 Pickup Roller 10.10.4.2 Removing the Feeding Roller 10.10.3.1 Removing the Cassette 0000-4714 1) Put your hand through the machine's front; then, 0000-4710 pick the tab [A] of the feed roller, and pull it out. MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. 1) Slide out the cassette. 10.10.3.2 Removing the Pickup Roller 0000-4711 1) Put your hand through the machine's front; then, F-10-40 pick the tab [A] of the pickup roller [1], and pull it out. 10.10.5 Separation Roller 10.10.5.1 Removing Cassette the 0000-4716 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. 1) Slide out the cassette. F-10-39 10.10.4 Feed Roller 10.10.4.1 Removing Cassette the 0000-4713 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. 1) Slide out the cassette. 10-38 Chapter 10 10.10.5.2 Removing the Separation Roller 0000-4717 1) Put your hand through the front of the machine; then, pick the tab [A] of the separation roller [1], and pull it out. F-10-42 10.10.6.5 Removing the Controller Box Cover 0000-4760 1) Disconnect the connector J1512 [1] from the power F-10-41 distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and 10.10.6 Cassette Pickup Motor detach the main controller cover [4]. 10.10.6.1 Removing the Upper Rear Cover 0006-7771 1) Remove the upper rear cover. 10.10.6.2 Removing the Lower Rear Cover 0000-4758 1) Remove the lower rear cover. 10.10.6.3 Removing the Left Upper Rear Cover 0000-4762 1) Removing the left rear upper cover. 10.10.6.4 Removing the DC Power Supply Unit 0000-4759 F-10-43 1) Remove the 2 screws [1], and disconnect all connectors of the fuse PCB; then, detach the DC power supply unit [2]. 10.10.6.6 Removing the DC Controller PCB Cover 0000-4761 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 10-39 Chapter 10 F-10-46 F-10-44 10.10.6.8 Removing Developing Drive Unit the 0000-4764 1) Disconnect the connector [2] of the developing When Attaching the DC Controller PCB Cover motor [1], and free the harness [3] from the cable When attaching the cover, take care so that the cut-off clamp [4]. will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-10-47 F-10-45 2) Remove the 2 screws [1], and detach the main controller base [2]. 10.10.6.7 Removing the Fixing Heat Discharge Fan 0000-4763 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-10-48 10-40 Chapter 10 3) Remove the 7 screws [1], and detach the developing drive assembly [2]. F-10-51 2) Remove the 6 screws [1], and remove the base plate F-10-49 [2]; then, detach the high-voltage unit [3]. 10.10.6.9 Removing the Lattice Controller Base 0000-4765 1) Remove the 2 screws [1], and disconnect all connectors; then, detach the lattice connector Mounting [2]. F-10-52 10.10.6.11 Removing the Manual Feed Cooling Fan Duct 0000-4767 1) Slide out the manual fee unit; then, disconnect the connector [1] and remove the 2 screws [2] to detach F-10-50 10.10.6.10 Removing High-Voltage Unit the manual feed cooling fan duct [3]. the 0000-4766 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. 10-41 Chapter 10 F-10-53 F-10-55 10.10.6.12 Removing the Rear Right Cover 2) Disconnect the connector [1], and remove the 4 0000-4768 screws [2]; then, detach the cassette pickup motor unit [3]. The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. 1) Remove the 2 screws [1], and detach the rear right cover [2]. F-10-56 3) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the cassette pickup motor unit [3]. F-10-54 10.10.6.13 Removing Cassette Pickup Motor 1) Remove the grip [1]. 10-42 the 0000-4769 Chapter 10 10.10.7.3 Removing the Rear Right Cover 0000-4734 The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. 1) Remove the 2 screws [1], and detach the rear right cover [2]. F-10-57 10.10.7 Cassette Retry Paper Sensor 10.10.7.1 Removing the Cassette 0000-4732 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. F-10-59 10.10.7.4 Removing the Pickup 1) Slide out the cassette. Vertical Path Cover 10.10.7.2 Removing the Front Right Cover 0000-4735 1) Remove the screw [2] to detach the pickup vertical 0000-4733 1) Slide out the manual feed unit, and open the pickup path lower cover [1]; then, detach the pickup vertical path cover [3]. vertical path cover. 2) Remove the 2 screws [1], and detach the machine's front right cover [2]. F-10-60 F-10-58 10-43 Chapter 10 10.10.7.5 Removing the Pickup Unit 0000-4736 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the pickup unit [3]. F-10-63 10.10.7.7 F-10-61 Removing the Cassette Retry Paper Sensor 0000-4738 1) Disconnect the connector [1], and detach the 10.10.7.6 Removing the Pick- cassette retry paper sensor [2]. up System Sensor Mounting Plate 0000-4737 1) Remove the 2 screws [1] at the rear, and remove the bracket [2]. F-10-64 10.10.7.8 Mounting the Pickup System Sensor Mounting Plate 0000-4739 F-10-62 Points to Note When Mounting the Sensor 2) Disconnect the connector [1], and remove the screw [1]; then, detach the cassette pickup solenoid [3]. Thereafter,remove the 5 screws [4], and detach the sensor mounting plate [5]. Mounting Plate Any of the gears can drop off. When attaching the sensor mounting plate, be sure that the pickup unit will not face downward. 1) Attach the bushing [1] to the frame; then, attach the gear shaft [2]. 10-44 Chapter 10 10.10.8 Cassette Paper Sensor 10.10.8.1 Removing the Cassette 0000-4740 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. F-10-65 1) Slide out the cassette. 2) Fit the 6 locations [A] indicated in the figure firmly into the holes of the mounting plate; then, secure the sensor mounting plate [2] in place. 10.10.8.2 Removing the Front Right Cover 0000-4741 1) Slide out the manual feed unit, and open the pickup vertical path cover. 2) Remove the 2 screws [1], and detach the machine's front right cover [2]. F-10-66 3) Attach the gear [1] and the E-ring [2]. F-10-68 10.10.8.3 Removing the Rear Right Cover 0000-4742 The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. F-10-67 1) Remove the 2 screws [1], and detach the rear right 4) Turn the gears to see that the movement is smooth. cover [2]. 10-45 Chapter 10 F-10-71 F-10-69 10.10.8.6 Removing the Pick10.10.8.4 Removing the Pickup Vertical Path Cover up System Sensor Mounting 0000-4743 1) Remove the screw [2] to detach the pickup vertical path lower cover [1]; then, detach the pickup Plate 0000-4745 1) Remove the 2 screws [1] at the rear, and remove the bracket [2]. vertical path cover [3]. F-10-70 F-10-72 10.10.8.5 Removing the Pickup Unit 2) Disconnect the connector [1], and remove the screw 0000-4744 [1]; then, detach the cassette pickup solenoid [3]. 1) Disconnect the connector [1], and remove the 4 Thereafter,remove the 5 screws [4], and detach the screws [2]; then, detach the pickup unit [3]. 10-46 sensor mounting plate [5]. Chapter 10 F-10-75 2) Fit the 6 locations [A] indicated in the figure firmly into the holes of the mounting plate; then, secure F-10-73 the sensor mounting plate [2] in place. 10.10.8.7 Removing the Cassette Paper Sensor 0000-4746 1) Disconnect the connector [1], and detach the cassette paper sensor [2]. F-10-76 3) Attach the gear [1] and the E-ring [2]. F-10-74 10.10.8.8 Mounting the Pickup System Sensor Mounting Plate 0000-4747 Points to Note When Mounting the Sensor Mounting Plate Any of the gears can drop off. When attaching the F-10-77 sensor mounting plate, be sure that the pickup unit will not face downward. 4) Turn the gears to see that the movement is smooth. 1) Attach the bushing [1] to the frame; then, attach the gear shaft [2]. 10-47 Chapter 10 10.10.9 Cassette Paper Level Sensor (A/B) 10.10.9.1 Removing the Cassette 0000-4748 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. 1) Slide out the cassette. F-10-79 10.10.9.2 Removing the Front Right Cover 10.10.9.4 Removing the Pickup 0000-4749 1) Slide out the manual feed unit, and open the pickup vertical path cover. Vertical Path Cover 0000-4751 1) Remove the screw [2] to detach the pickup vertical path lower cover [1]; then, detach the pickup 2) Remove the 2 screws [1], and detach the machine's vertical path cover [3]. front right cover [2]. F-10-80 F-10-78 10.10.9.5 Removing the Pickup 10.10.9.3 Removing the Rear Right Cover Unit 0000-4750 0000-4752 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the pickup unit [3]. The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. 1) Remove the 2 screws [1], and detach the rear right cover [2]. 10-48 Chapter 10 F-10-81 F-10-83 10.10.9.6 Removing the Pickup System Sensor Mounting Plate 10.10.9.7 0000-4753 1) Remove the 2 screws [1] at the rear, and remove the bracket [2]. Removing the Cassette Paper Level Sensor (A/B) 0000-4754 1) Disconnect the connector [1], and remove the cassette paper sensor (A/B) [2]. F-10-84 F-10-82 2) Disconnect the connector [1], and remove the screw 10.10.9.8 Mounting the Pick- [1]; then, detach the cassette pickup solenoid [3]. up System Sensor Mounting Thereafter,remove the 5 screws [4], and detach the Plate sensor mounting plate [5]. 0000-4755 Points to Note When Mounting the Sensor Mounting Plate Any of the gears can drop off. When attaching the sensor mounting plate, be sure that the pickup unit will not face downward. 10-49 Chapter 10 1) Attach the bushing [1] to the frame; then, attach the 10.10.10 Slide Resistor gear shaft [2]. 10.10.10.1 Removing the Manual Feed Unit 0000-4995 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-85 2) Fit the 6 locations [A] indicated in the figure firmly into the holes of the mounting plate; then, secure the sensor mounting plate [2] in place. F-10-88 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. F-10-86 3) Attach the gear [1] and the E-ring [2]. F-10-89 10.10.10.2 Removing Manual Feed Tray Unit the 0000-4996 1) Remove the 3 screws [1], and detach the base [2]. F-10-87 4) Turn the gears to see that the movement is smooth. 10-50 Chapter 10 F-10-92 F-10-90 2) Disconnect the connector [1] at the rear; then, while opening the face plate [2], shift the manual feed tray MEMO: [3] 90 deg or more to detach it upward. When attaching the upper cover [1] and the lower cover [2], match the markings [A] found on the side, and slide them into place. F-10-91 F-10-93 10.10.10.3 Removing the Manual Feed Tray Upper Cover/Lower Cover 0000-4997 1) Spread the side guide [1] of the manual feed tray unit, and separate it into the upper cover [2] and the lower cover [3] (for detachment). 10-51 Chapter 10 10.10.11 Cassette Pickup Solenoid 10.10.10.4 Removing the Slide Resistor 0000-4998 10.10.11.1 Removing the Cassette 0000-4771 Points to Note Removing the Slide Resistor When detaching the slide resistor, do not apply excess MEMO: force when spreading the claw of the lower cover; The cassette 1/2 and the pick-up unit 1/2 may also be otherwise, the claw can break. removed in the same way. When attaching the slide resistor, take care not to touch the connector [1] at the edge of the slide resistor. 1) Slide out the cassette. Try to match the black protrusion [A] behind the slide resistor against the hole [A] in the tray. 10.10.11.2 Removing the Front Right Cover 0000-4772 1) Slide out the manual feed unit, and open the pickup vertical path cover. 2) Remove the 2 screws [1], and detach the machine's front right cover [2]. F-10-94 1) Disconnect the connector [1] on the lower cover side, spread the claw [A], and detach the slide resistor [2]. F-10-96 10.10.11.3 Removing the Rear Right Cover 0000-4773 The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. 1) Remove the 2 screws [1], and detach the rear right cover [2]. F-10-95 10-52 Chapter 10 F-10-99 F-10-97 10.10.11.6 10.10.11.4 Removing the Cassette Pickup Solenoid the Pickup Vertical Path Cover Removing 0000-4776 0000-4774 1) Disconnect the connector [1], and remove the 2 1) Remove the screw [2] to detach the pickup vertical screws [2]; then, detach the cassette pickup path lower cover [1]; then, detach the pickup solenoid [3]. vertical path cover [3]. F-10-100 F-10-98 10.10.12 Manual Feed Tray Unit 10.10.11.5 Pickup Unit Removing the 0000-4775 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the pickup unit [3]. 10.10.12.1 Removing Manual Feed Unit Cover the 0000-4949 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. 10-53 Chapter 10 10.10.12.2 Removing the Manual Feed Tray Unit 0000-4950 1) Remove the 3 screws [1], and detach the base [2]. F-10-101 2) Remove the screw [1], and free the 3 claws [2] and the 3 snap-ons [3]; then, detach the manual feed unit cover [4]. F-10-104 2) Disconnect the connector [1] at the rear; then, while opening the face plate [2], shift the manual feed tray [3] 90 deg or more to detach it upward. F-10-102 F-10-105 10.10.13 Manual Feed Unit 10.10.13.1 Removing Manual Feed Unit F-10-103 the 0000-4947 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. 10-54 Chapter 10 F-10-106 F-10-108 2) Remove the screw [1] and the stopper plate [2]; 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. then, detach the manual feed unit [3]. F-10-109 F-10-107 10.10.14 Manual Feed Roller 10.10.14.2 Removing Manual Feed Unit Cover 10.10.14.1 Removing Manual Feed Unit the the 0000-4961 1) Press the release button [1] on the machine's right 0000-4960 side to slide out the manual feed unit [2]. 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-110 10-55 Chapter 10 2) Remove the screw [1], and free the 3 claws [2] and the 3 snap-ons [3]; then, detach the manual feed unit cover [4]. F-10-113 2) Remove the gear [1] at the front, and detach the F-10-111 bushing [2]. (For both gear and the bushing, free the claw fitted in the groove of the roller for detachment.) F-10-112 F-10-114 10.10.14.3 Removing Manual Feed Roller the 0000-4962 3) Remove the bushing [1] at the rear. 1) Remove the 3 screws [1], and detach the mounting plate [2]. F-10-115 4) Remove the resin clamp [1], and pull out the manual feed roller [2]. 10-56 Chapter 10 10.10.15 Manual Feed Separation Roller When attaching the manual feed roller, be sure that the groove of the parallel pin is toward the rear. 10.10.15.1 Removing the Manual Feed Unit 0000-4964 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-116 F-10-118 When attaching the bushing and the gear at the front, check to be sure that the claw is hooked on the groove of the roller. 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. F-10-119 10.10.15.2 F-10-117 Removing Manual Feed Unit Cover the 0000-4965 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. 10-57 Chapter 10 10.10.15.3 Removing the Motor Cover 0006-8853 1) Remove the screw [1], and detach the motor cover [2] at the rear. F-10-120 2) Remove the screw [1], and free the 3 claws [2] and the 3 snap-ons [3]; then, detach the manual feed unit cover [4]. F-10-123 10.10.15.4 Removing Manual Feed Roller the 0000-4966 1) Remove the 3 screws [1], and detach the mounting plate [2]. F-10-121 F-10-124 2) Remove the gear [1] at the front, and detach the bushing [2]. (For both gear and the bushing, free the claw fitted in the groove of the roller for detachment.) F-10-122 10-58 Chapter 10 When attaching the bushing and the gear at the front, check to be sure that the claw is hooked on the groove of the roller. F-10-125 3) Remove the bushing [1] at the rear. F-10-128 10.10.15.5 Manual F-10-126 Removing Feed Separation Roller 4) Remove the resin clamp [1], and pull out the the 0000-4968 1) manual feed roller [2]. Take care not to lose the spring found at the front when detaching the face plate. When attaching the manual feed roller, be sure that the groove of the parallel pin is toward the rear. Detach the face plate [1]. F-10-129 F-10-127 10-59 Chapter 10 When attaching the face plate, be sure that the spring [2] fits into the hole [1] found on the front side of the arm. F-10-132 10.10.16 Manual Feed Last Paper Sensor F-10-130 10.10.16.1 2) Detach the rear guide [1] and the middle guide [2]. (Free the snap-in claw.) Removing the Manual Feed Unit 0000-5000 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-131 F-10-133 3) Pick the tab [A] of the manual feed separation roller [2], and pull it out in the direction of the arrow. 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. 10-60 Chapter 10 F-10-134 10.10.16.2 Removing the Manual Feed Tray Unit F-10-136 0000-5001 1) Remove the 3 screws [1], and detach the base [2]. 10.10.16.3 Removing the Manual Feed Tray Upper Cover/Lower Cover 0000-5002 1) Spread the side guide [1] of the manual feed tray unit, and separate it into the upper cover [2] and the lower cover [3] (for detachment). F-10-135 2) Disconnect the connector [1] at the rear; then, while opening the face plate [2], shift the manual feed tray [3] 90 deg or more to detach it upward. F-10-137 MEMO: When attaching the upper cover [1] and the lower cover [2], match the markings [A] found on the side, and slide them into place. 10-61 Chapter 10 10.10.17 Manual Feed Sensor 10.10.17.1 Removing the Manual Feed Unit 0000-4970 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-138 10.10.16.4 Removing the Manual Feed Last Paper Sensor 0000-5003 1) Free the needle spring [1] from the hook, and detach the detecting roll [2]. F-10-141 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. F-10-139 2) Disconnect the connector [1], and detach the F-10-142 manual feed last paper sensor [2]. 10.10.17.2 Removing Manual Feed Unit Cover the 0000-4971 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-140 10-62 Chapter 10 10.10.17.3 Removing the Manual Feed Roller 0000-4973 1) Remove the 3 screws [1], and detach the mounting plate [2]. F-10-143 2) Remove the screw [1], and free the 3 claws [2] and the 3 snap-ons [3]; then, detach the manual feed unit cover [4]. F-10-146 2) Remove the gear [1] at the front, and detach the bushing [2]. (For both gear and the bushing, free the claw fitted in the groove of the roller for detachment.) F-10-144 F-10-147 3) Remove the bushing [1] at the rear. F-10-145 10-63 Chapter 10 F-10-148 4) Remove the resin clamp [1], and pull out the F-10-150 manual feed roller [2]. 10.10.17.4 Removing the Motor Cover When attaching the manual feed roller, be sure that the groove of the parallel pin is toward the rear. 0000-4974 1) Remove the screw [1], and detach the motor cover [2] at the rear. F-10-149 F-10-151 10.10.17.5 Removing Manual Feed sensor When attaching the bushing and the gear at the front, the 0000-4975 1) check to be sure that the claw is hooked on the groove of the roller. Take care not to lose the spring found at the front when detaching the face plate. Detach the face plate [1]. 10-64 Chapter 10 F-10-152 F-10-154 3) Remove the sensor flag [2] attached to the middle guide [1]. When attaching the face plate, be sure that the spring [2] fits into the hole [1] found on the front side of the arm. F-10-155 4) Disconnect the connector [1] from behind the F-10-153 middle guide, and detach the manual feed paper sensor [2]. 2) Detach the rear guide [1] and the middle guide [2]. (Free the snap-in claw.) F-10-156 10-65 Chapter 10 10.10.18 Transparency Sensor (Front/Rear) 10.10.18.1 Removing the Manual Feed Unit 0000-4952 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-159 10.10.18.3 Removing the Transparency Sensor (front/ rear) 0000-4954 1) While taking care not to touch the light-emitting face, detach the transparency sensor [1]. F-10-157 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. F-10-160 10.10.19 Manual Feed Pickup Solenoid F-10-158 10.10.18.2 Removing Transparency Mounting Plate 10.10.19.1 the Manual Feed Unit Sensor 0000-4953 1) Disconnect the 3 connectors [1], and remove the 2 screws [2]; then, detach the sensor base [3] found at the bottom. 10-66 Removing the 0000-4977 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. Chapter 10 2) Remove the screw [1], and free the 3 claws [2] and the 3 snap-ons [3]; then, detach the manual feed unit cover [4]. F-10-161 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. F-10-164 F-10-162 10.10.19.2 Removing Manual Feed Unit Cover F-10-165 the 0000-4978 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. 10.10.19.3 Removing Manual Feed Roller the 0000-4979 1) Remove the 3 screws [1], and detach the mounting plate [2]. F-10-163 10-67 Chapter 10 When attaching the manual feed roller, be sure that the groove of the parallel pin is toward the rear. F-10-166 2) Remove the gear [1] at the front, and detach the bushing [2]. F-10-169 (For both gear and the bushing, free the claw fitted in the groove of the roller for detachment.) When attaching the bushing and the gear at the front, check to be sure that the claw is hooked on the groove of the roller. F-10-167 3) Remove the bushing [1] at the rear. F-10-170 10.10.19.4 F-10-168 Removing Motor Cover the 0000-4980 1) Remove the screw [1], and detach the motor cover 4) Remove the resin clamp [1], and pull out the manual feed roller [2]. 10-68 [2] at the rear. Chapter 10 [A] [1] [B] [2] F-10-173 F-10-171 10.10.20 Registration Motor 10.10.19.5 Manual Removing Feed the Pickup Solenoid 10.10.20.1 0000-4981 1) Disconnect the connector [1], and remove the screw [2]; then, detach the manual feed pickup solenoid [3]. F-10-172 Removing the Manual Feed Unit 0000-4989 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-174 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. Points to Note When Attaching the Manual Feed Pickup Solenoid When attaching the solenoid [1], be sure to hook the flapper [A] on the claw [B] of the gear [2]. F-10-175 10-69 Chapter 10 10.10.20.2 Removing Manual Feed Unit Cover the 0000-4990 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-178 10.10.20.3 Removing the Motor Cover F-10-176 0000-4992 1) Remove the screw [1], and detach the motor cover [2] at the rear. 2) Remove the screw [1], and free the 3 claws [2] and the 3 snap-ons [3]; then, detach the manual feed unit cover [4]. F-10-179 10.10.20.4 Removing Registration Motor F-10-177 the 0000-4993 1) Disconnect the connector [1], and remove the 2 screws [2]; then, detach the registration motor [3]. 10-70 Chapter 10 F-10-182 F-10-180 10.10.21.2 10.10.21 Pre-Registration Motor Removing Manual Feed Unit Cover the 0000-4984 1) Press the release button [1] on the machine's right 10.10.21.1 Removing the Manual Feed Unit side to slide out the manual feed unit [2]. 0000-4983 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-183 2) Remove the screw [1], and free the 3 claws [2] and F-10-181 the 3 snap-ons [3]; then, detach the manual feed unit cover [4]. 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. F-10-184 10-71 Chapter 10 F-10-185 10.10.21.3 Removing F-10-187 the Motor Cover 10.10.22 0000-4986 Horizontal Registration Motor 1) Remove the screw [1], and detach the motor cover [2] at the rear. 10.10.22.1 Removing the Fixing Unit 0000-4882 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-10-186 10.10.21.4 Removing the PreRegistration Motor 0000-4987 1) Disconnect the connector [1], and remove the 2 F-10-188 screws [2]; then, detach the pre-registration motor [3]. 10.10.22.2 Removing Fixing/Feeder Unit the 0000-4883 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. 10-72 Chapter 10 F-10-191 1) Stand it so that the fixing feeder unit cover is at the F-10-189 bottom. 10.10.22.3 Removing 2) Free the 6 snap-ons [A] and the 3 hooks [B]; then, the Duplex Open/Close Guide 0000-4884 1) Remove the duplex open/close guide [1]. detach the sheet [1] from behind the fixing feeder assembly. F-10-190 10.10.22.4 Removing Fixing/Feeder F-10-192 the 10.10.22.5 Assembly Back Sheet Horizontal 0000-4885 Removing the Registration Motor Support Plate 0000-4886 1) Disconnect the connector [1], and remove the 2 screws [2]; then, detach the horizontal registration - When placing the fixing feeder unit upright, be sure motor support plate [3]. to use paper to prevent dirt from collecting. - If you forgot to use paper, make a double-sided test copy before ending the work. 10-73 Chapter 10 F-10-195 F-10-193 10.10.23 Registration Sensor - When attaching the horizontal registration motor support plate [1], be sure to bring the horizontal registration motor support plate firmly in contact with the grounding lead spring [2] found under the 10.10.23.1 Removing the Manual Feed Unit 0000-4956 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. guide plate. - After replacement, check to make sure that the sensor flag moves smoothly. F-10-196 2) Remove the screw [1] and the stopper plate [2]; F-10-194 then, detach the manual feed unit [3]. 10.10.22.6 Horizontal Motor Removing the Registration 0000-4887 1) Disconnect the connector [1], and remove the 2 screws [2]; then, detach the horizontal registration motor [3]. 10-74 Chapter 10 F-10-197 10.10.23.2 Removing Transparency F-10-199 the 10.10.24 Fixing/Feeder Unit Sensor Mounting Plate 0000-4957 1) Disconnect the 3 connectors [1], and remove the 2 screws [2]; then, detach the sensor base [3] found at 10.10.24.1 Removing the Fixing Unit 0006-7407 1) Slide out the fixing/feeding unit. the bottom. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-10-198 F-10-200 10.10.23.3 Removing Registration Sensor the 0000-4958 1) While taking care not to touch the light-emitting face of the transparency sensor [1], detach the registration sensor [2]. 10.10.24.2 Removing Fixing/Feeder Unit the 0000-4782 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. 10-75 Chapter 10 10.10.25.3 Removing the Rear Right Cover 0000-4720 The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. 1) Remove the 2 screws [1], and detach the rear right cover [2]. F-10-201 10.10.25 Vertical Path Roller 10.10.25.1 Removing the Cassette 0000-4718 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be F-10-203 removed in the same way. 10.10.25.4 1) Slide out the cassette. path lower cover [1]; then, detach the pickup vertical path cover [3]. 1) Slide out the manual feed unit, and open the pickup vertical path cover. 2) Remove the 2 screws [1], and detach the machine's front right cover [2]. F-10-204 10-76 0000-4721 1) Remove the screw [2] to detach the pickup vertical 0000-4719 F-10-202 the Pickup Vertical Path Cover 10.10.25.2 Removing the Front Right Cover Removing Chapter 10 10.10.25.5 Removing the Pickup Unit 0000-4722 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the pickup unit [3]. F-10-207 10.10.25.7 Mounting the PickF-10-205 up System Sensor Mounting Plate 10.10.25.6 Removing the Pick- 0000-4725 up System Sensor Mounting Plate 0000-4723 Points to Note When Mounting the Sensor 1) Remove the 2 screws [1] at the rear, and remove the bracket [2]. Mounting Plate Any of the gears can drop off. When attaching the sensor mounting plate, be sure that the pickup unit will not face downward. 1) Attach the bushing [1] to the frame; then, attach the gear shaft [2]. F-10-206 2) Disconnect the connector [1], and remove the screw [1]; then, detach the cassette pickup solenoid [3]. F-10-208 Thereafter,remove the 5 screws [4], and detach the sensor mounting plate [5]. 2) Fit the 6 locations [A] indicated in the figure firmly into the holes of the mounting plate; then, secure the sensor mounting plate [2] in place. 10-77 Chapter 10 2) Free the claw [A] of the bushing [1] at the front; shift the vertical path roller [2] to the rear and then pull it upward to detach. F-10-209 3) Attach the gear [1] and the E-ring [2]. F-10-212 10.10.26 Inside Delivery Roller 10.10.26.1 Removing the Inside Delivery Roller 0000-4945 1) Open the fixing feeder unit cover. F-10-210 4) Turn the gears to see that the movement is smooth. 10.10.25.8 Removing the Vertical Path Roller 0000-4724 1) Free the claw [A] of the gear [1] at the rear, and detach the gear and the bushing [2]. F-10-213 2) Remove the E-ring[1] and the bushing [2] at the front; then, remove the gear [3] and the bushing [4] at the rear. F-10-211 10-78 Chapter 10 F-10-216 F-10-214 3) Free the internal delivery roller [1] from the cut-off 10.10.27.2 Removing the Center Delivery Tray of the frame at the front; then, detach it. 0000-4786 1) Remove the 2 screws [1], and detach the center delivery tray [2]. F-10-215 10.10.27 Fixing/Feeder Unit Open/ F-10-217 Closed Sensor 10.10.27.3 10.10.27.1 Removing Upper Left Cover Removing the Delivery Vertical Path Unit the 0000-4785 (Old) 0000-4787 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover 10-79 Chapter 10 [2]. F-10-218 F-10-220 2) Remove the screw [1], and detach the delivery internal cover [2]. Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-219 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. F-10-221 10.10.27.4 Removing the Delivery Vertical Path Unit (New) 10-80 0006-8955 Chapter 10 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-224 F-10-222 3) Remove the screw [1], and detach the delivery inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) F-10-223 4) F-10-225 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; To detach the delivery vertical path unit, lift the unit then, fix it in place using the slip-stop [3]. and then pull it out toward the front. 10-81 Chapter 10 F-10-226 7) Remove the dummy connector [1] from the F-10-228 machine. (The dummy connector will no longer be 9) Using 4 screws, secure the delivery vertical path used.) unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. F-10-227 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. Engage the left and right hooks [3] on the machine F-10-229 plate [4] so as to set the new delivery vertical path unit in place. 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. 10-82 Chapter 10 F-10-230 F-10-232 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and 1) Disconnect the connector [1] and the 4 terminals put the fixing/feeding unit back in its initial [2], and remove the screw [1]; then, detach the position. fixing/feeder unit open/closed sensor mounting plate [4]. F-10-231 10.10.27.5 Removing Fixing/Feeder Closed Unit Sensor the Open/ Mounting Plate 0000-4788 Before detaching the fixing/feeder unit, be sure to mark its position using a scriber. F-10-233 10-83 Chapter 10 10.10.27.6 Removing Fixing/Feeder Unit the Open/ Closed Sensor 0000-4789 1) Remove the fixing/feeder open/closed sensor [1]. F-10-235 10.10.28.3 Removing the Rear Right Cover 0000-4728 F-10-234 10.10.28 Pickup Vertical Path Cover The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. Open/Closed Sensor 1) Remove the 2 screws [1], and detach the rear right 10.10.28.1 Removing the Cassette cover [2]. 0000-4726 MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. 1) Slide out the cassette. 10.10.28.2 Removing the Front Right Cover 0000-4727 1) Slide out the manual feed unit, and open the pickup F-10-236 vertical path cover. 2) Remove the 2 screws [1], and detach the machine's front right cover [2]. 10.10.28.4 Removing the Pickup Vertical Path Cover 0000-4729 1) Remove the screw [2] to detach the pickup vertical path lower cover [1]; then, detach the pickup vertical path cover [3]. 10-84 Chapter 10 F-10-237 10.10.28.5 Removing F-10-239 the Pickup Unit 2) Remove the spring [1], and detach the sensor flag 0000-4730 [2]. 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the pickup unit [3]. F-10-240 3) Remove the pickup vertical path cover open/closed F-10-238 10.10.28.6 Removing sensor [1]. the Pickup Vertical Path Cover Open/Closed Sensor 0000-4731 1) Disconnect the connector [1], and remove the screw [2]; then, detach the sensor mounting plate [3]. F-10-241 10-85 Chapter 10 10.10.29 Fixing/Feeder Unit Open/ 10.10.29.3 Removing the Delivery Vertical Path Unit Closed Detecting Switch (Old) 10.10.29.1 Removing 0000-4795 the Upper Left Cover 0000-4793 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 cover [3]. - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-242 10.10.29.2 Removing Center Delivery Tray the F-10-244 0000-4794 1) Remove the 2 screws [1], and detach the center 2) Remove the screw [1], and detach the delivery delivery tray [2]. internal cover [2]. F-10-243 F-10-245 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10-86 Chapter 10 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-246 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found F-10-248 on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with 3) Remove the screw [1], and detach the delivery screws. (Be sure to tighten the left screw first.) inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. F-10-247 F-10-249 4) 10.10.29.4 Removing the Delivery Vertical Path Unit (New) 0006-8956 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. 10-87 Chapter 10 Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) F-10-252 7) Remove the dummy connector [1] from the machine. (The dummy connector will no longer be F-10-250 used.) 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) F-10-253 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. F-10-251 Engage the left and right hooks [3] on the machine 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; then, fix it in place using the slip-stop [3]. 10-88 plate [4] so as to set the new delivery vertical path unit in place. Chapter 10 F-10-256 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-254 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. F-10-257 10.10.29.5 Removing Fixing/Feeder Closed Unit Sensor the Open/ Mounting Plate 0000-4796 Before detaching the fixing/feeder unit, be sure to mark its position using a scriber. F-10-255 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. 10-89 Chapter 10 1) Remove the 2 screws [1], and detach the fixing/ feeder open/closed sensor [2]. F-10-258 1) Disconnect the connector [1] and the 4 terminals [2], and remove the screw [1]; then, detach the fixing/feeder unit open/closed sensor mounting plate [4]. F-10-260 10.10.30 Drawer Connector (manual feed unit) 10.10.30.1 Removing the Manual Feed Unit 0000-8487 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-259 10.10.29.6 Removing Fixing/Feeder Unit the F-10-261 Open/ Closed Detecting Switch 0000-4797 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. MEMO: The fixing/feeder unit open/closed switches 1 and 2 may be removed in the same way. 10-90 Chapter 10 10.10.31 Drawer Connector (fixing/ feeder unit) 10.10.31.1 Removing the Fixing Unit 0000-5005 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-10-262 10.10.30.2 Removing the Disconnecting the Drawer Connector (manual feed unit) 0000-8485 1) Remove the 2 screws [1], and disconnect the drawer connector [2]. F-10-265 10.10.31.2 Removing Fixing/Feeder Unit the 0000-5006 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. F-10-263 2) Disconnect the 2 connectors [1] from behind, and disconnect the drawer connector [2]. F-10-266 F-10-264 10-91 Chapter 10 10.10.31.3 Drawer Removing Connector the (fixing feeder unit) 0000-5007 1) Free the harness [2] from the cable clamp [1], and disconnect the 2 connectors [3], and remove the 2 screws [4]; then, detach the connector base [5]. F-10-269 10.10.32.2 Removing the Fixing/Feeder Unit 0000-8926 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. F-10-267 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-10-270 10.10.32.3 Removing Duplex Roller 1 the 0000-4942 1) Open the cover of the fixing feeder unit [1]. F-10-268 10.10.32 Duplex Roller 1 10.10.32.1 Removing Fixing Unit the 0000-4939 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. 10-92 Chapter 10 F-10-271 2) Remove the duct. F-10-273 5) Remove the gear [1] and the bearing [2] at the rear. When removing the gear, pay attention not to lose the parallel pin found at the rear. 3) Remove the 2 E-rings [1], gear [2], and link [3]; then, remove the screw [4] to detach the grounding wire [5]. F-10-274 6) Remove the 2 duplex auxiliary guides [1] of the duplex roller. F-10-272 4) Remove the 2 screws [1], and detach the motor base [2]. F-10-275 10-93 Chapter 10 7) Remove the screw [1], and disconnect the connector [2]; then, detach the delivery path switching solenoid 2 [3] together with the base. Points to Note When Attaching the Duplex Roller 1) Be sure that the longer side [A] of the D-cut in the roller shaft [1] is toward the front. F-10-276 8) Free the claw of the gear [1] at the front; then, slide F-10-279 the roller to the rear, and remove the gear [1] and the bearing [2]. 2) When monting, be sure that the front tip of the roller shaft is in contact with the grounding plate [A]. F-10-277 9) Remove the duplexing roller [1]. F-10-280 10.10.33 Duplex Feed Motor 10.10.33.1 F-10-278 Removing Fixing Unit the 0000-4903 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit 10-94 Chapter 10 [2]. F-10-283 F-10-281 2) Open the cover of the fixing feeder unit [1], and 10.10.33.2 Removing the Fixing/Feeder Unit remove the screw [1], then detach the duct [2]. 0000-4904 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. F-10-284 3) Remove the screw [1] at the rear, and free the boss [A] and the hook [B]; then, detach the cover (rear) [2]. F-10-282 10.10.33.3 Removing Duplex Feed Motor the 0000-4907 1) Disconnect the connector [1] of the duplex feeder motor from the bottom. F-10-285 10-95 Chapter 10 4) Remove the 2 screws [1], and shift the duplex 10.10.34 Duplex Registration Sensor feeder motor [2] in the direction indicated to detach. 10.10.34.1 Removing the Fixing Unit 0000-8478 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-10-286 F-10-288 Points to Note When Attaching the Duplex Feed Motor 1) Be sure that the connector area is at the bottom. 2) Be sure to tighten the lower right screw [1] together with the grounding wire [2]. 10.10.34.2 Removing the Fixing/Feeder Unit 0000-8480 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. F-10-287 F-10-289 10.10.34.3 Removing Fixing/Feeder Back Sheet 10-96 the Assembly 0000-8481 Chapter 10 - When placing the fixing feeder unit upright, be sure to use paper to prevent dirt from collecting. - If you forgot to use paper, make a double-sided test copy before ending the work. F-10-290 F-10-292 1) Stand it so that the fixing feeder unit cover is at the bottom. 10.10.35 2) Free the 6 snap-ons [A] and the 3 hooks [B]; then, detach the sheet [1] from behind the fixing feeder Duplex Horizontal Registration Sensor assembly. 10.10.35.1 Removing Fixing Unit the 0000-4890 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-10-291 10.10.34.4 Removing the Duplex Registration Sensor 0000-8482 1) Disconnect the connector [1], free the 2 claws [2], F-10-293 and remove the sensor base [3]; then, detach the duplex registration sensor [4]. 10-97 Chapter 10 10.10.35.2 Removing the Fixing/Feeder Unit detach the sheet [1] from behind the fixing feeder 0000-4891 assembly. 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. F-10-296 10.10.35.4 Horizontal F-10-294 Removing Registration Motor Support Plate 10.10.35.3 Removing Fixing/Feeder the 0000-4893 the 1) Disconnect the connector [1], and remove the 2 Assembly screws [2]; then, detach the horizontal registration Back Sheet 0000-4892 motor support plate [3]. - When placing the fixing feeder unit upright, be sure to use paper to prevent dirt from collecting. - If you forgot to use paper, make a double-sided test copy before ending the work. F-10-297 F-10-295 - When attaching the horizontal registration motor support plate [1], be sure to bring the horizontal registration motor support plate firmly in contact 1) Stand it so that the fixing feeder unit cover is at the bottom. 2) Free the 6 snap-ons [A] and the 3 hooks [B]; then, 10-98 with the grounding lead spring [2] found under the guide plate. - After replacement, check to make sure that the Chapter 10 sensor flag moves smoothly. F-10-300 F-10-298 After replacement, check to make sure that the sensor flag moves smoothly. 10.10.35.5 Removing the Duplex Registration Sensor 0000-4894 1) Disconnect the connector [1], and detach the duplex 10.10.36 Duplex Pickup Sensor horizontal registration sensor [2]. 10.10.36.1 Removing the Cleaner Fan Cover 0000-4915 1) Open the front cover. 2) Remove the screw [1], and detach the cleaner fan cover [2]. F-10-299 Be sure to mach the protrusion [B] of the harness guide found behind the guide plate against the area F-10-301 [A] marked on the flat cable [1] coming from the duplex horizontal registration sensor. (if you twist it inadvertently, the loop area will not move smoothly.) 10.10.36.2 Removing the Intermediate Transfer Unit Releasing Lever 0000-4916 1) Remove the screw [1], and detach the intermediate transfer unit releasing lever [2]. 10-99 Chapter 10 10.10.36.5 Removing the Manual Feed Unit 0000-4920 1) Press the release button [1] on the machine's right side to slide out the manual feed unit [2]. F-10-302 10.10.36.3 Removing the Inside Cover (lower) 0000-4917 1) Disconnect the connector [1], and remove the 5 F-10-304 screws [2]; then, detach the inside cover (lower) [3]. 2) Remove the screw [1] and the stopper plate [2]; then, detach the manual feed unit [3]. F-10-305 F-10-303 10.10.36.4 Removing Cassette 10.10.36.6 Removing the Front the 0000-4918 Cover 0000-4921 1) Remove the screw [1] and the 2 hinge pins [2]; MEMO: The cassette 1/2 and the pick-up unit 1/2 may also be removed in the same way. 1) Slide out the cassette. 10-100 then, detach the front cover. Chapter 10 F-10-308 F-10-306 10.10.36.9 10.10.36.7 Removing the Rear Right Cover Removing the Pickup Unit 0000-4922 0000-4924 1) Disconnect the connector [1], and remove the 4 screws [2]; then, detach the pickup unit [3]. The rear right cover is fitted with the rear lower cover; shift it to the direction indicated to detach. 1) Remove the 2 screws [1], and detach the rear right cover [2]. F-10-309 10.10.36.10 Removing the Upper Rear Cover 0000-4925 1) Remove the upper rear cover. 10.10.36.11 F-10-307 10.10.36.8 Removing the Lower Rear Cover 0000-4926 1) Remove the lower rear cover. the Pickup Vertical Path Cover 0000-4923 1) Remove the screw [2] to detach the pickup vertical path lower cover [1]; then, detach the pickup vertical path cover [3]. Removing 10.10.36.12 Removing High-Voltage Unit the 0000-4927 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. 10-101 Chapter 10 F-10-310 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. F-10-312 10.10.36.14 Removing the DC Controller PCB Cover 0000-4930 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-10-311 10.10.36.13 Removing the Controller Box Cover 0000-4929 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-10-313 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. 10-102 Chapter 10 [1] F-10-314 F-10-317 3) Free the controller box from the hook [A/B] at the top of the main controller box. 10.10.36.15 Opening the Main Controller Box 0000-4931 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-10-318 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, F-10-315 and open it. 2) Remove the 9 screws [1] of the main controller box. F-10-319 F-10-316 10-103 Chapter 10 10.10.36.16 Removing the DC Controller Mounting 0000-4932 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-10-322 2) Remove the 2 screws [1], and detach the main controller base [2]. F-10-320 10.10.36.17 Removing the Fixing Heat Discharge Fan 0000-4933 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-10-323 3) Remove the 7 screws [1], and detach the developing drive assembly [2]. F-10-321 10.10.36.18 Removing Developing Drive Unit the 0000-4934 1) Disconnect the connector [2] of the developing motor [1], and free the harness [3] from the cable clamp [4]. 10-104 F-10-324 Chapter 10 10.10.36.19 Removing the Lattice Connector Mounting 0000-4935 1) Remove the 2 screws [1], and disconnect all connectors; then, detach the lattice connector Mounting [2]. F-10-327 10.10.36.22 Removing Duplex Pickup Sensor the 0000-4937 1) Remove the 2 screws [1] from the rear side plate F-10-325 side, and detach the rail support plate [2] of the manual feed unit. 10.10.36.20 Removing the Manual Feed Cooling Fan Duct 0000-4936 1) Slide out the manual fee unit; then, disconnect the connector [1] and remove the 2 screws [2] to detach the manual feed cooling fan duct [3]. F-10-328 2) Remove the 3 screws [1] from the side of the rear side plate and the 2 screws [2] from the side of the F-10-326 10.10.36.21 Removing Duplex Driver PCB front side plate; then, detach the rail guide [3] of the manual feed unit as shown. the 0006-3015 1) Remove the 4 screws [1], and detach the duplex driver PCB [2]. 10-105 Chapter 10 5) Disconnect the connector [1], and remove the screw [2]; then, detach the sensor support plate [3]. F-10-332 F-10-329 6) Remove the duplex pickup sensor [1]. 3) Remove the 2 screws [1], and detach the drawer connector support plate [2]. F-10-333 F-10-330 4) Remove the 2 screws [1], and detach the lower guide plate [2]. 10.10.37 Duplex Registration Clutch 10.10.37.1 Removing Fixing Unit the 0000-4876 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-10-331 10-106 Chapter 10 F-10-334 10.10.37.2 Removing F-10-336 the Fixing/Feeder Unit 10.10.37.4 0000-4877 1) Remove the 2 stoppers [1], and detach the fixing/ Removing the Duplex Open/Close Guide 0000-4879 1) Remove the duplex open/close guide [1]. feeder unit [2]. F-10-337 10.10.37.5 F-10-335 Removing the Duplex Registration Clutch 10.10.37.3 Duplex Removing Feeder Connector the 0000-4880 1) Remove the 2 E-rings [1]. Motor 0000-4878 1) Disconnect the connector [1] of the duplex feeder motor from the base side. F-10-338 10-107 Chapter 10 2) Slide the bushing [1] to free the duplex feed roller 3 [2]. F-10-341 F-10-339 4) Remove the E-ring [1], and detach the duplex registration clutch [2]. When attaching it, fit it while turning the duplex feed roller 3 [2] so as not to bend the sheet [1] of the duplex guide plate. (Do not shift up the sheet by hand.) F-10-342 10.10.38 Duplex Pickup Clutch 10.10.38.1 F-10-340 Removing Fixing Unit the 0000-4897 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit 3) Disconnect the connector [1], and remove the clutch stop [2]; then, pull the duplex registration clutch [3] upward to detach. 10-108 [2]. Chapter 10 F-10-343 10.10.38.2 Removing F-10-345 the Fixing/Feeder Unit 10.10.38.4 0000-4898 1) Remove the 2 stoppers [1], and detach the fixing/ feeder unit [2]. Removing Duplex Pickup Clutch the 0000-4901 1) Open the cover of the fixing feeder unit [1]. F-10-346 2) Remove the 2 E-rings [1]. F-10-344 10.10.38.3 Removing Duplex Open/Close Guide the 0000-4900 1) Remove the duplex open/close guide [1]. F-10-347 10-109 Chapter 10 3) Shift the bushing [1] to the inside of the duplex feeder guide. When attaching, be sure that the stop [A] of the clutch is at the bottommost. [A] F-10-351 F-10-348 4) Disconnect the connector [1] of the duplex pickup Make sure that the front side of the roller shaft is in clutch. contact with the leaf spring [1]. F-10-349 F-10-352 5) Remove the roller shaft, and remove the E-ring [1]; then, detach the duplex pickup clutch [2]. 10.10.39 Delivery Vertical Path Unit 10.10.39.1 Removing Fixing Unit the 0006-3193 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-10-350 10-110 Chapter 10 F-10-353 10.10.39.2 Removing F-10-355 the Center Delivery Tray 0000-4801 1) Remove the 2 screws [1], and detach the center delivery tray [2]. 10.10.39.4 Removing the Delivery Vertical Path Unit (Old) 0000-4802 In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-354 10.10.39.3 Removing Upper Left Cover the 0000-4800 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. F-10-356 2) Remove the screw [1], and detach the delivery internal cover [2]. 10-111 Chapter 10 F-10-357 F-10-359 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10.10.39.5 Removing the Delivery Vertical Path Unit (New) 0006-4883 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. F-10-358 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-360 3) Remove the screw [1], and detach the delivery 10-112 Chapter 10 inside cover [2]; then, detach the delivery vertical used.) path cover [3] from the machine. F-10-361 F-10-363 4) 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; To detach the delivery vertical path unit, lift the unit then, fix it in place using the slip-stop [3]. and then pull it out toward the front. Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) F-10-364 7) Remove the dummy connector [1] from the machine. (The dummy connector will no longer be used.) F-10-362 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be 10-113 Chapter 10 F-10-365 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. F-10-367 When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. 10) Mount the new delivery vertical path cover [1] to Engage the left and right hooks [3] on the machine the machine; then, fix the delivery inside cover [2] plate [4] so as to set the new delivery vertical path in place using a screw [3]. unit in place. F-10-368 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-366 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. 10-114 Chapter 10 F-10-369 F-10-371 10.10.40 Face-Down Delivery Roller 1 10.10.40.3 Removing the Delivery Vertical Path Unit 10.10.40.1 Removing the Upper Left Cover (Old) 0000-4823 0000-4821 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-370 10.10.40.2 Removing Center Delivery Tray the 0000-4822 1) Remove the 2 screws [1], and detach the center F-10-372 delivery tray [2]. 2) Remove the screw [1], and detach the delivery internal cover [2]. 10-115 Chapter 10 F-10-373 F-10-375 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10.10.40.4 Removing the Delivery Vertical Path Unit (New) 0006-8958 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. F-10-374 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-376 3) Remove the screw [1], and detach the delivery 10-116 Chapter 10 inside cover [2]; then, detach the delivery vertical used.) path cover [3] from the machine. F-10-377 F-10-379 4) 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; To detach the delivery vertical path unit, lift the unit then, fix it in place using the slip-stop [3]. and then pull it out toward the front. Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) F-10-380 7) Remove the dummy connector [1] from the machine. (The dummy connector will no longer be used.) F-10-378 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be 10-117 Chapter 10 F-10-381 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. F-10-383 When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. 10) Mount the new delivery vertical path cover [1] to Engage the left and right hooks [3] on the machine the machine; then, fix the delivery inside cover [2] plate [4] so as to set the new delivery vertical path in place using a screw [3]. unit in place. F-10-384 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-382 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. 10-118 Chapter 10 F-10-385 10.10.40.5 Removing F-10-387 the Delivery Sensor Mounting Plate MEMO: 0006-0709 1) Remove the screw [1], and detach the sensor The edge of the sensor flag is cut to an I-shape, permitting it to be removed upward. mounting plate [2]. F-10-388 Points to Note When Attaching the Sensor Flag When attaching the sensor flag, be sure to match the F-10-386 L-shaped area [A] of the spring against the groove [B] of the face-down delivery sub frame. Points to Note When Attaching the Delivery Sensor Mounting Plate When attaching the sensor mounting plate, secure it in place with screws first and then route the wire to facilitate the work. 10.10.40.6 Removing the FaceDown Delivery Sensor Flag 0006-3776 1) Shift up the sensor flag [1] of the face-down delivery sensor 1, and pull it upward to detach. F-10-389 10-119 Chapter 10 Spring When attaching, shape the grounding leaf plate 10.10.40.7 Removing the FaceDown Delivery Roller 1 removed in 3) into a half-loop, and work so that the 0000-4826 1) Shift up the grounding leaf spring [1] using a flat- frame plate [1] and the grounding leaf spring [2] are in contact. blade screwdriver, and free the 2 claws. F-10-392 3) Remove the E-ring [1] and the bushing [2], and remove the gear [3] and the bushing [4] found to the rear of the face-down delivery roller 1; then, detach F-10-390 the face-down delivery roller 1 [5]. 2) Disconnect the connector [1], and detach the sensor cable [2] from the face-down delivery sub frame; then, remove the flag [3] of the face-down delivery sensor 1, and detach the face-down delivery sub frame [4]. F-10-393 10.10.41 Face-Up Delivery Roller F-10-391 10.10.41.1 Removing Fixing/Feeder Unit Points to Note When Attaching the grounding Leaf 10-120 the 0006-2818 1) Remove the 2 stoppers [1], and detach the fixing/ Chapter 10 feeder unit [2]. F-10-396 10.10.41.3 F-10-394 10.10.41.2 Removing Fixing/Feeder Unit Cover Removing the Inside Delivery Roller 0000-4844 1) Open the fixing feeder unit cover. the 0000-4843 1) Remove the screw [1] at the rear, grounding wire [2], and E-ring [3]; then, release the link [4]. F-10-397 2) Remove the E-ring[1] and the bushing [2] at the front; then, remove the gear [3] and the bushing [4] at the rear. F-10-395 2) Remove the screw [1] at the front and the cover fixing pin [2]; then, detach the fixing/feeder unit cover. F-10-398 10-121 Chapter 10 3) Free the internal delivery roller [1] from the cut-off 3) of the frame at the front; then, detach it. The spring [1] hooked on the flapper of the upper guide is small and can easily be lost. Detach it in advance. F-10-399 10.10.41.4 Removing the FaceUp Delivery Roller 0000-4845 F-10-402 1) Remove the 2 screws [1], and detach the lower guide 2 [2]. Remove the screw [2] of the gear mounting plate [1], and remove the screw [3]; then, detach the upper guide [4]. F-10-400 2) Remove the E-ring [1] at the rear, and detach the gear [2]. F-10-403 4) Remove the 3 screws [1], and detach the lower guide [2]. F-10-401 10-122 Chapter 10 F-10-404 F-10-406 5) 10.10.42 When detaching the gear [3], be sure to pay attention Delivery Vertical Path Roller 1 so as not to lose the parallel pin found at the rear. 10.10.42.1 Remove the 3 E-rings [1], gear [2], bushing [4], and gear mounting plate [5] at the rear. Removing the Upper Left Cover 0000-4846 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. F-10-405 6) Remove the E-ring [1] and the bushing [2] at the F-10-407 front; then, detach the face-up delivery roller [3]. 10.10.42.2 Removing Center Delivery Tray the 0000-4847 1) Remove the 2 screws [1], and detach the center delivery tray [2]. 10-123 Chapter 10 F-10-410 F-10-408 10.10.42.3 Removing 3) Disconnect the 2 connectors [1], and remove the 4 the screws [2]; then, detach the delivery vertical path Delivery Vertical Path Unit (Old) unit [3]. 0000-4848 In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-411 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the F-10-409 plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) 2) Remove the screw [1], and detach the delivery internal cover [2]. 10-124 Chapter 10 inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. F-10-412 F-10-414 10.10.42.4 Removing 4) the Delivery Vertical Path Unit (New) 0006-8959 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-415 F-10-413 3) Remove the screw [1], and detach the delivery 10-125 Chapter 10 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) F-10-418 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure F-10-416 to lift it once before setting it in place. 6) Attach the strap [1] found on the delivery inside Engage the left and right hooks [3] on the machine cover to the new delivery vertical path cover [2]; plate [4] so as to set the new delivery vertical path then, fix it in place using the slip-stop [3]. unit in place. F-10-417 7) Remove the dummy connector [1] from the F-10-419 machine. (The dummy connector will no longer be used.) 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. 10-126 Chapter 10 F-10-422 10.10.42.5 Removing the FaceDown Delivery Sensor 2 0000-4849 1) Free the harness [2] from the wire saddle [1], disconnect the 2 connectors [3], and remove the 2 screws [4]; then, detach the face-down delivery motor mounting plate [5]. F-10-420 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. F-10-423 F-10-421 2) Remove the sensor flag [1], and detach the facedown delivery sensor 2 [2]. 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-424 10-127 Chapter 10 Points to Note When Attaching the Sensor Flag When attaching the sensor flag [1], hook one end of the inside spring [2] and hook the other end on the flag. F-10-427 10.10.43 Delivery Vertical Path Roller 2 F-10-425 10.10.43.1 Removing the Upper Left Cover 10.10.42.6 Removing 1) Open the delivery vertical path cover [1], and the remove the 2 screws [2]; then, detach the upper left Delivery Vertical Path Roller 1 0000-4852 cover [3]. 0000-4850 1) Remove the E-ring [1] and the bushing [2] at the front; then, remove the gear [3], and detach the belt [4]. Thereafter, remove the bushing [5], and detach the delivery vertical path roller 1 [6]. F-10-428 10.10.43.2 Removing Center Delivery Tray the 0000-4853 1) Remove the 2 screws [1], and detach the center F-10-426 10-128 delivery tray [2]. Chapter 10 F-10-431 F-10-429 10.10.43.3 Removing 3) Disconnect the 2 connectors [1], and remove the 4 the screws [2]; then, detach the delivery vertical path Delivery Vertical Path Unit (Old) unit [3]. 0000-4854 In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-432 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the F-10-430 plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) 2) Remove the screw [1], and detach the delivery internal cover [2]. 10-129 Chapter 10 inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. F-10-433 F-10-435 10.10.43.4 Removing 4) the Delivery Vertical Path Unit (New) 0006-8960 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-436 F-10-434 3) Remove the screw [1], and detach the delivery 10-130 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) Chapter 10 F-10-439 F-10-437 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; then, fix it in place using the slip-stop [3]. When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. Engage the left and right hooks [3] on the machine plate [4] so as to set the new delivery vertical path unit in place. F-10-438 7) Remove the dummy connector [1] from the machine. (The dummy connector will no longer be used.) F-10-440 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. 10-131 Chapter 10 F-10-443 10.10.43.5 Removing the Delivery Vertical Path Roller 2 0000-4855 1) Disconnect the connector [1[, and remove the 2 screws [2]; then, detach the delivery vertical path F-10-441 motor [3] together with the mounting plate. 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. F-10-444 F-10-442 2) Remove the gear [1] and the bushing [2]. 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-445 10-132 Chapter 10 3) Remove the gear [1] and detach the belt [2] at the rear; then, remove the bushing [3], and detach the delivery vertical roller 2 [4]. F-10-448 10.10.44.3 F-10-446 Removing the Delivery Vertical Path Unit 10.10.44 Face-Down Delivery Motor 10.10.44.1 Removing (Old) 0000-4835 the Upper Left Cover 0000-4833 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-447 10.10.44.2 Removing Center Delivery Tray the F-10-449 0000-4834 1) Remove the 2 screws [1], and detach the center delivery tray [2]. 2) Remove the screw [1], and detach the delivery internal cover [2]. 10-133 Chapter 10 F-10-450 F-10-452 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10.10.44.4 Removing the Delivery Vertical Path Unit (New) 0006-8961 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. F-10-451 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-453 10-134 Chapter 10 3) Remove the screw [1], and detach the delivery inside cover [2]; then, detach the delivery vertical (The delivery vertical path cover will no longer be used.) path cover [3] from the machine. F-10-454 F-10-456 4) 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; To detach the delivery vertical path unit, lift the unit then, fix it in place using the slip-stop [3]. and then pull it out toward the front. Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) F-10-457 7) Remove the dummy connector [1] from the machine. (The dummy connector will no longer be used.) F-10-455 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. 10-135 Chapter 10 F-10-458 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. F-10-460 When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. 10) Mount the new delivery vertical path cover [1] to Engage the left and right hooks [3] on the machine the machine; then, fix the delivery inside cover [2] plate [4] so as to set the new delivery vertical path in place using a screw [3]. unit in place. F-10-461 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-459 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. 10-136 Chapter 10 F-10-462 10.10.44.5 Removing the FaceDown Delivery Motor F-10-464 0000-4836 1) Disconnect the connector [1], and remove the 2 screws [2]; then, detach the face-down delivery 10.10.45.2 Removing the Center Delivery Tray motor [3]. 0000-4858 1) Remove the 2 screws [1], and detach the center delivery tray [2]. F-10-463 F-10-465 10.10.45 Delivery Vertical Path 10.10.45.3 Motor 10.10.45.1 Removing the Delivery Vertical Path Unit Removing Upper Left Cover (Old) the 0000-4859 0000-4857 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left In case following models, refer to "Removing the cover [3]. Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 10-137 Chapter 10 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-468 F-10-466 2) Remove the screw [1], and detach the delivery internal cover [2]. Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-467 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. F-10-469 10.10.45.4 Removing the Delivery Vertical Path Unit (New) 10-138 0006-8962 Chapter 10 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-472 F-10-470 3) Remove the screw [1], and detach the delivery inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) F-10-471 4) F-10-473 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; To detach the delivery vertical path unit, lift the unit then, fix it in place using the slip-stop [3]. and then pull it out toward the front. 10-139 Chapter 10 F-10-474 7) Remove the dummy connector [1] from the F-10-476 machine. (The dummy connector will no longer be 9) Using 4 screws, secure the delivery vertical path used.) unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. F-10-475 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. Engage the left and right hooks [3] on the machine F-10-477 plate [4] so as to set the new delivery vertical path unit in place. 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. 10-140 Chapter 10 10.10.46 Face-Down Delivery Sensor 1 10.10.46.1 Removing the Upper Left Cover 0000-4810 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. F-10-478 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-481 10.10.46.2 F-10-479 Removing Center Delivery Tray 10.10.45.5 Removing the Delivery Vertical Path Motor the 0000-4811 1) Remove the 2 screws [1], and detach the center 0000-4860 delivery tray [2]. 1) Disconnect the connector [1], and remove the 2 screws [2]; then, detach the delivery vertical path motor [3]. F-10-482 F-10-480 10-141 Chapter 10 10.10.46.3 Removing the Delivery Vertical Path Unit (Old) 0000-4812 In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-485 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-483 2) Remove the screw [1], and detach the delivery internal cover [2]. F-10-486 F-10-484 10.10.46.4 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10-142 Removing the Delivery Vertical Path Unit (New) 0006-8963 Chapter 10 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-489 F-10-487 3) Remove the screw [1], and detach the delivery inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) F-10-488 4) F-10-490 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; To detach the delivery vertical path unit, lift the unit then, fix it in place using the slip-stop [3]. and then pull it out toward the front. 10-143 Chapter 10 F-10-491 7) Remove the dummy connector [1] from the F-10-493 machine. (The dummy connector will no longer be 9) Using 4 screws, secure the delivery vertical path used.) unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. F-10-492 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. Engage the left and right hooks [3] on the machine F-10-494 plate [4] so as to set the new delivery vertical path unit in place. 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. 10-144 Chapter 10 F-10-495 F-10-498 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial MEMO: position. The edge of the sensor flag is cut to an I-shape, permitting it to be removed upward. F-10-496 F-10-499 10.10.46.5 Removing the FaceDown Delivery Sensor 1 0000-8470 1) Shift up the sensor flag [1] of the face-down delivery sensor 1, and pull it upward to detach. Points to Note When Attaching the Sensor Flag When attaching the sensor flag, be sure to match the L-shaped area [A] of the spring against the groove [B] in the face-down delivery sub frame. F-10-497 2) Disconnect the connector [1], and remove the facedown delivery sensor 1 [2]. F-10-500 10-145 Chapter 10 10.10.47.3 Removing the Delivery Vertical Path Unit 10.10.47 Center Delivery Tray Full (Old) 0000-4864 sensor 10.10.47.1 Removing the Upper Left Cover In case following models, refer to "Removing the 0000-4862 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 cover [3]. 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-501 F-10-503 10.10.47.2 Removing Center Delivery Tray the 0000-4863 1) Remove the 2 screws [1], and detach the center 2) Remove the screw [1], and detach the delivery internal cover [2]. delivery tray [2]. F-10-504 F-10-502 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10-146 Chapter 10 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-505 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found F-10-507 on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with 3) Remove the screw [1], and detach the delivery screws. (Be sure to tighten the left screw first.) inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. F-10-506 F-10-508 4) 10.10.47.4 Removing the Delivery Vertical Path Unit (New) 0006-8964 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. 10-147 Chapter 10 Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) F-10-511 7) Remove the dummy connector [1] from the machine. (The dummy connector will no longer be F-10-509 used.) 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) F-10-512 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. F-10-510 Engage the left and right hooks [3] on the machine 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; then, fix it in place using the slip-stop [3]. 10-148 plate [4] so as to set the new delivery vertical path unit in place. Chapter 10 F-10-515 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-513 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. F-10-516 10.10.47.5 Removing the Center Delivery Tray Full sensor 0000-4865 1) Remove the sensor flag [1]; then, disconnect the connector [2], and detach the center delivery tray full sensor [3]. F-10-514 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. F-10-517 10-149 Chapter 10 10.10.48 Face-Down Delivery 10.10.48.3 Removing the Delivery Vertical Path Unit Sensor 2 (Old) 10.10.48.1 Removing 0000-4818 the Upper Left Cover 0000-4816 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 cover [3]. - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-518 10.10.48.2 Removing Center Delivery Tray the F-10-520 0000-4817 1) Remove the 2 screws [1], and detach the center 2) Remove the screw [1], and detach the delivery delivery tray [2]. internal cover [2]. F-10-519 F-10-521 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10-150 Chapter 10 For the new delivery vertical path unit to function, the version of the DC controller must be 3.06 or later. Be sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-522 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found F-10-524 on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with 3) Remove the screw [1], and detach the delivery screws. (Be sure to tighten the left screw first.) inside cover [2]; then, detach the delivery vertical path cover [3] from the machine. F-10-523 F-10-525 4) 10.10.48.4 Removing the Delivery Vertical Path Unit (New) 0006-8965 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. 10-151 Chapter 10 Disconnect the 2 concoctors [1], and remove the 4 screws [2]; then, detach the delivery path unit [3]. (The delivery path unit will no longer be used.) F-10-528 7) Remove the dummy connector [1] from the machine. (The dummy connector will no longer be F-10-526 used.) 5) Using a flat-blade screwdriver, detach the slip-stop [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. (The delivery vertical path cover will no longer be used.) F-10-529 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure to lift it once before setting it in place. F-10-527 Engage the left and right hooks [3] on the machine 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; then, fix it in place using the slip-stop [3]. 10-152 plate [4] so as to set the new delivery vertical path unit in place. Chapter 10 F-10-532 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-530 9) Using 4 screws, secure the delivery vertical path unit [3] in place; then, connect the 3 connectors. At this time, check to make sure that the machine positioner [4] is properly in place. F-10-533 10.10.48.5 Removing the FaceDown Delivery Sensor 2 0000-4819 1) Free the harness [2] from the wire saddle [1], disconnect the 2 connectors [3], and remove the 2 screws [4]; then, detach the face-down delivery motor mounting plate [5]. F-10-531 10) Mount the new delivery vertical path cover [1] to the machine; then, fix the delivery inside cover [2] in place using a screw [3]. F-10-534 10-153 Chapter 10 2) Remove the sensor flag [1], and detach the face- remove the 2 screws [2]; then, detach the upper left cover [3]. down delivery sensor 2 [2]. F-10-535 F-10-537 10.10.49.2 Points to Note When Attaching the Sensor Flag When attaching the sensor flag [1], hook one end of the inside spring [2] and hook the other end on the flag. Removing the Center Delivery Tray 0000-4805 1) Remove the 2 screws [1], and detach the center delivery tray [2]. F-10-538 F-10-536 10.10.49.3 Removing the Delivery Vertical Path Unit (Old) 10.10.49 0000-4806 Delivery Vertical Path Cover Open/Closed Sensor In case following models, refer to "Removing the 10.10.49.1 Removing Upper Left Cover Delivery Vertical Path Unit (New)". the 0000-4804 1) Open the delivery vertical path cover [1], and 10-154 - flom MLW01838 - flom MLX02392 Chapter 10 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-541 F-10-539 2) Remove the screw [1], and detach the delivery internal cover [2]. Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-540 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. F-10-542 10-155 Chapter 10 10.10.49.4 Removing the Delivery Vertical Path Unit (New) 0006-8967 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. Disconnect the 2 concoctors [1], and remove the 4 For the new delivery vertical path unit to function, the screws [2]; then, detach the delivery path unit [3]. version of the DC controller must be 3.06 or later. Be (The delivery path unit will no longer be used.) sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-545 5) Using a flat-blade screwdriver, detach the slip-stop F-10-543 [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. 3) Remove the screw [1], and detach the delivery inside cover [2]; then, detach the delivery vertical (The delivery vertical path cover will no longer be used.) path cover [3] from the machine. F-10-544 F-10-546 4) 10-156 Chapter 10 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; then, fix it in place using the slip-stop [3]. F-10-549 F-10-547 9) Using 4 screws, secure the delivery vertical path 7) Remove the dummy connector [1] from the unit [3] in place; then, connect the 3 connectors. At machine. (The dummy connector will no longer be this time, check to make sure that the machine used.) positioner [4] is properly in place. F-10-548 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure F-10-550 to lift it once before setting it in place. 10) Mount the new delivery vertical path cover [1] to Engage the left and right hooks [3] on the machine the machine; then, fix the delivery inside cover [2] plate [4] so as to set the new delivery vertical path in place using a screw [3]. unit in place. 10-157 Chapter 10 10.10.50 Delivery Path Switching Solenoid 1 10.10.50.1 Removing the Upper Left Cover 0000-4867 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. F-10-551 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-554 10.10.50.2 F-10-552 Removing Center Delivery Tray 10.10.49.5 Removing the delivery tray [2]. 0000-4808 1) Disconnect the connector [1], and remove the delivery vertical path cover open/closed sensor [2]. F-10-555 F-10-553 10-158 0000-4868 1) Remove the 2 screws [1], and detach the center Delivery Vertical Path Cover Open/Closed Sensor the Chapter 10 10.10.50.3 Removing the Delivery Vertical Path Unit (Old) 0000-4869 In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-558 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-556 2) Remove the screw [1], and detach the delivery internal cover [2]. F-10-559 F-10-557 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10-159 Chapter 10 10.10.50.4 Removing the Delivery Vertical Path Unit (New) 0006-8966 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. Disconnect the 2 concoctors [1], and remove the 4 For the new delivery vertical path unit to function, the screws [2]; then, detach the delivery path unit [3]. version of the DC controller must be 3.06 or later. Be (The delivery path unit will no longer be used.) sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-562 5) Using a flat-blade screwdriver, detach the slip-stop F-10-560 [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. 3) Remove the screw [1], and detach the delivery inside cover [2]; then, detach the delivery vertical (The delivery vertical path cover will no longer be used.) path cover [3] from the machine. F-10-561 F-10-563 4) 10-160 Chapter 10 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; then, fix it in place using the slip-stop [3]. F-10-566 F-10-564 9) Using 4 screws, secure the delivery vertical path 7) Remove the dummy connector [1] from the unit [3] in place; then, connect the 3 connectors. At machine. (The dummy connector will no longer be this time, check to make sure that the machine used.) positioner [4] is properly in place. F-10-565 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure F-10-567 to lift it once before setting it in place. 10) Mount the new delivery vertical path cover [1] to Engage the left and right hooks [3] on the machine the machine; then, fix the delivery inside cover [2] plate [4] so as to set the new delivery vertical path in place using a screw [3]. unit in place. 10-161 Chapter 10 10.10.50.6 Removing the Cleaner Fan 0006-2819 1) Disconnect the connector [1], and free the 3 claws; then, detach the cleaner fan [2]. F-10-568 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial position. F-10-571 10.10.50.7 Delivery Removing Path the Switching Solenoid 1 0000-8475 1) Disconnect the connector [1], and remove the screw [2]; then, detach the delivery path switching solenoid 1 [3]. F-10-569 10.10.50.5 Removing Cleaner Fan Cover the 0000-4870 1) Open the front cover. 2) Remove the screw [1], and detach the cleaner fan cover [2]. F-10-572 F-10-570 10-162 Chapter 10 10.10.51 Delivery Path Switching Solenoid 2 10.10.51.1 Delivery 10.10.52 Face-Down Delivery Roller 1 Drive Belt Removing Path 10.10.52.1 the Switching Solenoid 2 Removing the Upper Left Cover 0000-4874 1) Open the fixing/feeder unit cover. 0000-4828 1) Open the delivery vertical path cover [1], and remove the 2 screws [2]; then, detach the upper left cover [3]. F-10-573 2) Remove the screw [1], and disconnect the F-10-575 connector [2]; then, detach the delivery path switching solenoid 2 [3] together with the mounting plate. 10.10.52.2 Removing Center Delivery Tray the 0000-4829 1) Remove the 2 screws [1], and detach the center delivery tray [2]. F-10-574 F-10-576 10-163 Chapter 10 10.10.52.3 Removing the Delivery Vertical Path Unit (Old) 0000-4830 In case following models, refer to "Removing the Delivery Vertical Path Unit (New)". - flom MLW01838 - flom MLX02392 1) Detach the strap [1] from the delivery vertical cover; then, detach the delivery vertical path cover [2]. F-10-579 Points to Note When Mounting the Delivery Vertical Path Unit When attaching, engage the left/right hook [1] found on the side of the delivery vertical path unit on the plate on the side of the machine, and secure it with screws. (Be sure to tighten the left screw first.) F-10-577 2) Remove the screw [1], and detach the delivery internal cover [2]. F-10-580 F-10-578 3) Disconnect the 2 connectors [1], and remove the 4 screws [2]; then, detach the delivery vertical path unit [3]. 10-164 Chapter 10 10.10.52.4 Removing the Delivery Vertical Path Unit (New) 0006-8968 To detach the delivery vertical path unit, lift the unit and then pull it out toward the front. Disconnect the 2 concoctors [1], and remove the 4 For the new delivery vertical path unit to function, the screws [2]; then, detach the delivery path unit [3]. version of the DC controller must be 3.06 or later. Be (The delivery path unit will no longer be used.) sure to check its version in service mode: COPIER>DISPLAY>VERSION>D-CON. 1) Slide out the fixing/feeding unit. 2) Open the delivery vertical path cover [1]; then, remove the 2 screws [2], and detach the upper left cover [3]. F-10-583 5) Using a flat-blade screwdriver, detach the slip-stop F-10-581 [2] from the delivery vertical path cover [1]; then, detach the strap [3] from the delivery inside cover. 3) Remove the screw [1], and detach the delivery inside cover [2]; then, detach the delivery vertical (The delivery vertical path cover will no longer be used.) path cover [3] from the machine. F-10-582 F-10-584 4) 10-165 Chapter 10 6) Attach the strap [1] found on the delivery inside cover to the new delivery vertical path cover [2]; then, fix it in place using the slip-stop [3]. F-10-587 F-10-585 9) Using 4 screws, secure the delivery vertical path 7) Remove the dummy connector [1] from the unit [3] in place; then, connect the 3 connectors. At machine. (The dummy connector will no longer be this time, check to make sure that the machine used.) positioner [4] is properly in place. F-10-586 8) Fit the top [1] of the new delivery vertical path inside of the machine plate [2]. When mounting the delivery vertical path unit, be sure F-10-588 to lift it once before setting it in place. 10) Mount the new delivery vertical path cover [1] to Engage the left and right hooks [3] on the machine the machine; then, fix the delivery inside cover [2] plate [4] so as to set the new delivery vertical path in place using a screw [3]. unit in place. 10-166 Chapter 10 F-10-589 11) Fix the upper left cover [1] using 2 screws [2]; then, close the delivery vertical path cover [3], and put the fixing/feeding unit back in its initial F-10-591 position. F-10-590 10.10.52.5 Removing the FaceDown Delivery Drive Belt Roller 1 0000-4831 1) Free the protrusion [1] of the belt pulley (upper or lower) from the groove of the shaft, and shift it; then, detach the belt [2]. 10-167 Chapter 10 10-168 Chapter 11 Fixing System Contents Contents 11.1 Construction .................................................................................................................................................. 11-1 11.1.1 Specifications, Control Mechanisms, and Functions ............................................................................. 11-1 11.1.2 Major Components ................................................................................................................................. 11-1 11.1.3 Construction of the Control System ....................................................................................................... 11-3 11.2 Basic Sequence .............................................................................................................................................. 11-4 11.2.1 Sequence of Operations at Power-On .................................................................................................... 11-4 11.2.2 Sequence of Operations (printing; plain paper, for less than 180 sec) ................................................... 11-5 11.2.3 Basic Sequence of Operations (during printing; plain paper, for 180 sec or more) ............................... 11-6 11.3 Various Control Mechanisms ........................................................................................................................ 11-7 11.3.1 Controlling the Speed of the Fixing Roller ............................................................................................ 11-7 11.3.1.1 Outline ............................................................................................................................................. 11-7 11.3.1.2 Controlling the Speed According to the Type of Paper .................................................................. 11-7 11.3.1.3 Controlling the Speed According to the Quantity of Printing ......................................................... 11-8 11.3.1.4 Preventing Partial Deformation of the Roller .................................................................................. 11-8 11.3.2 Controlling the Fixing Roller Temperature ............................................................................................ 11-8 11.3.2.1 Outline ............................................................................................................................................. 11-8 11.3.2.2 At Power-On .................................................................................................................................. 11-10 11.3.2.3 In Standby ...................................................................................................................................... 11-10 11.3.2.4 During Printing .............................................................................................................................. 11-11 11.3.2.5 Between Sheets .............................................................................................................................. 11-12 11.3.2.6 Overheating in Areas Without Paper ............................................................................................. 11-13 11.3.2.7 Return for Low-Power Mode ........................................................................................................ 11-13 11.3.3 Detecting the Passage of Paper ............................................................................................................ 11-14 11.3.3.1 Detecting the Passage of Paper ...................................................................................................... 11-14 11.4 Protective Functions .................................................................................................................................... 11-15 11.4.1 Turning Off the Power Against Overheating (in response to activation of thermal switch) ................ 11-15 11.4.2 Detecting Overheating by the Thermistors .......................................................................................... 11-16 11.5 Parts Replacement Procedure ...................................................................................................................... 11-17 11.5.1 Fixing Unit ........................................................................................................................................... 11-17 11.5.1.1 Removing the Fixing Unit ............................................................................................................. 11-17 11.5.1.2 After Disassembling the Fixing Unit ............................................................................................. 11-17 11.5.2 Fixing Upper Frame ............................................................................................................................. 11-18 11.5.2.1 Removing the Fixing Unit ............................................................................................................. 11-18 11.5.2.2 Removing the Delivery Upper Guide ............................................................................................ 11-18 11.5.2.3 Removing the Fixing Upper Frame ............................................................................................... 11-19 11.5.2.4 After Disassembling the Fixing Unit ............................................................................................. 11-20 11.5.3 Fixing Roller ......................................................................................................................................... 11-21 11.5.3.1 Removing the Fixing Unit ............................................................................................................. 11-21 11.5.3.2 Removing the Delivery Upper Guide ............................................................................................ 11-21 11.5.3.3 Removing the Fixing Upper Frame ............................................................................................... 11-22 11.5.3.4 Remove the Fixing Main Heater and the Fixing Sub Heater ........................................................ 11-23 11.5.3.5 Removing the Fixing Roller .......................................................................................................... 11-24 11.5.3.6 After Disassembling the Fixing Unit ............................................................................................. 11-25 11.5.4 Pressure Roller ..................................................................................................................................... 11-26 11.5.4.1 Removing the Fixing Unit ............................................................................................................. 11-26 11.5.4.2 Removing the Delivery Upper Guide ............................................................................................ 11-26 11.5.4.3 Removing the Fixing Upper Frame ............................................................................................... 11-27 11.5.4.4 Removing the Fixing Temperature Retainer Heater ..................................................................... 11-28 11.5.4.5 Removing the Pressure Roller ....................................................................................................... 11-29 Contents 11.5.4.6 After Disassembling the Fixing Unit ............................................................................................. 11-29 11.5.5 Fixing Main Thermistor ........................................................................................................................ 11-30 11.5.5.1 Removing the Fixing Unit ............................................................................................................. 11-30 11.5.5.2 Removing the Delivery Upper Guide ............................................................................................ 11-30 11.5.5.3 Removing the Fixing Upper Frame ............................................................................................... 11-31 11.5.5.4 Removing the Fixing Main Thermistor ......................................................................................... 11-32 11.5.5.5 After Disassembling the Fixing Unit ............................................................................................. 11-33 11.5.6 Fixing Sub Thermistor .......................................................................................................................... 11-34 11.5.6.1 Removing the Fixing Unit ............................................................................................................. 11-34 11.5.6.2 Removing the Delivery Upper Guide ............................................................................................ 11-34 11.5.6.3 Removing the Fixing Upper Frame ............................................................................................... 11-35 11.5.6.4 Removing the Fixing Sub thermistor ............................................................................................. 11-36 11.5.6.5 After Disassembling the Fixing Unit ............................................................................................. 11-36 11.5.7 Fixing Thermal Switch ......................................................................................................................... 11-37 11.5.7.1 Removing the Fixing Unit ............................................................................................................. 11-37 11.5.7.2 Removing the Delivery Upper Guide ............................................................................................ 11-38 11.5.7.3 Removing the Fixing Upper Frame ............................................................................................... 11-38 11.5.7.4 Removing the Fixing Thermal Switch ........................................................................................... 11-40 11.5.7.5 After Disassembling the Fixing Unit ............................................................................................. 11-41 11.5.8 Fixing Main Heater/Fixing Sub Heater ................................................................................................ 11-42 11.5.8.1 Removing the Fixing Unit ............................................................................................................. 11-42 11.5.8.2 Removing the Delivery Upper Guide ............................................................................................ 11-42 11.5.8.3 Removing the Fixing Upper Frame ............................................................................................... 11-43 11.5.8.4 Remove the Fixing Main Heater and the Fixing Sub Heater ......................................................... 11-44 11.5.8.5 After Disassembling the Fixing Unit ............................................................................................. 11-45 11.5.9 Fixing Heat Retaining Heater ............................................................................................................... 11-45 11.5.9.1 Removing the Fixing Unit ............................................................................................................. 11-45 11.5.9.2 Removing the Delivery Upper Guide ............................................................................................ 11-46 11.5.9.3 Removing the Fixing Upper Frame ............................................................................................... 11-46 11.5.9.4 Removing the Fixing Temperature Retainer Heater ...................................................................... 11-48 11.5.9.5 After Disassembling the Fixing Unit ............................................................................................. 11-49 11.5.10 Fixing Inlet Guide ............................................................................................................................... 11-50 11.5.10.1 Removing the Fixing Unit ........................................................................................................... 11-50 11.5.10.2 Removing the Fixing Inlet Guide ................................................................................................ 11-50 11.5.10.3 After Disassembling the Fixing Unit ........................................................................................... 11-50 11.5.11 Delivery Upper Guide ......................................................................................................................... 11-51 11.5.11.1 Removing the Fixing Unit ........................................................................................................... 11-51 11.5.11.2 Removing the Delivery Upper Guide .......................................................................................... 11-51 11.5.12 Delivery Lower Guide ........................................................................................................................ 11-52 11.5.12.1 Removing the Fixing Unit ........................................................................................................... 11-52 11.5.12.2 Removing the Delivery Upper Guide .......................................................................................... 11-52 11.5.12.3 Removing the Fixing Upper Frame ............................................................................................. 11-53 11.5.12.4 Removing the Fixing Temperature Retainer Heater .................................................................... 11-54 11.5.12.5 Removing the Pressure Roller ..................................................................................................... 11-55 11.5.12.6 Remove the Delivery Lower Guide ............................................................................................. 11-55 11.5.12.7 After Disassembling the Fixing Unit ........................................................................................... 11-56 11.5.13 Fixing Inlet Sensor .............................................................................................................................. 11-57 11.5.13.1 Removing the Fixing Unit ........................................................................................................... 11-57 11.5.13.2 Removing the Delivery Upper Guide .......................................................................................... 11-58 11.5.13.3 Removing the Fixing Upper Frame ............................................................................................. 11-58 11.5.13.4 Removing the Fixing Inlet Sensor ............................................................................................... 11-60 11.5.13.5 After Disassembling the Fixing Unit ........................................................................................... 11-60 11.5.14 Fixing Delivery Sensor ....................................................................................................................... 11-61 11.5.14.1 Removing the Fixing Unit ........................................................................................................... 11-61 Contents 11.5.14.2 Removing the Delivery Upper Guide .......................................................................................... 11-61 11.5.14.3 Removing the Fixing Upper Frame ............................................................................................. 11-62 11.5.14.4 Removing the Fixing Delivery Sensor ........................................................................................ 11-63 11.5.14.5 After Disassembling the Fixing Unit ........................................................................................... 11-63 11.5.15 Fixing Motor ....................................................................................................................................... 11-64 11.5.15.1 Removing the Upper Rear Cover ................................................................................................ 11-64 11.5.15.2 Removing the Lower Rear Cover ................................................................................................ 11-64 11.5.15.3 Removing the Left Upper Rear Cover ......................................................................................... 11-64 11.5.15.4 Removing the Controller Box Cover ........................................................................................... 11-65 11.5.15.5 Removing the DC Controller PCB Cover ................................................................................... 11-65 11.5.15.6 Opening the Main Controller Box ............................................................................................... 11-65 11.5.15.7 Removing the Fixing Heat Discharge Fan .................................................................................. 11-66 11.5.15.8 Removing the High-Voltage Unit ............................................................................................... 11-66 11.5.15.9 Removing the Left Lower Rear cover ......................................................................................... 11-67 11.5.15.10 Removing the Secondary Transfer High-Voltage Unit ............................................................. 11-67 11.5.15.11 Removing the Fixing Drive Unit ............................................................................................... 11-68 11.5.15.12 Removing the Fixing Motor ...................................................................................................... 11-69 Chapter 11 11.1 Construction 11.1.1 Specifications, Control Mechanisms, and Functions 0005-9875 The major functions of the fixing system are as follows: T-11-1 Item Description Fixing method Heat roller Fixing heater 2 fixing rollers (main heater, sub heater) 1 pressure roller (heat retaining heater) Control temperature 190 deg C (in PSTBY) Fixing drive control Fixing roller speed control (by paper type and mode) Fixing temperature Main thermistor (non-contact; TH1, center of fixing roller) detection Sub thermistor (TH2; rear end of fixing roller) Protective Error detection as follows; upon detection of error, cuts off mechanism power to fixing heater: - temperature detection by thermistor (TH1/TH2) - temperature control by fixing thermal switch (TP1;front end of fixing roller; operating temperature of 222 -/+8 deg C Separation claw Non-contact type (facilitates separation of paper in highhumidity environment; under normal conditions, separation by fixing/pressure roller) Cleaning None (cleaning-less mechanism; no element in paper path of fixing/pressure roller) 11.1.2 Major Components 0000-5012 The fixing system consists of the following major components: T-11-2 Component Notation Description Fixing roller 48.5 mm (external diameter) Pressure roller 38.0 mm (external diameter) Main heater (halogen) H1 100/120V: 500W 230V: 545W Sub heater (halogen) H2 100/120V: 330W 230V: 360W 11-1 Chapter 11 Component Notation Description Heat retaining heater H3 100/120/230V:80W (no temperature control) Main thermistor TH1 Non-contact type (temperature control/overheating detection) Sub thermistor TH2 Temperature control, overheating detection Thermal switch TP1 222 -/+8 deg C (operating temperature) Separation claw Non-contact type (facilitates paper separation in high-humidity environment) Fixing inlet sensor PS27 Detection of passage of paper to fixing unit) Fixing delivery sensor PS25 Detection of delivery of paper after fixing Sub thermistor Main thermistor (TH1; non-contact) Non-contact separation claw Thermal switch (TP1) Sub heater (H2) Fixing roller Pressure roller Main heater (H1) Fixing inlet guide Heat retaining heater F-11-1 Fixing roller Fixing delivery sensor (PS25) Pressure roller F-11-2 11-2 Fixing inlet sensor (PS27) Chapter 11 11.1.3 Construction of the Control System 0000-5013 The major components of the fixing system are arranged as follows: Fuse PCB J51_2 H1_ON J105A_14 J108A-2 J51_1 H2_ON J105A_13 J105-6 to 9 FUSER ENTER_SNS PM-FUSER FUSER DELI_SNS J108A-5 SUB_FUSER_THM J108-8 MAIN_FUSER_ THM1 J108-10 MAIN_FUSER_ THM2 J108-11 J105A_1 J54_11 H3_ON H2_ON H1_ON J69_1 DC controller PCB J51_14 J69_2 J54_12 J62 Sub thermistor (TH2) J2_1 J2_3 J2_2 Heater driver PCB Main thermistor (TH1; non-contact) Fixing motor Fixing delivery sensor (PS25) Thermal switch (TP1) Fixing inlet sensor (PS27) Sub heater(H2) Main heater(H1) Heat retaining heater(H3) F-11-3 11-3 Chapter 11 11.2 Basic Sequence 11.2.1 Sequence of Operations at Power-On 0000-5014 Starts here if the surface temperature of the fixing roller is 90˚C or more when the main power switch is turned on. Main power switch ON WMUP WMUPR PSTBY Fixing system Here, alternately ON for 3 sec and OFF for 1.5 sec Fixing main heater (H1) Fixing sub heater (H2) Fixing heat retaining heater (H3) Fixing motor (M24) 360sec 90˚C *1 190˚C *1 300 sec Rotates idly for 300 sec after end of drum ITB motor rotation *1: The main heater or the sub heater performs temperature control (to 190˚C) according to the reading of the main thermistor (TH1) or the sub thermistor (TH2). F-11-4 11-4 Chapter 11 11.2.2 Sequence of Operations (printing; plain paper, for less than 180 sec) 0000-5015 Start key ON PSTBY PINTR Controlled to 193˚C Fixing system Fixing motor (M24) PRINT Controlled to 185˚C Controlled to 174˚C LSTR PSTBY Controlled to 164˚C Fixing main heater (H1) *1 *1 Fixing sub heater (H2) *1 *1 Fixing heat retaining heater (H3) 1st sheet passed 193˚C 190˚C 185˚C 174˚C 164˚C 10 sec 20 sec 20 sec 130 sec *1: The main heater or the sub heater performs temperature control (to 190˚C) according to the reading of the main thermistor (TH1) or the sub thermistor (TH2). F-11-5 11-5 Chapter 11 11.2.3 Basic Sequence of Operations (during printing; plain paper, for 180 sec or more) 0000-5016 Start key ON PSTBY PINTR Fixing system Fixing motor (M24) Fixing main heater (H1) Fixing sub heater (H2) Controlled to 193˚C PRINT Controlled to 185˚C Controlled to 174˚C LSTR Controlled to 164˚C PSTBY Idle rotation *1 *1 Controlled to 170˚C *1 *1 Fixing heat retaining heater (H3) 1st sheet passed 193˚C 190˚C 185˚C 174˚C 164˚C 10 sec 20 sec 20 sec 130 sec or more 30 sec *1: The main heater or the sub heater performs temperature control (to 190˚C) according to the reading of the main thermistor (TH1) or the sub thermistor (TH2). F-11-6 11-6 Chapter 11 11.3 Various Control Mechanisms 11.3.1 Controlling the Speed of the Fixing Roller 11.3.1.1 Outline 0000-5017 The fixing roller is driven by a pulse motor used exclusively for it; The roller is controlled for the following: 1) speed to suit the type of medium used 2) speed to suit the (large) quantity of printing work Fixing motor M24 *PM-FUSER-B _6 PM-FUSER-B _7 *PM-FUSER-A _8 PM-FUSER-A _9 J105B 3) configuration to prevent partial deformation otherwise caused by a long period of no use Fixing roller DC controller PCB Pressure roller F-11-7 11.3.1.2 Controlling the Speed According to the Type of Paper 0000-5018 Controlling the Speed According to the Type of Paper The machine controls the fixing roller to the following 2 speeds to suit the type of medium used: T-11-3 Medium Fixing speed Plain paper 129.1 mm/sec Thick paper 64.55 mm/sec Monochrome transparency 129.1 mm/sec Color transparency 64.55 mm/sec Note: The speed of the fixing roller is reduced (to half) to ensure good fixing on thick paper (thick paper speed) or on a full-color transparency (full-color transparency mode). 11-7 Chapter 11 11.3.1.3 Controlling the Speed According to the Quantity of Printing 0000-5019 If left unattended, the heat of the pressure roller would be absorbed by paper when a large quality of printing is under way, causing the paper to curl appreciably upon delivery and, thus, making proper stacking difficult.To prevent excess curling, the speed of the roller is reduced to half (as set in service mode) when as many as 100 large-size sheets or as many as 200 small-size sheets have been handled. Service Mode (level 2) COPIER>OPTION>BODY>DWNSQ-SW 11.3.1.4 Preventing Partial Deformation of the Roller 0000-5020 To prevent deformation otherwise caused by the nip pressure of the fixing roller as occurring when the machine is left unattended for a long period of time, the fixing roller is rotated for 0.5 sec at half speed (64.55 mm/sec) every 30 min after it has stopped (i.e., during standby/low power mode). 11.3.2 Controlling the Fixing Roller Temperature 11.3.2.1 Outline The fixing roller is driven by a pulse motor used exclusively for it; The roller is controlled for the following: [1] speed to suit the type of medium used [2] speed to suit the (large) quantity of printing work [3] during printing [4] between long sheet intervals [5] in response to overheating in non-paper contact area [6] during return from low-power mode 11-8 0000-5021 Chapter 11 DC controller PCB H1_ON J51_1 H2_ON J105A_14 J105A_13 J2_1 J2_3 Sub thermistor (TH2) 24V J2_2 Heater drive PCB SUB_FUSER_THM J108-8 J51_2 J105A_1 MAIN_FUSER_ THM1 J108-10 J54_11 H2_ON H3_ON J69_2 J54_12 H1_ON J69_1 J51_14 MAIN_FUSER_ THM2 J108-11 Fuse PCB J62 Main thermistor (TH1) (non-contact) Thermal switch (TP1) Sub heater (H2) Main heater (H1) Heat retaining heater (H3) F-11-8 11-9 Chapter 11 11.3.2.2 At Power-On 0000-5022 The fixing roller is heated by 2 fixing heaters (main heater H1, sub heater H2). The main heater repeats remaining ON for 3.5 sec and OFF for 1.5 sec until the fixing temperature reaches 190 deg C. The sub heater, on the other hand, remains ON throughout. The pressure roller is kept warm by the heat retaining heater (which remains ON throughout). The fixing motor starts to rotate when the temperature of the fixing roller reaches 90 deg C. It keeps rotating for a further 300 sec after the temperature of the fixing roller reaches 190 deg C (warm-up state; so as to maintain the temperature of the pressure roller; the machine accepts a print job during this period). Starts here if the surface temperature of the fixing roller is 90˚C or more when the main power switch is turned on. Main power switch ON WMUP WMUPR PSTBY Fixing system Repeats ON for 3.5 sec and OFF for 1.5 sec. Fixing main heater (H1) Fixing sub heater (H2) Fixing heat retaining heater (H3) Fixing motor (M24) 360sec 90˚C *1 190˚C *1 300 sec Rotates idly for 300 sec after the drum ITB motor stops. *1: The main thermistor (TH1) or the sub thermistor (TH2) performs temperature control (to 190˚C) according to the reading of the main sub heater or the sub heater. F-11-9 11.3.2.3 In Standby 0000-5023 The machine controls the fixing roller (to 190 deg C) according to the reading of the non-contact thermistor TH1 or sub thermistor TH2. If the reading of the main thermistor is assumed to be Th1 and that of the sub thermistor is assumed to be Th2, if Th1 > Th2, the temperature control will be by the sub heater. if Th1 <= Th2, the temperature control will be by the main heater. The temperature of the pressure roller is controlled by the heat retaining heater, which repeatedly remains on for 480 sec and, thereafter, remainsON for 4.2 sec and OFF for 1.6 sec. 11-10 Chapter 11 Fixing system WMUPR PSTBY Fixing main heater (H1) Fixing sub heater (H2) Fixing heat retaining heater (H3) Fixing motor (M24) *1 *1 *2 300 sec 480 sec *1: The main heater or the sub heater performs temperature control (to 190˚C) according to the reading of the main thermistor (TH1) or the sub thermistor (TH2). *2: The fixing heat retaining heater repeatedly remains ON for 4.2 sec and OFF for 1.6 sec. F-11-10 11.3.2.4 During Printing 0000-5024 The temperature of the fixing roller is controlled by turning on and off the main heater according to the reading taken by the main thermistor. During printing, the control (i.e., timing at which control is initiated) varies according to the type of paper being used. The following shows the sequence of temperature control when printing on plain paper: Start key ON PSTBY PINTR PRINT LSTR PSTBY Fixing system Fixing motor (M24) Fixing main heater (H1) *1 Fixing sub heater (H2) *1 Controlled to 193˚C Controlled to 185˚C Controlled to 174˚C *1 *1 Fixing heat retaining heater (H3) 1st sheet passed 193˚C 190˚C 185˚C 174˚C 164˚C Controlled to 164˚C 10 sec 20 sec 20 sec 130 sec *1: The main heater or the sub heater performs temperature control (to 190˚C) according to the reading of the main thermistor (TH1) and the sub thermistor (TH2). F-11-11 11-11 Chapter 11 If a print job exceeds 180 sec, the fixing roller is rotated for 30 sec after the job (so that the heat of the fixing roller is transmitted evenly to the pressure roller). Start key ON PSTBY PINTR PRINT Fixing system PSTBY LSTR Fixing motor (M24) Idle rotation Fixing main heater (H1) *1 Fixing sub heater (H2) Controlled to 193˚C Controlled to 185˚C Controlled to 174˚C Controlled to 164˚C *1 Controlled to 170˚C *1 *1 Fixing heat retaining heater (H3) 1st sheet passed 193˚C 190˚C 185˚C 174˚C 164˚C 10 sec 20 sec 20 sec 130 sec or more 30 sec *1: The main heater or the sub heater performs temperature control (to 190˚C) according to the reading of the main thermistor (TH1) and the sub thermistor (TH2). F-11-12 11.3.2.5 Between Sheets 0000-5025 The temperature of the fixing roller is controlled over the distance between sheets within a print job: 1. If the distance is 15 sec or more and less than 60 sec, The fixing temperature sequence and the heater (main/sub) control sequence are continued over the distance. 2. If the distance is 60 sec or more The fixing temperature control sequence and the heater (main/sub) control sequence are performed over the distance up to 60 sec; thereafter, only the heater sequence control is performed. 11-12 Chapter 11 Start key ON PSTBY PINTR PRINT LSTR PSTBY Fixing system Fixing motor (M24) Fixing main heater (H1) *1 Fixing sub heater (H2) *1 Controlled Controlled Controlled Controlled to 164˚C to 193˚C to 185˚C to 174˚C Controlled to 164˚C Controlled Controlled Controlled Controlled to 174˚C to 185˚C to 174˚C to 164˚C *1 *1 Fixing heat retaining heater (H3) 1st sheet passed 193˚C 190˚C 185˚C 174˚C Passage of paper (60 sec and later) 164˚C Paper passed 10 sec 20 sec 20 sec 15 to 60 sec 60 to sec 10 sec 20 sec N *1: The main heater or the sub heater performs temperature control (to 190˚C) according to the reading of the main thermistor (TH1) and the sub thermistor (TH2). N: sheet-to-sheet distance after 60 sec. F-11-13 11.3.2.6 Overheating in Areas Without Paper 0000-5026 If the sub thermistor (TH2) registers 195 deg C or more, the machine turns off the sub heater. If it registers 210 deg C or more, the machine also turns off the main heater. When the temperature at the ends falls below 210 deg C, the machine turns on the main heater. If the temperature at the ends falls below 195 deg C, the machine also turns on the sub heater. If the reading of the main thermistor is below the control temperature at this time, the heaters are turned on. 11.3.2.7 Return for Low-Power Mode 0000-5027 After a lapse of 30 sec, the machine becomes ready to accept a job only in black mono mode. In the case of color mode, the machine will not accept a job until the temperature of the fixing roller reaches 190 deg C after a lapse of 30 sec. 11-13 Chapter 11 11.3.3 Detecting the Passage of Paper 11.3.3.1 Detecting the Passage of Paper 0000-5028 The mechanisms involved in the detection of the passage of paper in the fixing unit are as follows: 1. Fixing Inlet Sensor Detects passage of paper being moved into the fixing unit. 2. Fixing Delivery Sensor Detects the passage of paper being moved from the fixing assembly. Fixing roller Fixing delivery sensor (PS25) DC controller PCB Pressure roller Fixing inlet sensor (PS27) J108_6 J108_5 J108_4 J108_3 J108_2 J108_1 F-11-14 11-14 +5V FUSER_ENTER_SNS +5V FUSER_DELI_SNS Chapter 11 11.4 Protective Functions 11.4.1 Turning Off the Power Against Overheating (in response to activation of thermal switch) 0006-0741 Once its contact has opened, the thermal switch will not return to its initial state even after the error temperature has been corrected. Be sure to replace it. If the internal temperature of the thermal switch exceeds 222 -/+8 deg C, the thermal switch goes OFF to cut the power to the fixing heater. Heater control PCB J4 J5 DC controller PCB CB 13 14 12 9 J105A RL J2_1 Triac shortHeater circuit detection drive circuit PCB Triac shortHeater circuit detection drive circuit PCB Q20 2 1 3 6 Q10 J51 Q11 Q22 Q21 TP J2_3 J69_7 HRLY_ON J69_9 TR_ERR* J69_11 H2_ON J69_12 H1_ON J2_2 J54 Fuse PCB Q23 6 3 2 1 H1 Fixing roller H2 F-11-15 11-15 Chapter 11 11.4.2 Detecting Overheating by the Thermistors 0000-5029 When the sub thermistor mounted at the end of the fixing roller detects 239 deg C, the signal from the DC controller turns off the heater drive circuit, thus cutting off power to the main heater and the sub heater. DC controller PCB CPU J105 -14 -6 -3 -2 -1 Sub thermistor detection signal -8 Main thermistor detection signal (by infrared) -10 Main thermistor detection signal (by temperature) -11 -1 -9 -12 -13 -14 J108 CB Fuse PCB RL SW Fuse (1sec) TH2 Heater control PCB J51 Triac shortcircuit detection circuit -2 -1 J62 TH1 Fixing roller H1 H2 H3 F-11-16 11-16 Heater drive circuit Triac shortcircuit detection circuit Heater drive circuit Chapter 11 11.5 Parts Procedure Replacement 11.5.1 Fixing Unit 11.5.1.1 Removing the Fixing Unit 0000-5031 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-18 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c Paper movement Standard: |a c| = 0.5mm or less F-11-17 a 11.5.1.2 After Disassembling the Fixing Unit 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-19 0000-8566 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the nip at the front by 0.3 mm, decreasing the nip at the rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. 11-17 Chapter 11 F-11-21 11.5.2.2 Removing Delivery Upper Guide the 0000-5042 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-20 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. F-11-22 11.5.2 Fixing Upper Frame 2) Remove the insulating cover [1]. 11.5.2.1 Removing the Fixing Unit 0000-5041 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-23 3) Remove the rear cover [1]. (2 snap-on claws) 11-18 Chapter 11 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-24 4) Pick the tab [2] of the lower guide [1], and free the F-11-27 4 snap-ons to detach the delivery upper guide [3]. 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-25 F-11-28 11.5.2.3 Removing the Fixing Upper Frame 0000-5043 4) Remove the 2 adjusting screws [1]. 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-29 F-11-26 11-19 Chapter 11 5) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) in place and the gear [2]. 11.5.2.4 After Disassembling the Fixing Unit 0000-5044 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. F-11-30 6) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) at the front. F-11-33 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c F-11-31 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-34 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. F-11-32 11-20 Chapter 11 11.5.3 Fixing Roller MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the nip at the front by 0.3 mm, decreasing the nip at the 11.5.3.1 Removing the Fixing Unit 0000-5052 1) Slide out the fixing/feeding unit. rear by 0.2 mm. 2) Remove the 2 screws [1], and detach the fixing unit If the median value of the measured nip is toward the [2]. higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-36 11.5.3.2 Removing Delivery Upper Guide the 0000-5053 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-35 F-11-37 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK 2) Remove the insulating cover [1]. Use it to generate output for fixing nip width auto measurement. 11-21 Chapter 11 11.5.3.3 Removing the Fixing Upper Frame 0000-5054 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-38 3) Remove the rear cover [1]. (2 snap-on claws) F-11-41 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-39 4) Pick the tab [2] of the lower guide [1], and free the 4 snap-ons to detach the delivery upper guide [3]. F-11-42 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-40 11-22 Chapter 11 F-11-43 F-11-46 4) Remove the 2 adjusting screws [1]. 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. F-11-44 5) Remove the shaft [1] (used to secure the fixing F-11-47 upper frame/lower frame) in place and the gear [2]. 11.5.3.4 Remove the Fixing Main Heater and the Fixing Sub Heater 0000-5055 1) Remove the heater retaining spring (needle-shaped) [1] at the rear. F-11-45 6) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) at the front. 11-23 Chapter 11 11.5.3.5 Removing the Fixing Roller 0000-5057 1) Remove the separation claw [1]. F-11-48 2) Remove the 2 screws [1] from the end of the heater at the front. F-11-51 Points to Note When Attaching hte Separation Claw When attaching the separation claw, be sure that it is mounted as indicated. F-11-49 3) Pull out the fixing main heater [1] and the fixing sub heater [2]. F-11-52 2) Remove the fixing roller [1]. F-11-50 11-24 Chapter 11 c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-55 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on F-11-53 the side with a lower nip value at the edge. 11.5.3.6 After Disassembling the Fixing Unit MEMO: 0000-5058 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the nip at the front by 0.3 mm, decreasing the nip at the rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-54 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK 11-25 Chapter 11 F-11-57 11.5.4.2 Removing Delivery Upper Guide the 0000-5067 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-56 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. F-11-58 11.5.4 Pressure Roller 2) Remove the insulating cover [1]. 11.5.4.1 Removing the Fixing Unit 0000-5066 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-59 3) Remove the rear cover [1]. (2 snap-on claws) 11-26 Chapter 11 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-60 4) Pick the tab [2] of the lower guide [1], and free the F-11-63 4 snap-ons to detach the delivery upper guide [3]. 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-61 F-11-64 11.5.4.3 Removing the Fixing Upper Frame 0000-5068 4) Remove the 2 adjusting screws [1]. 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-65 F-11-62 11-27 Chapter 11 5) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) in place and the gear [2]. 11.5.4.4 Removing the Fixing Temperature Retainer Heater 0000-5069 1) Disconnect the connector [1], and pull out the 2 fastons [2]. F-11-66 6) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) at the front. F-11-69 2) Remove the screw [1] front the sub heater contact at the front. F-11-67 F-11-70 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. 3) Remove the screw [1] at the rear, and detach the heater retaining plate [2]. F-11-68 11-28 Chapter 11 11.5.4.6 After Disassembling the Fixing Unit 0000-5071 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. F-11-71 4) Remove the fixing heat retaining heater [1]. F-11-74 F-11-72 2) Fit the fixing unit in the machine, and execute the 11.5.4.5 Removing the Pressure Roller following service mode to measure the nip: 0000-5070 COPIER>FUNCTION>FIXING>NIP-CHK 1) While opening the delivery lower guide [1], remove c the pressure roller [2]. Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-75 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. F-11-73 11-29 Chapter 11 11.5.5 Fixing Main Thermistor MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the nip at the front by 0.3 mm, decreasing the nip at the 11.5.5.1 Removing the Fixing Unit 0000-5073 1) Slide out the fixing/feeding unit. rear by 0.2 mm. 2) Remove the 2 screws [1], and detach the fixing unit If the median value of the measured nip is toward the [2]. higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-77 11.5.5.2 Removing Delivery Upper Guide the 0000-5074 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-76 F-11-78 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. 11-30 2) Remove the insulating cover [1]. Chapter 11 11.5.5.3 Removing the Fixing Upper Frame 0000-5075 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-79 3) Remove the rear cover [1]. (2 snap-on claws) F-11-82 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-80 4) Pick the tab [2] of the lower guide [1], and free the 4 snap-ons to detach the delivery upper guide [3]. F-11-83 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-81 11-31 Chapter 11 F-11-84 F-11-87 4) Remove the 2 adjusting screws [1]. 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. F-11-85 5) Remove the shaft [1] (used to secure the fixing F-11-88 upper frame/lower frame) in place and the gear [2]. 11.5.5.4 Removing the Fixing Main Thermistor 0006-2112 1) While freeing the retaining screw [1] of the upper frame, detach the fixing main thermistor [2]. F-11-86 6) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) at the front. 11-32 Chapter 11 F-11-90 F-11-89 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK Points to Note When Attaching hte Main Thermistor c When attaching, be sure so that the retaining spring forces the fixing thermistor in place. Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-91 11.5.5.5 After Disassembling the Fixing Unit 0000-5077 3) Adjust the balance between the front and the rear: If you have loosened the adjusting screw used to 4) If the median value of the measured nip is toward secure the upper frame and the lower frame of the the lower limit of the standard, tighten the screw on fixing unit in place (as when replacing a roller), be the side with a lower nip value at the edge. sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the nip at the front by 0.3 mm, decreasing the nip at the rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. 11-33 Chapter 11 F-11-93 11.5.6.2 Removing Delivery Upper Guide the 0000-5080 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-92 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. F-11-94 11.5.6 Fixing Sub Thermistor 2) Remove the insulating cover [1]. 11.5.6.1 Removing the Fixing Unit 0000-5079 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-95 3) Remove the rear cover [1]. (2 snap-on claws) 11-34 Chapter 11 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-96 4) Pick the tab [2] of the lower guide [1], and free the F-11-99 4 snap-ons to detach the delivery upper guide [3]. 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-97 F-11-100 11.5.6.3 Removing the Fixing Upper Frame 0000-5081 4) Remove the 2 adjusting screws [1]. 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-101 F-11-98 11-35 Chapter 11 5) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) in place and the gear [2]. 11.5.6.4 Removing the Fixing Sub thermistor 0000-5082 1) Remove the screw [1], and detach the fixing sub thermistor [2]. F-11-102 6) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) at the front. F-11-105 11.5.6.5 After Disassembling the Fixing Unit 0000-5083 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. F-11-103 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. F-11-106 F-11-104 11-36 Chapter 11 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-107 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the F-11-108 nip at the front by 0.3 mm, decreasing the nip at the rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. 11.5.7 Fixing Thermal Switch 11.5.7.1 Removing the Fixing Unit 0000-5085 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. 11-37 Chapter 11 F-11-109 11.5.7.2 Removing Delivery Upper Guide F-11-112 the 4) Pick the tab [2] of the lower guide [1], and free the 0000-5086 4 snap-ons to detach the delivery upper guide [3]. 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-113 F-11-110 2) Remove the insulating cover [1]. 11.5.7.3 Removing the Fixing Upper Frame 0000-5087 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-111 3) Remove the rear cover [1]. (2 snap-on claws) 11-38 F-11-114 Chapter 11 2) Remove the 2 screws [1], and detach the drawer upper frame/lower frame) in place and the gear [2]. connector [2]. F-11-118 F-11-115 6) Remove the shaft [1] (used to secure the fixing 3) Disconnect the 2 connectors [1] (for the thermistor/ upper frame/lower frame) at the front. thermal switch). F-11-116 4) Remove the 2 adjusting screws [1]. F-11-119 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. F-11-117 F-11-120 5) Remove the shaft [1] (used to secure the fixing 11-39 Chapter 11 11.5.7.4 Removing the Fixing Thermal Switch 0000-5088 1) Remove the 2 screws [1] of the upper frame, and detach the fixing thermal switch [2]. F-11-122 - Check the thermal switch for improper installation 1) After attaching the thermal switch to the fixing F-11-121 assembly, use the scale to measure the intervals (A/ B) between the leaf spring and the fixing assembly frame. Points to Note When Attaching the Thermal Switch Ensure to check the following points when attaching the thermal switch to the fixing assembly. - Check the leaf springs on the thermal switch for deformation 1) Place a scale on the leaf springs on the thermal switch (See the illustration below), and check the B A leaf springs for deformation. F-11-123 2) Check that the gap between the intervals (A and B) is within 3.1mm+/-1mm. When the gap is more than 3.1mm+/-1mm, it means that the springs are not properly attached or that the springs are deformed. Therefore, it is necessary to use another thermal switch. 11-40 Chapter 11 11.5.7.5 After Disassembling the Fixing Unit nip at the front by 0.3 mm, decreasing the nip at the 0000-5089 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-124 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-125 F-11-126 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto 3) Adjust the balance between the front and the rear: measurement. 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the 11-41 Chapter 11 11.5.8 Fixing Main Heater/Fixing Sub Heater 11.5.8.1 Removing the Fixing Unit 0000-5046 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-129 3) Remove the rear cover [1]. (2 snap-on claws) F-11-127 11.5.8.2 Removing Delivery Upper Guide the 0000-5047 1) Remove the insulating cover fixing plate [1]. (3 F-11-130 snap-on claws) 4) Pick the tab [2] of the lower guide [1], and free the 4 snap-ons to detach the delivery upper guide [3]. F-11-128 2) Remove the insulating cover [1]. F-11-131 11-42 Chapter 11 11.5.8.3 Removing the Fixing Upper Frame 0000-5048 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-134 4) Remove the 2 adjusting screws [1]. F-11-132 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-135 5) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) in place and the gear [2]. F-11-133 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-136 6) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) at the front. 11-43 Chapter 11 F-11-139 F-11-137 2) Remove the 2 screws [1] from the end of the heater 7) Separate the fixing upper frame and the lower at the front. frame, and detach the fixing upper frame [1]. F-11-140 F-11-138 3) Pull out the fixing main heater [1] and the fixing 11.5.8.4 Remove the Fixing sub heater [2]. Main Heater and the Fixing Sub Heater 0000-5049 1) Remove the heater retaining spring (needle-shaped) [1] at the rear. F-11-141 11-44 Chapter 11 11.5.8.5 After Disassembling the Fixing Unit nip at the front by 0.3 mm, decreasing the nip at the 0000-5050 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-142 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-143 F-11-144 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto 3) Adjust the balance between the front and the rear: measurement. 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. 11.5.9 Fixing Heat Retaining Heater MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the 11.5.9.1 Removing the Fixing Unit 0000-5060 1) Slide out the fixing/feeding unit. 11-45 Chapter 11 2) Remove the 2 screws [1], and detach the fixing unit 3) Remove the rear cover [1]. (2 snap-on claws) [2]. F-11-148 F-11-145 4) Pick the tab [2] of the lower guide [1], and free the 11.5.9.2 Removing Delivery Upper Guide the 4 snap-ons to detach the delivery upper guide [3]. 0000-5061 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-149 F-11-146 2) Remove the insulating cover [1]. 11.5.9.3 Removing the Fixing Upper Frame 0000-5062 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-147 11-46 Chapter 11 F-11-150 F-11-153 2) Remove the 2 screws [1], and detach the drawer 5) Remove the shaft [1] (used to secure the fixing connector [2]. upper frame/lower frame) in place and the gear [2]. F-11-151 F-11-154 3) Disconnect the 2 connectors [1] (for the thermistor/ 6) Remove the shaft [1] (used to secure the fixing thermal switch). upper frame/lower frame) at the front. F-11-152 4) Remove the 2 adjusting screws [1]. F-11-155 11-47 Chapter 11 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. F-11-158 3) Remove the screw [1] at the rear, and detach the F-11-156 heater retaining plate [2]. 11.5.9.4 Removing the Fixing Temperature Retainer Heater 0000-5063 1) Disconnect the connector [1], and pull out the 2 fastons [2]. F-11-159 4) Remove the fixing heat retaining heater [1]. F-11-157 2) Remove the screw [1] front the sub heater contact at the front. F-11-160 11-48 Chapter 11 11.5.9.5 After Disassembling the Fixing Unit nip at the front by 0.3 mm, decreasing the nip at the 0000-5064 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-161 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-162 F-11-163 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto 3) Adjust the balance between the front and the rear: measurement. 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the 11-49 Chapter 11 11.5.10 Fixing Inlet Guide 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. 11.5.10.1 Removing the Fixing Unit 0000-5037 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-166 F-11-164 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: 11.5.10.2 Removing the Fixing Inlet Guide COPIER>FUNCTION>FIXING>NIP-CHK 0000-5038 c 1) While pushing its claw [2] at the front, detach the fixing inlet guide [1] to the front. Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-167 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about F-11-165 0.4 mm. A 1/2 turn on the screw at the front will increase the 11.5.10.3 After Disassembling the Fixing Unit nip at the front by 0.3 mm, decreasing the nip at the 0000-5039 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 11-50 rear by 0.2 mm. Chapter 11 If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-169 11.5.11.2 Removing Delivery Upper Guide the 0000-5034 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-168 F-11-170 2) Remove the insulating cover [1]. Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. 11.5.11 Delivery Upper Guide 11.5.11.1 Removing the Fixing Unit 0000-5033 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-171 3) Remove the rear cover [1]. (2 snap-on claws) 11-51 Chapter 11 F-11-174 F-11-172 4) Pick the tab [2] of the lower guide [1], and free the 4 snap-ons to detach the delivery upper guide [3]. 11.5.12.2 Removing Delivery Upper Guide the 0000-5104 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-173 F-11-175 11.5.12 Delivery Lower Guide 2) Remove the insulating cover [1]. 11.5.12.1 Removing the Fixing Unit 0000-5103 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-176 3) Remove the rear cover [1]. (2 snap-on claws) 11-52 Chapter 11 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-177 4) Pick the tab [2] of the lower guide [1], and free the F-11-180 4 snap-ons to detach the delivery upper guide [3]. 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-178 F-11-181 11.5.12.3 Removing the Fixing Upper Frame 0000-5105 4) Remove the 2 adjusting screws [1]. 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-182 F-11-179 11-53 Chapter 11 5) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) in place and the gear [2]. 11.5.12.4 Removing the Fixing Temperature Retainer Heater 0000-5106 1) Disconnect the connector [1], and pull out the 2 fastons [2]. F-11-183 6) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) at the front. F-11-186 2) Remove the screw [1] front the sub heater contact at the front. F-11-184 F-11-187 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. 3) Remove the screw [1] at the rear, and detach the heater retaining plate [2]. F-11-185 11-54 Chapter 11 11.5.12.6 Remove the Delivery Lower Guide 0000-5108 1) Remove the mounting screw [1] of the static eliminator. F-11-188 4) Remove the fixing heat retaining heater [1]. F-11-191 2) Remove the fixing pin [1] of the delivery lower guide. F-11-189 11.5.12.5 Removing Pressure Roller the 0000-5107 F-11-192 1) While opening the delivery lower guide [1], remove the pressure roller [2]. 3) When removing the side plate at the front/rear, be sure to start at the rear. Otherwise, the side plate at the rear can break the boss on the lower frame. Remove the 2 screws [1] from the bottom face of the lower frame, and detach the side plate [2] at the front and the side plate [3] at the rear (the releasing shaft [4] F-11-190 and the delivery lower guide [5] are kept attached). 11-55 Chapter 11 Guide When mounting, be sure to set the spring [1] on either end of the delivery lower guide as indicated. F-11-193 F-11-196 F-11-194 F-11-197 4) Remove the delivery lower guide [1] from the front/ rear side plate. 11.5.12.7 After Disassembling the Fixing Unit 0000-5109 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. F-11-195 Point to Attaching When the Delivery Lower 11-56 Chapter 11 about 0.3 mm. F-11-198 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-199 F-11-200 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto 3) Adjust the balance between the front and the rear: measurement. 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. 11.5.13 Fixing Inlet Sensor 11.5.13.1 Removing the Fixing Unit 0000-5091 A 1/2 turn on the screw at the front will increase the 1) Slide out the fixing/feeding unit. nip at the front by 0.3 mm, decreasing the nip at the 2) Remove the 2 screws [1], and detach the fixing unit rear by 0.2 mm. [2]. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by 11-57 Chapter 11 F-11-201 11.5.13.2 Removing Delivery Upper Guide F-11-204 the 4) Pick the tab [2] of the lower guide [1], and free the 0000-5092 4 snap-ons to detach the delivery upper guide [3]. 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-205 F-11-202 2) Remove the insulating cover [1]. 11.5.13.3 Removing the Fixing Upper Frame 0000-5093 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-203 3) Remove the rear cover [1]. (2 snap-on claws) 11-58 F-11-206 Chapter 11 2) Remove the 2 screws [1], and detach the drawer upper frame/lower frame) in place and the gear [2]. connector [2]. F-11-210 F-11-207 6) Remove the shaft [1] (used to secure the fixing 3) Disconnect the 2 connectors [1] (for the thermistor/ upper frame/lower frame) at the front. thermal switch). F-11-208 4) Remove the 2 adjusting screws [1]. F-11-211 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. F-11-209 F-11-212 5) Remove the shaft [1] (used to secure the fixing 11-59 Chapter 11 11.5.13.4 Removing the Fixing c Inlet Sensor 0000-5094 1) Disconnect the connector [1] from the lower frame Paper movement Standard: |a c| = 0.5mm or less side, and detach the fixing inlet sensor [2]. a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-215 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. F-11-213 A 1/2 turn on the screw at the front will increase the nip at the front by 0.3 mm, decreasing the nip at the 11.5.13.5 After Disassembling the Fixing Unit 0000-5095 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. rear by 0.2 mm. If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-11-214 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK 11-60 Chapter 11 F-11-217 11.5.14.2 Removing Delivery Upper Guide the 0000-5098 1) Remove the insulating cover fixing plate [1]. (3 snap-on claws) F-11-216 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. F-11-218 11.5.14 Fixing Delivery Sensor 2) Remove the insulating cover [1]. 11.5.14.1 Removing the Fixing Unit 0000-5097 1) Slide out the fixing/feeding unit. 2) Remove the 2 screws [1], and detach the fixing unit [2]. F-11-219 3) Remove the rear cover [1]. (2 snap-on claws) 11-61 Chapter 11 2) Remove the 2 screws [1], and detach the drawer connector [2]. F-11-220 4) Pick the tab [2] of the lower guide [1], and free the F-11-223 4 snap-ons to detach the delivery upper guide [3]. 3) Disconnect the 2 connectors [1] (for the thermistor/ thermal switch). F-11-221 F-11-224 11.5.14.3 Removing the Fixing Upper Frame 0000-5099 4) Remove the 2 adjusting screws [1]. 1) Remove the 2 screws [2] of the grounding wire. (AC heater line) F-11-225 F-11-222 11-62 Chapter 11 5) Remove the shaft [1] (used to secure the fixing upper frame/lower frame) in place and the gear [2]. 11.5.14.4 Removing the Fixing Delivery Sensor 0000-5100 1) Detach the fixing delivery sensor [1] form the lower frame side. F-11-226 6) Remove the shaft [1] (used to secure the fixing F-11-229 upper frame/lower frame) at the front. 11.5.14.5 After Disassembling the Fixing Unit 0000-5101 If you have loosened the adjusting screw used to secure the upper frame and the lower frame of the fixing unit in place (as when replacing a roller), be sure to adjust the nip of the fixing roller as follows: 1) Turn the adjusting screw [1] at the front/rear so that the length of the pressure spring is 31.5mm. F-11-227 7) Separate the fixing upper frame and the lower frame, and detach the fixing upper frame [1]. F-11-230 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: F-11-228 COPIER>FUNCTION>FIXING>NIP-CHK 11-63 Chapter 11 c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-11-231 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the nip at the front by 0.3 mm, decreasing the nip at the rear by 0.2 mm. F-11-232 If the median value of the measured nip is toward the higher limit of the standard, tighten the screw on the side with a higher nip value at the edge. If the nip needs adjustment while the nip balance is correct, the adjusting screw both at the front and rear may be given a 1/2 turn so that the nip may change by about 0.3 mm. Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto measurement. 11.5.15 Fixing Motor 11.5.15.1 Removing the Upper Rear Cover 0006-2270 1) Remove the upper rear cover. 11.5.15.2 Removing the Lower Rear Cover 0006-2282 1) Remove the lower rear cover. 11.5.15.3 Removing the Left Upper Rear Cover 1) Removing the left rear upper cover. 11-64 0006-2285 Chapter 11 11.5.15.4 Removing the Controller Box Cover 0006-2289 1) Disconnect the connector J1512 [1] from the power When Attaching the DC Controller PCB Cover distribution PCB, and free the harness from the When attaching the cover, take care so that the cut-off wire saddle [2]; then, remove the 6 screws [3], and will not come into contact with the latch of the flat detach the main controller cover [4]. cable. Otherwise, the flat cable can come loose. [1] F-11-235 11.5.15.6 Opening the Main Controller Box F-11-233 0006-2304 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 11.5.15.5 Removing the DC Controller PCB Cover 0006-2302 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-11-236 2) Remove the 9 screws [1] of the main controller box. F-11-234 11-65 Chapter 11 F-11-237 F-11-240 11.5.15.7 Removing the Fixing Heat Discharge Fan 0006-2305 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-11-238 3) Free the controller box from the hook [A/B] at the top of the main controller box. F-11-241 11.5.15.8 Removing the HighVoltage Unit 0006-2306 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-11-239 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. 11-66 Chapter 11 F-11-242 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. F-11-244 2) Remove the mounting screw [1] of the high-voltage cable, and free the high-voltage cable [2] from the cable clamp [3]; then, detach it from the edge saddle [4] of the high-voltage unit base. F-11-243 11.5.15.9 Removing the Left Lower Rear cover 0006-2308 F-11-245 1) Removing the left lower rear cover. 11.5.15.10 Removing Secondary Voltage Unit Transfer 3) Pull the secondary transfer high-voltage unit [1] the slightly to the front, and free the high-voltage cable High- [3] from the cable clamp [2]. 0006-2309 1) Free the DC harness [1] from the edge saddle [2]; then, disconnect the 3 connectors [3], and remove the 2 screws [4]. 11-67 Chapter 11 11.5.15.11 Removing the Fixing Drive Unit 0006-2311 1) Slide out the fixing feeder assembly. Disconnect the connector [1], and remove the 3 screws [2]; then, detach the fixing drive unit [3]. F-11-246 4) Remove the secondary transfer high-voltage unit together with the delivery cooling fan. 5) Remove the screw [1], and disconnect the connector [2]; then, detach the secondary transfer high-voltage unit [3]. F-11-248 F-11-247 11-68 Chapter 11 11.5.15.12 Removing Fixing Motor the 0006-2312 1) When mounting the fixing motor to the motor base, be sure that the connector [2] of the motor [1] is located as shown. F-11-249 Remove the tension spring [1] and the 3 screws [2] found inside the fixing drive assembly; then, detach the fixing motor [3]. F-11-250 11-69 Chapter 11 11-70 Chapter 12 Externals and Controls Contents Contents 12.1 Control Panel ................................................................................................................................................. 12-1 12.1.1 Outline .................................................................................................................................................... 12-1 12.1.2 LCD Processing ...................................................................................................................................... 12-1 12.1.3 LCD Contras Adjustment ....................................................................................................................... 12-1 12.1.4 Functions of the Control Panel CPU ...................................................................................................... 12-2 12.2 Counters ......................................................................................................................................................... 12-3 12.2.1 Outline .................................................................................................................................................... 12-3 12.2.2 Signal-Sided Print and 2nd Side of a Double-Sided Print ...................................................................... 12-5 12.2.3 Side of a Duplex Print (duplex model only) ........................................................................................... 12-5 12.3 Fans ............................................................................................................................................................... 12-6 12.3.1 Outline .................................................................................................................................................... 12-6 12.3.2 Sequence of Operations (fan) ................................................................................................................. 12-7 12.4 Power Supply ................................................................................................................................................ 12-8 12.4.1 Power Supply ......................................................................................................................................... 12-8 12.4.1.1 Timing of Power Supply ................................................................................................................. 12-8 12.4.1.2 Wiring to Various Accessories ........................................................................................................ 12-8 12.4.1.3 Route of Power Supply .................................................................................................................... 12-9 12.4.1.4 Power Supply Route lnside the Printer Unit .................................................................................. 12-10 12.4.2 Rated Output of DC Power Supply PCB .............................................................................................. 12-11 12.4.2.1 Rated Output of the Machine Power Suppy .................................................................................. 12-11 12.4.3 Protection Function .............................................................................................................................. 12-12 12.4.3.1 Protective Mechanisms .................................................................................................................. 12-12 12.4.4 Backup Battery ..................................................................................................................................... 12-12 12.4.4.1 Backup Power Supply ................................................................................................................... 12-12 12.4.5 Energy-Saving Function ....................................................................................................................... 12-13 12.4.5.1 Outline ........................................................................................................................................... 12-13 12.5 Parts Replacement Procedure ...................................................................................................................... 12-15 12.5.1 Fixing Drive Unit ................................................................................................................................. 12-15 12.5.1.1 Removing the Upper Rear Cover .................................................................................................. 12-15 12.5.1.2 Removing the Lower Rear Cover .................................................................................................. 12-15 12.5.1.3 Removing the Left Upper Rear Cover ........................................................................................... 12-15 12.5.1.4 Removing the Controller Box Cover ............................................................................................. 12-15 12.5.1.5 Removing the DC Controller PCB Cover ..................................................................................... 12-15 12.5.1.6 Opening the Main Controller Box ................................................................................................. 12-15 12.5.1.7 Removing the Fixing Heat Discharge Fan .................................................................................... 12-16 12.5.1.8 Removing the High-Voltage Unit ................................................................................................. 12-17 12.5.1.9 Removing the Left Lower Rear cover ........................................................................................... 12-17 12.5.1.10 Removing the Secondary Transfer High-Voltage Unit ............................................................... 12-17 12.5.1.11 Removing the Fixing Drive Unit ................................................................................................. 12-18 12.5.2 Developing Drive Unit ......................................................................................................................... 12-18 12.5.2.1 Removing the Upper Rear Cover .................................................................................................. 12-18 12.5.2.2 Removing the Lower Rear Cover .................................................................................................. 12-19 12.5.2.3 Removing the Left Upper Rear Cover ........................................................................................... 12-19 12.5.2.4 Removing the Controller Box Cover ............................................................................................. 12-19 12.5.2.5 Removing the DC Controller PCB Cover ..................................................................................... 12-19 12.5.2.6 Opening the Main Controller Box ................................................................................................. 12-19 12.5.2.7 Removing the DC Controller Mounting ........................................................................................ 12-20 12.5.2.8 Removing the Fixing Heat Discharge Fan .................................................................................... 12-21 12.5.2.9 Removing the Machine Heat Discharge Fan ................................................................................. 12-21 Contents 12.5.2.10 Removing the Developing Drive Unit ......................................................................................... 12-21 12.5.3 High-Voltage Unit ................................................................................................................................ 12-22 12.5.3.1 Removing the Upper Rear Cover ................................................................................................... 12-22 12.5.3.2 Removing the Lower Rear Cover .................................................................................................. 12-22 12.5.3.3 Removing the High-Voltage Unit .................................................................................................. 12-22 12.5.4 Secondary Transfer High-Voltage Unit ................................................................................................ 12-23 12.5.4.1 Removing the Upper Rear Cover ................................................................................................... 12-23 12.5.4.2 Removing the Lower Rear Cover .................................................................................................. 12-23 12.5.4.3 Removing the High-Voltage Unit .................................................................................................. 12-23 12.5.4.4 Removing the Left Lower Rear cover ........................................................................................... 12-23 12.5.4.5 Removing the Secondary Transfer High-Voltage Unit ................................................................. 12-23 12.5.5 DC Power Supply Unit ......................................................................................................................... 12-24 12.5.5.1 Removing the Upper Rear Cover ................................................................................................... 12-24 12.5.5.2 Removing the Lower Rear Cover .................................................................................................. 12-24 12.5.5.3 Removing the DC Power Supply Unit ........................................................................................... 12-24 12.5.6 Control Panel ........................................................................................................................................ 12-25 12.5.6.1 Removing the Upper Left Cover (small) ....................................................................................... 12-25 12.5.6.2 Removing the Inside Cover ........................................................................................................... 12-25 12.5.6.3 Removing the Control Panel .......................................................................................................... 12-25 12.5.7 Control Panel LCD Unit ....................................................................................................................... 12-25 12.5.7.1 Removing the Upper Left Cover (small) ....................................................................................... 12-25 12.5.7.2 Removing the Inside Cover ........................................................................................................... 12-25 12.5.7.3 Removing the Control Panel .......................................................................................................... 12-25 12.5.7.4 Removing the Control Panel Back Plate ........................................................................................ 12-26 12.5.7.5 Removing the Control Panel LCD Unit ......................................................................................... 12-26 12.5.8 DC Controller PCB ............................................................................................................................... 12-26 12.5.8.1 Removing the Upper Rear Cover ................................................................................................... 12-26 12.5.8.2 Removing the Lower Rear Cover .................................................................................................. 12-26 12.5.8.3 Removing the Controller Box Cover ............................................................................................. 12-27 12.5.8.4 Removing the DC Controller PCB Cover ...................................................................................... 12-27 12.5.8.5 Removing the DC Controller PCB ................................................................................................ 12-27 12.5.8.6 When Replacing the DC Controller PCB ...................................................................................... 12-28 12.5.9 Counter Memory PCB .......................................................................................................................... 12-28 12.5.9.1 Removing the Upper Rear Cover ................................................................................................... 12-28 12.5.9.2 Removing the Lower Rear Cover .................................................................................................. 12-28 12.5.9.3 Removing the Left Upper Rear Cover ........................................................................................... 12-28 12.5.9.4 Removing the Controller Box Cover ............................................................................................. 12-28 12.5.9.5 Removing the DC Controller PCB Cover ...................................................................................... 12-28 12.5.9.6 Opening the Main Controller Box ................................................................................................. 12-29 12.5.9.7 Removing the Counter Memory PCB ............................................................................................ 12-30 12.5.10 Fuse PCB ............................................................................................................................................ 12-30 12.5.10.1 Removing the Upper Rear Cover ................................................................................................. 12-30 12.5.10.2 Removing the Lower Rear Cover ................................................................................................ 12-30 12.5.10.3 Removing the DC Power Supply Unit ......................................................................................... 12-30 12.5.10.4 Removing the Fuse PCB .............................................................................................................. 12-31 12.5.11 Leakage Breaker ................................................................................................................................. 12-31 12.5.11.1 Removing the Upper Rear Cover ................................................................................................. 12-31 12.5.11.2 Removing the Lower Rear Cover ................................................................................................ 12-31 12.5.11.3 Removing the DC Power Supply Unit ......................................................................................... 12-31 12.5.11.4 Removing the Power Supply Cooling Fan Mounting .................................................................. 12-31 12.5.11.5 Removing the Leakage Breaker ................................................................................................... 12-31 12.5.12 Duplex Driver PCB ............................................................................................................................. 12-32 12.5.12.1 Removing the Upper Rear Cover ................................................................................................. 12-32 12.5.12.2 Removing the Lower Rear Cover ................................................................................................ 12-32 Contents 12.5.12.3 Removing the Lattice Connector Mounting ................................................................................ 12-32 12.5.12.4 Removing the Duplex Driver PCB .............................................................................................. 12-33 12.5.13 Relay PCB 1 ....................................................................................................................................... 12-33 12.5.13.1 Removing the Upper Rear Cover ................................................................................................ 12-33 12.5.13.2 Removing the Lower Rear Cover ................................................................................................ 12-33 12.5.13.3 Removing the Left Upper Rear Cover ......................................................................................... 12-33 12.5.13.4 Removing the Controller Box Cover ........................................................................................... 12-33 12.5.13.5 Removing the DC Controller PCB Cover ................................................................................... 12-33 12.5.13.6 Opening the Main Controller Box ............................................................................................... 12-34 12.5.13.7 Removing the DC Controller Mounting ...................................................................................... 12-35 12.5.13.8 Removing the Relay PCB 1 ......................................................................................................... 12-35 12.5.14 Control Panel CPU PCB ..................................................................................................................... 12-35 12.5.14.1 Removing the Upper Left Cover (small) ..................................................................................... 12-35 12.5.14.2 Removing the Inside Cover ......................................................................................................... 12-35 12.5.14.3 Removing the Control Panel ....................................................................................................... 12-35 12.5.14.4 Removing the Control Panel CPU PCB ...................................................................................... 12-36 12.5.15 Control Panel Key Switch PCB .......................................................................................................... 12-36 12.5.15.1 Removing the Upper Left Cover (small) ..................................................................................... 12-36 12.5.15.2 Removing the Inside Cover ......................................................................................................... 12-36 12.5.15.3 Removing the Control Panel ....................................................................................................... 12-36 12.5.15.4 Removing the Control Panel Back Plate ..................................................................................... 12-37 12.5.15.5 Removing the Control Panel Key PCB ....................................................................................... 12-37 12.5.16 Control Panel Inverter PCB ................................................................................................................ 12-37 12.5.16.1 Removing the Upper Left Cover (small) ..................................................................................... 12-37 12.5.16.2 Removing the Inside Cover ......................................................................................................... 12-37 12.5.16.3 Removing the Control Panel ....................................................................................................... 12-37 12.5.16.4 Removing the Control Panel Back Plate ..................................................................................... 12-38 12.5.16.5 Removing the Control Panel Inverter PCB ................................................................................. 12-38 12.5.17 Environment Sensor ........................................................................................................................... 12-38 12.5.17.1 Pressure Release of the Intermediate Transfer Unit .................................................................... 12-38 12.5.17.2 Removing the Upper Right Cover ............................................................................................... 12-39 12.5.17.3 Removing the Environment Sensor ............................................................................................. 12-39 12.5.18 Manual Feed Unit Open/Closed Sensor ............................................................................................. 12-39 12.5.18.1 Removing the Upper Rear Cover ................................................................................................ 12-39 12.5.18.2 Removing the Lower Rear Cover ................................................................................................ 12-40 12.5.18.3 Removing the Left Upper Rear Cover ......................................................................................... 12-40 12.5.18.4 Removing the Controller Box Cover ........................................................................................... 12-40 12.5.18.5 Removing the DC Controller PCB Cover ................................................................................... 12-40 12.5.18.6 Opening the Main Controller Box ............................................................................................... 12-40 12.5.18.7 Removing the DC Controller Mounting ...................................................................................... 12-41 12.5.18.8 Removing the Registration Unit Open/Closed Sensor Mounting ............................................... 12-42 12.5.18.9 Removing the Manual Feed Unit Open/Closed Sensor ............................................................... 12-42 12.5.19 Front Cover Open/Closed Sensor ....................................................................................................... 12-42 12.5.19.1 Removing the Tonner Container release Lever ........................................................................... 12-42 12.5.19.2 Removing the Cleaner Fan Cover ............................................................................................... 12-42 12.5.19.3 Removing the Inside Cover ......................................................................................................... 12-43 12.5.19.4 Removing the Upper Rear Cover ................................................................................................ 12-43 12.5.19.5 Removing the Lower Rear Cover ................................................................................................ 12-43 12.5.19.6 Removing the Left Upper Rear Cover ......................................................................................... 12-43 12.5.19.7 Removing the DC Controller PCB Cover ................................................................................... 12-43 12.5.19.8 Removing the DC Controller Mounting ...................................................................................... 12-44 12.5.19.9 Removing the Front Cover Open/Closed Sensor .................................................................... 12-44 12.5.20 Main Power Switch ............................................................................................................................ 12-44 12.5.20.1 Removing the Upper Rear Cover ................................................................................................ 12-44 Contents 12.5.20.2 Removing the Lower Rear Cover ................................................................................................ 12-44 12.5.20.3 Removing the Left Upper Rear Cover ......................................................................................... 12-44 12.5.20.4 Removing the Controller Box Cover ........................................................................................... 12-44 12.5.20.5 Removing the DC Controller PCB Cover .................................................................................... 12-45 12.5.20.6 Opening the Main Controller Box ............................................................................................... 12-45 12.5.20.7 Removing the DC Controller Mounting ...................................................................................... 12-46 12.5.20.8 Removing the Fixing Heat Discharge Fan ................................................................................... 12-46 12.5.20.9 Removing the Fixing Drive Unit ................................................................................................. 12-46 12.5.20.10 Removing the Lattice Connector Mounting .............................................................................. 12-47 12.5.20.11 Removing the High-Voltage Unit .............................................................................................. 12-47 12.5.20.12 Removing the Manual Feed Cooling Fan Duct ......................................................................... 12-47 12.5.20.13 Removing the Main Power Supply Switch ................................................................................ 12-48 12.5.21 Manual Feed Unit Open/Closed Detecting Switch ............................................................................. 12-48 12.5.21.1 Removing the Upper Rear Cover ................................................................................................. 12-48 12.5.21.2 Removing the Lower Rear Cover ................................................................................................ 12-48 12.5.21.3 Removing the Left Upper Rear Cover ......................................................................................... 12-48 12.5.21.4 Removing the Controller Box Cover ........................................................................................... 12-48 12.5.21.5 Removing the DC Controller PCB Cover .................................................................................... 12-49 12.5.21.6 Opening the Main Controller Box ............................................................................................... 12-49 12.5.21.7 Removing the DC Controller Mounting ...................................................................................... 12-50 12.5.21.8 Removing the Registration Unit Open/Closed Sensor Mounting ................................................ 12-50 12.5.21.9 Removing the Manual Feed Unit Open/Close Switch ................................................................. 12-50 12.5.22 Front Cover Open/Closed Detecting Switch ...................................................................................... 12-51 12.5.22.1 Removing the Tonner Container release Lever ........................................................................... 12-51 12.5.22.2 Removing the Cleaner Fan Cover ................................................................................................ 12-51 12.5.22.3 Removing the Inside Cover ......................................................................................................... 12-51 12.5.22.4 Removing the Upper Rear Cover ................................................................................................. 12-51 12.5.22.5 Removing the Lower Rear Cover ................................................................................................ 12-51 12.5.22.6 Removing the Left Upper Rear Cover ......................................................................................... 12-52 12.5.22.7 Removing the DC Controller PCB Cover .................................................................................... 12-52 12.5.22.8 Removing the DC Controller Mounting ...................................................................................... 12-52 12.5.22.9 Removing the Front Cover Open/Close Switch .......................................................................... 12-52 12.5.23 Cleaner Fan ......................................................................................................................................... 12-53 12.5.23.1 Removing the Cleaner Fan Cover ................................................................................................ 12-53 12.5.23.2 Removing the Cleaner Fan .......................................................................................................... 12-53 12.5.24 Manual Feed Cooling Fan .................................................................................................................. 12-53 12.5.24.1 Removing the Upper Rear Cover ................................................................................................. 12-53 12.5.24.2 Removing the Lower Rear Cover ................................................................................................ 12-53 12.5.24.3 Removing the Left Upper Rear Cover ......................................................................................... 12-54 12.5.24.4 Removing the Controller Box Cover ........................................................................................... 12-54 12.5.24.5 Removing the DC Controller PCB Cover .................................................................................... 12-54 12.5.24.6 Opening the Main Controller Box ............................................................................................... 12-54 12.5.24.7 Removing the DC Controller Mounting ...................................................................................... 12-55 12.5.24.8 Removing the Fixing Heat Discharge Fan ................................................................................... 12-56 12.5.24.9 Removing the Developing Drive Unit ......................................................................................... 12-56 12.5.24.10 Removing the Lattice Connector Mounting .............................................................................. 12-57 12.5.24.11 Removing the High-Voltage Unit .............................................................................................. 12-57 12.5.24.12 Removing the Manual Feed Cooling Fan Duct ......................................................................... 12-57 12.5.24.13 Removing the Manual Feed Cooling Fan .................................................................................. 12-57 12.5.25 Fixing Heat Discharge Fan ................................................................................................................. 12-58 12.5.25.1 Removing the Upper Rear Cover ................................................................................................. 12-58 12.5.25.2 Removing the Lower Rear Cover ................................................................................................ 12-58 12.5.25.3 Removing the Left Upper Rear Cover ......................................................................................... 12-58 12.5.25.4 Removing the Controller Box Cover ........................................................................................... 12-58 Contents 12.5.25.5 Removing the DC Controller PCB Cover ................................................................................... 12-58 12.5.25.6 Opening the Main Controller Box ............................................................................................... 12-59 12.5.25.7 Removing the Fixing Heat Discharge Fan .................................................................................. 12-60 12.5.26 Power Supply Cooing Fan .................................................................................................................. 12-60 12.5.26.1 Removing the Upper Rear Cover ................................................................................................ 12-60 12.5.26.2 Removing the Lower Rear Cover ................................................................................................ 12-60 12.5.26.3 Removing the DC Power Supply Unit ........................................................................................ 12-60 12.5.26.4 Removing the Power Supply Cooling Fan Mounting ................................................................. 12-60 12.5.26.5 Removing the Power Supply Cooing Fan ................................................................................... 12-60 12.5.27 Delivery Cooling Fan ......................................................................................................................... 12-61 12.5.27.1 Removing the Upper Rear Cover ................................................................................................ 12-61 12.5.27.2 Removing the Lower Rear Cover ................................................................................................ 12-61 12.5.27.3 Removing the High-Voltage Unit ............................................................................................... 12-61 12.5.27.4 Removing the Left Lower Rear cover ......................................................................................... 12-61 12.5.27.5 Removing the Secondary Transfer High-Voltage Unit ............................................................... 12-61 12.5.27.6 Removing the Delivery Cooling Fan ........................................................................................... 12-62 12.5.28 Machine Heat Discharge Fan ............................................................................................................. 12-62 12.5.28.1 Removing the Upper Rear Cover ................................................................................................ 12-62 12.5.28.2 Removing the Lower Rear Cover ................................................................................................ 12-62 12.5.28.3 Removing the Left Upper Rear Cover ......................................................................................... 12-63 12.5.28.4 Removing the Controller Box Cover ........................................................................................... 12-63 12.5.28.5 Removing the DC Controller PCB Cover ................................................................................... 12-63 12.5.28.6 Opening the Main Controller Box ............................................................................................... 12-63 12.5.28.7 Removing the Machine Heat Discharge Fan ............................................................................... 12-64 12.5.29 Drum Unit Drive Belt ......................................................................................................................... 12-65 12.5.29.1 Removing the Upper Rear Cover ................................................................................................ 12-65 12.5.29.2 Removing the Lower Rear Cover ................................................................................................ 12-65 12.5.29.3 Removing the Left Upper Rear Cover ......................................................................................... 12-65 12.5.29.4 Removing the Controller Box Cover ........................................................................................... 12-65 12.5.29.5 Removing the DC Controller PCB Cover ................................................................................... 12-65 12.5.29.6 Opening the Main Controller Box ............................................................................................... 12-66 12.5.29.7 Removing the DC Controller Mounting ...................................................................................... 12-67 12.5.29.8 Removing the Fixing Heat Discharge Fan .................................................................................. 12-67 12.5.29.9 Removing the Developing Drive Unit ......................................................................................... 12-67 12.5.29.10 Removing the Lattice Connector Mounting .............................................................................. 12-68 12.5.29.11 Removing the High-Voltage Unit ............................................................................................. 12-68 12.5.29.12 Removing the Manual Feed Cooling Fan Duct ......................................................................... 12-69 12.5.29.13 Removing the Drum ITB Motor Mounting ............................................................................... 12-69 12.5.29.14 Removing the Drum Drive Unit ................................................................................................ 12-70 12.5.29.15 Detaching the Drum Unit Drive Belt ......................................................................................... 12-70 Contents Chapter 12 12.1 Control Panel 12.1.1 Outline 0000-5110 The machine's control panel consists of PCBs, LCD, and touch panel as shown below; the control panel is associated with the following functions: - LCD indication - contrast adjustment - touch switch input - hard key input Main controller PCB (sub) J1304A,J1304B J511A,J511B Touch panel J1114 Control panel CPU PCB J1112 J1113 J1110,J1111 J1119 Control panel inverter PCB J1116,J1117 Color LCD Keypad PCB Control panel F-12-1 12.1.2 LCD Processing 0000-5111 The CPU on the main controller PCB sends data (display information) to the control panel CPU PCB as instructed by various programs. The data is moved through the control panel CPU PCB to reach the color LCD. 12.1.3 LCD Contras Adjustment 0000-5112 The machine is equipped with a dial on its control panel designed for use by the user for adjustment of the LCD contrast. 12-1 Chapter 12 12.1.4 Functions of the Control Panel CPU 0000-5113 - Monitoring key inputs (relays the inputs made by keypad keys and function keys to the CPU on the main controller PCB) - Controlling the buzzer sound - Turning on/off thecontrolpanel LEDs 12-2 Chapter 12 12.2 Counters 12.2.1 Outline 0000-5114 The machine is equipped with counters that keep track of the number of prints made according to the type of print; a specific counter reading is shown in response to a press on the Check key on the control panel.The particulars of the counter settings made at time of shipment from factory and grouped by model are as follows: T-12-1 Model Counter 1 Counter 2 Counter 3 Counter 4 Counter 5 Counter 6 100V Total 1 Total Copy Print (disabled at (disabled at (full color + (full color + default) default) mono color/1) mono color/1) May be May be changed changed in service in service mode mode (*1) (B&W 1) 101 120V Total 1 (*2) 108 232 324 0 0 Total Copy + print Copy + print Total (disabled at (B&W 1) (full color/ (full color/ (mono default) large) small) color/1) May be changed in service mode 120V 101 108 401 402 118 0 Total 1 Total Copy Copy Print Print (B&W 1) (full color + (full color (full color + (full color mono color/ +mono color/ mono color/ +mono color/ large) small) large) small) (*3) 230V 101 108 229 230 321 322 Total 1 Total Copy + print Copy + print Total Total (duplex) (B&W 1) (full color/ (full color/ (mono large) small) color/1) 401 402 118 (*4) 101 108 114 12-3 Chapter 12 Model Counter 1 240V Total 1 (*5) Counter 2 Counter 3 Counter 4 Counter 5 Counter 6 scan (total 1) total (full total (full color total (black- total (black- color + + mono color; and-white; and-white; mono small) large) small) color; large) 240V 101 122 123 112 113 501 Total 1 Total Copy Copy Print Print (B&W 1) (full color + (full color (full color + (full color mono color/ +mono color/ mono color/ +mono color/ large) small) large) small) (*6) 230V 101 108 229 230 321 322 Total 1 total (full total (full color total (black- total (black- scan (total 1) color + + mono color; and-white; and-white; mono small) large) small) 122 123 112 113 501 scan (total 1) (*7) color; large) 101 230V Total 1 (*8) total (full total (full color total (black- total (black- color + + mono color; and-white; and-white; mono small) large) small) 122 123 112 113 501 scan (total 1) color; large) 101 230V Total 1 (*9) total (full total (full color total (black- total (black- color + + mono color; and-white; and-white; mono large) large) small) 122 123 112 113 501 scan (total 1) color; large) 101 230V Total 1 (*10) total (full total (full color total (black- total (back- color + + mono color; and-white; and-white; mono large) large) small) 123 112 113 color; large) 101 12-4 122 501 Chapter 12 T-12-2 Guide to Notation: large: large-size paper (in excess of 364 mm in feed length; increment by 1) small: small-size paper (364 mm or less in feed direction) total: all copies (C + P); increment by 1 duplex: auto duplex copy; increment by 1 3 digits in Counter column: settings in following: COPIER>OPTION>USER>COUNTER1 through 6 (for details, see description in Service Mode) These counters may be set in service mode to serve for different counter readings. (In the case of the 120/230V model, all counters may be assigned different counter readings.) T-12-3 Medium Order (printer unit) *1: F14-2412/2413/2416/2417/2512/2514/2516/2518 *2: F14-2501 *3: F14-2531/ 2532 *4: F14-2541/2560/2570 *5: F14-2551 *6: F14-2561 *8: F14-2581 *9: F14-2591 *10: F14-2521 *7: F14-2571 12.2.2 Signal-Sided Print and 2nd Side of a Double-Sided Print 0000-5116 When making a single-side print or printing on the 2nd side of a double-side print, the counter reading is incremented when the trailing edge of paper leaves the machine, as indicated by the output of the following sensor: T-12-4 Condition Sensor Finisher absent face-down delivery (center tray): center delivery tray full sensor (PS8) face-down delivery (copy tray): face-down delivery sensor 2 (PS6) face-up delivery (side tray): fixing delivery sensor (PS25) Finisher present finisher delivery sensor 12.2.3 Side of a Duplex Print (duplex model only) 0000-5117 The machine identifies the end of printing on the 1st side of a double-sided print and increments the counter reading when the duplex pickup sensor (PS24) goes ON. 12-5 Chapter 12 12.3 Fans 12.3.1 Outline 0000-5118 The names and functions of the fans used inside the machine are as follows: T-12-5 Notation Name Description FM3 machine cooling fan cools the drum cartridge and the developing motor FM2 fixing heat exhaust fan discharges the heat generated by the fixing assembly to the outside of the machine FM1 power supply cooling fan cools the power supply FM4 cleaner cooling fan cools the cleaner FM5 delivery cooling fan cools the delivery assembly FM6 manual feed cooling fan cools the pre-registration motor (duplex model only) FM7 controller fan FM7 cools the controller FM6 FM3 FM2 FM8 FM4 FM1 F-12-2 12-6 Chapter 12 12.3.2 Sequence of Operations (fan) 0000-5119 The following is the sequence of operations used by the machine to drive the fans: When the control panel power switch is pressed to start sleep mode, the control panel LCD goes OFF. If the reading of the environment sensor is 30 deg C or higher at this timing, the machine rotates the fixing heat discharge fan, power supply cooling fan, and cleaner cooling fan for 30 min continuously and, thereafter, moves into sleep mode. Main power switch ON Warm-up Control panel power switch OFF Print request signal Standby Printing Standby Main power switch OFF Low-power mode Power-save mode Sleep mode Power supply cooling fan (FM3) Fixing heat exhaust fan (FM2) Cleaner cooling fan (FM4) Delivery cooling fan (FM5) Machine cooling fan (FM1) Manual feed cooling fan (FM6) Controller fan (FM7) Delivery vertical path fan (FM8)* *: FM8 rotates in case either thick paper (210 to 253 g/m2) or glossy paper is fed to face-down delivery. : half speed. : full speed. F-12-3 12-7 Chapter 12 12.4 Power Supply 12.4.1 Power Supply 12.4.1.1 Timing of Power Supply 0005-9431 The reader unit is supplied with 24 VDC by the printer unit at the following timing of operation: Standby Sleep mode Main power switch turned ON Power plug connected to outlet Power save mode PSTBY DC 24V F-12-4 12.4.1.2 Wiring to Various Accessories 0006-0745 The power supply of the printer unit and the various accessories are wired as follows: The anti-condensation heater inside the reader unit and the power supply cable are as shown. The machine's power supply uses no more than 2 lines to connect to any external power outlet. T-12-6 12-8 Pedestal Target of reader heater power supply cable Absent External outlet Present Pedestal outlet Chapter 12 For heater (If a pedestal is installed, connect it to its outlet.) DADF-K1 Inlet Reader C1 FinisherM1/N1/N2 PS Print Server Unit-C1 Side Paper Deck-P1 Cable for deck heater Printer Inlet Outlet1 Outlet2 Outlet3 Inlet Pedestal If a pedestal is installed, connect the pedestal power cable to its outlet 2. F-12-5 12.4.1.3 Route of Power Supply 0005-9433 The machine uses the I/F PCB to produce the following types of DC voltage from the 24 VDC supplied by the printer unit: - 5 VDC (for sensors) - 3.3 VDC (for ICs) - 2.5 VDC (for ICs) - 15 VDC (for scanner motor drive) - 24 VDC (for scanner motor drive) The reader controller PCB produces the following type of DC voltage: - 12 VDC (for CCD unit) 12-9 Chapter 12 Interface PCB 5 VDC generation 3.3 VDC generation 2.5 VDC generation 15 VDC generation To DF 24 VDC generation 24 VDC 15 VDC 24 VDC 12 VDC generation Reader controller PCB 5 VDC 12 VDC J3 06 05 J3 01 J3 J3 09 11 J3 24 VDC From printer unit 04 J2 J2 01 100/230 VAC 06 J2 24 VDC J6 01 100/230 VAC Fuse PCB 24 VDC 15 VDC 5 VDC 3.3 VDC Inverter PCB F-12-6 12.4.1.4 Power Supply Route lnside the Printer Unit 0006-1651 The machine's DC power supply is fed with power by the 2 DC power supply PCB (DCP1, DCP2) and the DC power supply PCB (for accessories) built inside the pedestal (plain, cassette pedestal). DC Power Supply PCB - generates DC power from AC power - protects against current/voltage - supplies DC power to loads DC Power Supply PCB for Accessories (inside pedestal) - generates DC power from AC power - protects against overcurrent/voltage - supplies DC power to accessories (paper deck, finisher) 12-10 Chapter 12 Power supply unit Leakage breaker Heater control PCB Main power switch 3.3V 3.3VAN 12VAN DCP1 PCB 24V 5V 12V 3.3V DCP2 PCB 3.3VAN 12VAN 5V 3.3V 12V 24V Fuse PCB Power distribution PCB Main controller PCB (main) 5V 3.3V 3.3VAN Main controller PCB (sub) 12V 5V HDD 24V 24V 5V 12V 3.3V DC controller PCB 24V Reader 24V Intermediate transfer motor 5V PDL board 5V 5V Control panel unit Coin manager or Card reader Laser scanner motor (Y,M,C,K) Laser driver PCB (Y,M,C,K) Scanner unit 24V 5V 3.3V 3.3VAN 5V 5VAN 24VATR Drum drive unit (Y,M,C,K) Duplex driver PCB HVI(Y,M,C,K) FAX board (option) HVI-SUB HV2 24V HV2-SUB HV4(YM/CK) HV3 High-voltage unit VAN: All Night Voltage 24V,5V Cassette feeder unit 1/2 F-12-7 12.4.2 Rated Output of DC Power Supply PCB 12.4.2.1 Rated Output of the Machine Power Suppy 0006-0760 The rated output and the power supply tolerance of the DC power supply PCB (DCP1 PCB, DCP2 PCB) of the printer unit are as follows: T-12-7 Output Tolerance 3.3 V 3.3 VAN -4%/ -4%/+5% +5% 5V 5 VAN 12 V 12 VAN 24 V -5%/ -5%/ -8%/ -9%/ -9%/ +5% +5% +10% +10% +10% 12-11 Chapter 12 12.4.3 Protection Function 12.4.3.1 Protective Mechanisms 0006-0766 The machine's power supply PCB and the power supply PCBs of its accessories are equipped with an overcurrent/ voltage protective mechanisms that prevent damage to the power supply circuit by automatically cutting off the output voltage in the event of an overcurrent/voltage caused, for example, by a short-circuit in any of its loads. If the protective function has gone ON, turn off the power switch of the printer unit, disconnect the power plug of the printer unit or the accessories power supply circuit, and remove the cause of activation; then, leave the machine alone for about 3 min, and turn it on to reset. 12.4.4 Backup Battery 12.4.4.1 Backup Power Supply 0006-0767 The SRAM PCB and the DC controller PCB of the machine's main controller PCB are each equipped with a lithium battery for backup in the event of a power outage or disconnection of the power plug. T-12-8 SRAM PCB manganese dioxide/lithium battery (3 V, 1000 mAh) DC controller PCB lithium battery (3 V, 560 mAh) T-12-9 Battery life 10 yr or more (for both; with power plug disconnected) Battery replacement not possible (on its own, in the field) After replacement of battery in input of values indicated on service label workshop The lithium battery must be replaced only with the one indicated in the Parts Catalog; otherwise, it may trigger a fire or explosion. Do not charge, disassemble, or incinerate the lithium battery; mishandling can lead to a fire or a chemical explosion. Keep the lithium battery out of reach of children. Be sure to dispose of a used battery strictly in accordance with all applicable regulations. 12-12 Chapter 12 12.4.5 Energy-Saving Function 12.4.5.1 Outline 0006-0772 1. Standby Mode In standby mode, the machine is in operation or is ready to operate, with all its parts supplied with power. 2. Power-Save Mode The term "power-save mode" is used generically to refer to the following modes, in which the machine is supplied with power differently than it is in normal mode: power-save, low-power, sleep. A shift in the direction of 'resent power-save mode' to 'low-power mode' and then to 'sleep' mode occurs automatically. - Power-Save Mode T-12-10 Shift: A shift to power-save mode is initiated only in response to a press on the Save Power button on the control panel. Description: The power used by the machine is reduced according to the settings made in user mode (immediate recovery, -10%, -25%, -50%; the fixing unit is controlled to 190 deg C). - Low-Power Mode (factory setting) This mode conforms to the standards under Energy Star. T-12-11 Shift: A shift is made only in response to the passage of time (auto low-power shift time) selected in user mode. Description: The power used by the machine is reduced to enable the machine to remain in a state that satisfies the standards under Energy Star.The power supplied to the reader unit will remain ON except the +24V power, which the reader unit uses to generate internal power. (All operations remain at rest.) The printer unit keeps the temperature of the fixing unit to a specific level (190 deg C) which is lower than when the machine is in normal operating mode. - Sleep Mode (sleep mode 1 or sleep mode 2) T-12-12 Shift: A shift is made in response to the passage of time (auto sleep shift time) specified in user mode or in response to a press on the control panel software power switch. 12-13 Chapter 12 Description: In sleep mode 1 (relatively higher power consumption), the fixing assembly is totally deprived of power. The DC controller PCB, however, remains supplied with power. In sleep mode 2 (relatively lower power consumption), on the other hand, the printer unit (including the fixing assembly) remains OFF; the main controller PCB is supplied with all-night power as indicated in the table: T-12-13 Controller FAX +3.3 VAN CPU, main memory +12 VAN controller cooling fan +5 VAN fax arrival detection 3. AC OFF Mode AC OFF mode occurs when the main power switch is turned off, i.e., all parts of the machine is deprived of power. The supply of power to the various systems of the machine in each of the foregoing modes is as follows: T-12-14 Main Non-all controller night power Standby Power- Low- Sleep Sleep AC mode save power mode 1 mode 2 OFF mode mode mode +12V ON ON ON ON OFF OFF +5V ON ON ON ON OFF OFF +3.3V ON ON ON ON OFF OFF +3.3VAN ON ON ON ON ON OFF +12VAN ON ON ON ON ON OFF Reader unit +24V ON OFF OFF OFF OFF OFF Printer unit +24V ON ON ON ON OFF OFF +12V ON ON ON ON OFF OFF +5V ON ON ON ON OFF OFF +3.3V ON ON ON ON OFF OFF +5V ON ON ON ON OFF OFF +3.3V ON ON ON ON OFF OFF +5VAN ON ON ON ON ON OFF All-night power FAX Non-all night power All-night power 12-14 Chapter 12 12.5 Parts Procedure Replacement 12.5.1.5 Removing the DC Controller PCB Cover 0000-5130 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 12.5.1 Fixing Drive Unit 12.5.1.1 Removing the Upper Rear Cover 0000-5127 1) Remove the upper rear cover. 12.5.1.2 Removing the Lower Rear Cover 0000-5128 1) Remove the lower rear cover. 12.5.1.3 Removing the Left Upper Rear Cover 0000-5131 F-12-9 1) Removing the left rear upper cover. 12.5.1.4 Removing the Controller Box Cover 0000-5129 When Attaching the DC Controller PCB Cover 1) Disconnect the connector J1512 [1] from the power When attaching the cover, take care so that the cut-off distribution PCB, and free the harness from the will not come into contact with the latch of the flat wire saddle [2]; then, remove the 6 screws [3], and cable. Otherwise, the flat cable can come loose. detach the main controller cover [4]. [1] F-12-10 12.5.1.6 Opening the Main Controller Box 0000-5132 1) Remove the 2 flat cables [1] used to connect the DC F-12-8 controller PCB and the main controller PCB. 12-15 Chapter 12 F-12-11 F-12-14 2) Remove the 9 screws [1] of the main controller box. 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. F-12-12 F-12-15 12.5.1.7 Removing the Fixing Heat Discharge Fan 0000-5133 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-12-13 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12-16 Chapter 12 F-12-16 F-12-18 12.5.1.8 Removing the HighVoltage Unit 12.5.1.9 Removing the Left 0000-5134 1) Disconnect all connectors of the high-voltage unit; Lower Rear cover 0000-5135 1) Removing the left lower rear cover. then, remove the 5 screws [1], and detach the highvoltage unit [2]. 12.5.1.10 Removing Secondary Transfer the High- Voltage Unit 0000-5136 1) Free the DC harness [1] from the edge saddle [2]; then, disconnect the 3 connectors [3], and remove the 2 screws [4]. F-12-17 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. F-12-19 2) Remove the mounting screw [1] of the high-voltage cable, and free the high-voltage cable [2] from the cable clamp [3]; then, detach it from the edge saddle [4] of the high-voltage unit base. 12-17 Chapter 12 F-12-20 3) Pull the secondary transfer high-voltage unit [1] slightly to the front, and free the high-voltage cable [3] from the cable clamp [2]. F-12-22 12.5.1.11 Removing the Fixing Drive Unit 0000-5137 1) Slide out the fixing feeder assembly. Disconnect the connector [1], and remove the 3 screws [2]; then, detach the fixing drive unit [3]. F-12-21 4) Remove the secondary transfer high-voltage unit together with the delivery cooling fan. 5) Remove the screw [1], and disconnect the connector [2]; then, detach the secondary transfer F-12-23 high-voltage unit [3]. 12.5.2 Developing Drive Unit 12.5.2.1 Removing the Upper Rear Cover 1) Remove the upper rear cover. 12-18 0000-5146 Chapter 12 12.5.2.2 Removing the Lower Rear Cover 0000-5147 1) Remove the lower rear cover. 12.5.2.3 Removing the Left Upper Rear Cover 0000-5150 1) Removing the left rear upper cover. 12.5.2.4 Removing the Controller Box Cover 0000-5148 1) Disconnect the connector J1512 [1] from the power F-12-25 distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-12-26 F-12-24 12.5.2.5 Removing the DC Controller PCB Cover 0000-5149 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 12.5.2.6 Opening the Main Controller Box 0000-5151 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 12-19 Chapter 12 F-12-27 F-12-30 2) Remove the 9 screws [1] of the main controller box. 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. F-12-28 F-12-31 12.5.2.7 Removing the DC Controller Mounting 0000-5152 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-12-29 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12-20 Chapter 12 F-12-32 F-12-34 12.5.2.8 Removing the Fixing Heat Discharge Fan 0000-5153 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge 2) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the heat exhaust fan unit [3]. fan [3]. F-12-35 F-12-33 12.5.2.9 Removing 12.5.2.10 the Machine Heat Discharge Fan Removing Developing Drive Unit 0000-5154 1) Remove the screw [1], and detach the fan duct [2]. the 0000-5155 1) Disconnect the connector [2] of the developing motor [1], and free the harness [3] from the cable clamp [4]. 12-21 Chapter 12 12.5.3 High-Voltage Unit 12.5.3.1 Removing the Upper Rear Cover 0000-5138 1) Remove the upper rear cover. 12.5.3.2 Removing the Lower Rear Cover 0000-5139 1) Remove the lower rear cover. F-12-36 12.5.3.3 Removing the HighVoltage Unit 2) Remove the 2 screws [1], and detach the main controller base [2]. 0000-5140 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-12-37 3) Remove the 7 screws [1], and detach the F-12-39 developing drive assembly [2]. 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. F-12-38 12-22 Chapter 12 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. F-12-40 12.5.4 Secondary Transfer HighVoltage Unit F-12-42 12.5.4.4 Removing the Left Lower Rear cover 12.5.4.1 Removing the Upper Rear Cover 0000-5144 1) Removing the left lower rear cover. 0000-5141 1) Remove the upper rear cover. 12.5.4.5 the Transfer High- Secondary 12.5.4.2 Removing the Lower Rear Cover Removing Voltage Unit 0000-5142 1) Remove the lower rear cover. 0000-5145 1) Free the DC harness [1] from the edge saddle [2]; then, disconnect the 3 connectors [3], and remove the 2 screws [4]. 12.5.4.3 Removing the HighVoltage Unit 0000-5143 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-12-43 F-12-41 12-23 Chapter 12 2) Remove the mounting screw [1] of the high-voltage cable, and free the high-voltage cable [2] from the cable clamp [3]; then, detach it from the edge saddle [4] of the high-voltage unit base. F-12-46 12.5.5 DC Power Supply Unit F-12-44 12.5.5.1 Removing the Upper 3) Pull the secondary transfer high-voltage unit [1] slightly to the front, and free the high-voltage cable [3] from the cable clamp [2]. Rear Cover 0000-5168 1) Remove the upper rear cover. 12.5.5.2 Removing the Lower Rear Cover 0000-5169 1) Remove the lower rear cover. 12.5.5.3 Removing the DC Power Supply Unit 0000-5170 1) Remove the 2 screws [1], and disconnect all connectors of the fuse PCB; then, detach the DC F-12-45 power supply unit [2]. 4) Remove the secondary transfer high-voltage unit together with the delivery cooling fan. 5) Remove the screw [1], and disconnect the connector [2]; then, detach the secondary transfer high-voltage unit [3]. F-12-47 12-24 Chapter 12 12.5.6 Control Panel control panel [2]. 12.5.6.1 Removing the Upper Left Cover (small) 0000-5171 1) Remove the upper left cover (small). 12.5.6.2 Removing the Inside Cover 0000-5172 1) Open the front cover and the drum unit cover. 2) Remove the 5 screws [1], and detach the inside F-12-50 cover [2]. 12.5.7 Control Panel LCD Unit 12.5.7.1 Removing the Upper Left Cover (small) 0000-5187 1) Remove the upper left cover (small). 12.5.7.2 Removing the Inside Cover 0000-5188 1) Open the front cover and the drum unit cover. 2) Remove the 5 screws [1], and detach the inside F-12-48 cover [2]. 12.5.6.3 Removing the Control Panel 0000-5173 1) Remove the 4 screws [1], and detach the control panel [2] toward the front. F-12-51 12.5.7.3 Removing the Control F-12-49 Panel 0000-5189 1) Remove the 4 screws [1], and detach the control 2) Disconnect the connector [1], and detach the panel [2] toward the front. 12-25 Chapter 12 F-12-52 F-12-54 2) Disconnect the connector [1], and detach the 12.5.7.5 Removing the Control control panel [2]. Panel LCD Unit 0000-5191 1) Remove the 3 screws [1], and detach the control panel LCD unit [2]. F-12-53 12.5.7.4 Removing the Control Panel Back Plate 0000-5190 1) Disconnect the 3 connectors [1] from the CPU F-12-55 PCB, remove the 2 flat cables [2], disconnect the 2 connectors [3] from the inverter PCB, remove the binding screw [4], and remove the 8 self-tapping 12.5.8 DC Controller PCB screws [5]; then, detach the control panel back plate [6]. 12.5.8.1 Removing the Upper Rear Cover 0000-5279 1) Remove the upper rear cover. 12.5.8.2 Removing the Lower Rear Cover 1) Remove the lower rear cover. 12-26 0000-5280 Chapter 12 12.5.8.3 Removing the Controller Box Cover 0000-5281 1) Disconnect the connector J1512 [1] from the power When Attaching the DC Controller PCB Cover distribution PCB, and free the harness from the When attaching the cover, take care so that the cut-off wire saddle [2]; then, remove the 6 screws [3], and will not come into contact with the latch of the flat detach the main controller cover [4]. cable. Otherwise, the flat cable can come loose. [1] F-12-58 12.5.8.5 Removing the DC Controller PCB F-12-56 0000-5283 1) Disconnect all connectors of the PCB, and remove the 2 flat cables [1] and the 10 screws [2]; then, 12.5.8.4 Removing the DC Controller PCB Cover detach the DC controller PCB [3]. 0000-5282 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-12-59 F-12-57 12-27 Chapter 12 12.5.8.6 When Replacing the DC Controller PCB 12.5.9.3 Removing the Left 0000-5284 1) After replacing the DC controller PCB, use the Upper Rear Cover 0000-5319 1) Removing the left rear upper cover. following service mode to initialize the memory of 12.5.9.4 the DC controller PCB: COPIER>FUNCTION>CLEAR>DC-CON 2) Enter the settings indicated on the service label using the following service mode: COPIER>ADJUST>LASER>PVE-OFST Use it to enter an adjustment value for the laser beam position. Removing the Controller Box Cover 0000-5317 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. COPIER>ADJUST>FEED-ADJ>REGIST Use it to adjust the timing at which the registration roller clutch goes ON. COPIER>ADJUST>FEED-ADJ>ADJ-REFE Use it to adjust the horizontal registration for repickup. COPIER>ADJUST>CST-ADJ>MF-A4R Use it to adjust the paper width basic value for the manual feed tray. COPIER>ADJUST>CST-ADJ>MF-A6R Use it to adjust the paper width basic value for the manual feed tray. COPIER>ADJUST>CST-ADJ>MF-A4 Use it to adjust the paper width basic value for the manual feed tray. 3) Turn off and then on the main power switch. 4) Make the following selections in service mode: F-12-60 COPIER>FUNCTION>LASER>L-ADJ-0. 5) Press the OK key. (The machine starts auto adjustment and will indicate 'END' at its end.) 12.5.9.5 Removing the DC Controller PCB Cover 0000-5318 1) Remove the 8 screws [1], and detach the DC 12.5.9 Counter Memory PCB controller PCB cover [2]. 12.5.9.1 Removing the Upper Rear Cover 0000-5315 1) Remove the upper rear cover. 12.5.9.2 Removing the Lower Rear Cover 1) Remove the lower rear cover. 12-28 0000-5316 Chapter 12 F-12-63 F-12-61 2) Remove the 9 screws [1] of the main controller box. When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-12-64 F-12-62 12.5.9.6 Opening the Main Controller Box 0000-5320 1) Remove the 2 flat cables [1] used to connect the DC F-12-65 controller PCB and the main controller PCB. 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12-29 Chapter 12 F-12-66 F-12-68 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, 12.5.10 Fuse PCB and open it. 12.5.10.1 Removing the Upper Rear Cover 0000-5322 1) Remove the upper rear cover. 12.5.10.2 Removing the Lower Rear Cover 0000-5323 1) Remove the lower rear cover. 12.5.10.3 Removing the DC Power Supply Unit F-12-67 1) Remove the 2 screws [1], and disconnect all connectors of the fuse PCB; then, detach the DC 12.5.9.7 Removing the Counter Memory PCB power supply unit [2]. 0000-5321 1) Disconnect the connector [1], and remove the 2 screws [2]; then, detach the counter memory PCB [3]. F-12-69 12-30 0000-5324 Chapter 12 12.5.10.4 Removing the Fuse PCB 0000-5325 1) Disconnect the 2 connectors [1], and free the 5 card spacers [2]; then, detach the fuse PCB [3]. F-12-71 12.5.11.4 Removing the Power Supply Cooling Fan Mounting F-12-70 0000-5301 1) Remove the 5 screws [1], and remove the power supply cooling fan mointing plate[2]; then, detach 12.5.11 Leakage Breaker the connector [3]. 12.5.11.1 Removing the Upper Rear Cover 0000-5298 1) Remove the upper rear cover. 12.5.11.2 Removing the Lower Rear Cover 0000-5299 1) Remove the lower rear cover. 12.5.11.3 Removing the DC Power Supply Unit F-12-72 0000-5300 1) Remove the 2 screws [1], and disconnect all connectors of the fuse PCB; then, detach the DC power supply unit [2]. 12.5.11.5 Removing Leakage Breaker the 0000-5302 1) Remove the 5 screws [1], and disconnect the connectors from the fuse PCB; then, detach the power supply PCB base [2]. 12-31 Chapter 12 F-12-76 F-12-73 2) Remove the 2 screws [1], and detach the protective 12.5.12 Duplex Driver PCB plate [1]. 12.5.12.1 Removing the Upper Rear Cover 0000-5311 1) Remove the upper rear cover. 12.5.12.2 Removing the Lower Rear Cover 0000-5312 1) Remove the lower rear cover. 12.5.12.3 Removing the Lattice F-12-74 Connector Mounting 0000-5313 1) Remove the 2 screws [1], and disconnect all 3) Remove the 4 terminals [1] and the 2 screws [2]; then, detach the leakage breaker [3]. connectors; then, detach the lattice connector Mounting [2]. F-12-75 F-12-77 12-32 Chapter 12 12.5.12.4 Removing the Duplex Driver PCB 0000-5314 1) Remove the 4 screws [1], and detach the duplex driver PCB [2]. F-12-79 F-12-78 12.5.13.5 Removing the DC 12.5.13 Relay PCB 1 Controller PCB Cover 0000-5306 1) Remove the 8 screws [1], and detach the DC 12.5.13.1 Removing the Upper Rear Cover controller PCB cover [2]. 0000-5303 1) Remove the upper rear cover. 12.5.13.2 Removing the Lower Rear Cover 0000-5304 1) Remove the lower rear cover. 12.5.13.3 Removing the Left Upper Rear Cover 0000-5307 1) Removing the left rear upper cover. 12.5.13.4 Removing F-12-80 the Controller Box Cover 0000-5305 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and When Attaching the DC Controller PCB Cover detach the main controller cover [4]. When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. 12-33 Chapter 12 [1] F-12-81 F-12-84 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12.5.13.6 Opening the Main Controller Box 0000-5308 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-12-85 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, F-12-82 and open it. 2) Remove the 9 screws [1] of the main controller box. F-12-86 F-12-83 12-34 Chapter 12 12.5.13.7 Removing the DC Controller Mounting 12.5.14.2 Removing the Inside 0000-5309 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB Cover 0000-5180 1) Open the front cover and the drum unit cover. 2) Remove the 5 screws [1], and detach the inside cover [2]. [2] together with its base. F-12-89 F-12-87 12.5.14.3 12.5.13.8 Removing the Relay PCB 1 Removing Control Panel 0000-5310 1) Disconnect the 9 connectors [1] and the 8 screws the 0000-5181 1) Remove the 4 screws [1], and detach the control panel [2] toward the front. [2] from the PCB; then, detach the relay PCB 1 [3]. F-12-88 F-12-90 12.5.14 Control Panel CPU PCB 2) Disconnect the connector [1], and detach the control panel [2]. 12.5.14.1 Removing the Upper Left Cover (small) 0000-5179 1) Remove the upper left cover (small). 12-35 Chapter 12 12.5.15.2 Removing the Inside Cover 0000-5175 1) Open the front cover and the drum unit cover. 2) Remove the 5 screws [1], and detach the inside cover [2]. F-12-91 12.5.14.4 Removing the Control Panel CPU PCB 0000-5182 1) Disconnect the 3 connectors [1], and remove the 2 flat cables [2]; then, detach the control panel CPU PCB [4]. F-12-93 12.5.15.3 Removing Control Panel the 0000-5176 1) Remove the 4 screws [1], and detach the control panel [2] toward the front. F-12-92 F-12-94 12.5.15 Control Panel Key Switch 2) Disconnect the connector [1], and detach the PCB control panel [2]. 12.5.15.1 Removing the Upper Left Cover (small) 1) Remove the upper left cover (small). 12-36 0000-5174 Chapter 12 F-12-95 F-12-97 12.5.15.4 Removing the Control Panel Back Plate 0000-5177 12.5.16 Control Panel Inverter PCB 1) Disconnect the 3 connectors [1] from the CPU PCB, remove the 2 flat cables [2], disconnect the 2 connectors [3] from the inverter PCB, remove the binding screw [4], and remove the 8 self-tapping screws [5]; then, detach the control panel back plate [6]. 12.5.16.1 Removing the Upper Left Cover (small) 0000-5183 1) Remove the upper left cover (small). 12.5.16.2 Removing the Inside Cover 0000-5184 1) Open the front cover and the drum unit cover. 2) Remove the 5 screws [1], and detach the inside cover [2]. F-12-96 12.5.15.5 Removing Control Panel Key PCB the 0000-5178 1) Remove the 7 screws [1], and detach the control panel key PCB [2]. F-12-98 12.5.16.3 Removing Control Panel the 0000-5185 1) Remove the 4 screws [1], and detach the control panel [2] toward the front. 12-37 Chapter 12 F-12-99 F-12-101 2) Disconnect the connector [1], and detach the 12.5.16.5 control panel [2]. Removing the Control Panel Inverter PCB 0000-5186 1) Disconnect the 3 connectors [1], and remove the 4 screws [2]; then, detach the control panel inverter PCB [3]. F-12-100 12.5.16.4 Removing Control Panel Back Plate the 0006-2163 1) Disconnect the 3 connectors [1] from the CPU PCB, remove the 2 flat cables [2], disconnect the 2 connectors [3] from the inverter PCB, remove the binding screw [4], and remove the 8 self-tapping screws [5]; then, detach the control panel back plate F-12-102 [6]. 12.5.17 Environment Sensor 12.5.17.1 Pressure Release of the Intermediate Transfer Unit 0006-2169 1) Open the front cover, and turn the intermediate transfer unit releasing lever to unlock it. 12-38 Chapter 12 12.5.17.3 2) Slide out the manual feed unit. 3) Remove the screw [1], and detach the middle right cover [2]. Removing the Environment Sensor 0000-5344 1) Insert a screwdriver through the hole in the upper right stay of the machine, and remove the screw [1]; then, detach the environment sensor mounting plate [2]. F-12-103 4) Release the escape lever [1]. F-12-106 2) Disconnect the connector [1], and free the claw [2] of the sensor base; then, detach the environment sensor [3]. F-12-104 12.5.17.2 Removing the Upper Right Cover 0000-5343 1) Remove the 4 screws [1], and detach the upper right F-12-107 cover [2]. 12.5.18 Manual Feed Unit Open/ Closed Sensor 12.5.18.1 Removing the Upper Rear Cover 0000-5227 1) Remove the upper rear cover. F-12-105 12-39 Chapter 12 12.5.18.2 Removing the Lower Rear Cover 0000-5228 1) Remove the lower rear cover. 12.5.18.3 Removing the Left Upper Rear Cover 0000-5231 1) Removing the left rear upper cover. 12.5.18.4 Removing the Controller Box Cover 0000-5229 1) Disconnect the connector J1512 [1] from the power F-12-109 distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-12-110 F-12-108 12.5.18.5 Removing the DC Controller PCB Cover 0000-5230 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 12.5.18.6 Opening the Main Controller Box 0000-5232 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 12-40 Chapter 12 F-12-111 F-12-114 2) Remove the 9 screws [1] of the main controller box. 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. F-12-112 F-12-115 12.5.18.7 Removing the DC Controller Mounting 0000-5233 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-12-113 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12-41 Chapter 12 F-12-118 F-12-116 12.5.19 Front Cover Open/Closed 12.5.18.8 Removing Registration Unit the Sensor Open/ Closed Sensor Mounting 0000-5234 12.5.19.1 1) Disconnect the 2 connectors [1], and remove the Tonner screw [2]; then, detach the registration unit open/ closed sensor mounting [3]. Removing Container the release Lever 0006-2360 1) Open the front cover. 2) Remove the 4 screws [1], and the 4 tonner container release levers [2]. F-12-117 12.5.18.9 Removing the Manual Feed Unit Open/ Closed Sensor F-12-119 0000-5235 1) Disconnect the connector [1], and remove the registration unit open/closed sensor [2]. 12.5.19.2 Removing Cleaner Fan Cover the 0000-5216 1) Open the front cover. 2) Remove the screw [1], and detach the cleaner fan cover [2]. 12-42 Chapter 12 12.5.19.6 Removing the Left Upper Rear Cover 0000-5222 1) Removing the left rear upper cover. 12.5.19.7 Removing the DC Controller PCB Cover 0000-5221 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-12-120 12.5.19.3 Removing the Inside Cover 0000-5217 1) Open the front cover and the drum unit cover. 2) Remove the 5 screws [1], and detach the inside cover [2]. F-12-122 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. F-12-121 [1] 12.5.19.4 Removing the Upper Rear Cover 0000-5218 1) Remove the upper rear cover. 12.5.19.5 Removing the Lower Rear Cover 0000-5219 1) Remove the lower rear cover. F-12-123 12-43 Chapter 12 12.5.19.8 Removing the DC Controller Mounting 0000-5224 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-12-126 12.5.20 Main Power Switch 12.5.20.1 Removing the Upper Rear Cover 0000-5192 1) Remove the upper rear cover. F-12-124 12.5.20.2 Removing the Lower 12.5.19.9 Removing the Front Cover Open/Closed Sensor Rear Cover 0000-5226 0000-5193 1) Remove the lower rear cover. 1) Remove the 2 screws [1], and detach the sensor cover [2]. 12.5.20.3 Removing the Left Upper Rear Cover 0000-5196 1) Removing the left rear upper cover. 12.5.20.4 Removing the Controller Box Cover 0000-5194 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-12-125 2) Remove the front cover open closed sensor [1]. 12-44 Chapter 12 [1] F-12-129 12.5.20.6 Opening the Main Controller Box F-12-127 0000-5197 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 12.5.20.5 Removing the DC Controller PCB Cover 0000-5195 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-12-130 2) Remove the 9 screws [1] of the main controller box. F-12-128 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. F-12-131 12-45 Chapter 12 12.5.20.7 Removing the DC Controller Mounting 0000-5198 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-12-132 3) Free the controller box from the hook [A/B] at the top of the main controller box. F-12-135 12.5.20.8 Removing the Fixing Heat Discharge Fan 0000-5199 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge F-12-133 fan [3]. 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. F-12-136 12.5.20.9 Removing the Fixing Drive Unit 0000-5200 1) Slide out the fixing feeder assembly. Disconnect F-12-134 the connector [1], and remove the 3 screws [2]; then, detach the fixing drive unit [3]. 12-46 Chapter 12 F-12-139 F-12-137 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. 12.5.20.10 Removing the Lattice Connector Mounting 0000-5201 1) Remove the 2 screws [1], and disconnect all connectors; then, detach the lattice connector Mounting [2]. F-12-140 12.5.20.12 Removing the Manual Feed Cooling Fan Duct 0000-5203 1) Slide out the manual fee unit; then, disconnect the F-12-138 connector [1] and remove the 2 screws [2] to detach the manual feed cooling fan duct [3]. 12.5.20.11 Removing High-Voltage Unit the 0000-5202 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. 12-47 Chapter 12 12.5.21 Manual Feed Unit Open/ Closed Detecting Switch 12.5.21.1 Removing the Upper Rear Cover 0000-5236 1) Remove the upper rear cover. 12.5.21.2 Removing the Lower Rear Cover F-12-141 0000-5237 1) Remove the lower rear cover. 12.5.20.13 Removing the Main Power Supply Switch 0000-5204 1) Remove the 2 terminals [1]. 12.5.21.3 Removing the Left Upper Rear Cover 0000-5240 1) Removing the left rear upper cover. 12.5.21.4 Removing the Controller Box Cover 0000-5238 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-12-142 2) Pick the stopper segment [A], and detach it. F-12-143 12-48 F-12-144 Chapter 12 12.5.21.5 Removing the DC Controller PCB Cover 0000-5239 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-12-147 2) Remove the 9 screws [1] of the main controller box. F-12-145 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. F-12-148 [1] F-12-146 F-12-149 3) Free the controller box from the hook [A/B] at the 12.5.21.6 Opening the Main Controller Box 0000-5241 top of the main controller box. 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 12-49 Chapter 12 F-12-150 F-12-152 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. 12.5.21.8 Removing Registration Unit the Open/ Closed Sensor Mounting 0000-5243 1) Disconnect the 2 connectors [1], and remove the screw [2]; then, detach the registration unit open/ closed sensor mounting [3]. F-12-151 12.5.21.7 Removing the DC Controller Mounting 0000-5242 F-12-153 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. 12.5.21.9 Removing the Manual Feed Unit Open/ Close Switch 0000-5244 1) Remove the screw [1], and detach the manual feed unit open/close switch [2]. 12-50 Chapter 12 F-12-156 F-12-154 12.5.22 Front Cover Open/Closed Detecting Switch 12.5.22.3 Removing the Inside Cover 0000-5206 1) Open the front cover and the drum unit cover. 2) Remove the 5 screws [1], and detach the inside 12.5.22.1 Tonner Removing Container the cover [2]. release Lever 0006-2374 1) Open the front cover. 2) Remove the 4 screws [1], and the 4 tonner container release levers [2]. F-12-157 12.5.22.4 Removing the Upper Rear Cover 1) Remove the upper rear cover. F-12-155 12.5.22.2 0000-5207 Removing Cleaner Fan Cover 12.5.22.5 Removing the Lower the 0000-5205 1) Open the front cover. Rear Cover 0000-5208 1) Remove the lower rear cover. 2) Remove the screw [1], and detach the cleaner fan cover [2]. 12-51 Chapter 12 12.5.22.6 Removing the Left Upper Rear Cover 12.5.22.8 Removing the DC 0000-5211 1) Removing the left rear upper cover. Controller Mounting 0000-5213 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove 12.5.22.7 Removing the DC Controller PCB Cover the 7 screws [1], and detach the DC controller PCB 0000-5210 [2] together with its base. 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. F-12-160 12.5.22.9 Removing the Front F-12-158 Cover Open/Close Switch 0000-5215 1) Remove the screw [1], and detach the retaining plate [2]; then, push it inside the front side cover. When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-12-161 2) Disconnect the 2 connectors [1], and remove the 2 screws [2]; then, slide out the sensor base [3]. (The sensor flag pushing plate is found running from the F-12-159 12-52 front side plate to the rear side plate.) Chapter 12 F-12-164 F-12-162 12.5.23.2 3) Remove the screw [1], and detach the front cover open/close switch [2]. Removing the Cleaner Fan 0000-5292 1) Disconnect the connector [1], and free the 3 claws; then, detach the cleaner fan [2]. F-12-163 12.5.23 Cleaner Fan 12.5.23.1 Removing Cleaner Fan Cover F-12-165 12.5.24 Manual Feed Cooling Fan the 0000-5291 1) Open the front cover. 2) Remove the screw [1], and detach the cleaner fan cover [2]. 12.5.24.1 Removing the Upper Rear Cover 0000-5245 1) Remove the upper rear cover. 12.5.24.2 Removing the Lower Rear Cover 0000-5246 1) Remove the lower rear cover. 12-53 Chapter 12 12.5.24.3 Removing the Left Upper Rear Cover 0000-5249 1) Removing the left rear upper cover. 12.5.24.4 Removing the Controller Box Cover 0000-5247 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-12-167 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-12-166 12.5.24.5 Removing the DC Controller PCB Cover 0000-5248 F-12-168 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 12.5.24.6 Opening the Main Controller Box 0000-5250 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 12-54 Chapter 12 F-12-169 F-12-172 2) Remove the 9 screws [1] of the main controller box. 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. F-12-170 F-12-173 12.5.24.7 Removing the DC Controller Mounting 0000-5251 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-12-171 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12-55 Chapter 12 F-12-174 F-12-176 12.5.24.8 Removing the Fixing Heat Discharge Fan 2) Remove the 2 screws [1], and detach the main 0000-5252 controller base [2]. 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-12-177 3) Remove the 7 screws [1], and detach the developing drive assembly [2]. F-12-175 12.5.24.9 Removing Developing Drive Unit the 0000-5253 1) Disconnect the connector [2] of the developing motor [1], and free the harness [3] from the cable clamp [4]. F-12-178 12-56 Chapter 12 12.5.24.10 Removing the Lattice Connector Mounting 0000-5254 1) Remove the 2 screws [1], and disconnect all connectors; then, detach the lattice connector Mounting [2]. F-12-181 12.5.24.12 Removing the Manual Feed Cooling Fan Duct 0000-5256 1) Slide out the manual fee unit; then, disconnect the connector [1] and remove the 2 screws [2] to detach F-12-179 the manual feed cooling fan duct [3]. 12.5.24.11 Removing High-Voltage Unit the 0000-5255 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-12-182 12.5.24.13 Removing Manual Feed Cooling Fan the 0000-5257 1) Remove the 2 screws [1], and detach the manual feed cooling fan [2]. F-12-180 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. 12-57 Chapter 12 F-12-183 12.5.25 Fixing Heat Discharge Fan 12.5.25.1 Removing the Upper Rear Cover 0000-5258 1) Remove the upper rear cover. F-12-184 12.5.25.5 Removing the DC Controller PCB Cover 12.5.25.2 Removing the Lower Rear Cover 0000-5259 0000-5261 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 1) Remove the lower rear cover. 12.5.25.3 Removing the Left Upper Rear Cover 0000-5262 1) Removing the left rear upper cover. 12.5.25.4 Removing the Controller Box Cover 0000-5260 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-12-185 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. 12-58 Chapter 12 [1] F-12-186 F-12-189 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12.5.25.6 Opening the Main Controller Box 0000-5263 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. F-12-190 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, F-12-187 and open it. 2) Remove the 9 screws [1] of the main controller box. F-12-191 F-12-188 12-59 Chapter 12 12.5.25.7 Removing the Fixing Heat Discharge Fan 0000-5264 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-12-193 12.5.26.4 Removing the Power Supply Cooling Fan Mounting 0000-5296 1) Remove the 5 screws [1], and remove the power F-12-192 supply cooling fan mointing plate[2]; then, detach 12.5.26 Power Supply Cooing Fan the connector [3]. 12.5.26.1 Removing the Upper Rear Cover 0000-5293 1) Remove the upper rear cover. 12.5.26.2 Removing the Lower Rear Cover 0000-5294 1) Remove the lower rear cover. 12.5.26.3 Removing the DC Power Supply Unit F-12-194 0000-5295 1) Remove the 2 screws [1], and disconnect all connectors of the fuse PCB; then, detach the DC power supply unit [2]. 12.5.26.5 Removing the Power Supply Cooing Fan 1) Remove the 2 screws [1], and detach the power supply cooling fan [2]. 12-60 0000-5297 Chapter 12 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. F-12-195 F-12-197 12.5.27 Delivery Cooling Fan 12.5.27.4 Removing the Left 12.5.27.1 Removing the Upper Rear Cover Lower Rear cover 0000-5285 0000-5288 1) Removing the left lower rear cover. 1) Remove the upper rear cover. 12.5.27.5 12.5.27.2 Removing the Lower Rear Cover Removing Secondary 0000-5286 1) Remove the lower rear cover. Transfer Voltage Unit the High0000-5289 1) Free the DC harness [1] from the edge saddle [2]; then, disconnect the 3 connectors [3], and remove 12.5.27.3 Removing the HighVoltage Unit the 2 screws [4]. 0000-5287 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-12-198 F-12-196 12-61 Chapter 12 2) Remove the mounting screw [1] of the high-voltage cable, and free the high-voltage cable [2] from the cable clamp [3]; then, detach it from the edge saddle [4] of the high-voltage unit base. F-12-201 12.5.27.6 F-12-199 Removing the Delivery Cooling Fan 0000-5290 1) Disconnect the connector [1], and remove the 2 3) Pull the secondary transfer high-voltage unit [1] screws [2]; then, detach the fan [3]. slightly to the front, and free the high-voltage cable [3] from the cable clamp [2]. F-12-202 F-12-200 12.5.28 Machine Heat Discharge Fan 4) Remove the secondary transfer high-voltage unit together with the delivery cooling fan. 5) Remove the screw [1], and disconnect the connector [2]; then, detach the secondary transfer high-voltage unit [3]. 12.5.28.1 Removing the Upper Rear Cover 0000-5272 1) Remove the upper rear cover. 12.5.28.2 Removing the Lower Rear Cover 1) Remove the lower rear cover. 12-62 0000-5273 Chapter 12 12.5.28.3 Removing the Left Upper Rear Cover 0000-5276 1) Removing the left rear upper cover. 12.5.28.4 Removing the Controller Box Cover 0000-5274 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-12-204 When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-12-203 12.5.28.5 Removing the DC Controller PCB Cover 0000-5275 F-12-205 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 12.5.28.6 Opening the Main Controller Box 0000-5277 1) Remove the 2 flat cables [1] used to connect the DC controller PCB and the main controller PCB. 12-63 Chapter 12 F-12-206 F-12-209 2) Remove the 9 screws [1] of the main controller box. 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. F-12-207 F-12-210 12.5.28.7 Removing the Machine Heat Discharge Fan 0000-5278 1) Remove the screw [1], and detach the fan duct [2]. F-12-208 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12-64 Chapter 12 12.5.29.3 Removing the Left Upper Rear Cover 0000-5330 1) Removing the left rear upper cover. 12.5.29.4 Removing the Controller Box Cover 0000-5328 1) Disconnect the connector J1512 [1] from the power distribution PCB, and free the harness from the wire saddle [2]; then, remove the 6 screws [3], and detach the main controller cover [4]. F-12-211 2) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the heat exhaust fan unit [3]. F-12-213 F-12-212 12.5.29.5 Removing the DC 12.5.29 Drum Unit Drive Belt Controller PCB Cover 0000-5329 1) Remove the 8 screws [1], and detach the DC controller PCB cover [2]. 12.5.29.1 Removing the Upper Rear Cover 0000-5326 1) Remove the upper rear cover. 12.5.29.2 Removing the Lower Rear Cover 0000-5327 1) Remove the lower rear cover. 12-65 Chapter 12 F-12-216 F-12-214 2) Remove the 9 screws [1] of the main controller box. When Attaching the DC Controller PCB Cover When attaching the cover, take care so that the cut-off will not come into contact with the latch of the flat cable. Otherwise, the flat cable can come loose. [1] F-12-217 F-12-215 12.5.29.6 Opening the Main Controller Box 0000-5331 1) Remove the 2 flat cables [1] used to connect the DC F-12-218 controller PCB and the main controller PCB. 3) Free the controller box from the hook [A/B] at the top of the main controller box. 12-66 Chapter 12 F-12-219 F-12-221 4) Engage the hook [1] found on the right side of the main controller box on the stay [2] of the machine, and open it. 12.5.29.8 Removing the Fixing Heat Discharge Fan 0000-5333 1) Remove the 2 screws [1], and disconnect the connector [2]; then, detach the fixing heat discharge fan [3]. F-12-220 12.5.29.7 Removing the DC Controller Mounting 1) Disconnect all connectors from the PCB, and free all harnesses from the cable clamps; then, remove the 7 screws [1], and detach the DC controller PCB [2] together with its base. F-12-222 0000-5332 12.5.29.9 Removing Developing Drive Unit the 0000-5334 1) Disconnect the connector [2] of the developing motor [1], and free the harness [3] from the cable clamp [4]. 12-67 Chapter 12 12.5.29.10 Removing the Lattice Connector Mounting 0000-5335 1) Remove the 2 screws [1], and disconnect all connectors; then, detach the lattice connector Mounting [2]. F-12-223 2) Remove the 2 screws [1], and detach the main controller base [2]. F-12-226 12.5.29.11 Removing High-Voltage Unit the 0000-5336 1) Disconnect all connectors of the high-voltage unit; then, remove the 5 screws [1], and detach the highvoltage unit [2]. F-12-224 3) Remove the 7 screws [1], and detach the developing drive assembly [2]. F-12-227 2) Remove the 6 screws [1], and remove the base plate [2]; then, detach the high-voltage unit [3]. F-12-225 12-68 Chapter 12 the rear side plate; lift it slightly to detach. F-12-228 12.5.29.12 Removing F-12-230 the Manual Feed Cooling Fan Duct 1) Free the DC harness [1] found at the front of the 0000-5337 drum ITB motor base from the cable clamp [2]. 1) Slide out the manual fee unit; then, disconnect the connector [1] and remove the 2 screws [2] to detach the manual feed cooling fan duct [3]. F-12-231 F-12-229 2) Disconnect the 2 connectors [1], and remove the 3 screws [2]; then, detach the drum ITB motor base 12.5.29.13 Removing the Drum ITB Motor Mounting [3]. 0000-5338 Points to Note When Removing the Drum ITB Motor Mounting To remove, put your hand into the inside where you have slid out the manual feed unit; then, while holding down the swing plate [1] found to the rear of the drum drive unit, remove from the machine's rear side plate. The drum drive unit is hooked on the protrusion from 12-69 Chapter 12 tension on the belt.) F-12-234 F-12-232 12.5.29.14 Removing 1) Remove the 2 screws [1], and detach the belt the Drum Drive Unit tension pulley cover [2]. (2 locations left/right) 0000-5339 1) Disconnect the 6 connectors [1], and remove the 7 screws [2]: then, take out the drum drive unit [3]. F-12-235 2) Remove the belt retaining roll [1] found on the right side, and detach the drum unit drive belt [2]. F-12-233 12.5.29.15 Detaching the Drum Unit Drive Belt 0000-5340 Never remove the screws [1] (identified by a red marking) used to secure the belt tension plate in place. (The plate is used to maintain a specific degree of 12-70 F-12-236 Chapter 13 MEAP Contents Contents 13.1 Overview ....................................................................................................................................................... 13-1 13.2 MEAP Counter .............................................................................................................................................. 13-2 13.3 Construction of the MEAP Platform ............................................................................................................. 13-4 Chapter 13 13.1 Overview 0007-0341 The term MEAP stands for Multifunctional Embedded Application Platform, and is used to generically refer to a platform for software built into MFPs and peripheral equipment. The architecture is based on Java (J2ME, i.e., Java 2 Platform Micro Edition), and is designed to enable the execution of Java applications. A MEAP application behaves independently from its host printer's system software, and may be installed or uninstalled using SMS (Service Management Service), which is an interface that runs as part of the browser on a PC. As long as the device supports MEAP, most MEAP applications may be added to the device in the field. 13-1 Chapter 13 13.2 MEAP Counter 0007-0359 In addition to the commonly found print counters, a device that supports MEAP is equipped with a counter mechanism used to keep track of which functions are used as well as how often they are used for individual MEAP applications that are installed. The MEAP counter readings may be checked by making the following selections on the device control panel: Counter Check Key>MEAP Counter Check. A device may possess the following MEAP counters, and which counter to use and, therefore, to display all depend on the application in question. A counter reading may be of a type that is forced to increase as a job is expected or of a type that is increased when the application sends instructions; or, it may be of a type that increases independently of the host device, thus increasing solely in response to the application being run; specifics are as follows: T-13-1 Type Count item forced total total (black-and-white 1) total (black-and-while large) scan (total 1) black-and-white scan (total 1) in response to instructions from application black-and-white scan 1 black-and-white scan 2 black-and-white scan 3 black-and-white scan 4 application-independent free 1 free 2 free 3 free 4 free 5 free 6 free 7 free 8 free 9 free 10 free 11 free 12 13-2 Chapter 13 Notes: forced: the device forces the counter to increase its reading in response to execution of a job. in response to instructions from application: the counter increases its reading only in response to instructions from the application. application independent: the counter operates according to the specifications of the application. 13-3 Chapter 13 13.3 Construction of the MEAP Platform 0007-0346 In addition to the installation of the system software, language file, and RUI, a printer equipped with MEAP functions calls for the installation of MEAP content, which offers functions (system services) needed to run MEAP applications and class libraries needed by the MEAP applications to control the device. It is important that the version of the system software be fully compatible with the version of the MEAP content, calling for special care. (In the case of a mismatch, the device will not be able to run the MEAP application.) For version information, refer to the Service Information bulletin that is released in conjunction with the system software. The following shows the components of a MEAP application: [5] [7] [8] [1] [6] [4] [2] [3] F-13-1 [1] User Interface Control Bock installed as part of the system software [2] Device Control Block installed as part of the system software [3] Operating System installed as part of the system software [4] Java VM installed as part of the system software [5] MEAP System Services (includes SDL/SSO) installed as part of MEAP content [6] Device Control Class Library installed as part of MEAP content [7] internally developed application [8] externally developed application 13-4 Chapter 14 Maintenance and Inspection Contents Contents 14.1 Periodically Replaced Parts ........................................................................................................................... 14-1 14.1.1 Periodically Replaced Parts .................................................................................................................... 14-1 14.1.2 Reader Unit/Color Image Reader-C1 ..................................................................................................... 14-1 14.1.3 Printer Unit ............................................................................................................................................. 14-1 14.2 Durables and Consumables ........................................................................................................................... 14-2 14.2.1 Outline .................................................................................................................................................... 14-2 14.2.2 Reader Unit/Color Image Reader-C1 ..................................................................................................... 14-2 14.2.3 Printer Unit ............................................................................................................................................. 14-2 14.3 Scheduled Servicing Basic Procedure ........................................................................................................... 14-4 14.3.1 Scheduled Servicing (Reader Unit) ........................................................................................................ 14-4 14.3.2 Scheduled Servicing (Printer Unit) ........................................................................................................ 14-6 Chapter 14 14.1 Periodically Replaced Parts 14.1.1 Periodically Replaced Parts 0005-9998 Some parts of the machine must be periodically replaced to ensure a specific level of product performance (i.e., they may not show wear but can significantly affect the machine performance once they fail). If possible, schedule any periodical replacement so that it coincides with scheduled servicing. The guide to periodical replacement is subject to change according to the site of installation and habits of use. 14.1.2 Reader Unit/Color Image Reader-C1 0006-0000 The reader unit/Color Image Reader-C1 does not have parts that require periodical replacement. 14.1.3 Printer Unit 0006-0001 The printer unit does not have parts that require periodical replacement. 14-1 Chapter 14 14.2 Durables and Consumables 14.2.1 Outline 0006-0002 Some parts of the machine may require replacement once or more over the life of the product because of deterioration or damage. Replace them as needed by referring to the guide. Find Out When to Replace Use the following service mode to find out when it is best to replace a specific durable part. - Copier COPIER>COUNTER>DRBL-1 - Option COPIER>COUNTER>DRBL-2 14.2.2 Reader Unit/Color Image Reader-C1 0006-0004 The reader unit/Color Image Reader-C1 does not have parts that are designated as "durables." 14.2.3 Printer Unit 0006-0005 T-14-1 as of May 2004 Ref. Parts name Parts No. Q'ty Life [1] Waste toner container FG6-8992 1 60,000 prints* [2] Secondary transfer outside FG6-8997 1 300,000 prints* roller (120/230-V) Remarks actual number of prints [3] Transfer cleaning unit FG6-8989 1 100,000 prints* [4] Fixing roller FB6-3641 1 100,000 prints* actual number of prints [5] Pressure roller FB6-3653 1 100,000 prints* actual number of prints [6] Transfer belt FB6-2930 1 300,000 prints* actual number of prints [7] Drive roller FB6-2931 1 300,000 prints* actual number of prints [8] Primary toner roller RB2-6870 4 300,000 prints* [9] Secondary transfer inside FB6-2934 1 300,000 prints* roller [10] Feed roller (each cassette holder) 14-2 actual number of prints FB6-3406 2 250,000 prints* actual number of prints Chapter 14 as of May 2004 Ref. Parts name Parts No. Q'ty Life Remarks [11] Separation roller (each FB6-3406 2 250,000 prints* actual number of cassette holder) [12] prints Feed roller (manual feeder) FB1-8581 1 120,000 prints* actual number of prints [13] Separation roller (manual FB5-0873 1 120,000 prints* feeder) actual number of prints [14] Fixing upper frame unit FG6-9645 1 100,000 prints* [15] Fixing unit (100 V) FG6-9070 1 200,000 prints* [15] Fixing unit (120 V) FG6-9069 1 200,000 prints* [15] Fixing unit (230 V) FG6-9070 1 200,000 prints* [16] Pressure roller bearing XG9-0478 2 100,000 prints* actual number of prints *: Assumes the use of A4 originals with a 5% image ratio. [8] [7] [12] [6] [13] [9] [10] [3] [2] [4] [11] [1] [15] [16] [5] [16] F-14-1 14-3 Chapter 14 14.3 Scheduled Servicing Basic Procedure 14.3.1 Scheduled Servicing (Reader Unit) 0006-0013 Do not use solvents or oils that are not indicated herein. T-14-2 Unit name Location Cleaning Remarks Optical assembly Scanner cable inspect if dirt is appreciable Optical path Scanner rail lubricate if dirt is appreciable Copyboard glass clean if dirt is appreciable No. 1 through No. 3 clean if dirt is appreciable Original reflecting plate clean if dirt is appreciable Original size sensor clean if dirt is appreciable Lens clean if dirt is appreciable mirrors Points to Note About Scheduled Servicing Unless otherwise specifically mentioned, use lint-free paper and alcohol for cleaning. - If you used solvent for cleaning, be sure that the solvent has completely dried before mounting the part back to the machine. - Unless specifically mentioned, do not use a wet (moist) cloth for cleaning. - See to it that scheduled servicing and replacement are conducted as indicated. 14-4 Chapter 14 Scanning lamp Dry wipe with lint-free paper. Reflecting plate Clean with a blower brush. No. 1 through No. 3 mirror Use a blower brush; if dirt cannot be removed, dry wipe with lint-free paper. Copyboard glass Clean the face/back and white plate. Scanner rail Lubricate. Scanner cable Inspect. Original size sensor Lens Use a blower brush. Use a blower brush. Face-down delivery roller 1 Intermediate transfer belt Face-down delivery roller 2 (ITB; when replacing it) Drive roller Reversing roller (when replacing the ITB) Tension roller (when replacing the ITB) Pre-registration roller Reversing roller Pickup vertical path roller External delivery roller Internal delivery roller Registration upper roller Duplex feed roller Duplex feed roller Delivery upper Secondary Duplex guide transfer rear feed Delivery lower guide roller guide Fixing inlet guide Dry wipe with lint-free paper. Secondary Duplex feed transfer roller internal roller Registration lower roller (when replacing the ITB) Note: Unless otherwise indicated and for guides coming into contact with paper, use lint-free paper and alcohol. F-14-2 14-5 Chapter 14 14.3.2 Scheduled Servicing (Printer Unit) 0006-0015 Do not use solvents or oils that are not indicated herein. T-14-3 Maintenance intervals Unit name Location every 150,000 Other Remarks 40,000 Delivery unit Internal delivery clean roller External delivery clean roller Duplex feed unit if dirt is appreciable if dirt is appreciable Duplex roller 1 clean if dirt is appreciable Duplex roller 2 clean if dirt is appreciable Duplex roller 3 clean if dirt is appreciable Duplex roller 4 clean if dirt is appreciable Delivery vertical path unit Reversing roller clean Face-down delivery clean roller 1 Face-down delivery clean roller 2 Fixing unit Fixing inlet guide clean if dirt is appreciable Fixing inlet roll clean if dirt is appreciable Delivery upper guide clean if dirt is appreciable Delivery lower guide clean if dirt is appreciable 14-6 Maintenance intervals Unit name Location every 150,000 Other Remarks clean if dirt is 40,000 Manual feed Pre-registration registration unit roller appreciable Registration upper clean roller appreciable Registration lower clean roller clean roller Drive roller if dirt is appreciable Pickup vertical path Intermediate if dirt is if dirt is appreciable clean or, when replacing transfer unit the intermediate transfer belt Tension roller clean or, when replacing the intermediate transfer belt Secondary transfer clean or, when replacing internal roller the intermediate transfer belt Internal transfer belt clean or, when replacing (inside) the intermediate transfer belt Secondary Secondary transfer transfer unit rear guide clean if dirt is appreciable Points to Note About Scheduled Servicing Unless otherwise specifically mentioned, use lint-free paper and alcohol for cleaning. - If you used solvent for cleaning, be sure that the solvent has completely dried before mounting the part back to the machine. - Unless specifically mentioned, do not use a wet (moist) cloth for cleaning. - See to it that scheduled servicing and replacement are conducted as indicated. Chapter 14 Scanning lamp Dry wipe with lint-free paper. Reflecting plate Clean with a blower brush. No. 1 through No. 3 mirror Use a blower brush; if dirt cannot be removed, dry wipe with lint-free paper. Copyboard glass Clean the face/back and white plate. Scanner rail Lubricate. Scanner cable Inspect. Original size sensor Lens Use a blower brush. Use a blower brush. Face-down delivery roller 1 Intermediate transfer belt Face-down delivery roller 2 (ITB; when replacing it) Drive roller Reversing roller (when replacing the ITB) Tension roller (when replacing the ITB) Pre-registration roller Reversing roller Pickup vertical path roller External delivery roller Internal delivery roller Registration upper roller Duplex feed roller Duplex feed roller Delivery upper Secondary Duplex guide transfer rear feed Delivery lower guide roller guide Fixing inlet guide Dry wipe with lint-free paper. Secondary Duplex feed transfer roller internal roller Registration lower roller (when replacing the ITB) Note: Unless otherwise indicated and for guides coming into contact with paper, use lint-free paper and alcohol. F-14-3 14-8 Chapter 15 Standards and Adjustments Contents Contents 15.1 Image Adjustments ........................................................................................................................................ 15-1 15.1.1 Standards for Image Position ................................................................................................................. 15-1 15.1.2 Checking the Image Position .................................................................................................................. 15-1 15.1.3 Adjusting the Left/Right Margin (Cassette) ........................................................................................... 15-2 15.1.4 Adjusting the Left/Right Margin (Manual Feed Tray) ........................................................................... 15-3 15.1.5 Adjusting the Left/Right Margin (Side Paper Deck) .............................................................................. 15-3 15.1.6 Duplex Unit ............................................................................................................................................ 15-4 15.2 Scanning System ........................................................................................................................................... 15-5 15.2.1 After Replacing the Scanning Lamp ...................................................................................................... 15-5 15.2.2 After Replacing the Copyboard Glass .................................................................................................... 15-5 15.2.3 After Replacing the CCD Unit ............................................................................................................... 15-5 15.3 Laser Exposure System ................................................................................................................................. 15-6 15.3.1 After Replacing the Laser Unit .............................................................................................................. 15-6 15.4 Image Formation System ............................................................................................................................... 15-7 15.4.1 After Replacing the Drum Unit .............................................................................................................. 15-7 15.4.2 After Replacing the Transfer Unit .......................................................................................................... 15-7 15.4.3 After Replacing the Pattern Reading Unit .............................................................................................. 15-7 15.5 Fixing System ................................................................................................................................................ 15-8 15.5.1 After Disassembling the Fixing Unit ...................................................................................................... 15-8 15.6 Electrical Components .................................................................................................................................. 15-9 15.6.1 When Replacing the Reader Controller PCB ......................................................................................... 15-9 15.6.2 When Replacing the DC Controller PCB ............................................................................................... 15-9 15.6.3 When Replacing the Main Controller PCB (main) .............................................................................. 15-10 15.6.4 When Replacing the Main Controller PCB (sub) ................................................................................. 15-10 15.6.5 When Replacing the SRAM PCB ........................................................................................................ 15-10 15.6.6 When Replacing the HDD .................................................................................................................... 15-11 15.6.7 When Replacing the Power Supply PCB ............................................................................................. 15-11 15.7 Pickup/Feeding System ............................................................................................................................... 15-12 15.7.1 Adjusting the Horizontal Registration When Replacing the Pickup Cassette ...................................... 15-12 15.7.2 Adjusting the Horizontal Registration When Replacing the Duplex Unit ........................................... 15-13 Chapter 15 15.1 Image Adjustments 2.0±1.5mm (2nd side of double-side copy: 2.0±1.5mm) 15.1.1 Standards for Image Position 0 0000-5345 2 The standards for the image margin/non-image width 4 5 6 of prints made at 100% are as follows: 8 2.5±1.5mm (2nd side of double-sided copy: 2.5±2.0mm) 10 F-15-4 0 2 4 5 6 8 10 12 14 16 18 20 F-15-1 15.1.2 Checking the Image Position 0000-5346 Make 10 prints each using the following as the source 2.0±1.5mm (2nd side of double-sided copy: 2.0±1.5mm) of paper, and check to see that the image margin and non-image width are as indicated: [1] individual cassettes 0 [2] manual feed tray 2 [3] side paper deck 4 5 6 [4] duplex unit 8 1) left/right image margin adjustment (horizontal If not, perform the following: registration adjustment) 10 F-15-2 2) leading edge image margin adjustment (registration adjustment) 3) left-right non-image width adjustment (CCD read 2.5±1.5mm (2nd side of double-sided copy:2.5±2.0mm) start cell position adjustment) 4) leading edge non-image width adjustment (scanner image leading edge position adjustment) Adjusting the Image Leading Edge Margin 1) Make the following selections in service mode, and 0 2 4 5 6 8 10 12 14 16 18 20 F-15-3 see that the image margin is as indicated: COPIER>ADJUST>FEED-ADJ>REGIST. 15-1 Chapter 15 2) Remove the 2 screws [1], and detach the right front Decease the value of REGIST. (A decrease of ‘10’ 2.5±1.5mm (2nd side of duplex will increase copy: 2.5±2.0mm) the margin by 1 mm.) Leading edge of paper cover [2]. Increase the value of REGIST. (An increase of ‘10’ will decrease the margin by 1 mm.) 0 2 456 8 101214161820 F-15-5 Adjusting the Left/Right Non-Image Width 1) Make the following selections in service mode, and see that the non-image width is as indicated: F-15-8 COPIER>ADJUST>ADJ-XY>ADJ-Y. Decrease the value of ADJ-X. 2.5±1.5mm (A decrease of ‘10’ (2nd side of will decrease double-sided the non-image copy: 2.5±2.0mm) width by 1 mm.) Image leading edge 3) Detach the grip [1] found at the right front. (If only the cassette 2.) Increase the value of ADJ-X. (An increase of ‘10’ will increase the non-image width by 1 mm.) 0 2 456 8 101214161820 F-15-6 Adjusting the Leading Edge Non-Image Width 1) Make the following selections in service mode, and F-15-9 see that the non-image width is as indicated: COPIER>ADJUST>ADJ-XY>ADJ-X. Decrease the value of ADJ-Y. (A decrease of ‘10’ will decrease the non-image width by 1 mm.) Edge of image Increase the value of ADJ-Y. (An increase of ‘10’ will increase the non-image width by 1 mm.) 4) Insert a screwdriver through the hole in the right front stay, and loosen the screw [1] to adjust the position of the adjusting plate [2]. 2.0±1.5mm (2nd side of double-sided copy: 2.5±1.5mm) 0 2 4 5 6 8 10 F-15-7 15.1.3 Adjusting the Left/ Right Margin (Cassette) 0000-5347 1) Slide out the cassette 1/2, and open the pickup vertical path cover. 15-2 F-15-10 Chapter 15 15.1.4 Adjusting the Left/ Right Margin (Manual Feed Tray) 0000-5348 Loosen the 2 screws [1], and move the position of the Moving the adjusting plate to the right slide guide [2] to make adjustments. L2 Image Decrease the margin at the front of the paper. F-15-11 - For output from each cassette, check to make sure that the margin (L1) along the leading edge is 2.5±1.5 mm; if not, make the following adjustments: 1) Make the following selections in service mode: COPIER>ADJUST>FEED-ADJ>REGIST. 2) Change the setting to make adjustments. F-15-13 (A change of '1' will cause a shift of 0.1 mm, and a higher value will move the image toward the leading edge.) 15.1.5 Adjusting the Left/ Right Margin (Side Paper L1 Deck) 0000-5349 1) Slide out the compartment, and adjust the position of the latch plate [1] of the compartment opening Image solenoid (SL102) using the 2 screws. (When doing so, refer to the index [3] on the latch plate.) Increasing the value of FEED-ADJ will move the image toward the leading edge of the paper. [1] [3] [2] F-15-12 - Adjusting the Image Area (non-image width) 1) Make the following selections in service mode: COPIER>ADJUST>BLANK>BLANK-T/L/B/R. 2) Change the setting to make adjustments. (An increase by '24'increases the non-image width by about 1mm, with the range of settings being between 0 and 100.) (left rear of compartment) F-15-14 15-3 Chapter 15 15.1.6 Duplex Unit 0000-5350 Loosen the adjusting screw [1] to make adjustments. (A single graduation in the index will cause a change of approximately 1 mm.) - To move the paper to the rear, move it to the left. - To move the paper to the front, move it to the right. [1] right left F-15-15 15-4 Chapter 15 15.2 Scanning System 15.2.1 After Replacing the Scanning Lamp 0000-5354 There is no particular work to perform after replacing the scanning lamp. 15.2.2 After Replacing the Copyboard Glass 0000-5355 Enter the value indicated on the copyboard glass (F01301-04) using the following service mode items: COPIER>ADJUST>CCD>W-PLT-X/Y/Z Use it to enter data for the standard white plate. 820686679349 F-15-16 15.2.3 After Replacing the CCD Unit 0000-5356 When you have replaced the CCD unit, enter the values (for color displacement correction in sub scanning direction) indicated on the label attached to the unit in service mode: COPIER>ADJUST>CCD>CCDU-RG/GB Use it to enter the image position correction value (dependent on the CCD unit). 15-5 Chapter 15 15.3 Laser Exposure System 15.3.1 After Replacing the Laser Unit 0000-5357 If you have replaced the laser unit, execute the following service mode: COPIER>FUNCTION>LASER>L-ADJ-0 Use it to execute automatic adjustment of laser intensity. 15-6 Chapter 15 15.4 Image System Formation 15.4.1 After Replacing the Drum Unit 0000-5358 There is no particular work to perform after replacing the drum unit. 15.4.2 After Replacing the Transfer Unit 0000-5359 There is no particular work to perform after replacing the transfer unit (intermediate transfer unit, secondary transfer unit). 15.4.3 After Replacing the Pattern Reading Unit 0000-5360 There is no particular work to perform after replacing the pattern reading unit. 15-7 Chapter 15 15.5 Fixing System A 1/2 turn of the screw shifts the nip balance by about 0.4 mm. A 1/2 turn on the screw at the front will increase the 15.5.1 After Disassembling the Fixing Unit nip at the front by 0.3 mm, decreasing the nip at the 0000-5361 rear by 0.2 mm. If you have loosened the adjusting screw used to If the median value of the measured nip is toward the secure the upper frame and the lower frame of the higher limit of the standard, tighten the screw on the fixing unit in place (as when replacing a roller), be side with a higher nip value at the edge. sure to adjust the nip of the fixing roller as follows: If the nip needs adjustment while the nip balance is 1) Turn the adjusting screw [1] at the front/rear so that correct, the adjusting screw both at the front and rear the length of the pressure spring is 31.5mm. may be given a 1/2 turn so that the nip may change by about 0.3 mm. F-15-17 2) Fit the fixing unit in the machine, and execute the following service mode to measure the nip: COPIER>FUNCTION>FIXING>NIP-CHK c Paper movement Standard: |a c| = 0.5mm or less a 1.5mm Standard: 8.75mm±0.25mm (less than b Center 5000 sheets) of paper 9.25mm±0.25mm (5000 sheets or more) 1.5mm F-15-18 F-15-19 Service Mode COPIER>FUNCTION>FIXING>NIP-CHK Use it to generate output for fixing nip width auto 3) Adjust the balance between the front and the rear: 4) If the median value of the measured nip is toward the lower limit of the standard, tighten the screw on the side with a lower nip value at the edge. MEMO: 15-8 measurement. Chapter 15 15.6 Electrical Components Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>CLF-R-GB 15.6.1 When Replacing the Use it to enter a color displacement correction value Reader Controller PCB 0000-5362 for sub scanning direction. COPIER>ADJUST>CCD>CL-R-RG - Set the DIP switch on the reader controller PCB to the same settings as the initial PCB. Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>CL-R-GB J203 J202 J210 IC5 (CPU) IC16 J201 J206 J205 IC7 IC14 ON J204 OFF SW1 1 2J208 J207 IC3 Use it to enter a color displacement correction value for sub scanning direction. COPIER>ADJUST>CCD>BW-R-RG Use it to enter a color displacement correction value F-15-20 for sub scanning direction. COPIER>ADJUST>CCD>BW-R-GB T-15-1 Use it to enter a color displacement correction value for sub scanning direction. SW-1 SW-2 AB OFF OFF A ON OFF A/INCH OFF ON COPIER>ADJUST>CCD>CCDU-GB AB/INCH ON ON Use it to enter a color displacement correction value COPIER>ADJUST>CCD>CCDU-RG Use it to enter a color displacement correction value for sub scanning direction. for sub scanning direction. - Using the SST, download the latest firmware. COPIER>ADJUST>CCD>FCCDU-RG - Enter the values indicated on the service label in Use it to enter a color displacement correction value service mode (refer to the following list). for sub scanning direction. COPIER>ADJUST>ADJ-XY>ADJ-X COPIER>ADJUST>CCD>FCCDU-GB Use it to adjust the scanner leading edge position. Use it to enter a color displacement correction value COPIER>ADJUST>ADJ-XY>ADJ-Y for sub scanning direction. Use it to adjust the CCD read start cell position. COPIER>ADJUST>ADJ-XY>ADJ-S Use it to enter an adjustment value for the scanner shading measurement point. COPIER>ADJUST>CCD>W-PLT-X 15.6.2 When Replacing the DC Controller PCB 0000-5363 1) After replacing the DC controller PCB, use the Use it to enter white level data for the standard following service mode to initialize the memory of while plate. the DC controller PCB: COPIER>ADJUST>CCD>W-PLT-Y COPIER>FUNCTION>CLEAR>DC-CON Use it to enter white level data for the standard 2) Enter the settings indicated on the service label white plate. using the following service mode: COPIER>ADJUST>CCD>W-PLT-Z COPIER>ADJUST>LASER>PVE-OFST Use it to enter white level data for the standard Use it to enter an adjustment value for the laser while plate. beam position. COPIER>ADJUST>CCD>CLF-R-RG COPIER>ADJUST>FEED-ADJ>REGIST 15-9 Chapter 15 Use it to adjust the timing at which the registration roller clutch goes ON. COPIER>ADJUST>FEED-ADJ>ADJ-REFE Use it to adjust the horizontal registration for repickup. COPIER>ADJUST>CST-ADJ>MF-A4R Use it to adjust the paper width basic value for the manual feed tray. COPIER>ADJUST>CST-ADJ>MF-A6R Use it to adjust the paper width basic value for the F-15-22 manual feed tray. COPIER>ADJUST>CST-ADJ>MF-A4 Use it to adjust the paper width basic value for the 15.6.4 When Replacing the Main manual feed tray. 3) Turn off and then on the main power switch. 4) Make the following selections in service mode: COPIER>FUNCTION>LASER>L-ADJ-0. 5) Press the OK key. (The machine starts auto Controller PCB (sub) 0006-3263 Be sure to use the SRAM PCB [1] from the old PCB on the new main controller PCB (sub) [2]. adjustment and will indicate 'END' at its end.) 15.6.3 When Replacing the Main Controller (main) PCB 0000-5364 Be sure to use the image memory (SDRAM) [1] PCB and the boot ROM [2] from the old PCB on the new main controller PCB (main). F-15-23 15.6.5 When Replacing the SRAM PCB 0000-5365 When the SRAM PCB is replaced, all data in its memory will be lost (file-related, user mode-related, F-15-21 service mode-related, history-related files). There will be no error operation, and initialization will take place automatically. If you pull out the SRAM PCB from machine B and mount it to machine A, the PCB will be initialized and be rendered useless for machine A or B. Take full 15-10 Chapter 15 2) Turn off and then on the machine; when the care. machine has started up, perform the following in 1) When you turn on the power after replacing the user mode: SRAM PCB, the machine will execute automatic Make the following selections: user mode>system initialization and will indicate a message on its control settings>group ID control>count control; panel to the effect that you are to turn off and then then, check to see that IDs from 00000001 through on the power switch found on its right side. Follow 00001000 have been prepared. the message and turn off and then on the machine. Make the following selections: user mode>system 2) Using service mode, initialize the RAM. COPIER>FUNCTION>CLEAR>MN-CON control settings>network settings>TCP/IP settings>IP address; then, set up 'IP address' 'gateway address' and 'subnet mask' Make the following selections: user mode>system Before starting the work, be sure to inform the user that all image data stored in the Box will be lost and administrator setup; then, fill in 'system control group ID' and 'system control ID No.' thereafter, turn off and then on the machine. obtain his/her consent. If you leave out 'system control group ID' and 'system control ID No.' the service engineer will not be able to 'register card to device' as part of setup 15.6.6 When Replacing the HDD work for NSA. 0000-5366 3) With the machine in standby state, download the card ID to be used from NSA. If NetSpot Accountant (NSA) Is Not Used 1) Formatting the HDD 4) When the card data has been downloaded from NSA, check to see that the ID data has correctly While holding down the 2 and 8 keys on the control panel, turn on the power to start up. Using the HD been downloaded on the screen brought up by making the following selections: formatting function of the SST, format all user mode>system control settings>group ID control partitions. (Only the downloaded ID data must be indicated.) 2) Downloading the Software 5) Make copies using a user card registered with NSA, Using the SST, download the various software and check to see that statistical operations are made (system, language, RUI). The machine will take for the device in question. about 10 min to start up after downloading. If NetSpot Accountant (NSA) Is Used Together with a Card Reader The card ID used by the NSA resides on the HDD. If 15.6.7 When Replacing the Power Supply PCB 0000-5367 you have replaced the HDD, therefore, you will have to newly download the card data from NSA to enable the statistical operations of NSA. After going through There is no particular work to perform after replacing the power supply PCB. steps 1) and 2) above, perform the following: 1) Set the following in service mode: Make the following selections: COPIER>FUNCTION>INSTALL>CARD; then, enter the number of the first card, and press [OK]. (For instance, if cards No. 1 through No. 1000 are used for group control, enter '1') 15-11 Chapter 15 15.7 Pickup/Feeding System 15.7.1 Adjusting Horizontal When the Registration Replacing the Pickup Cassette 0000-5368 Make a test copy of the A3 Test Chart, and check to F-15-25 be sure that the margin on the front side of the image is correct (L2 = 2.0 ±1.5 mm); otherwise, go through the following steps to make adjustments, starting with the 1st side and then the 2nd side: Adjusting the Horizontal Registration on the 1st Side 1) Slide out the manual feed unit and the cassette 1/2; then, open the pickup vertical path cover. 2) Remove the 2 screws [1], and detach the front right Moving the adjusting plate to the right cover [2]. L2 Image will decrease the margin on the front side of the paper. F-15-26 - Adjusting the Cassette 2 Side F-15-24 3) Remove the grip [1] from the front right. - Adjusting the Cassette 1 Side 3) Insert a screwdriver through the hole in the front right stay, and loosen the screw [1] to adjust the position of the adjusting plate [2]. F-15-27 4) Insert a screwdriver through the hole in the front right stay, and loosen the screw [1] to adjust the position of the adjusting plate [2]. 15-12 Chapter 15 F-15-28 Moving the adjusting plate to the right L2 Image will decrease the margin on the front side of the paper. F-15-29 Adjusting the Horizontal Registration on the 2nd Side Use the following service mode to make adjustments: COPIER>ADJUST>FEED-ADJ>ADJ-REFE 15.7.2 Adjusting Horizontal When Registration Replacing Duplex Unit the the 0000-5370 After replacing the horizontal registration motor, horizontal registration sensor, duplex unit, and fixing delivery unit, follow the adjustment showing below. COPIER>ADJUST>FEED>ADJ>ADJ-REFE 15-13 Chapter 15 15-14 Chapter 16 Correcting Faulty Images Contents Contents 16.1 Making lnitial Checks ................................................................................................................................... 16-1 16.1.1 Site Environment .................................................................................................................................... 16-1 16.1.2 Checking the Paper ................................................................................................................................. 16-1 16.1.3 Checking the Placement of Paper ........................................................................................................... 16-1 16.1.4 Checking the Durables ........................................................................................................................... 16-1 16.1.5 Checking the Periodically Replaced Parts .............................................................................................. 16-1 16.1.6 Checking the Units and Functional Blocks ............................................................................................ 16-1 16.1.7 Others ..................................................................................................................................................... 16-3 16.2 Test Print ....................................................................................................................................................... 16-4 16.2.1 Outline .................................................................................................................................................... 16-4 16.2.2 Test Print TYPE ..................................................................................................................................... 16-4 16.2.3 Selecting a Test Print TYPE ................................................................................................................... 16-4 16.2.4 Gradations (TYPE=4) ............................................................................................................................. 16-5 16.2.5 Full Halftone (TYPE=5) ......................................................................................................................... 16-5 16.2.6 Grid (TYPE=6) ....................................................................................................................................... 16-6 16.2.7 MCYBk Horizontal Stripe (TYPE=10) .................................................................................................. 16-7 16.2.8 Gradations (TYPE=12) ........................................................................................................................... 16-8 16.2.9 Full Color 16 Gradations (TYPE=14) .................................................................................................... 16-8 16.3 Troubleshooting ............................................................................................................................................. 16-9 16.3.1 Symptoms ............................................................................................................................................... 16-9 16.3.1.1 Image Fault Case Studies (A4) ........................................................................................................ 16-9 16.3.1.2 Image Fault Case Samples (A3) .................................................................................................... 16-14 16.3.2 Image Faults .......................................................................................................................................... 16-18 16.3.2.1 Blank Image ................................................................................................................................... 16-18 16.3.2.2 Solid Image .................................................................................................................................... 16-18 16.3.2.3 Light Image / Weak Density .......................................................................................................... 16-18 16.3.2.4 Foggy Image .................................................................................................................................. 16-24 16.3.2.5 Uneven Density ............................................................................................................................. 16-35 16.3.2.6 Out of Focus .................................................................................................................................. 16-40 16.3.2.7 Partially Blank/Streaked ................................................................................................................ 16-43 16.3.2.8 Smudged/Streaked ......................................................................................................................... 16-54 16.3.2.9 Ghost / Memory ............................................................................................................................. 16-60 16.3.2.10 Poor Finxing ................................................................................................................................ 16-62 16.3.2.11 Faulty Color Reproduction .......................................................................................................... 16-64 16.3.2.12 Stretching/Shrinking .................................................................................................................... 16-65 16.3.3 Faulty Feeding ...................................................................................................................................... 16-66 16.3.3.1 Double-Feed/ Multiple Feed .......................................................................................................... 16-66 16.3.3.2 Skew Feed ..................................................................................................................................... 16-66 16.3.3.3 Wrinkle .......................................................................................................................................... 16-67 16.3.3.4 Ripple/Curl .................................................................................................................................... 16-67 16.3.3.5 Wrap .............................................................................................................................................. 16-68 16.3.4 Malfunction ........................................................................................................................................... 16-68 16.3.4.1 No Power ....................................................................................................................................... 16-68 16.3.4.2 Control Panel-Related ................................................................................................................... 16-70 16.3.4.3 Counter Malfunction ..................................................................................................................... 16-72 16.3.4.4 Malfunction/Faulty Detection ....................................................................................................... 16-72 16.3.4.5 Noise .............................................................................................................................................. 16-77 16.3.4.6 User Warning Message .................................................................................................................. 16-78 16.3.4.7 Other Defect .................................................................................................................................. 16-83 Contents 16.3.4.8 Part Breakage/Detachment ............................................................................................................ 16-88 16.3.5 Printing/scanning ................................................................................................................................... 16-88 16.3.5.1 No Output ...................................................................................................................................... 16-88 16.3.5.2 Installation Failure ......................................................................................................................... 16-91 16.3.5.3 Faulty Printing/Scanning Result .................................................................................................... 16-92 16.3.6 Network ............................................................................................................................................... 16-107 16.3.6.1 Start-Up Failure ........................................................................................................................... 16-107 16.3.6.2 Connection Problem .................................................................................................................... 16-107 16.3.7 Transmission/Fax-Related ................................................................................................................... 16-108 16.3.7.1 Transmission Problem ................................................................................................................. 16-108 16.3.7.2 Reception Problem ....................................................................................................................... 16-115 16.3.7.3 Other Operational Defect ............................................................................................................. 16-116 16.3.8 Jam (Main Unit) .................................................................................................................................. 16-116 16.3.8.1 Paper not picked up: although the paper sensor detects paper inside the cassette ....................... 16-116 16.3.8.2 0102 Jam Code ............................................................................................................................. 16-117 16.3.8.3 0105 Jam Code: Occurs with machine having mylar sheet to fixing/feeder sensor flag ............. 16-117 16.3.8.4 JAM CODE 0107 ......................................................................................................................... 16-117 16.3.8.5 JAM CODE 0108, 0207 ............................................................................................................... 16-118 16.3.8.6 JAM CODE 0207 ......................................................................................................................... 16-118 16.3.8.7 0207 Jam Code: Because of deformation of internal delivery roller ........................................... 16-118 16.3.8.8 0A06 Jam Code ............................................................................................................................ 16-119 16.3.8.9 JAM CODE 0A0A: At about 41 sec. after the power is turned ON, due to a duplexing driver PCB failure .................................................................................................................................. 16-119 16.3.8.10 JAM CODE 0B00/0105 ............................................................................................................. 16-120 16.3.9 Jam (Document Feeder) ...................................................................................................................... 16-120 16.3.9.1 JAM CODE 008C: frequent occurrence recorded in jam history under service mode, although unable to reproduce during paper feeding test. ....................................................................... 16-120 16.3.10 Error Code ......................................................................................................................................... 16-121 16.3.10.1 E000 Error code detail The rise in temperature in the fixing unit at time of power-on is inadequate. ........................................................................................................................................ 16-121 16.3.10.2 E001 Error code detail The fixing unit is overheating. ............................................................ 16-121 16.3.10.3 E002 Error code detail The rise in temperature of the fixing unit is inadequate. .................... 16-122 16.3.10.4 E003 Error code detai The temperature of the fixing unit is abnormally low after standby. ... 16-123 16.3.10.5 E004 Error code detail The protection circuit of the fixing unit is faulty. ............................... 16-123 16.3.10.6 E004-0003 Error code Or message 'Remove the paper from the finisher trays.': after implementing countermeasure against malfunction of fixing feeder unit open/closed sensor .............. 16-124 16.3.10.7 E004-0005 Error Code: Because of faulty DC Controller PCB ................................................ 16-124 16.3.10.8 E004-0007 Error Code: Occasionally occurs first in the morning ............................................ 16-125 16.3.10.9 E004-0006/E004-0007 Error Code Descriptions ....................................................................... 16-125 16.3.10.10 E012 Error code detail The drum ITB motor is faulty. .......................................................... 16-126 16.3.10.11 E012-0001 Error code ITB motor not rotating ....................................................................... 16-126 16.3.10.12 E012-0001 Error code At about 37 sec. after the power is turned ON, due to a drum ITB motor failure .................................................................................................................................. 16-126 16.3.10.13 E012-0001 Error code At about 37 sec. after the power is turned ON, due to a microswitch PCB failure ....................................................................................................................... 16-127 16.3.10.14 E012-0001 Error Code: Drum ITB Motor, DC Power Supply PCB and Fuse PCB work normally ........................................................................................................................................ 16-128 16.3.10.15 E012-0001 Error Code: Because Drum ITB Motor is faulty, or Fuse PCB is faulty .............. 16-128 16.3.10.16 E020-0134 Error code Recurring even after replacement of yellow drum unit ..................... 16-129 16.3.10.17 E020 Error code detail There is a fault associated with the drum/developer. ........................ 16-129 16.3.10.18 E020-xx81: generally E020-0181 Error Code ......................................................................... 16-131 16.3.10.19 E020-0081 Error code Displaying when a copy is made with the service case removed ..... 16-132 16.3.10.20 E020-0X34, E020-0X21 Error code Upon installation in a cold season ................................ 16-132 16.3.10.21 E020-04B0 Error code At about 200 to 300 sheets from installation, toner container Contents motor (Bk) not rotating (Refer to SymptomExplanation.) .................................................................... 16-132 16.3.10.22 E020-04B0 Cautions in replacing the drum unit ..................................................................... 16-133 16.3.10.23 E020-0X81 Error Code Displaying because of an open/close failure of the SALT sensor shutter ......................................................................................................................................... 16-134 16.3.10.24 E020-0124 Error Code ........................................................................................................... 16-134 16.3.10.25 E020-OXB0 Error Code .......................................................................................................... 16-135 16.3.10.26 E020-xx24 Error Code ............................................................................................................ 16-135 16.3.10.27 E020-xxA0 Error Code ............................................................................................................ 16-136 16.3.10.28 E020-xxD0 Error Code ............................................................................................................ 16-136 16.3.10.29 E020-xx34 Error Code ............................................................................................................ 16-136 16.3.10.30 E020-0125 Error Code ............................................................................................................ 16-137 16.3.10.31 E020-03B0 Error Code: Overall fogging (no margin) occurred after replacement of Cyan drum unit ............................................................................................................................................... 16-137 16.3.10.32 E032 Error code detail The counter of the NE controller fails to operate. ............................ 16-137 16.3.10.33 E110 Error code detail The operation of the laser scanner motor is faulty. ........................... 16-137 16.3.10.34 E110-0x10 Error Code ............................................................................................................ 16-138 16.3.10.35 E202 Error code detail A fault has occurred in detecting the No. 1 mirror home position. .. 16-139 16.3.10.36 E202-0000 Error Code ............................................................................................................ 16-139 16.3.10.37 E220 Error code detail A fault has occurred in activating the scanning lamp. ..................... 16-140 16.3.10.38 E220-0000 Error Code: Entire image sometimes becomes tinged with red ........................... 16-140 16.3.10.39 E220-0000 Error Code ............................................................................................................ 16-141 16.3.10.40 E220-0000 Error code Faulty connection in the flat cable from the CCD unit into R-CON J205 causes. ............................................................................................................................. 16-141 16.3.10.41 E220-0000 Error Code: Scanning lamp did not light up after turning power ON .................. 16-142 16.3.10.42 E220-0000 Error Code when turning power ON while opening platen cover ........................ 16-142 16.3.10.43 E220-0000 Error Code: No problem with CCD unit and Reader Controller PCB ................. 16-142 16.3.10.44 E220-0000 Error Code: At power-on upon installation, because of poor contact of J204 on Reader Controller PCB, iRC3220 ............................................................................................ 16-143 16.3.10.45 E240 Error code detail The communication between the main motor controller and the DC controller is faulty. ................................................................................................................... 16-143 16.3.10.46 E243 Error code detail The control panel is faulty. ................................................................ 16-143 16.3.10.47 E302 Error code detail A fault has occurred in relation to shading correction. .................... 16-144 16.3.10.48 E315 Error code detail The image data is faulty. ................................................................... 16-144 16.3.10.49 E315-0010 Error code Only for FAX is transmitted .............................................................. 16-144 16.3.10.50 E351 Error code detail The ECO-ID PCB is faulty. .............................................................. 16-145 16.3.10.51 E351-0000 Error Code: Because of poor connection of connector on ECO-ID PCB ............. 16-145 16.3.10.52 E402 Error code detail There is a fault in the feeder motor. .................................................. 16-145 16.3.10.53 E402 Error Code ...................................................................................................................... 16-146 16.3.10.54 E404 Error code detail There is a fault in the delivery motor. ............................................... 16-146 16.3.10.55 E500 Error code detail There is a fault in finisher communication. (Finisher-N1) .............. 16-146 16.3.10.56 E500 Error code detail There is a fault in finisher communication. (Finisher-M1) ............... 16-147 16.3.10.57 E503 Error code detail There is a fault in saddle communication. ........................................ 16-147 16.3.10.58 E504 Error code detail There is a fault in stack size detection. ............................................. 16-148 16.3.10.59 E505 Error code detail There is a fault in the backup RAM. ................................................. 16-148 16.3.10.60 E512 Error code detail There is a fault in delivery. (Finisher-N1) ........................................ 16-149 16.3.10.61 E512 Error code detail There is a fault in delivery. (Finisher-M1) ....................................... 16-149 16.3.10.62 E514 Error code detail There is a fault in stack processing (clockwise direction) ................ 16-150 16.3.10.63 E530 Error code detail There is a fault in alignment.(Finisher-N1) ...................................... 16-150 16.3.10.64 E530 Error code detail There is a fault in rear alignment. (Finisher-M1) .............................. 16-151 16.3.10.65 E531 Error code detail There is a fault in stapling. (Finisher-M1) ........................................ 16-151 16.3.10.66 E531 Error code detail There is a fault in stapling. (Finisher-N1) ........................................ 16-152 16.3.10.67 E532 Error code detail There is a fault in the shift of the stapler ........................................... 16-152 16.3.10.68 E535 Error code detail There is a fault in the swing mechanism. ......................................... 16-153 16.3.10.69 E537 Error code detail There is a fault in front alignment. .................................................... 16-153 Contents 16.3.10.70 E540 Error code detail There is a fault in the ascent/descent of the tray. .............................. 16-154 16.3.10.71 E577 Error code detail There is a fault in stack processing (counterclockwise direction). .... 16-154 16.3.10.72 E580 Error code detail There is a fault in ascent/descent of the stack tray. .......................... 16-155 16.3.10.73 E584 Error code detail There is a fault in feed operation (No. 2). ......................................... 16-155 16.3.10.74 E5F0 Error code detail There is a fault in paper positioning for the saddle. .......................... 16-156 16.3.10.75 E5F1 Error code detail There is a fault in paper folding for the saddle. ............................... 16-156 16.3.10.76 E5F2 Error code detail There is a fault in the saddle guide. ................................................... 16-157 16.3.10.77 E5F3 Error code detail There is a fault in saddle alignment. ................................................ 16-157 16.3.10.78 E5F4 Error code detail There is a fault in stapling at the saddle rear. ................................... 16-158 16.3.10.79 E5F5 Error code detail There is a fault in stapling at the saddle front. ................................. 16-158 16.3.10.80 E5F6 Error code detail There is a fault in stapling by the saddle paper pushing plate. ......... 16-159 16.3.10.81 E5F8 Error code detail There is a fault in the saddle connector. ........................................... 16-160 16.3.10.82 E5F9 Error code detail There is a fault in the saddle switch. ................................................ 16-160 16.3.10.83 E601-0xdd: after performing [COPIER>ADJUST>V-CONT-Y/M/C/K] to improve faint image ............................................................................................................................................. 16-161 16.3.10.84 E602-0001/E602-0002/E602-0003 Error Code: Remedy upon occurrence of error code ...... 16-162 16.3.10.85 E602 Error code detail The hard disk is faulty. ...................................................................... 16-163 16.3.10.86 E602-0001 Error code At about 5 sec. after the power is turned ON, due to a failure of the Distribution Board PCB Ass'y .............................................................................................................. 16-165 16.3.10.87 E602-0001 Error code At about 5 sec. after the power is turned ON, due to a connection failure of the flat cable between the HDD unit and the main controller ............................................... 16-165 16.3.10.88 E602-0202 Error Code: Recovered after performing HD-CHECK ......................................... 16-166 16.3.10.89 E602-0202 Error Code: Because of faulty SRAM Board PCB ............................................... 16-166 16.3.10.90 Progress bar on machine starting-up window is slower than usual, then E602 Error Code is displayed ................................................................................................................................... 16-166 16.3.10.91 E602-0402 Error Code: not recovered after replacement of main controller PCB ................. 16-166 16.3.10.92 E602-0x02 Error Code ............................................................................................................. 16-167 16.3.10.93 E602-0001 Error Code ............................................................................................................. 16-167 16.3.10.94 E602-0402 Error Code: At power-on upon installation, iRC3220 .......................................... 16-167 16.3.10.95 E604 Error code detail There is a shortage in image memory (SDRAM). ............................ 16-167 16.3.10.96 E604-0000 Error Code: Because of faulty expansion RAM ................................................... 16-168 16.3.10.97 E605 Error code detail The battery for image memory is faulty. ........................................... 16-168 16.3.10.98 E606 Error code detail The hard disk is faulty. ...................................................................... 16-169 16.3.10.99 E674 Error code detail The fax board is faulty. ..................................................................... 16-169 16.3.10.100 E677-0002 Error Code ........................................................................................................... 16-169 16.3.10.101 E711 Error code detail There is a fault in IPC communication.(DADF-K1) ...................... 16-170 16.3.10.102 E711 Error code detail There is a fault in IPC communication. ........................................... 16-170 16.3.10.103 E712 Error code detail There is a fault in the communication between the ADF and the reader unit. ................................................................................................................................ 16-171 16.3.10.104 E713 Error code detail There is a fault in the communication between the finisher and the cassette pedestal. ....................................................................................................................... 16-171 16.3.10.105 E716 Error code detail There is a fault in the communication between the cassette pedestal and the printer unit. .................................................................................................................. 16-172 16.3.10.106 E716-0000 Error code Recorded only in the error history ................................................... 16-172 16.3.10.107 E717 Error code detail The communication with the NE controller is faulty. ..................... 16-172 16.3.10.108 E719 Error code detail The coin vendor is faulty. ............................................................... 16-173 16.3.10.109 E719-0011 Error code After the cable is disconnected because of a scanning fault in card reader D1 .................................................................................................................................... 16-173 16.3.10.110 E719-0001 Error code When the coin vendor is disconnected, unable to be cleared ........... 16-174 16.3.10.111 E731 Error code detail There is a fault in the UFR board. .................................................. 16-174 16.3.10.112 E732 Error code detail There is a reader communication error. ........................................... 16-174 16.3.10.113 E732-9999 Error Code: Recorded in error log after performing service mode COPIER> Function> CLEAR> MN-CON ............................................................................................ 16-175 16.3.10.114 E732-0001 Error code A message 'Starting up. Please wait' keeps displaying for about Contents 2 min. 40 sec. after the power is turned ON, and then the error code results (DC power supply unit PCB J158 output failure) ............................................................................................................... 16-175 16.3.10.115 E732-0001 Error Code: After turning power ON, message "Starting up. Please wait" changes to error code indication ............................................................................................................ 16-176 16.3.10.116 E732-0001 Error code A message 'Starting up. Please wait' keeps displaying for about 2 min. 40 sec. after the power is turned ON, and then the error code results ............................. 16-177 16.3.10.117 E733 Error code detail There is a printer communication error. ......................................... 16-177 16.3.10.118 E733-0001 Error code Printer communication error ........................................................... 16-178 16.3.10.119 E740 Error code detail The Ethernet board is faulty. ........................................................... 16-178 16.3.10.120 E744 Error code detail The language file is faulty. ............................................................. 16-178 16.3.10.121 E745 Error code detail The TokenRing board is faulty. ..................................................... 16-179 16.3.10.122 E747-8702 Error Code .......................................................................................................... 16-179 16.3.10.123 E747 Error code detail The image processing ASIC or the memory control/ communication ASIC is faulty. ............................................................................................................. 16-179 16.3.10.124 E747-00FF Error code Only with printing operation ......................................................... 16-180 16.3.10.125 E747-8701 Error Code .......................................................................................................... 16-180 16.3.10.126 E747-00FF Error Code .......................................................................................................... 16-180 16.3.10.127 E751-0304 Error Code .......................................................................................................... 16-181 16.3.10.128 E804 Error code detail The power supply cooling fan is faulty. .......................................... 16-181 16.3.10.129 E804-0004 Error Code .......................................................................................................... 16-181 16.3.10.130 E804-0004 Error code Displaying if the jack of the controller fan (FM7) which is fixed on the controller box ................................................................................................................... 16-182 16.3.10.131 E804-0004 due to faulty fuse PCB Error Code .................................................................... 16-182 16.3.10.132 E805 Error code detail The cleaner fan is faulty. ................................................................ 16-182 16.3.10.133 E805 Error code detail The fixing heat discharge fan is faulty. .......................................... 16-183 16.3.11 FAX # Code ...................................................................................................................................... 16-183 16.3.11.1 Åî037 ......................................................................................................................................... 16-183 16.3.12 FAX ## Code .................................................................................................................................... 16-183 16.3.12.1 ##111, ##228 FAX Error Code ................................................................................................. 16-183 16.3.12.2 ##281/##104 FAX Error Code .................................................................................................. 16-184 16.3.12.3 ##796 FAX Error Code ............................................................................................................. 16-184 16.4 Outline of Electrical Components ............................................................................................................. 16-185 16.4.1 Clutch/Solenoid ................................................................................................................................... 16-185 16.4.1.1 Reader Unit .................................................................................................................................. 16-185 16.4.1.2 Printer Unit .................................................................................................................................. 16-185 16.4.2 Motor ................................................................................................................................................... 16-186 16.4.2.1 Reader Unit .................................................................................................................................. 16-186 16.4.2.2 Printer Unit .................................................................................................................................. 16-186 16.4.3 Fan ....................................................................................................................................................... 16-188 16.4.3.1 Reader Unit .................................................................................................................................. 16-188 16.4.3.2 Printer Unit .................................................................................................................................. 16-188 16.4.4 Sensor .................................................................................................................................................. 16-189 16.4.4.1 Reader Unit .................................................................................................................................. 16-189 16.4.4.2 Printer Unit .................................................................................................................................. 16-190 16.4.5 Switch ................................................................................................................................................. 16-192 16.4.5.1 Reader Unit .................................................................................................................................. 16-192 16.4.5.2 Printer Unit .................................................................................................................................. 16-192 16.4.6 Lamps, Heaters, and Others ................................................................................................................ 16-194 16.4.6.1 Reader Unit .................................................................................................................................. 16-194 16.4.6.2 Printer Unit .................................................................................................................................. 16-194 16.4.7 PCBs ................................................................................................................................................... 16-195 16.4.7.1 Reader Unit .................................................................................................................................. 16-195 16.4.7.2 Printer Unit .................................................................................................................................. 16-196 16.4.8 Plane Pedistal ...................................................................................................................................... 16-198 Contents 16.4.8.1 Plain Pedestal-C1 ......................................................................................................................... 16-198 16.4.9 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB ............................ 16-199 16.4.9.1 Adjusting the Variable Resistors (VR), the Light-Emitting Diodes (LED), and the Check Pins by PCB ........................................................................................................................................... 16-199 16.4.9.2 Main Controller PCB (main) ....................................................................................................... 16-200 16.4.9.3 Main Controller PCB (sub) .......................................................................................................... 16-201 16.4.9.4 Reader Controller PCB ................................................................................................................ 16-201 16.4.9.5 Inverter PCB ................................................................................................................................ 16-202 16.4.9.6 Differential PCB .......................................................................................................................... 16-202 Chapter 16 16.1 Making lnitial Checks 16.1.1 Site Environment 0006-5663 Be sure of the following: a. The voltage of the power supply is as rated (±10%). The power plug remains connected throughout day and night. b. The site is not a high temperature/humidity environment (near a water faucet, water boiler, humidifier), and it is not in a cold place. The machine is not near a source of fire or dust. c. The site is not subject to ammonium gas. d. The site is not exposed to direct rays of the sun. (Otherwise, provide curtains.) e. The site is well ventilated, and the floor keeps the machine level. f. The machine's power plug remains connected to the power outlet. 16.1.2 Checking the Paper 0006-5664 a. The paper is of a recommended type. b. The paper is not moist. Try paper fresh out of package. 16.1.3 Checking the Placement of Paper 0006-5665 a. Check the cassette and the manual feed tray to see if the paper is not in excess of a specific level. b. If a transparency is used, check to make sure that it is placed in the correct orientation in the manual feed tray. 16.1.4 Checking the Durables 0006-5666 Check the table of durables to see if any has reached the end of its life. 16.1.5 Checking the Periodically Replaced Parts 0006-5667 Check the scheduled servicing table and the periodically replaced parts table, and replace any part that has reached the time of replacement. 16.1.6 Checking the Units and Functional Blocks 0006-5668 [Reader Unit] - Check the optical system (mirror, while plate, copyboard glass, reflecting plate) for damage and foreign matter. - Check the mirror base to see that it moves smoothly and its rail is free of dirt. - Check the scanning lamp to see it is free of flickering. - Check the scanner cable to see that it is correctly routed. - Check the scanner to see that it is free of condensation. [Process System] - Check to see that the toner container contains toner. - Check to see that the drum unit is properly fitted. - Check the photosensitive drum to see that it is free of damage and dirt. 16-1 Chapter 16 - Check the window of the SALT sensor to see if it is free of dirt. [Transfer System] - Check the secondary transfer unit to see that it is free of foreign matter. - Check the ITB/secondary transfer external roller for wear, scratches, dirt, and deformation. - Check the blade of the ITB cleaning unit for tear, peeling, deformation, and stray toner. [Fixing System] - Check the fixing roller/pressure roller for wear, tear, and deformation. - Check the fixing heater (main/sub) to see that it operates when power is turned on. - Check the fixing thermistor to see that it is free of an open circuit. - Check the thermal switch to see that there is electrical continuity. [Paper Feeding System] - Check to see if there is residual paper or other foreign matter. - Check to see if there is a buildup of paper lint on the pickup, feeding, and separation rollers. Check the rollers for wear, tear, dirt, and deformation. - Check the pre-registration roller, registration roller (upper/lower), and paper path roller for wear, tear, and dirt, and deformation. - Check the feeding guide for wear, tear, dirt, and deformation. - Check the paper for a bent leading edge, curling, waving, and absorption of moisture. - Check the paper and/or transparency to see if it is a recommended type. If not, try a recommended type to see if the symptom in question still occurs. [Mechanical System] - Check to see if the load of the drive system is excessive. - Check the gears for wear and tear (chipping). [Cassettes] - Check to see if the cassettes are properly fitted. Check to see if the paper size is correctly set. Try replacing with a normal cassette to see if the symptom in question still occurs. - Check to see that the holding plate of the cassette moves smoothly and that it is free of deformation. - Check to see that the side guide plate and the rear guide plate of the cassette are fitted correctly. - Check to see if the switch of the cassette heater is turned on (if the machine is equipped with a cassette heater). [Service Mode] - Check to see if the various CCD adjustment values are as indicated on the service label. (COPIER>ADJUST>CCD>all items) - Check to see if the machine executes registration adjustment. (COPIER>ADJUST>FEED-ADJ>REGIST/ADJ-REFE) - Check to see if the machine correctly detects the internal temperature/humidity. (COPIER>DISPLAY>ANALOG>TEMP/ABS-HUM) - Check to see if the image read position is correctly adjusted. (COPIER>ADJUST>ADJ-XY>ADJ-X/ADJ-Y/ADJ-Z) - Check to see if the paper reference value data is correct. (COPIER>FUNCTION>CST-ADJ) - Check to see that the value of ADJUST/OPTION is as indicated on the service label. - Check to see if 'error clear' has been initialized. (COPIER>FUNCTION>CLEAR>ERR) [General] 16-2 Chapter 16 - Is the power plug properly connected? - Is the rated AC voltage present at the power outlet? - Are the sensors, clutches, motors, and solenoids operating normally? Are the connectors free of poor contact? (Be sure to check the routes of power and signals by referring to the general circuit diagram.) - Has the leakage breaker or the circuit breaker gone ON? - Is there biting of a wire or a loose screw? - Are all eternal covers attached properly? - Are the main power switch and the control panel power switch ON? - Are the power cable and the signal cable to all accessories routed correctly? - Does the cover switch operate normally? - Is the fuse on each PCB blown? - Is the user aware of the correct use of the machine? 16.1.7 Others 0006-5670 If a machine is brought from a cold to warm place, condensation can occur inside it, leading to various problems: a. condensation on the BD sensor can cause problems associated with E110. b. condensation on the LDE lens can cause image in sub scanning direction to be too light. c. condensation on the mirror of the reader unit or on the copyboard glass can cause images to be too light. d. condensation on the pickup or feeder guide can cause paper feeding faults. If any of the foregoing (a through c) occurs, use the following service mode to correct it COPIER>FUNCTION>INSTALL>DRY-RT Use it to eliminate condensation at time of installation work. If d has occurred, dry wipe the pickup and feeder units. Moreover, the toner container and the drum unit can also develop condensation if it is brought in from a cold to warm place (unpacked). To prevent condensation, advise the user to leave them alone for 1 to 2 hours before unpacking them at the site. As necessary after installation, use the following service mode COPIER>OPTION>BODY>SLPOFF01 to SLPOFF12 Use it to disable sleep mode. 16-3 Chapter 16 16.2 Test Print 16.2.1 Outline 0006-5673 The machine offers 6 types of test prints (TYPE), enabling identification of a fault in images with reference to test prints. If a fault appearing on a normal print does not show on a test print, the cause may be assumed to be on the PDL input side or the reader unit side. 16.2.2 Test Print TYPE 0006-5686 T-16-1 TYPE NO. Description 0 normal copy/print 1 to 3 - (for R&D) 4 16 gradations 5 full halftone 6 grid 7 to 9 - (for R&D) 10 MCYBk horizontal stripe (sub scanning direction) 11 - (for R&D) 12 64 gradations 13 - (for R&D) 14 full color 16 gradations 15 to 100 - (for R&D) 16.2.3 Selecting a Test Print TYPE 1) Set the print count and paper size. 2) Make the following selections in service mode: COPIER>TEST>FG. 3) Make the following selections: COPIER>TEST>PG>TYPE. 4) Using the keypad, enter the desired TYPE No., and press the OK key. 5) Using 'COLOR-Y/M/C/K', select the desired color (output at '1'). 6) Using 'DENS-Y/M/C/K', set the desired density. (valid only for TYPE=5) 7) Press the Start key. 16-4 0006-5694 Chapter 16 16.2.4 Gradations (TYPE=4) 0006-5696 Use this test print to check gradation, fogging, white lines, or uneven density at the front/rear. a. Gradation If the reproduction of 16 gradations is not as expected, suspect a fault in the drum unit or the laser exposure system. b. Fogging If fogging is limited to the white area of the following illustration, suspect a fault in the drum unit or the laser exposure unit. c. Vertical White Lines/Black Lines If a white line is found in the image, suspect a fault in the developing system. d. Uneven Density at the Front/Rear If uneven density is found at the front/rear, suspect a fault in the drum unit, laser exposure system, or transfer unit. 16 gradations F-16-1 16.2.5 Full Halftone (TYPE=5) 0006-5698 Use this test print to check transfer failure, black lines, white lines, or irregular intervals. MEMO: 1. You can select a specific color to develop in user mode using 'COLORY/M/C/K' in service mode (COPIER>TEST>PG). 2. If you want to change the density of the test print, use the following in service mode: TEST>PG>DENS-Y/M/C/K. a. Transfer Failure If transfer failure occurs, suspect a fault in the transfer (intermediate/secondary) unit. b. Uneven Density in Horizontal Direction If uneven density occurs in horizontal direction, suspect a fault in the photosensitive drum drive unit, drum ITB motor, or drum unit. c. Uneven Density in Vertical Direction If uneven density occurs in horizontal direction, suspect dirt on the LDE lens, a fault in the drum unit, or deterioration of the intermediate transfer belt. 16-5 Chapter 16 COLOR-M=1, COLOR-Y/C/K=0 F-16-2 16.2.6 Grid (TYPE=6) 0006-5700 Use this test print to check color displacement, right angle, or straight line. a. Color Displacement If color displacement occurs, suspect a fault in any of the laser exposure system, transfer (intermediate/secondary) unit, or photosensitive drum drive unit. b. Right Angle, Straight Line If right angles or straight lines are faulty, suspect a fault in the laser exposure system, registration (upper/lower) roller, or secondary external roller (i.e., the shape of the rollers). F-16-3 16-6 Chapter 16 16.2.7 MCYBk Horizontal Stripe (TYPE=10) 0006-5702 Use this test print to check the density of dark areas of individual colors, balance among colors, and white lines in relation to development. a. Solid Density of Colors and Balance Among Colors - The density must not be appreciably low (light). - If the density of a specific color is too low, suspect a fault in the developer, primary transfer roller, laser exposure system, or high-voltage system used for that color. b. White/Black Lines If a white/black line occurs for a specific color, suspect a fault in the drum unit used for that color or dirt in the laser optical path. c. Uneven Density at the Front/Rear If uneven density occurs for a specific color, suspect a fault in the drum unit, laser exposure system, or transfer (intermediate/secondary) unit. If uneven density occurs for all colors, suspect deterioration of the intermediate transfer unit. 2.5±1.5 mm 2.0±1.5 mm F-16-4 16-7 Chapter 16 16.2.8 Gradations (TYPE=12) 0006-5704 Use this test print to check the reproduction of gradation for all colors (YMCBk) at once. F-16-5 16.2.9 Full Color 16 Gradations (TYPE=14) 0006-5705 Use this test print to check gray balance, the reproduction of gradation for individual colors (YMCBk), or fogging. a. Gray Balance Check to see if each color is reproduced at an even level of density in the gray scale area. b. Gradation Check the reproduction of gradation of individual colors (YMCBk) and for the difference, if any, in density. c. Fogging If fogging occurs in the white area, suspect a fault in the developing system or the photosensitive drum, or improper adjustment of the laser exposure system. Light area White area White area F-16-6 16-8 Chapter 16 16.3 Troubleshooting 16.3.1 Symptoms 16.3.1.1 Image Fault Case Studies (A4) 0000-5378 The following is a collection of faulty images that can occur on A4 or larger paper; they have been artificially created, and may slightly differ from actual faulty copies. A. Image Fault Case Samples 1. Light Image in Middle F-16-7 2. Toner Collection Along Image End F-16-8 16-9 Chapter 16 3. Uneven Density at 44-mm Intervals F-16-9 4. Uneven Density at Angle at 12-mm Intervals F-16-10 5. Uneven Density in vertical direction F-16-11 16-10 Chapter 16 6. Mottled Image F-16-12 7. Flow image on Side F-16-13 8. Toner Stray F-16-14 16-11 Chapter 16 9. 47-mm Horizontal Line F-16-15 10. 100-mm Horizontal Line F-16-16 11. White Spot Along Trailing Edge F-16-17 16-12 Chapter 16 12. Vertical Lines (Charging Roller) F-16-18 13. Trace of Delivery Clip F-16-19 14. Trace of Pickup Roller Along Leading Edge F-16-20 16-13 Chapter 16 15. Trace of Pickup Roller F-16-21 16.3.1.2 Image Fault Case Samples (A3) 0000-5379 The following is a collection of faulty images that can occur on A3 or larger paper; they have been artificially created, and may slightly differ from actual faulty copies. 1. White Spot on Edge F-16-22 16-14 Chapter 16 2. 20 to 30-mm White Spot F-16-23 3. White Spots Leading Edge F-16-24 16-15 Chapter 16 4. Fine White Spot Near 30 mm of Trailing Edge F-16-25 5. Line Along Trailing Edge F-16-26 16-16 Chapter 16 6. Poor Parallel Reproduction Along Trailing Edge F-16-27 7. Rub off Along Trailing Edge F-16-28 16-17 Chapter 16 16.3.2 Image Faults 16.3.2.1 Blank Image 16.3.2.1.1 Blank page is output when printing scanned image 0004-0707 [ Case in the field ] Field Remedy Launch the file in question with 'Imaging' (selectable software by right-clicking) and print it. If the result is OK, the application software is likely to be a cause, so check its settings. 16.3.2.2 Solid Image 16.3.2.2.1 Solid black image on prints and FAX RX documents 0005-6110 [ Case in the field ] < Field Remedy > In the field, this symptom occurred because the Main Controller PCB (Main) was faulty. Unplug and reinsert the connectors on it. If the symptom still recurs, replace it with a new one. Main Controller PCB (Main): FG6-2854 16.3.2.3 Light Image / Weak Density 16.3.2.3.1 Density is light on paper corresponding to machine rear side: Occurs concurrently with diagonal uneven density of 12mm intervals when continuously outputting high image duty original 0002-3362 [ Manual-related ] Cause This symptom occurs because toner replenishment cannot keep pace with toner consumption. Field Remedy In service mode (Level 2) [COPIER> Option> BODY> SLV-UP], select "1" or "2". Note: The drum life will be shortened as a negative effect of "1". In addition to this, the print productivity will decrease as a negative effect of "2". 16.3.2.3.2 Density fluctuation: appreciable after outputting images of a high color ratio continuously 0002-3372 Cause The balance in toner inside the developing assembly fails; when the image stabilization mechanism goes ON in this condition, the machine tends to base its contrast potential on the existing condition. When the balance between the toner and the carrier inside the developing assembly returns, the density fluctuates in relation to the selected contrast potential. Field Remedy Execute the following in user mode: adjust/clean>auto gradation correction>full correction 16-18 Chapter 16 16.3.2.3.3 Uneven density of 12mm intervals in diagonal direction/Density at the rear is light: when continuously generating an image with a high color ratio 0002-3391 Symptom When an image with a high color ratio is generated continuously, the density at the rear tends to become too low (light). It tends to occur simultaneously with uneven density in diagonal direction at intervals of 12 mm. Cause The amount of toner supplied cannot keep up with the amount of toner being consumed. Field Remedy Set '1'or '2'to the following in service mode: COPIER>OPTION>BODY>SLV-UP.adverse effect of setting it to'1' the life of the drum unit will decrease. adverse effect of setting it to '2' the life of the drum unit will decrease, and the print productivity will also decrease. 16.3.2.3.4 Uneven gloss of 155mm width along the leading edge of the 1st print: when attempting to print an image with a high color ratio on thick paper (209g or more and coated paper) 0002-3398 Symptom Uneven gloss (about 155 mm) occurs along the leading edge of the 1st print when an image with a high color ratio is printed on thick paper (209 g or more and coated paper). Cause There is an appreciable difference in temperature between the 1st rotation of the fixing roller and its 2nd and subsequent rotations (with a peripheral length of 155 mm). Field Remedy If prints are made continuously, the fault does not occur on the 2nd and subsequent prints.If prints are made continuously, the fault does not occur on the 2nd and subsequent prints. 16.3.2.3.5 Flow image along the edges of the sheet: after the machine has been left alone in a high humidity environment for a long time (e.g., 2 days) 0002-3411 Symptom If the machine has been left alone in a high humidity environment for a long time (e.g., 2 days), flow image can occur along the edges of the sheet. Cause The chemical elements on the surface of the photosensitive drum absorbs moisture from the atmosphere, thus decreasing the resistance on the surface of the drum. 16-19 Chapter 16 Field Remedy Add a cassette heater (to keep the inside of the machine warm). Execute the following in user mode: adjust/clean>internal cleaning. The symptom may disappear when several prints have been made on A3 paper. 16.3.2.3.6 Traces of delivery roller on thick paper (particularly, coated paper): When making copy of high image duty original 0002-3503 [ Manual-related ] Description If thick paper (particularly, coated paper) is used on machines manufactured in the early stage of production (old type of the delivery vertical path ass'y is installed), there might occur a difference in gloss between the area where the delivery rollers come in contact and the other area, when the paper passes through the rollers, depending on the paper in use and the toner duty of the original document. Field Remedy 1. Replace the three parts listed below with a new one respectively. 2. In service mode (Level 2) [COPIER> Option> BODY> CTM-MARK], change the set value to "1". Note: As a result of the setting change above, the paper delivery speed when the delivery vertical path ass'y is used will be changed and thus the productivity might be affected. Therefore, be sure not to change it if the machine operates normally. FG6-9654 Delivery Vertical Path Ass'y FG6-9655 Vertical Path Panel Ass'y VS1-6318-003 Snap Tight Connector 16.3.2.3.7 Traces of pickup roller in Bk solid image printed on paper with a high moisture content 0002-3506 Symptom Traces of the pickup roller occur in Bk solid images printed on moist paper. Cause The moisture content of the area coming into contact with the pickup roller is low, showing a resistance higher than the areas with a higher moisture content. Field Remedy Add a cassette heater and/or cassette internal sheet. 16.3.2.3.8 Uneven density of 12mm intervals in diagonal direction/Density at the rear is light: when 0002-4598 Symptom When an image with a high color ratio is generated continuously, the density at the rear tends to become too low (light) and, thereafter, the overall density tends to decrease. Cause The amount of toner supplied cannot keep up with the amount of toner being consumed. 16-20 Chapter 16 Field Remedy Set '1'or '2'to the following in service mode: COPIER>OPTION>BODY>SLV-UP.adverse effect of setting it to '1' the life of the drum unit will decrease. adverse effect of setting it to '2' the life of the drum unit will decrease, and the print productivity will also decrease. 16.3.2.3.9 Light image at the rear side: 1cm from the edge of paper, when making a copy with A4 or A3 0002-4782 Symptom Light image at the rear side: 1cm from the edge of paper, when making a copy with A4 or A3 Description This symptom occurs only on copied images, not on the test print or printed images. Cause As a result of inspection, the CCD unit was found to be faulty. Field Remedy Make a reduction copy, and if the portion of light image moves together with the image, replace the CCD unit with a new one. 16-21 Chapter 16 F-16-29 16.3.2.3.10 Light image: appearing all over the page 0002-8528 Symptom Light image: appearing all over the page Cause As a result of inspection, reinstallation of the secondary transfer external roller solved the symptom. Field Remedy It is possible that the secondary transfer external roller is not installed properly, thus reinstall it again. 16-22 Chapter 16 F-16-30 16.3.2.3.11 Fine lines are not printed sharply when printing via UFR 0004-2919 [ Case in the field ] Field Remedy On the window of UFR printer properties, press 'Quality' tab and select 'Designs (CAD)' that appears under 'Objective'. 16.3.2.3.12 When executing UFR printing in monochrome, density of color area of original is too light 0005-1894 [ Case in the field ] Field Remedy There is a case in the field that the setting changes on the printer driver improved the symptom. Follow the steps below: Click [Quality] tab> select [Designs (CAD)] under [Objective]> click [Details]> select [Pattern 1] under [Halftones]. 16-23 Chapter 16 16.3.2.4 Foggy Image 16.3.2.4.1 Ground color of cut-and-paste newspaper transferred to the copied image 0002-3252 Symptom When you use a cut-and-paste newspaper as an original, the ground color of the newspaper remains on the printed document. Description When you put newspaper on the whole copy board glass for an original, the ground color of the newspaper can be suppressed with the AE Function. Cause The AE measurement fails, because the cut-and-paste newspaper is located outside of the AE measurement coverage. Spot Disposal Expalin to the users that they should select 'Application Mode>Image adjustment> Ground Color Suppression' to make a copy in using a cut-and-paste newspaper as an original. 16.3.2.4.2 Fogging on the entire Magenta image: as if it were combed with a brush 0002-3322 Symptom Image appears to have been given a magenta wash. Cause The earth plate of the magenta drum unit contacts the earth pin of the main unit drum unit door guide (FF62110-000). The earth pin is moved out of place or there is contact failure due to soiling. Field Remedy Correct or clean the magenta earth pin of the drum unit door guide. 16.3.2.4.3 Fogging appears on the entire image as if it were combed with brush: all colors affected 0002-3327 [ Case in the field ] Cause In the field, this symptom occurred because the grounding pins of the drum unit door guide, which come in contact with the grounding plates of each color's drum unit, were misaligned or soiled and finally had poor contact with the grounding plate. Field Remedy Align or clean the grounding pin for the affected color in the drum unit door guide. 16-24 Chapter 16 F-16-31 16.3.2.4.4 Fogging appearing on the entire Black image as if it were combed with a brush 0002-3330 Symptom Image appears to have been given a black wash. Cause The earth plate of the black drum unit contacts the earth pin of the main unit drum unit door guide (FF6-2110000). The earth pin is moved out of place or there is contact failure due to soiling. Field Remedy Correct or clean the black earth pin of the drum unit door guide. 16.3.2.4.5 Density fluctuation (increase): immediately after replacement of the drum unit in a high humidity environment 0002-3368 Symptom In a high humidity environment, the density tends to fluctuate (increase) immediately after replacement of the drum unit.In a high humidity environment, the density tends to fluctuate (increase) immediately after replacement of the drum unit.In a high humidity environment, the density tends to fluctuate (increase) immediately after replacement of the drum unit.In a high humidity environment, the density tends to fluctuate (increase) immediately after replacement of the drum unit. 16-25 Chapter 16 Cause The developer is exposed to the moisture of the environment and, as a result, the charge on the toner decreases to increase the density. Field Remedy Execute the following in user mode: adjust/clean>auto gradation adjustment>full correction. 16.3.2.4.6 Reverse fogging: appreciable when the drum unit has been in use for a long time in a low humidity environment 0002-3373 Symptom In a low humidity environment, reverse fogging tends to occur when the drum unit has been in use for a long time. Cause The toner has deteriorated, thus not being able to take on adequate negative charge. Field Remedy Replace the drum unit of the color in question.As a temporary measure, turn off and then on the main power switch so that the formation of a sample image (for image stabilization control) will remove the faulty toner from the drum. 16.3.2.4.7 Fogging in Y area: appreciable after the machine has been left along for a long time (e.g., 2 days) in a high humidity environment 0002-3375 Symptom In a high humidity environment, fogging occurs in Y areas if the machine has been left alone for a long time (e.g., 2 days). Cause The toner (MCBk) charged to a positive potential and existing on the photosensitive drum is drawn to the Y toner charged to a negative potential and existing on the ITB. Field Remedy Generate about 10 prints of solid images of the color in question using A3 paper. 16.3.2.4.8 Fogging in Y area: appreciable after the machine has been left along for a long time (e.g., 2 days) in a high humidity environment 0002-3377 Symptom Toner collection occurs along image end when the machine is left alone for a long time (e.g., 1 week). 16-26 Chapter 16 Cause When the machine is left alone for a long time, the level of charge on the toner tends to decrease. Field Remedy Generate about 10 prints of solid images of the color in question using A3 paper. 16.3.2.4.9 Color shift/Uneven density (rough texture): when continuously generating an image with low color ratio 0002-3406 Symptom The hues are not appropriate or the density is not even when images with a low color ratio have been generated continuously. Cause The toner inside the developing assembly has remained unconsumed without being stirred for a long time, thus increasing the charge of the toner and, ultimately, causing re-transfer or mixing of colors. Field Remedy Set '1'to the following in service mode: COPIER>OPTION>BODY>DEVL-PTH. Adverse effect of setting it to'1' the life of the toner container will decrease. 16.3.2.4.10 Yellow spots or yellow ghosting on skin colored-area 0002-3590 Symptom Yellow spots or yellow ghosting on skin colored-area Description This symptom appears only on copied images, not on printed ones. Cause Main Controller PCB Ass'y is faulty. Field Remedy Replace the Main Controller PCB Ass'y with a new one. 16.3.2.4.11 Light density at center of halftone image: appreciable after feeding transparencies in a high humidity environment 0002-4638 Symptom In a high humidity environment, the middle of a halftone image tends to become low in density after passage of a transparency. Cause The coating agent on the surface of the transparency sticks to the ITB, making transfer of toner from the ITB to paper difficult. 16-27 Chapter 16 Field Remedy Execute the following in user mode: adjust/clean>internal cleaning. 16.3.2.4.12 Fogging on the entire Cyan and Yellow images 0003-2364 [ Case in the field ] Description This symptom does not appear on the test print. Cause There is a case in the field that replacement of the CCD unit solved the problem. Field Remedy Try replacing the CCD unit with a new one. After replacement, be sure to execute CCD-ADJ in service mode. 16.3.2.4.13 Fogging on the entire Cyan image 0003-2390 [ Inspected by Canon Inc. ] Description This symptom does not appear on the test print. Cause There is a case in the field that unplugging/insertion of the connectors on the reader controller PCB solved the problem. Field Remedy Unplug and insert the connectors J204, J205 and J206 on the reader controller PCB. If the problem is not solved, replace the reader controller PCB with a new one. F-16-32 16-28 Chapter 16 16.3.2.4.14 Fogging on white area 0003-2700 [ Case in the field ] Description Fogging on white area Cause There is an actual case in the field that the symptom was solved by the following actions: unplugging/reinsertion of the flat cables of the Interface PCB, replacement of the Interface PCB. Field Remedy Try unplugging/inserting the flat cables J307 and J308 on the Interface PCB. If the symptom is still not solved, try replacing the Interface PCB with a new one. 16.3.2.4.15 Fogging in Magenta appearing on entire image 0003-3077 [ Inspected by Canon Inc. ] Description This symptom does not appear on the test print. Cause As a result of inspection, the CCD unit was found to be faulty. Field Remedy At first, output a test print to check whether fogging does not appear on the entire image. Next, unplug and insert the connectors J204 and J205 on the reader controller PCB. If the symptom still appears, replace the CCD unit with a new one. F-16-33 16-29 Chapter 16 16.3.2.4.16 86mm-wide fogging in sub scanning direction 0003-8743 [ Inspected by Canon Inc. ] Description This symptom occurs only on copied images, not on a test print or printed images. Cause As a result of inspection, the main controller PCB (sub) was found to be faulty. Field Remedy 1. Execute 'CCD0ADJ' and 'SH-PS-ST' in service mode [COPIER>Function>CCD]. 2. If the symptom still recurs, replace the CCD unit and the reader controller PCB with a new one in this order. 3. If the symptom still recurs, this indicates that the reader unit is normal. Replace the DDI-S board with a new one. 4. If the symptom still recurs, this indicates that the interface between the reader unit and the printer unit is normal. Replace the main controller PCB (sub) with a new one. CCD unit:FM2-0023 READER CONTROLLER:FG3-2570 SUB CONTROLLER:FG3-3129 F-16-34 16-30 Chapter 16 16.3.2.4.17 Fogging: after upgrading System Software to Ver.9.05 0003-8768 [ Verified by Canon Inc. ] Field Remedy On System Software Ver.9.05, the gradation adjustment was improved. When upgrading it from Ver.8.04 and earlier to Ver.9.05 and later, be sure to execute auto gradation adjustment (full adjustment) after upgrading. 16.3.2.4.18 Background is fogged when making a copy of newspaper 0004-2926 Field Remedy Press [Special Features>Image Quality Adjustment>Remove Background]. If the symptom still recurs, press [Fine Adjustment] that appears by the side of 'Remove Background' key to adjust the density of the background you want to remove. Adjusting it to the direction of 'minus' will lighten the background. 16.3.2.4.19 Fogging in Magenta as if noise had occurred 0004-9715 [ Inspected by Canon Inc. ] Field Remedy It is possible that the flexible cables inside the CCD unit (two cables are aligned at the back of the CCD unit) are not securely fitted. Make sure that they are securely fitted. F-16-35 16-31 Chapter 16 F-16-36 16.3.2.4.20 Fogging in Magenta appearing at position corresponding to machine front side, during continuous copying 0004-9720 [ Case in the field ] Field Remedy There is a case in the field that the symptom was corrected by adjusting the auto gradation adjustment (full adjustment). So, execute it in user mode [Adjustment/Cleaning> Auto Gradation Adjustment> Full Adjustment]. 16.3.2.4.21 Fogging under low humidity environment 0004-9774 [ Verified by Canon Inc. ] Field Remedy Ever since DCON Ver.10.02 (DCON software which is to be installed simultaneously with System Ver.10.01), the service mode described below has been newly added in order to ease fogging which might occur under low humidity environment. This service mode switches a bias of the lower auxiliary brush under low humidity environment from -800V to -850V. If fogging occurs under low humidity environment, upgrade DCON to Ver.10.02 and later. The current setting can be checked in the service mode below. Service mode (level2) [COPIER> Option> BODY>LSUB-DWY/DWM/DWC] 0: -850V [Factory default/A setting value after RAM is cleared: 0] 1: -800V 16-32 Chapter 16 16.3.2.4.22 Fogging with BK cartridge that has been used for a certain period of time 0004-9776 [ Verified by Canon Inc. ] Field Remedy Ever since DCON Ver.10.02 (DCON software which is to be installed simultaneously with System Ver.10.01), the service mode described below has been newly added in order to ease fogging which might occur with the BK cartridge that has been used for a certain period of time. This service mode switches the amount of toner in the BK developing assembly whose cartridge has been used for a certain period of time. If fogging occurs under such environment, upgrade DCON to Ver.10.02 and later. Service mode (level2) [COPIER> Option> BODY>BKTC-DWN] 0: The amount of toner in the developing assembly: small [Factory default/A setting value after RAM is cleared: 0] 1: The amount of toner in the developing assembly: large 16.3.2.4.23 Adjustments to be executed upon occurrence of fogging (Addition of service mode items) 0004-9782 [ Verified by Canon Inc. ] Field Remedy The service mode items below have newly been added to DCON Ver.10.02 (DCON software which is to be installed simultaneously with System Ver.10.01) in order to ease fogging. - Adjusting the upper limit of VD: Service mode (level 2) [COPIER> Adjust> VCONT> VD-LIM-Y/M/C/K] The smaller the set value is, the lesser the fogging becomes. - Adjusting the amount of toner replenishment: Service mode (level 2) [COPIER> Adjust> DENS> T-SPLY-Y/M/C/K] The smaller the set value is, the lesser the fogging becomes. - Enables to switch a bias of the lower auxiliary brush under low humidity environment (-800V to -850V): Service mode (level2) [COPIER> Option> BODY>LSUB-DWY/DWM/DWC] - Enables to change the toner amount in the developing ass'y which has been used for a certain period of time: Service mode (level2) [COPIER> Option> BODY>BKTC-DWN] 16.3.2.4.24 Fogging during continuous duplex copying or printing 0004-9813 [ Verified by Canon Inc. ] Field Remedy During continuous duplex-copying or -printing the image in low density, it is likely to be fogging. This symptom has been corrected with System Ver.10.01. So, if this happens, upgrade the system to Ver.10.01 and later. 16-33 Chapter 16 16.3.2.4.25 Fogging in reddish purple appears on entire page, Message [Correctly place the test print on the platen glass.] is displayed: No problem on print from computer and test print 0005-1922 [ Inspected by Canon Inc. ] Field Remedy As a result of inspection, it was found that the Reader Controller PCB was faulty. If this symptom occurs, replace it with a new one. Reader Controller PCB Ass'y: FG3-2564 (100V), FG3-2570 (120/220/240V) F-16-37 16.3.2.4.26 Fogging in Cyan on entire page; no problem with test prints 0005-6106 [ Inspected by Canon Inc. ] < Field Remedy > As a result of inspection, it was found that this symptom occurred because the flat cable connecting to J203 on the Reader Controller PCB was not securely fitted. Unplug and reinsert the flat cable of J203 once again. 16.3.2.4.27 Overall fogging with margins: Occurs only on black-and-white copies, no problem with color copies and test prints [ Inspected by Canon Inc. ] Cause As a result of inspection, it was found that this symptom occurred because the CCD unit was faulty. Field Remedy 16-34 0006-4448 Chapter 16 Follow the steps below: 1. Make sure that the interface cable connecting the reader unit and the printer unit is securely fitted. 2. Check whether this symptom was resolved by performing "CCD-ADJ" and "SH-PS-ST" in service mode [COPIER> Function> CCD> CCD-ADJ, SH-PS-ST]. When selecting the item, the adjustment will start automatically. 3. Make sure that the connectors between the CCD unit, the Reader Controller PCB and the Interface PCB are securely fitted. 4) If the symptom still recurs even after the Steps 1 through 3, replace the CCD unit with a new one. After replacement of the CCD unit, enter the values (for color displacement correction in sub scanning direction) indicated on the label attached to the unit in service mode [COPIER> Adjust> CCD> CCDU-RG, CCDU-GB]. CCD Unit: FM2-0023 F-16-38 16.3.2.5 Uneven Density 16.3.2.5.1 Uneven color around characters: when being printed on half-tone background in combination with MacOS and QuarkXpress 0002-3290 [ Case in the field ] Field Remedy In the field, the setting change on Mac side improved the symptom. Select [Printer Functions> Halftone> Resolution]. Description When "Resolution" is selected for the Halftone setting, the reproductivity for halftone will be improved and thus uneven color will be relieved. 16-35 Chapter 16 16.3.2.5.2 Uneven density at about 6mm intervals in the sub scanning direction 0002-3292 [ Inspected by Canon Inc. ] Cause As a result of inspection, this symptom occurred because the secondary transfer roller was not properly installed at the designated position. Field Remedy Reinstall the secondary transfer roller once again. 16.3.2.5.3 Uneven density at 44 mm intervals: when the drum unit has been in use for a long time 0002-3389 Symptom Uneven density at an angle and at 12 mm intervals; tending to occur simultaneously with low density at the rear or over the entire image when an original of a high color ratio is printed continuously. Cause Toner sticks to the charging roller, and soils it. Field Remedy Set '1'or '2'to the following in service mode:COPIER>OPTION>BODY>SLV-UP. adverse effect of setting it to '1' the life of the drum unit will decrease. adverse effect of setting it to '2' the life of the drum unit will decrease, and the print productivity will also decrease. 16.3.2.5.4 Uneven density in vertical direction occurs when images with a high color ratio are generated in large volumes. 0002-3393 Symptom Uneven density in vertical direction occurs when images with a high color ratio are generated in large volumes. Cause Filming (white soiling) occurs on the surface of the photosensitive drum, affecting exposure. Field Remedy Be sure to refer to the instructions indicated on how to clean the photosensitive drum (dry wiping the photosensitive drum of the color in question). 16.3.2.5.5 Uneven density at 0.8mm intervals Symptom Uneven density occurs at 0.8 mm intervals, tending to be noticeable in halftone images. Cause The rotation of the photosensitive drum drive gear is uneven. 16-36 0002-3396 Chapter 16 Field Remedy Set '2'to the following in service mode: COPIER>OPTION>BODY>TMC-SLCT. 16.3.2.5.6 Mottled image: when large numbers of prints are made daily and, the drum unit has been in use for a long time 0002-3400 [ Inspected by Canon Inc. ] Cause The toner in the developing assembly is caking into lumps. Field Remedy Clean the inside of the machine in user mode [Adjustment/Cleaning> Cleaning inside Main Unit]. Note: It is recommended to execute the mode every 4000 prints or more, as a guide. 16.3.2.5.7 Uneven image (rough texture) in halftone images 0002-3404 [ Inspected by Canon Inc. ] Cause The level of secondary transfer current is so high that the transfer efficiency decreases because of re-transfer. Field Remedy 1. Clean the inside of the machine in user mode [Adjustment/Cleaning> Cleaning inside Main Unit]. 2. In service mode level 2 [COPIER> Adjust> HV-TR> 2TR-TGT/2TR-SHR/TR-ENV/TR-PPR/TR-CLR/TRDUP], change the set value with extra care. Note: As adverse effects of changing the setting, it is possible toner scattering or spots will worsen. 16.3.2.5.8 Uneven density (rough texture) in Bk solid images: in a high humidity environment 0002-3408 Symptom In a high humidity environment, uneven density occurs in Bk solid images. (rough texture) Cause The level of secondary transfer current is too high, thus decreasing the transfer efficiency because of re-transfer. Field Remedy Execute the following in user mode: adjust/clean>auto gradation correction>full correction. Or, add a cassette heater. 16.3.2.5.9 Toner scattering around image with a high color ration in a low humidity environment 0002-3413 Symptom Toner stray tends to occur around an
