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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
16.3.11.1 037 ......................................................................................................................................... 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

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

A4

32

19

32

13.5

10.25

STMT-R

16

16

LTR

32

19

13.5

10.25

B5R

16

16

7.5

LTR-R

16

16

7.5

A4R

16

16

7.5

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

3.75

3.5

LTR-R

11

3.75

3.5

A4R

11

3.75

3.5

LGL

9.5

3.25

2.75

B4

9.5

3.25

2.75

A3

6.5

3.25

2.75

279mm x 432mm

6.5

3.25

2.75

7.5

6.5

3.25

2.75

A5

9.5

Jpn postcard

9.5

Tab paper

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

LTR

LTR-R

A4R

Chapter 1

- Monochrome, transparency
T-1-22
unit: prints/min
Paper size

Cassette, single-sided

Manual feeder, single-sided

B5

A4

LTR

LTR-R

A4R

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

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

BAT1

SW3

SW2

LED5
LED6
LED4

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

BAT1

LED5
LED6
LED4

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
SW3

SW2

LED5
LED6
LED4

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

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

SW3

SW2

LED5
LED6
LED4

[16]

IC6

SW1

CN3

CN2

F-2-105

2-38

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

BAT1

SW3

SW2

LED5
LED6
LED4

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

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

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

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]

SW3
SW4

[16]

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

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

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 90C or more
Standby (at this time, the surface
temperature of the fixing roller must
have reached 190C)

WMUP

WMUPR

PSTBY

360 sec
Fixing main heater
(H1)
Fixing sub heater
(H2)

90C

*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 100C,
if 100C or higher
(control at 190C)
[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 190C)

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 190C)

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

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

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 90C or more
Standby (at this time, the surface
temperature of the fixing roller must
have reached 190C)

WMUP

WMUPR

PSTBY

360 sec
Fixing main heater
(H1)
Fixing sub heater
(H2)

90C

*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 100C,
if 100C or higher
(control at 190C)
[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 190C)

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 90C)

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 machines 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

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

When data is being read from BOOTDEV, the machine


detects a read error sector.

Action:
H

NG

NG

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

NG

- 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

NG

NG

- xxyy = 0801, FF01

Action:
A

02

NG

NG

There is a file system error.

Action:
B

NG

- 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

- if xxyy = 0802, FF02

Action:
B

03

NG

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

NG

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

There is a read error.

Action:
A

NG

NG

- if xxyy= 0713, 0725


Action:
A

NG

NG

- if xxyy = 0813, 0825

Action:
A

10,12,14,2

NG

NG

There is a system error or a packet data error.

2,23,24

Action:
B

NG

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

PDL spool

PDLDEV

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

unselected

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 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)

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.

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 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

[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
279.4431.8mm
(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

sensor 1

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

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

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

Status of laser A

Status of laser B

OFF

OFF

OFF

APC control

(bias current applied)


0

APC control

OIFF
(bias current applied)

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

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

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

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

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

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

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

ITB
cleaning
block

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 100C
(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 100C 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 100C 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 100C 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

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

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

SALT-Dmax control

SALT-Dmax control

(determines developing DC,

(determines developing DC,

charging DC, primary current

charging DC, and primary

levels)

transfer levels)

Chapter 9

Full correction

Quick correction

PASCAL control

(prepares image correction

table A)

Image position correction

Image position correction

SALT-Dhalf control

SALT-Dhalf control

(prepares image correction

(prepares image correction

table B)

table C)

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

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

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

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

STMT R

ON

LTR

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

LGL

ON

11X17*1

A5 R

ON

A4

ON

A4 R

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

(1)

(3)

(2)

2
1 check on horizontal
registration

(4)

3
1

in wait for
re-pickup

1
2

(6) with 2 sheets inside duplex unit


(5)

(7)

10-27

Chapter 10

1
4
3

(8)

2
1

2
5

5
5

(10)
thereafter, repeats (7) through (10)

(9)

3
2
1

(12)

10-28

(11)

Chapter 10

5
4
3
2
1

4
3
2
1

(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)

(2)

(3)

10-29

Chapter 10

check on horizontal
registration

(4)

2 point of reversal

1
1 in wait for

1
2

re-pickup

(5)

(6)

3
2

(8)
thereafter, repeats (6) through (8)

10-30

non-contact reversal

(7)

Chapter 10

3
2
1

2
1

(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

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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

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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].

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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

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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];