Canon Ir2200 Ir2800 Ir3300 Service Manual

Confidential
New Product Information
iR2200/2800/3300
Date : January 25, 2001 File No. : C-17-01-001 Released by : Canon Inc. OIP QA Center OIP TS Division
This document precedes the Service Manual for the product in question and serves as a reference, thereby providing the Sales Companies with a good understanding of the product in advance. Most of the contents of this document are not official and, therefore, are subject to change before the product is brought into being, making it important to bear in mind that the descriptions are true only as of the date indicated on the cover.
Yoshiaki Takase, General Manager OIP QA Division
(TS001102)
New Product Information
Introduction to New Product Information The document New Product Information replaces the Trainers Manual (TR) most of you are familiar with, and is the result of our efforts to provide information useful to all departments concerned in each Sales Company. Most of the contents of this document are not official and, therefore, are subject to change before the product is brought into being, making it important to bear in mind that the descriptions are true only as of the date indicated on the cover. The Service Manual for the product will have descriptions updated to reflect the changes that may have occurred. Kindly make arrangements so that this document is properly disposed of as soon as the Service Manual is released.
January,25, 2001 Canon Inc. OIP QA Center OIP QA Division
CHAPTER 1 GENERAL DESCRIPTION
COPYRIGHT 2001 CANON INC. 2000 2000 2000 2000 CANON iR3300/2800/2200 REV.0 JAN. 2001
1 Specifications
1.1 Main Body
1.1.1 Type
Item Body Copyboard Light source Lens Photosensitive medium Description Desktop Fixed Xenon lamp Lens array OPC drum (30-mm dia.)
T01-101-01
1.1.2 Systems
Item Reproduction Charging Exposure Copy density adjustment Development Pickup Auto Description Indirect electrostatic AC roller Laser Auto or manual Single-component toner projection Front cassette (2 cassettes) Retard method (about 500 sheets of 80 g/m2 paper, about 550 sheets of 64 g/m2 paper) Multifeeder Dual process method (about 50 sheets of 80 g/m2 paper) Roller Static eliminator (static separation) + curvature Blade SURF method (plane heater and fixing film)
Manual Transfer Separation Cleaning Fixing
T01-101-02
1-1
1.1.3 Functions
Item Resolution Description 600dpi600dpi 1200dpi600dpi 2400dpi600dpi Sheet, book 3-D object (2 kg max.) A3/279.4431.8mm (11"17") Direct (1:1), Reduce I (1:0.250), Reduce II (1:0.500), Reduce III (1:0.611), Reduce IV (1:0.707), Reduce III (1:1.414), Enlarge IV (1:2.000), Enlarge V (1:4.000), Enlarge VI (1:8.000), Zoom (1:0.250 to 8.000 in 1% increments) 10 sec or less (at 20C) 5.4 sec (book mode, cassette 1, Direct, A4/LTR, text mode) 999 copies max. A3 max., A5 (vertical feed) min. 279.4431.8 mm (11"17") max., STMT (vertical feed) min. A3 max., postcard (vertical feed) min. 279.4431.8 mm (11"17") max., STMT (vertical feed) min. Plain paper (64 to 80 g/m2):A3, B4, A4, B5, A5R, A4R, B5R, 279.4431.8mm (11"17"), LGL, LTR, LTRR, STMT, STMTR Tracing paper (SM-1):A3, B4, A4, B5, A4R, B5R Colored paper (Canon-recommended):B4, A4, A4R Plain paper (64 to 80 g/m2):A3, B4, A4, B5, A5R, A4R, B5R, 279.4431.8mm (11"17"), LGL, LTR, LTRR, STMT, STMTR Tracing paper (SM-1, GSN-75):A3, B4, A4, B5, A4R, B5R Transparency (Canon-recommended):A4, A4R, LTR, LTRR Colored paper (Canon-recommended):B4, A4, A4R Postcard: Jpn (vertical feed), double-card, 4-sheet card Label sheet (Canon-recommended):B4, A4, A4R, LTR, LTRR Thick paper (90 to 128 g/m2):A3, B4, A4, B5, A4R, B5R, LTR, LTRR Envelope
Reading Copying Printer output
Original type Maximum original size Reproduction ratio
Wait time First copy time Continuous copying Copy size Cassette
A/B Inch AB Inch
Manual feed
Cassette 1/2
Multifeeder
T01-101-03
1-2
Item Single-sided copying mode
Description Plain paper (64 to 80 g/m2):A3, B4, A4, B5, A5R, A4R, B5R, 279.4431.5mm (11"17"), LGL, LTR, LTRR, STMT, STMTR Tracing paper (SM-1, GSN-75):A3, B4, A4, B5, A4R, B5R Transparency (Canon-recommended)A4, A4R, LTR, LTRR Colored paper (Canon-recommended):B4, A4, A4R Postcard: Jpn postcard (vertical feed), double-card, 4-sheet card Label sheet (Canon-recommended):B4, A4, A4R, LTR, LTRR Thick paper (90 to 128 g/m2):A3, B4, A4, B5, A4R, B5R, LTR, LTRR Envelope
Double-sided copying mode (automatic) Plain paper (64 to 80 g/m2):A3, B4, A4, B5, A5R, A4R, B5R, 279.4431.8mm (11"17"), LGL, LTR, LTRR, STMT, STMTR Colored paper (Canon-recommended):B4, A4, A4R Thick paper (90 to 128 g/m2):A3, B4, A4, B5, A4R, B5R, LTR, LTRR Double-sided copying mode (multifeeder) Plain paper (64 to 80 g/m2):A3, B4, A4, B5, A5R, A4R, B5R, 279.4431.8mm (11"17"), LGL, LTR, LTRR, STMT, STMTR Colored paper (Canon-recommended):B4, A4, A4R Postcard: Jpn (vertical feed), double-card, 4-sheet card Thick paper (90 to 128 g/m2):A3, B4, A4, B5, A4R, B5R, LTR, LTRR
T01-101-04
1-3
Description None 55 mm deep (approx.; about 500 sheets of 80 g/m2 paper) Hard disk 6.4GB (*1) Non-image width Leading edge Direct, Enlarge/Reduce:4.01.5/-1.0mm <4.51.8mm>*2 Trailing edge Direct, Enlarge/Reduce:2.01.5mm <2.01.8mm>*2 Left/right (1st side) Direct, Enlarge/Reduce:2.51.5mm <2.52.0mm>*2 Auto clear Yes (2 min standard; may be changed in 1-min increments between 0 and 9 min) Auto power-off Yes Low-power mode Yes (15 min standard; may be changed in user mode to 10, 15, 20, 30, 40, 50, 60, 90 min, 2, 3, or 4 hr) Sleep mode Yes (60 min standard; may be changed in user mode to 10, 15, 20, 30, 40, 50, 60, 90 min, 2, 3, or 4 hr) Yes (-10% standard; may be changed in user mode to 10%, -25%, -50%, or no return (0%)) Accessory DADF-H1 Copyboard Cover Type-E Copyboard-D1 Copy Tray-F1 Saddle Finisher-G1 Puncher Unit-G1 Finisher-J1 Inner 2-Way Tray-A1 Side Paper Deck-L1 2-cassette Pedestal-W1 Options Power Supply-B1 (required for SF, PD) Cassette Heater Kit-16N Control Card-IV Network LIPS Printer Kit-A1 (100V model only) Network Multi-PDL Printer Kit-A1 (120/230V model only) *1:The HDD that comes with the machine and the HDD that is made available as a service part may have different memory sizes; however, the area of the HDD used by the machine will be the same, and either may be used without a problem. *2:The values within parentheses indicate when the DADF is used. Claw Capacity
Item Cassette
T01-101-05 The above specifications are subject to change for product improvement.
1-4
1.1.4 Others
Item Operating environment Temperature range Humidity range Atmospheric pressure Power supply 100V (50/60Hz) 120V (50/60Hz) 220V/60Hz 230V (50/60Hz) Description 15 to 30C 5 to 80% 810.6 to 1013.3 hpa (0.8 to 1.0 atm) E201 LQHxxxxx LQJxxxxx NRFxxxxx NRGxxxxx PKMxxxxx PKKxxxxx PKLxxxxx QCWxxxxx RBZxxxxx SCKxxxxx TBZxxxxx UFMxxxxx E201: 1.5 kW or less E201: 282 W (approx.; reference only) E201: 995 W (approx.; reference only) Sound power level (Impulse mode) E201: 66 dB or less, E202: 71 dB or less E201: 40 dB or less, E202: 50 dB or less 0.01 ppm or less avg., 0.02 ppm or less max. 565 (W) 678 (D) 1020 (H) 565 (W) 678 (D) 1040 (H) 80 kg (approx.) Keep wrapped to protect against humidity. Keep away from direct sunshine, and keep at 40C/85% or less.
Power consumption
Maximum Standby Continuous Copying Standby
Noise
Ozone Dimensions (mm)
(iP-Lite) (iP-Std)
Weight Consumables Toner
Copy paper
T01-101-06
1-5
Reproduction mode Direct
Side A3 (297420mm) A4 (210297mm) A5 (149210mm) B4 (257364mm) B5 (182257mm) A4R (297210mm) B5R (257182mm) A5R (210149mm)
Paper size A3 A5 A4 B4 B5 A4R B5R A5R
copies /min (1-to-N) E201 E202 16 22 33 14 28 -
Reduce II (50.0%) III (61.1%) IV (70.7%) V (81.6%) VI (86.5%)
A3 A5R A3 B5R B4 B5R A3 A4R B4 A4R B5R A5R A4 B5 A3 B4
A5R B5R B5R A4R A4R A5R B5 B4
Enlarge IV (200.0%) III (141.4%) II (122.4%) I (115.4%)
A5R A3 A4R A3 B5R B4 A4R B4 A5 B5 B4 A3 B5 A4
A3 A3 B4 B4 B5 A3 A4
Delivery by copier, Auto paper select ON, Auto density, Non-sort, Deck/Cassette T01-101-07 Copying Speeds (copier only)
1-6
Reproduction mode Direct
Size 279.4431.8mm (11"17") LTR LGL LTRR STMTR 279.4431.8mm (11"17") STMTR 279.4431.8mm (11"17") LTRR 279.4431.8mm (11"17") LGL LGL LTRR 279.4431.8mm (11"17") LTR LGL LTRR STMTR STMTR LTRR LGL LTRR
(1toN) E201 22 -
E202 16 33 14 -
Reduce II (50.0%) III (64.7%) IV (73.3%) V (78.6%) Enlarge IV (200.0%) III (129.4%) II (121.4%)
STMTR* 279.4431.8mm (11"17") LTRR 279.4431.8mm (11"17") LGL 279.4431.8mm (11"17") Paper size
279.4431.8mm (11"17") 279.4431.8mm (11"17") 279.4431.8mm (11"17") copies/min
*STMTR cannot be used as an original. Delivery by copier, Auto paper select ON, Auto density, Non-sort, Deck/Cassette T01-101-08 Copying Speeds (copier only) The above specifications are subject to change for product improvement.
1-7
1.2 Side Paper Deck-L1

Item Pickup method Paper accommodation Paper type (horizontal feed only) Capacity Serial number Paper size switch Dimensions Weight Power supply Operating conditions Description Retard Front loading Plain paper (65 to 80 g/m2): A4, B5, LTR Colored paper (Canon-recommended): A4 2,500 sheets (approx.; 80 g/m2 paper) A4 type:XCQxxxxx LTR type: XCRxxxxx By size guide plate/in service mode 324 (W) 591 (D) 432 (H) mm 30 kg (approx.) None (DC power supplied by accessories power supply of host machine) Same as host machine
T01-200-01 The above specifications are subject to change for product improvement.
1-8
2 Names of Parts
2.1 External View
[1] [2]
[3]
[7]
[4] [8]
[5]
[6] [9]
[1] [2] [3] [4] [5] [6] [7] [8]
ADF Original tray Control panel Front cover Cassette 1 Cassette 2 Delivery tray Multifeeder
[9] Right lower cover [10] DIMM ROM replacement cover [11] Network card slot [12] Parallel connector [13] Extension board slot [14] Main power switch [15] Cassette heater switch
F01-201-01 External View 1
1-9
[1] [2]
[3]
[5]
[4] [6]
[7]
[1] [2] [3] [4]
Copyboard glass DADF reading glass Left cover Left lower rear cover (waste toner case cover)
[5] Developing assembly releasing lever [6] Feeding assembly releasing lever [7] Duplex feeding assembly releasing lever
F01-201-02 External View 2
1-10
2.2 Cross Section
F01-202-01 Cross Section
1-11
[1] DADF reading glass [2] No. 1 mirror [3] Scanning lamp [4] Copyboard glass [5] Fixing assembly [6] Feeding assembly [7] Laser mirror 3 [8] Laser mirror 2 [9] Laser mirror 1 [10] Drum cleaner assembly [11] Primary charging assembly [12] Photosensitive drum [13] Laser mirror 4 [14] CCD unit [15] Laser unit [16] Dust-proofing glass [17] Developing cylinder [18] Pre-transfer charging assembly [19] Multifeeder pickup roller T01-202-01
[20] Multifeeder separation roller [21] Registration roller [22] Transfer roller [23] Static eliminator [24] Cassette 1 pickup roller [25] Cassette 1 feeding roller [26] Cassette 1 separation roller [27] Cassette 2 pickup roller [28] Cassette 2 feeding roller [29] Cassette 2 separation roller [30] Cassette 1 [31] Cassette 2 [32] Lower fixing roller [33] Inside delivery roller [34] Outside delivery roller [35] Upper fixing roller [36] No. 3 mirror [37] No. 2 mirror
1-12
3. System Configuration
3.1 Functional Construction
The machine may be broadly divided into the following six functional blocks:
Original Optical path Original illumination
Various networks or public telephone network
CCD PCB Original Exposure Block
Control panel
Various accessory boards
Reader controller PCB
Main controller PCB Image Processing Block HDD
DC controller PCB DC power supply PCB Control Block Laser driver PCB Laser scanner Laser Exposure Block
Charging Cleaning Photosensitive drum Development Image Formation Block Pickup control Multifeeder Side paper deck (accessory) Pickup/Feeding Block
Delivery tray
Feeding
Lower feeding assembly Cassette 1 Cassette 2
F01-301-01
Transfer
Separation
Fixing
1-13
3.2.1 Construction of the Electrical Circuit
3.2 Outline of the Electrical Circuitry
The major electrical mechanisms of the machine are controlled by the following PCBs: [1] Man controller PCB; controls the system as a whole, processes images [2] DC controller PCB; controls the printer unit, controls the finisher communication [3] Reader controller PCB; controls the reader unit, controls the DADF communication
1-14
Hard disk drive (HDD) Accessory boards IC5025 (CPU) IC1010 (CPU) (RAM) Main controller PCB IC125 (CPU) IC121 IC122 (RAM) DIMM/ ROM (IC117) IC104,105 IC109,110 IC127,130 (EEPROM) IC5027 (EEPROM) IC5008 IC5009 (RAM) CCD PCB IC5016 (ROM) (DIMMROM) IC5021 (IPC communication 2) Reader controller PCB LA2 Inverter Scanner PCB motor M3 ADF Accessories power supply PCB Drum Composite Main power power sensor supply supply PCB PCB PCB
IC6501 Control (CPU) panel PCB
Finisher (accessory)
IC120 (IPC communication 2)
F01-302-01
DC loads Clutch Solenoid Motor Sensor Fan Etc.
DC controller PCB
Pickup PCB
BD Laser PCB drive PCB
3.3 Inputs to and Outputs from the Major PCBs

3.3.1 Wiring Diagram of the Major PCBs
Potential control PCB J3
J103 J6604
LCD panel (LCD)
J6503
J6502 J6509 J6601 J6504 Keypad panel J6602 J6501 J6603 J6508 J6605 J6801 J1018
J107 Duplex driver PCB J2302
J6507 Control
Laser scanner J116 motor M15 J2511 Laser drive PCB

J121
Inverter PCB
J956
CPU PCB
J6506
PCB
J2501 J120
J6505 J1012 J122 J1015
BD PCB
J2701 J101
DC power supply PCB HVT PCB
J4003 J102 J4502
DC controller PCB
J1017
Hard disk
J1551
Environment sensor PCB J8492
J113
Control Card-IV (accessory)

J1532
Controller assembly
J1060
J5004
J1014
J113 Cassette 3 paper level detection PCB J806
Cassette 4 paper level detection PCB J810 AC driver PCB
J113
Copy Data Controller (accessory)

J1530
J1022
Reader controller PCB
J102 J2052 J104 J2101 J105 J2108
CCD/AP PCB Scanner motor M3 Inverter PCB
J5003
J6002 J5011
Motor driver PCB
J5007
J5101
Note: The
in the diagram indicates connection between PCBs, NOT the flow of signals.
F01-303-01
1-15
3.4 Configuration with Accessories

3.4.1 Accessories for Original/Paper Feeding
[1] [3]
[4]
[2]
[7]
[5]
[6] [8]
[9]
[10]
[1] [2] [3] [4] [5] [6]
DADF-H1 Copyboard Cover Type-E Copyboard-D1 Copy Tray-F1 Saddle Finisher-G1 Puncher Unit-E1 F01-304-01
[7] Finisher-J1 [8] Inner 2-Way Tray-A1 [9] Side Paper Deck-L1 [10] 2-Cassette Pedestal-W1 [11] Options Power supply-N1 (required when [5] or [9] is used)
1-16
3.4.2 Accessory Boards

LIPS Printer Kit-B1
LPS PCB
Relay PCB
Network PCB
Network Multi-PDL Printer Kit-B1
RIP1 PCB
Relay PCB
Network PCB
Ethernet network
Network Network PCB
Relay PCB Relay PCB
Token Ring TokenRing PCB TokenRing network
Super G3 FAX Board-J1 Multiport Kit-B1
Public telephone network
G4 FAX Board-B1
ISDN network
F01-304-02
1-17
CHAPTER 2 ORIGINAL EXPOSURE SYSTEM
1. Outline of Operations
1.1 Outline
The original exposure system has the following major functions:
Item Original illumination Original scanning Description Xenon tube In Book mode: by moving scanner With ADF in use: by fixed No. 1 mirror base at stream reading position Scanner HP sensor (PS400) [1] Copyboard Mode (25% to 800%) Main scanning direction: image processing by controller assembly Sub scanning direction: for a ratio of 50% or higher, changing scanning speed of No. 1 mirror; for a ratio of lower than 50% and 400% or higher, chaining scanning speed and image processing [2] ADF Mode (25% to 400%) Main scanning direction: image processing by controller assembly Sub scanning direction: for a ratio of 50% or higher, changing original feeding speed; for a ratio of lower than 50% and 200% or higher, No. 1/No. 2 mirror base: control by stepping motor (M400) Lens array, fixed type [1] Control of activation by inverter circuit [2] Control for error detection [1] In Book Mode Sub scanning direction: by reflection type sensor Main scanning direction: by CCD [2] With ADF in Use By ADF
scanner position detection Reproduction ratio (zoom)
Scanner drive control Lens Scanning lamp control Original size detection
2-1
1.2 Changing the Reproduction Ratio (Zoom)

[1] In Copyboard Mode If for a reproduction ratio of 25% to 800%, the speed of the scanner is changed. [2] With ADF in Use If for a reproduction ratio of 25% to 400%, the speed of the movement of the original is changed.
1.2.1 Changing the Reproduction Ratio in Main Scanning Direction

For scanning direction, reading is always at 100% in both copyboard and ADF modes; the ratio is changed in the course of data processing in the main controller assembly. To reduce, data units are skipped. To enlarge, data units are repeated.
1.2.2 Changing the Reproduction Ratio in Sub Scanning Direction

For sub scanning direction, the speed of the scanner/movement of the original is changed. However, for a reduction between 25% and 49% and enlargement between 401% and 800%, data processing in the main controller assembly is also used in combination. [1] For enlargement, the speed of the mirror/original is reduced from that used in Direct: e.g., at 200%, the speed is 1/2 of the speed used in Direct. [2] For reduction between 50% and 99%, the speed of the mirror/original is increased; e.g., at 50%, the speed is twice as high as that used in Direct.
(speed ratio) 2
1 1/2 1/4 (reproduction ratio) 50% 100% 200% 400%
F02-102-01 [3] For a reduction between 25% and 49%, image data read at 50% to 98% is subjected to skipping (1/2) in the main controller assembly. [4] For an enlargement between 401% and 800%, image data read at 200% to 400% is subjected to repeating (doubling) in the main controller assembly.
2-2
CHAPTER 3 LASER EXPOSURE SYSTEM
1 Outline of Operations
1.1 Outline
Part 2>Chapter 4>1.1 Outline of Laser Exposure The reader controller PCB serves to read image signals from the CCD and send image signals to the main controller assembly. The video signals from the main controller assembly are converted by the DC controller PCB into laser drive signals, and are turned into laser intensity signals to suit signal levels by the laser driver PCB. The laser intensity signals are used to cause the laser unit to generate a laser beam, which is directed to the photosensitive drum for the formation of latent static images. The laser beam is also used for blank exposure to create non-image areas. Item
Laser intensity control Laser scanning Synchronization control Laser scanner motor control
Description
Laser power auto control (APC control) By semiconductor laser Main scanning direction: control by BD signal Sub scanning direction: control by image leading edge signal Constant speed rotation control
T03-101-01
3-1
F03-101-01 shows the major components for the laser exposure system; the machines laser scanning is performed by means of a 6-facet polygon mirror and a single-beam laser unit:
Laser unit Cylindrical lens Polygon mirror (6-faceted)
Laser scanner motor BD mirror
Collimating lens
BD PCB
Laser mirror Photosensitive drum
F03-101-01 External View Component

Laser semiconductor Laser scanner motor (M10) Polygon mirror BD mirror/BD PCB Laser driver PCB DC controller PCB
Description
Visible laser light (about 6760 nm), single-beam DC brush-less motor, constant speed control 6-faceted Laser beam detection Laser activation control Laser scanner motor rotation control
T03-101-02 List of Components
3-2
1.2 Sequence of Operations (laser exposure system)

Main power switch ON/sleep mode OFF Original set/ADF opened Start key ON 180C AINTR STBY INTR PRINT LSTR STBY
8 sec Laser scanner motor Image leading edge signal Laser BD signal *: If silent mode (in user mode) is selected, the motor stops after a specific period of time.
F03-102-01 Basic Sequence of Operations
3-3
2 Generating Sync Signals

2.1 Outline
Part 2>Chapter 4>2 Generating BD Signals The BD signal used to synchronize the video signals in laser scanning direction is generated by the BD PCB with reference to the laser beam reflected by the BD mirror mounted in the path of the laser beam. The edge of paper re-picked in double-sided mode is detected by the horizontal registration sensor to measure the displacement to the rear/front. Based on the measurement, the timing of laser activation is changed with reference to the BD signal so that the image will be placed at a specific position on the paper without fail.
Laser unit Polygon mirror (6-faceted)
BD mirror
BD PCB
Photosensitive drum
F03-201-01 Construction of the Control System
3-4
2.2 Flow of Sync signals

[1] [2] [3] [4] [5] [6] The BD signal goes 0 when laser light is detected. The phase is matched with the phase of the printer, and a sync signal is generated. Based on the printer sync signal, image data is read from the image memory. Video signal The 2-pixel parallel signal is converted into a single-pixel serial signal. The laser drive signal is used to drive the laser unit to suit the video signal.
BD PCB
J3129 J312 GND 4 B11 GND 3 B12 [1] 2 B13 5V 1 B14
Sync signal generation [2]
J122 A18 [3]
J1015 A18 Memory control
J500 Laser driver PCB [6]
J307
Parallel/ serial conversion [5] DC controller PCB
J122 [4]
J1015
Controller assembly
F03-202-01 Flow of Signals E100 Indicates that the BD signal cannot be detected within a specific period of time after the laser has been turned on.
3-5
3 Laser Driver Circuit

3.1 Controlling the Laser Unit
The laser driver circuit is used to drive the semiconductor laser according to the laser drive signal from the DC controller PCB. The laser driver circuit performs the following: 1. Turning on/off the laser. 2. Controlling the light intensity of the laser (APC control). The signals have the following meanings and functions: [1] Laser drive signal; used to drive the semiconductor laser. [2] Sample laser activation signal; used to turn on the laser for intensity sampling (the result is used for activation for imaging). [3] Laser enable signal; goes 0 when the laser is ready after the Start key is pressed. [4] Image leading edge signal; used to start laser writing when paper reaches the image leading edge sensor (PSS12) mounted in front of the photosensitive drum. [5] Used to monitor the laser intensity when the laser is turned on for sampling, and feeds back the level appropriate to the intensity to the laser driver circuit. [6] Used to control the output so that the feedback level and the reference level from the DC controller will be identical. [7] Laser intensity reference signal; used as the laser activation reference level determined by the DC controller. [8] Horizontal registration paper detection signal; used to adjust the image position by changing the timing of laser activation with reference to the result of detection of the edge of paper re-picked in double-sided mode by the horizontal registration sensor (PS11).
3-6
J307
1 2 3 4 GND DATA(+) [1] DATA(-) [1] GND
J500
4 3 3 2 2 1
Laser assembly
[6]
Laser drive circuit
Laser Intensity monitor [5]
J310
1 2 3 4 5 GND +5V DAOUT [7] S/H [2] LDE [3] 5 4 3 2 1
J501
Laser driver PCB Laser unit J312 INT_TOPO_PD [4] Image leading edge sensor (PS12)
A8
A14
J304 Y_REG_PD [8] Horizontal registration paper sensor (PS11)
DC controller PCB
F03-301-01 1. The laser power of the laser unit is adjusted when the unit is shipped out of the factory.
REF.
3-7
DISPLAY>DPOT>LLMT-P Use it to indicate the laser power voltage control for printer (PDL) images. DISPLAY>DPOT>LLMT Use it to indicate the laser power voltage control for the copier. DISPLAY>DPOT>LPOWER-P Use it to indicate the result of potential control for the laser intensity during output of printer (PDL) images. DISPLAY>DPOT>LPOWER-C Use it to indicate the result of potential control for laser intensity during output of copier images. ADJUST>LASER>PVE-OFST Use it to adjust the position of laser illumination. ADJUST>LASER>LA-OFF Use it to adjust the timing of laser trailing edge de-activation for non-default size papers.
3-8
4 Controlling the Laser Scanner Motor

4.1 Outline
Part 2> Chapter 4> 4.1 Outline The following items are related to laser scanner motor control: [1] Laser scanner motor drive signal; when 1, the laser scanner motor goes ON (turning on/off the motor). [2] Laser scanner motor ready signal; when 0, the laser scanner motor rotates at a specific speed (constant speed rotation control).
J312 DC controller PCB
B9 B10
[2] [1] GND +24V
J3128 4 3 2 1
Speed control circuit
Motor driver
Main power supply PCB
2 1 J204
Reference pulse generation circuit
M10 Laser scanner motor
F03-401-01 Functional Block Diagram E110 Indicates the presence of an error in the laser scanner motor.
3-9
5.1 Laser Scanner Assembly

5.1.1 Removing the Laser Unit
[2]
[4]
1) Remove the delivery tray. (See p. ?.) 2) Open the harness guide [1], and disconnect the two connectors [2]. [3] 3) Disconnect the connector [3] of the BD PCB, and disconnect the two connectors [4] of the laser PCB.
[1]
F03-501-01 4) Remove the two springs [1] and the two stepped screws [2] on the left side, and remove the two screws [3] (w/washer) on the right; then, detach the laser unit.
[2] [1] [1] [3]
F03-501-02 When mounting, be sure to do so while butting it against the two leaf springs [1] at the front.
[1]
[1]
F03-501-03
3-10
When installing the Finisher-J1 (Chapter 10), be sure to attach the protective sheet [2] along the line marking [1] on the laser unit.
[1]
[2]
F03-501-04
3-11
CHAPTER 4 IMAGE FORMATION SYSTEM
1 Outline of Processes
1.1 Outline
T04-101-01 shows the functions of and the methods used in the image formation system:
Item Photosensitive drum drum cleaning Developing assembly Description OPC (30-mm dia.) cleaning blade Developing cylinder (20-mm dia.) Development method:dry, 1-component, toner projection Toner:magnetic, negative Fuse lamp (8 pc.) ON/OFF control (activated in sync with main motor) Primary charging roller DC bias corrected to temperature around photosensitive drum Primary charging roller AC bias corrected to suit humidity reading Pad push-on type DC constant voltage control (-500 to -850 V) AC constant current control (2000 to 2300 A; about 1800 Hz) DC constant voltage control (0 to -650 V) AC constant voltage control (810 Vp-p; about 1800 Hz) Transfer bias:DC constant current control (switching among +15 A, +10 A, +7 A) + DC constant voltage control (up to 7 kVmax) Cleaning bias: DC constant voltage control (-2.6 kV) DC constant voltage (-600 v) DC constant voltage (switching between -2.3 KV and -3.0 KV)
Pre-exposure (LAMP2) Drum sensor (U701) Environment sensor (S3) Primary charging roller auto cleaning Primary charging roller bias control Developing bias control Transfer charging roller bias control
Transfer guide bias control Separation static eliminating bias control
T04-101-01
4-1
F04-101-01 shows the major components of the image formation system:

Primary charging roller Pre-exposure lamp Cleaner unit Developing assembly
Photosensitive drum Separation static eliminator Transfer guide Transfer charging roller
F04-101-01
4-2
1.2 Basic Sequence of Operations (image formation system)

1 Original, 2 Prints
Control panel power switch Main power ON Start key ON supply switch ON AINRT SLEEP STBY INRT PRINT LSTR STBY
Main motor Pre-exposure lamp Laser activation Primary charging bias Primary charging bias Transfer charging [1] [2] bias Image leading edge sensor Developing bias Developing bias Transfer guide bias Separation static eliminating bias [1] transfer charging reference bias [2] transfer charging cleaning bias [3] transfer sheet-to-sheet interval bias
[2] [3]
[3]
[2]
F04-102-01
4-3
2 Controlling the Primary Charging Roller Bias

2.1 Outline
Part 2>Chapter 5>4.4 Controlling the Primary Charging Roller Bias The machines primary charging is a direct charging method that uses a charging roller. In addition to a DC bias, the charging roller is subjected to an AC bias to ensure stable charging. The following items relate to the control of primary charging: [1] Turning on/off the bias. [2] Controlling the DC bias to a specific level of voltage. [3] Controlling the AC bias to a specific level of current. [4] Controlling the photosensitive drum resistance detection mechanism (APVC control). [5] Controlling the AC bias based on the readings of the environment sensor (humidity) and the soft counters. [6] Controlling the DC bias based on the reading of the drum sensor (temperature).
Composite power supply PCB
+24V 24 VDC input J135 Transformer drive signal Primary DC charging highDC bias voltage output ON transformer signal (T502) DC bias output Output control signal control Current level (APVC measureCurrent ment) control Voltage level AC bias Primary AC output charging highvoltage trans former Current Drive detection control
Primary charging J301 output enable J136 signal -B4 -B9
DC controller PCB
Print/standby mode signal AC bias level signal DC bias level signal APVC measurement data
PW-CPU
Serial communication
Voltage DC bias output detection
Primary charging roller J130-4
Photosensitive drum
-A3 -A1
-A10 -A12
Transformer drive signal AC bias output control signal
Drum sensor (temperature)
J311-A2 J302-B14
Measurement result Measurement result
Environment sensor (humidity)
F04-201-01 The primary charging output enable signal is used as the AC pulse ON signal when the developing bias is being controlled.
Memo
4-4
2.2 Turning On/Off the Bias

The primary charging roller bias is turned on/off as follows:
2.2.1 DC Bias
[1] When the primary charging output enable signal from the DC controller PCB goes 0, the DC bias output control signal (pulse signal) is generated. [2] The DC bias is sent to the primary charging roller.
2.2.2 AC Bias
[1] When the primary charging output enable signal from the DC controller PCB goes 0, the AC bias output control signal is generated. [2] The AC bias is generated to the primary charging roller.
2.3 Controlling the Current Voltage/Current to a Specific Level

The output level of the DC/AC bias applied to the primary charging roller is controlled by the DC/AC bias output control signal from the PW-CPU.
2.3.1 Controlling the DC Bias to a Specific Level

[1] The output voltage level of the DC bias is fed back to the PW-CPU, and the DC bias output control signal is varied as needed to suit the level when driving the transformer. [2] The DC bias is made to assume a specific voltage level.
2.3.2 Controlling the AC Bias to a Specific Current Level

[1] The output current level of the AC bias is communicated to the drive control circuit and is compared against the reference current level; the result is used to vary the AC bias output control signal as needed to drive the transformer. [2] The AC bias is made to assume a specific current level.
4-5
2.4 Temperature Correction of the DC Bias

When the temperature inside the machine increases, the resistance of the photosensitive drum will decrease, thereby lowering the charging characteristics. To ensure a stable potential level, the drum sensor (U701) mounted to the rear side plate is used to check the temperature inside the machine; when the temperature increases, the absolute value of the DC bias level is increased.
Primary DC bias
-800V
-750V (reference value)
23C 40C Low High Machine inside temperature
F04-204-01
2.5 Humidity Correction of the AC Bias

The current level of the AC bias needs to be kept on the higher side to prevent uneven charging because of a lower changing efficiency occurring in a low-humidity environment. The AC bias, therefore, is varied as shown in F04-205-01 to suit the readings of the environment sensor (humidity). When the resistance of the drum surface decreases because of advancing wear, the current level is decreased to facilitate the flow of current.
Counter reading: 0 to 10,000 sheets Counter reading: 10,001 or higher
2300A
Primary AC bias
2150A 2000A
Low
35% Humidity
High
Low
35% Humidity
High
F04-205-01 4-6
2.6 Controlling the Detection of the Photosensitive Drum Resistance (APVC control)
The primary charging efficiency changes because of changes in the site environment (temperature, humidity), deterioration of the charging roller, and wear of the photosensitive drum. The reference voltage is applied to the charging roller when the main power switch is turned on, and the resulting output current level is measured for correction. [1] When the main power switch is turned on, the reference voltage is applied to the charging roller, and the output is measured as the current level for use as feedback to the PWCPU. [2] The photosensitive drum is charged (primary charging) using the voltage level determined by the PW-CPU.
4-7
2.7 Controlling the Output Mode

In continuous print mode, the outputs of both AC bias and DC bias are varied between image areas and non-image areas to prevent stray toner in the non-image areas. E064 Indicates the presence of a high-voltage (primary charging, transfer charging, developing) output fault. COPIER>DISPLAY>HV-STS>PRIMARY Use it to indicate the current level of primary charging. COPIER>ADJUST>HV-PRI>P-DC Use it to enter the adjustment value of the primary charging DC component for the image area. COPIER>ADJUST>HV-PRI>P-AC Use it to enter the adjustment value of the primary charging AC component for the image area. COPIER>ADJUST>HV-PRI>AGS-GAIN Use it to enter the gain adjustment value of the application voltage level correction for the primary charging bias. CCOPIER>ADJUST>HV-PRI>AGS-OFST Use it to enter the offset adjustment value of the application voltage level correction for the primary charging bias. CCOPIER>ADJUST>HV-PRI>OFST1-DC Use it to enter the adjustment value of offset 1 for the primary charging DC component. CCOPIER>ADJUST>HV-PRI>OFST1-AC Use it to enter the adjustment value of offset 1 for the primary charging AC component. CCOPIER>ADJUST>HV-PRI>P-AC2 Use it to enter the adjustment value of primary charging AC component 2 of the image area. CCOPIER>ADJUST>HV-PRI>P-AC3 Use it to enter the adjustment value of primary charging AC component for the image area.
4-8
3 Controlling the Transfer Charging Roller Bias

3.1 Outline
Part 2>Chapter 5>7.8.3 Controlling the Transfer Roller The machines transfer charging is a direct charging method that uses a transfer charging roller. A DC bias is applied to the transfer charging roller. The following relate to the transfer charging system: [1] Turning on/off the bias. [2] Controlling the DC bias to a specific voltage/current level. [3] Controlling the detection of transfer charging roller resistance (ATVC control) [4] Controlling the output by operation mode [5] Controlling the output by the environment sensor (humidity)
+24V 24 VDC input J135 Transfer charging J301 output enable J136 signal -B9 -B4 Transfer output -B8 mode signal 4 -B5 Serial communication
Transformer drive signal
Transfer cleaning bias high-voltage Cleaning bias output transformer ON signal (T506)
Cleaning bias out
Photosensitive drum T133 Transfer charging roller
Voltage level (ATVC measurement result)
DC controller PCB
Print/standby mode signal Transfer bias output data ATVC measurement data
PW-CPU
Voltage detection Transformer drive signal Transfer bias output ON signal Transfer bias output control signal Transfer bias high-voltage transformer (T133) Transfer bias output
-A3 -A1
-A10 -A12 Transfer output -B5 mode signal 1 -B8 Transfer output -B6 mode signal 2 -B7
Drive control
Current level
Current detection
Environment sensor (humidity)
Transfer output -B7 mode signal 3 -B6
Transfer bias output current switching signal
J302-B14
Measurement result
F04-301-01
4-9

The transfer charging roller bias is turned on/off as follows: [1] When the transfer charging output enable signal from the DC controller PCB goes 0, the transfer bias output signal (serial communication) is generated. [2] The transfer bias output control signal (pulse) is generated, and the DC bias is sent to the transfer charging roller.
3.3 Controlling the Detection of the Transfer Charging Roller Resistance (ATVC control)
The transfer charging efficiency changes because of changes in humidity and deterioration in the transfer charging roller. The reference current is applied to the transfer charging roller during initial multiple rotation after the main power switch is turned on, and the resulting output voltage is measured for correction. [1] The reference current is applied to the transfer charging roller, and the output is checked as a voltage level for use as feedback to the PW-CPU. [2] The transfer charging mechanism operate using the voltage level determined by the PWCPU.
4-10
3.4 Controlling the Output by Operating Mode

3.4.1 Types of Modes
The transfer charging output may be any of the following output modes, and the output is varied to suit each mode. The switch-over among these is based on the combination of transfer output mode signals from the DC controller PCB. a. Image Transfer Bias This bias is used to transfer toner from the photosensitive drum to paper, and is a positive voltage. b. Cleaning Bias This bias is used to return toner sticking to the transfer charging roller to the photosensitive drum, and applies a negative voltage. During initial rotation after the Start key is pressed During last rotation During initial rotation after jam removal or error resetting During execution of roller cleaning in user mode (adjust/clean; in this case, the primary charging roller is also cleaned) During multiple rotation after the main power switch is turned on c. Reference Bias This bias is used to control the detection of the photosensitive drum, and is applied during multiple initial rotation after the main power switch is turned on. d. Sheet-to-Sheet Interval Bias This bias is used in a non-image area (between sheets) in continuous print mode; the bias level is reduced to prevent adhesion of toner to the transfer charging roller. E064 Indicates the presence of a high-voltage (primary charging, transfer charging, development) output fault.
4-11
Control panel Main power power switch ON Start key ON switch ON AINTR SLEEP STBY INTR PRINT LSTR STBY
Main motor (M1) Cleaning bias Reference bias Sheet-to-sheet bias Image transfer bias
F04-304-01
3.4.2 Turning On/Off the Cleaning Bias

When the cleaning bias output ON signal (composite power supply PCB) goes 1, the output of the transfer cleaning bias transformer is applied to the transfer charging roller.
4-12
3.5 Controlling the Output

The output of the DC bias applied to the transfer charging roller is controlled as follows: The optimum transfer charging roller bias differs depending on paper size and site environment; as such, the DC controller is designed to automatically control the output level to suit the paper size and the site environment in question. COPIER>DIPLAY>HV-STS>TR Use it to indicate the current level of transfer charging. COPIER>DIPLAY>HV-STS>TR-V Use it to indicate the voltage level of the transfer charging roller resistance detection. COPIER>ADJUST>HV-TR>TR-N1 Use it to enter the output adjustment value for transfer charging (plain paper; single-sided print or 1st side of double-sided print). COPIER>ADJUST>HV-TR>TR-N2 Use it to enter the output adjustment value for transfer charging (plain paper; 2nd side of double-sided print) COPIER>ADJUST>HV-TR>TR-OFST Use it to enter the offset output adjustment value for transfer charging roller resistance detection. COPIER>ADJUST>HV-TR>TR-SPP Use it to enter the output adjustment value for transfer charging (special paper; single-sided print and double-sided print) COPIER>OPTION>BODY>TRANS-SW Use it to set the transfer charging roller bias output control method for large-size paper.
4-13
4 Controlling the Separation Static Eliminator Bias

4.1 Outline
Part 2>Chapter 5>8.3 Separation by the Static Eliminator The machine uses a static eliminator for separation. A DC bias is applied to the static eliminator; the following are items of control: [1] Turning on/off the bias [2] Controlling the bias to a specific voltage level [3] Controlling the output to suit paper type and reading by the environment sensor (humidity)
+24V 24 VDC input J135 Static J301 eliminator bias J136 -B3 enable signal -B10 High-voltage main transformer (T504) Output control Photosensitive Static drum eliminator bias output J132 Separation static eliminator
DC controller PCB
Voltage detection Voltage level
Serial communication Print/standby mode signal Static eliminator bias mode signal
PW-CPU
Static eliminator bias output ON signal
Static eliminator bias mode signal
-A3 -A1
-A10 -A12
F04-401-01
4-14

The separation static eliminator bias is turned on/off as follows: [1] When the static eliminator bias enable signal from the DC controller PCB goes 0, the static eliminator bias output ON signal is generated. [2] A DC bias is sent to the separation static eliminator.
4.3 Controlling the Bias to a Specific Voltage Level

The bias output is fed back to the output control circuit, thereby ensuring a specific level of voltage.
4.4 Controlling the Output by Paper Type and Environment Sensor (humidity)
In a low-humidity environment, separation can fail when thin paper is used or when the second side of a double-sided sheet is hadled. To ensure good separation, the voltage applied is increased between -2.3 and -3.0 KV with reference to the type of paper and the reading of the environment sensor (humidity). The selection of an application voltage is done in response to the static eliminator bias mode signal (serial communication) from the DC controller PCB.
4-15
5 Controlling the Transfer Guide Bias

5.1 Transfer Guide Bias
Part 2>Chapter 5>7.2 Transfer Guide Method The transfer guide bias is used to prevent adhesion of toner to the transfer guide, and is a negative component (-600 VDC), which is of the same polarity as the toner. The transfer guide bias is continuously applied as long as printing is under way.
Composite power supply PCB +24V 24 VDC input J135
DC controller PCB
Serial communication Print/standby mode signal J301 -A3 -A1 J136 -A10 -A12
PW-CPU
Transfer guide output High-voltage main transformer (T504)
Photosensitive drum J131-3 Transfer guide
F04-501-01
4-16
6 Primary Charging Roller Cleaning Mechanism

6.1 Outline
Part 2>Chapter 5>10.1.5 Primary Charging Roller Cleaning Mechanism The machines primary charging roller is cleaned by turning on the primary charging roller cleaning solenoid (SL6) while the primary charging roller is rotating, thereby butting the cleaning pad against the primary charging roller. At the same time, the cleaning pad is moved back and forth in the axial direction of the primary charging roller. Cleaning is executed under the following conditions: During last rotation after the cumulative count reaches 500 sheets During execution of roller cleaning in user mode (adjust/clean; in this case, the cleaning bias is applied to the transfer charging roller pad for cleaning)
SL6 (ON)
Back-and-forth movement
Cleaning pad
Primary charging roller
Photosensitive drum
F04-601-01
4-17
7 Developing Assembly
7.1 Outline
The developing assembly consists of the developing cylinder, toner sensor (S1), and toner stirring rod; its is locked manually together with the developing rail using the locking lever. The developing cylinder and the toner stirring rod are rotated by the drive of the main motor (M1) transmitted by way of the developing clutch (CL3).
Developing cylinder Developing bias control signal J301 J136 Toner stirring rods
Developing bias
PW-CPU
J130-1 Photosensitive drum
DC controller PCB
Toner sensor(S1)
Main motor drive signal J308
Main motor M1
Developing clutch CL3 Toner detention signal
J302-5
F04-701-01
4-18
7.2 Controlling the Developing Bias

7.2.1 Outline
Both DC bias and AC bias are applied to the developing cylinder. The output is controlled by the composite power supply PCB based on the control signal from the DC controller PCB. The following relate to the developing bias control system: [1] Controlling the DC developing bias to a specific voltage level [2] Controlling the AC developing bias to a specific voltage level
+24V 24 VDC input J135 High-voltage main transformer Transformer (for DC) drive signal Output control Voltage detection Developing cylinder
J301 DC bias J136 -B1 ON signal -B12 AC pulse ON signal
Photosensitive drum J130-1
-B4
-B9
DC controller PCB
PW-CPU
DC bias control signal Voltage level
Serial communication DC bias level signal -A3 -A1 -A10 -A12
Transformer Developing drive signal high-voltage AC bias transformer (for AC)
-B2
AC bias ON signal
-B11
F04-702-01 The AC pulse ON signal is used as the primary charging output enable signal when controlling primary charging.
Memo
4-19
7.2.2 Controlling the DC Developing Bias

[1] When the DC bias ON signal from the DC controller PCB goes 0, the bias control signals (pulse signals) are generated by the PW-CPU of the high-vole power supply PCB. [2] The DC bias from the high-voltage main transformer is applied to the developing cylinder. [3] The output voltage level of the DC bias is fed back to the HV-CPU. [4] The pulse width of the DC control signal is varied to suit the return voltage, thereby maintaining the DC bias to a specific level.
7.2.3 Controlling the AC Developing Bias

[1] When the AC bias ON signal and the AC pulse ON signal from the DC controller PCB goes 0, the AC transformer is driven. [2] An AC bias is added to the DC bias and applied to the developing cylinder.
7.2.4 Controlling the Level of the DC Developing Bias

the level of the DC developing bias is varied between image area and non-image area to prevent stray toner inside the machine. In memory copy mode, the laser is driven based on binary image data which lacks density information, not enabling adjustment using a density correction curve for the density of the image being generated. To make up for the lack, the DC developing bias is varied for density adjustment. E064 Indicates the presence of a high-voltage (primary charging, transfer charging, development) output fault. COPIER>ADJUST>DEVELOP>DE-DC Use it to enter the adjustment value of the developing bias DC component for the image area. COPIER>ADJUST>DEVELOP>DE-OFST Use it to enter the offset value for the developing bias DC component.
4-20
7.3 Detecting the Level of Toner

Part 2>Chapter 5>6.2.2 Piezoelectric Sensor A toner sensor (S1) of a piezoelectric oscillation type is mounted inside the developing assembly for detection of the level of toner. The DC-CPU on the DC controller PCB reads the output of the toner sensor as long as the developing clutch (CL3) remains on; it keeps track of the 0 state of the toner sensor (most recent two readings), and indicates the Add Toner message as needed.
toner absent level 2 Toner absent level 1 The cumulative period of absence of toner fro the most recent two readings is 7 sec or more, Copying FAX reception Printer output enabled enabled enabled OK NG OK (6 sec in total) (8 sec in total) (5 sec in total) The cumulative period of absence of toner for the most recent two readings is 20 sec or more, Copying FAX reception FAX output Printer output disabled enabled disabled disabled
FAX transmission enabled
NG
(22 sec)
Check point
Developing clutch (CL3) Toner sensor(S1) 2 sec 4 sec 4 sec 1 sec 22 sec
When the power switch is turned off and then on, recovery occurs after stirring the toner for 6 sec.
When the power switch is turned off and then on, the presence of toner is detected; recovery occurs after stirring the toner for 30 sec.
F04-703-01
4-21
8 Drum Cleaner
8.1 Outline
The drum cleaner assembly is rotated by the drive of the main motor (M1) transmitted through drive gears; the waste toner is colleted by the cleaning blade, and is sent to the waste toner case using the waste toner feedscrew. The amount of waste toner inside the waste toner case is monitored by the waste toner case full sensor (S2); when the amount exceeds a specific level, the Waste Toner Full message will be indicated on the control panel.
Waste toner feedscrew
Waste toner case full sensor (S2)
S2
Waste toner case full signal
M1
Main motor
Waste toner box
J311-B9 J308 DC controller PCB
F04-801-01
4-22
Main motor M1
Waste toner case full sensor (S2; light-receiving)
Cleaning blade
Photosensitive drum
Waste toner case full sensor (S2; light-emitting) Waste toner feedscrew Waste toner case
F04-801-02
4-23
8.2 Monitoring the Waste Toner Case

The machine checks the waste toner case in reference to two levels. The amount of waste toner inside the waste toner case is monitored by the waste toner case full sensor (S2); the sensor is a pair of photosensors (light-emitting unit piece and light-receiving piece). The machine will assume that the waste toner case has become full when waste toner blocks the light between the two photosensors. The DC controller PCB checks the waste toner case full sensor when the power is tuned on and at time of delivery; it will assume a waste toner full warning after making a total of 100 prints (A4/LTR) after the waste toner case has become full, thereby indicating the Waste Toner Case Full message on the control panel. Thereafter, if the waste toner case is not replaced after making a total of about 2000 prints (A4/LTR), the machine will indicate E019 on the control panel; the error code can be reset by replacing the waste toner case and then turning off and then on the power switch. If the waste toner case is not set, the light-blocking plate will block the light between the photosensors, causing the Waste Toner Case Full message to appear. The light between the photosensors is not visible to the eye.
Memo
DC controller PCB
+5V
Waste toner case full sensor (light-receiving)
J311-B7
Waste toner case full signal -B9

a-B8
Waste toner case full sensor (light-emitting) Waste toner case
F04-802-01
4-24
8.3 Locking of the Waste Toner Feedscrew

The waste toner feedscrew is rotated by the drive of the main motor transmitted by the coupling built into the main motor drive assembly. The coupling is butted against the gear used to rotate the screw by the work of a spring. If the drum cleaning assembly is clogged with waste toner, the coupling will start to move back and forth in the axial direction, causing a clicking sound. The machine is not equipped with a sensor to detect the locking of the waste toner feedscrew.
Memo
Photosensitive drum Main motor M1 Spring
Coupling
Waste toner feedscrew
F04-803-01 E019 Indicates that the waste toner case is full.
The waste toner case can hold waste toner equivalent of about 200,000 prints.
Memo
4-25
9.1 Pre-Exposure Lamp Unit

9.1.1 Handling of the Pre-Exposure Lamp Unit
1) Remove the drum unit. (See p. $.) 2) Remove the inside cover. (See p. $.) 3) Disconnect the connector [1], and remove the screw [2]. 4) Take out the pre-exposure lamp unit [3].
[1]
[3]
[2]
F04-901-01
4-26
9.2 Photosensitive Drum

9.2.1 Removing the Drum Unit
1) 2) 3) 4) 5) Open the front cover. Release the feeding assembly. Release the developing assembly. Remove the fixing screw [1]. Slide out the drum unit [2] slowly to the front.
[2]
[1]
F04-902-01 Take care not to damage or soil the photosensitive drum. Further, be sure to protect the photosensitive drum against light once it is outside the machine; it is highly susceptible to light.
As many as 19 stirrups [1] (4 types) are attached to the bottom of the drum unit. Take care not to crush them. Further, be sure to place the drum unit on a flat surface once it has been removed out of the machine.
[1]
F04-902-02
4-27
9.2.2 Cleaning the Photosensitive Drum

If the surface of the photosensitive drum has become soiled, wipe it with a flannel cloth coated with toner. (Do not use paper, lint-free or otherwise.) Never dry-wipe the photosensitive drum or use solvent.
9.2.3 When Replacing the Drum Unit

Be sure to record the date of replacement and the latest counter reading to the label [1], and attach it to the front cover of the drum unit; then, make adjustments according to the Image Adjustment Basic Procedure (p. $).
[1]
F04-902-03 After replacing the drum unit, be sure to perform the work under 7.7 Removing Paper Lint.
4-28
9.3 Transfer Charging Roller

9.3.1 Removing the Transfer Charging Roller
Do not touch the surface of the transfer charging roller when removing it. Otherwise, image faults can occur. 1) Remove the feeding assembly. (See p. $.) 2) Pull off the static eliminator [1]. 3) Remove the screw [2], and detach the hinge bin [3].
[3]
[2]
[1]
F04-903-01 4) Remove the transfer arm [1] equipped with a spring to the left together with the transfer charging roller [2].
[3]
(1) (2) [1] [2] [4]
F04-903-02 5) Pull it off to the front.
4-29
9.4 Charging Roller Solenoid

9.4.1 Removing the Charging Roller Solenoid (SL6)
1) Remove the photosensitive drum. (See p. $.) 2) Open the rear cover. (7 screws) 3) Remove the DC controller PCB. (see p. $.) 4) Remove the four screws [1], and detach the DC controller base [2].
[1] [1]
[2]
F04-904-01 5) Disconnect that two connectors [1] of the harness. 6) Remove the three screws [2], and pull out the duct unit [3] to the front.
[2] [1]
[1]
[1]
[3]
[2]
F04-904-02 7) Remove the claw, and detach the two relay PCBs [1].
[1]
F04-904-03 4-30
8) Remove the faston [1] of the harness, and detach the duct unit [2].
[1]
[2]
F04-904-04 9) Remove the two screws [1], and disconnect the connector [2]; then, detach the charging roller solenoid [3].
[2] [1] [3]
F04-904-05
4-31
9.5 Developing Assembly

Keep the following in mind when disassembling/assembling the developing assembly: 1. When holding the developing assembly, avoid touching the developing cylinder. 2. After mounting the developing assembly, be sure to mount the developing assembly stopper. 3. The blade and the blade base of the blade base unit are adjusted at the factory to a high accuracy; do not separate them.
9.5.1 Removing the Developing Assembly

1) Open the front cover. 2) Shift down the developing assembly releasing lever [1] to free the developing assembly [2]. 3) Remove the screw [3], and lift the bottom of the developing assembly stopper [4] to the front to remove it to the bottom. 4) Holding the grip of the developing assembly with one hand and supporting it on its bottom with the other, pull it to the front.
[2]
[3]
[4]
[4]
[1]
(1)
(2)
F04-905-01
4-32
9.5.2 Removing the Grip Assembly

1) Remove the developing assembly. (See p. $.) 2) Remove the screw [1] and the three claws [23], and detach the grip assembly [3].
[3]
[1]
[2]
F04-905-02
9.5.3 Removing the Tone Sensor

1) Remove the grip assembly. (See 7.6.2.) 2) Remove the two screws [1], and disconnect the connector [2]. 3) Detach the toner sensor [3].
[3]
[2]
[1]
F04-905-03
9.5.4 Removing the Developing Assembly Upper Cover

1) Remove the grip assembly. (See 7.6.2.) 2) Remove the two screws [1] and the three claws [2]. 3) Remove the developing assembly upper cover [3].
[2]
[1]
[3]
F04-905-04
4-33
9.5.5 Removing the Developing Cylinder

1) Remove the developing assembly upper cover. (See p. $.) 2) Remove the two screws [1], and detach the blade base unit [2].
[2]
[1]
F04-905-05 The blade [1] and the blade base [2] of the blade base unit are assembled to a high accuracy at the factory. Do not separate them.
[2]
[1]
F04-905-06
9.5.6 Developing Assembly Cylinder

1) Remove the developing assembly upper cover. (See p. $.) 2) Remove the E-ring [1], bearing [2], and gear [3].
[3] [1] [2]
F04-905-07 4-34
3) Remove the two screws [1], and detach the gear cover [2]. 4) Remove the two gears [3].
[2]
[1]
[3]
F04-905-08 5) Put copy paper [3] between the developing cylinder [1] and the blade [2].
[2]
[1]
[3]
F04-905-09 6) Remove the screw [1] and the grounding plate [2]. 7) Remove the grip ring [3].
[1] [3] [2]
F04-905-10
4-35
8) Remove the two screws [1], and detach the member [2] and the front sleeve holder [3].
[3]
[1]
[2] [1]
F04-905-11 9) Remove the two screws [1], and detach the member [2] and the rear sleeve holder [3].
[1] [2]
[3]
[1]
F04-905-12 10) Detach the developing cylinder [2] together with the two bearings [1].
[1]
[1]
[2]
F04-905-13
4-36
9.5.7 Position of the Developing Assembly Magnetic Seal

1) Mount the front magnetic seal [1] and the rear magnetic seal [2] while butting them against the opening [3] (reference). Check to be sure that the magnetic seal is in firm contact with the housing.
A
[1]([2]) [3] [2] [1]
A
F04-905-14
9.5.8 Mounting the Developing Assembly Blade

The blade [1] and the blade base [2] of the blade base unit are assembled to high accuracy at the factory. Do not separate them.
[1] [2]
If you happened to have removed the blade by mistake, be sure to adjust the position of the blade using a gap gauge (CK0057-000) so that the gap between the blade and the developing cylinder [3] is 0.210.3 mm.
[3]
F04-905-15 The surface of the developing cylinder is susceptible to damage. Be sure to limit the gap gauge to both sides of the developing cylinder.
4-37
9.6 Removing Paper Lint

9.6.1 Removing Paper Lint
1) Open the front cover. 2) Remove the lever cover [1].
[1]
F04-906-01 3) Slide out the paper lint cleaning lever [1], and move it back and forth.
[1]
F04-906-02
4-38
9.7 Waste Toner Case

9.7.1 Replacing the Waste Toner Bottle
When the control panel indicates the Waste Toner Case Full message, be sure to replace the waste toner case. Never use the waste toner case for a second time. Otherwise, the sensor will malfunction.
[2] [1]
1) Remove the screw [1], and detach the waste toner cover [2]. 2) Remove the waste toner case [3].
[3]
F04-907-01 3) Remove the case cap [1] taped to the waste toner case, and close the case.
[1]
[1]
F04-907-02 4) Fit the new waste toner case [1], and secure the waste toner cover [2] in place with a screw [3].
[3]
[2]
[1]
F04-907-03
4-39
CHAPTER 5 PICK-UP/FEEDING SYSTEM
1 Outline
1.1 Specifications and Construction
T05-101-01 shows the major functions and the construction of the pickup/feeding system:
Item Paper feed reference Paper stack Paper size switching Description Center Cassette (1, 2):500 sheets each (980 g/m2) Multifeeder:50 sheets (80 g/m2) Cassette 1:by user Cassette 2 (100V model): by user Cassette 2 (120/230V model):by service person Multifeeder:by user Through path Cassette auto selection (enabled/disabled) Paper icon Cassette horizontal registration adjustment Multifeeder horizontal adjustment
Duplex copying Related user mode Related mechanical adjustments
T05-101-01
5-1
1.2 Arrangement of Rollers and Sensors
[12] [11] [8]
[14] [10] [9] [7] [6] [5] [2] [4]
[13]
[13]
[1]
[3]
[2] [4] [3]
[1]
F05-101-01 The following rollers are mainly used to move paper:

Ref. [1] [2] [3] [4] [5] [6] [7] [8] [9] Name Pre-registration roller Registration roller Photosensitive drum Duplex roller Duplex roller Multifeeder pickup roller Pickup roller Feeding roller Separation roller
5-2
The following sensors are used to monitor the movement of paper:

Notation PS1 PS2 PS7 PS8 PS9 PS10 PS11 PS12 PS13 PS15 PS16 PS17 PS18 PS22 Name Cassette 1 paper sensor Cassette 2 paper sensor Cassette 1 retry paper sensor Cassette 2 retry paper sensor Pre-registration paper sensor Registration paper sensor Horizontal registration paper sensor Image leading edge paper sensor fixing feeding sensor No. 1 delivery paper sensor No. 1 delivery full sensor Duplex inlet paper sensor Duplex outlet paper sensor Multifeeder paper sensor Delay jam No No Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes No Stationary jam No No No No No Yes No No Yes Yes No No No No Power-on stationary jam No No No No No No No No No No No No No No
T05-102-01
5-3
1.3 Arrangement of Motors, Clutches, and Solenoids

M5 M1
CL2
M9
SL5 CL1
M6
M2
SL1
F05-103-01 The following motors, clutches, and solenoids are used to move paper:
Notation M1 M2 M5 M6 M9 CL1 CL2 SL1 SL5 Name Main motor Pickup motor Delivery motor Duplex motor Registration motor Vertical path clutch Multifeeder clutch Pickup DOWN solenoid Multifeeder rely releasing solenoid
5-4
2 Detecting Jams
2.1 Sequence of Operations (jam detection)
2.1.1 Delay Jam
a. Cassette Pickup Assembly (cassette 1, 2) The leading edge of paper does not reach the sensor within a specific period of time after the motor has gone ON.
Start key ON or PRINT setting ON INTR / PRINT
Motor N-1 Jam check Sensor N
[1]
[1]
Normal [1]:specific feed period.
Error
F05-201-01
Pickup assembly Cassette 1 Cassette 2 Motor Pickup motor (M2) Pickup motor (M2) Sensor Cassette 1 retry sensor (PS7) Cassette 2 retry sensor (PS8)
T05-201-01
5-5
b. Other Delay Jams Other than pickup sensor delay jams, jams are found by other sensors at the following timing of detection. The period of time for travel between sensor N-1 and delay jam sensor N are monitored with reference to the clock pulses from the main motor; a delay jam will be identified if the leading edge of paper does not reach the delay jam sensor N in question within a specific period of time after the sensor N-1 goes ON.
Start key ON or PRINT settings ON INTR / PRINT
Sensor N-1 Jam check Sensor N
[1]
[1]
Normal [1]:specific feed period.
Error
F05-201-02
Notation PS9 PS10 PS11 PS12 PS13 PS15 PS17 PS18 PS22 Name Pre-registration paper sensor Registration paper sensor Horizontal registration paper sensor Image leading edge sensor Fixing feeding sensor No. 1 delivery paper sensor Duplex inlet paper sensor Duplex outlet paper sensor Multifeeder paper Delay jam Yes Yes Yes Yes Yes Yes Yes Yes No
T05-201-02
5-6
2.1.2 Stationary Jam

a. Common Stationary Jam Registration paper sensor (PS10), Fixing feeding sensor (PS13), No. 1 delivery paper sensor (PS15)
Start key ON or PRINT setting ON INTR / PRINT
Jam check Sensor N
L+A Normal
L+A Error
(L: paper length; A: specific feed distance)
F05-201-03 b. Power-On Stationary Jam A stationary jam at power on is identified based on the presence/absence of paper over a specific sensor about 1 sec after the control panel power switch is turned on.
2.1.3 Jam History

The host machine maintains a history of jams that occur inside it, and the history may be checked in service mode. COPIER>DIPLAY>JAM Use it to indicate jam data. COPIER>FUNCTION>JAM-HIST Use it to clear the jam history. The following are retained in response to a jam, and brought back to use after the jam has been removed. Remaining number of copies to make Selected copying mode
5-7
3 Pickup Assembly
3.1 Pickup Control System
[10]
M9 [11] [8] [9] [11] M1
[2] [1]
[3] CL1
M2
[4] [5] [2] [3]
[6]
SL1 [7]
[4] [5]
F05-301-01
Notation [1] [2] [3] [4] [5] [6] [7] [8] Name Gear Pickup roller Feeding roller Separation roller Lifter Vertical path roller Cam Registration roller Notation [9] [10] [11] M1 M2 M5 CL1 SL1 Name Pre-registration roller DC controller PCB Cassette pickup PCB Main motor Pickup motor Registration motor Vertical path clutch Pickup DOWN solenoid
5-8
3.2 Outline
The paper inside the cassette is held up by the lifter, and remains in contact with the pickup roller when pickup takes place: (1) The pickup motor (M2) is used to drive the pickup roller. The pickup roller is moved down in relation to the feeding roller, and is brought into contact with paper only when pickup takes place. (2) The pickup roller is moved down when the cam released by the DOWN solenoid (SL1) rotates by the drive of the main motor (M1). The feeding roller and the separation roller serve to make sure that only one sheet of paper from the pickup roller is sent to the feeding path; the No. 2 registration roller and the vertical path roller then forwards the paper as far as the registration roller. The drive for the vertical path roller and the No. 2 registration roller is provided by the pickup motor (M2) through the vertical path clutch (CL1). The registration roller is driven by the registration motor (M9).
5-9
3.3 Sequence of Operations (pickup)

a. Cassette 1 A4, 2 Copies, Continuous
Start key ON INTR Cassette 1 pickup solenoid Pickup motor Retry sensor Vertical path roller clutch Pre-registration paper sensor Registration paper sensor Registration motor PRINT LSTR
F05-303-01 Sequence of Operations (cassette)
5-10
3.4 Operation of the Cassette Lifter

The lifter is operated as necessary in the course of printing to maintain the stack of sheets to a specific height.
3.4.1 Operation of the Lifter During Printing

The lifter is controlled by the movement of the pickup roller shaft. When the pickup roller shaft pushes the lifter trigger lever, the cam is released, and the lifter starts to move up until the lifter trigger lever stops the cam. 1) Each time the pickup roller DOWN soSL1 lenoid (SL1) goes ON, the pickup roller shaft [2] moves down to initiate pickup [1] [2] operation. 2) When the sheets decrease and, as a re[3] sult, the descent distance [3] of the pickup roller increases, the pickup roller shift pushes down the lifter trigger lever [4]. [4] 3) When the lever is pushed down, the cam [7] [6] [5] is released, causing it to rotate. [5] 4) The rotation of the cam turns the eccentric cam [3] mounted to the same shaft. The eccentric cam operates the lifter UP lever [2] to move up the lifter gear [1]. 5) The lifter moves up and, as a result, the paper stack moves up; when the pickup roller shaft reaches a specific height, the lifter trigger lever is drawn back by the work of a spring, thereby stopping the cam. The foregoing series of operation is repeated to maintain the height of the paper stack to a specific level. The cassette pickup operation ends when paper runs out and the cassette paper sensor detects the absence of paper.
[1] [2] [3]
F05-304-01 Cassette Lifter Operation
5-11
3.4.2 Releasing the Lifter

The lifter is released mechanically when the cassette is slid out. When the machine is in standby state, the lifter gear is held in place by the lifter gear retaining lever. When the cassette is slid out, the lifter gear retaining lever is freed, thereby allowing the lifter to move down. If the main power is cut while the lifter is moving up, the lifter is held up with the claw used to move up the lifter remaining in contact with the lifter gear; the lifter will not be fully released in this condition, and damage can occur if the cassette is forced out. Be sure to turn off and then on the main power so that the machine will be in standby state whenever the cassette must be slid out.
5-12
3.5 Cassette Pickup Operation

3.5.1 Rotating the Pickup Roller
The drive used to rotate the pickup roller is transmitted through gears. The cassette motor rotates clockwise and counterclockwise to initiate pickup operation of the cassette 1/2.
3.5.2 Switching the Pickup Roller Drive

When the pickup roller rotates clockwise, the gear 1 moves up to drive the pickup roller of the upper cassette holder; when the motor rotates counterclockwise, on the other hand, the gear 1 moves down to drive the pickup roller of the lower cassette holder. The figure below shows how the drive of the pickup roller is controlled.
3.5.3 Pickup Roller Shaft Reference

The up and down movement of the pickup roller when the cassette is set in the machine is driven with reference to the position of the pickup roller shaft.
[1]
[2]
F05-305-01
5-13
Feeding roller
Cassette pickup motor (M5) Gear 1
Pickup roller Separation roller
F05-305-02 Pickup Drive for the Upper Cassette Holder (pickup motor in CW rotation)
Feeding roller Cassette pickup motor (M5)
Pickup roller
Separation roller Gear 1
F05-305-03 Pickup Drive for the Lower Cassette Holder (pickup motor CCW rotation)
5-14
3.6 Moving Up/Down the Pickup Roller

The pickup roller and the feeding roller are supported by a roller holder, and the pickup roller is moved up and down in relation to the feeding roller. In standby state, the pickup roller is at the uppermost position; during pickup operation, on the other hand, it moves down to reach the paper surface. It operates as follows to pick up a single sheet of paper: 1) When the pickup solenoid (SL1) goes ON, the drive of the main motor (M1) causes the cam 1 to rotate. 2) The rotation of the cam 1 causes the pickup lever to swing. 3) The swing of the lever causes the pickup roller to move down to come into contact with the paper, and the pickup motor (M2) starts pickup operation. 4) The rotation of the cam 1 moves up the pickup roller shaft.
Roller holder
Pickup roller shaft
F05-306-01 Arrangement of the Pickup Roller

Feeding roller Feeding roller shaft
ON
Pickup roller shaft
Pickup roller Roller holder
Pickup lever Cam 1 (rotates when SL1 goes ON)
Pickup solenoid (SL1)
ON
F05-306-02 Up/Down Movement of the Pickup Roller Shaft
5-15
3.7 Detecting the Presence/Absence of Paper Inside the Cassette

When the cassette runs out of paper, the paper detecting lever falls through the detecting hole of the cassette, causing the light-blocking plate linked to the lever to block the light of the photointerrupter (Q1604 for cassette 1; Q1605 for cassette 2).
Q1604: cassette 1. Q1605: cassette 2.
Paper detecting lever
F05-307-01 Arrangement of the Paper Detecting Lever
5-16
3.8 Pickup Retry Operation

When a delay is detected by a pickup sensor because of wear on the pick roller, pickup retry operation is executed. If a delay is still detected after a retry, the control panel indicates the Jam message.
3.8.1 Conditions for Detecting a Delay

Paper does not reach the retry sensor when it has been moved over a specific distance after the pickup DOWN solenoid (SL1) has gone ON.
Start key ON Retry operation started
Pick DOWN solenoid Pickup motor *1 Retry paper sensor Vertical path sensor Hereafter, the same sequence as common pickup sequence.
*1:retry operation is executed if paper does not arrive after moving it over distance to the retry sensor + 100 mm.
F05-308-01 Retry Operation
5-17
3.8.2 Paper Retraction

If a delay is detected once again after a retry and the jam must be removed, the paper can become torn if an attempt is made form the cassette side. To enable removal from the right cover side, the following operation takes plate: 1) After detecting the jam, the retracting roller is driven for a period equivalent to a distance over which paper may be moved 10 cm. The paper will be moved to a point where it is in view when the right cover is opened. 2) The control panel indicates an instruction to the effect that the jam may be removed from the right cover side. 3) The right cover may be opened to remove the jam. If the jam is not in view when the right cover is opened, it may be removed from the cassette side.
Start key ON Retry started Jam indicator (removal from right cover side)
Pickup roller DOWN solenoid Pickup motor *1 Pickup sensor *1 *2
*1:paper does not arrive about 1 sec after detection. *2:paper moved by the retracting roller for a equivalent of a distance over which paper may be moved 10 cm.
F05-308-02
5-18
3.9 Operation Other Than Cassette Pickup (standby)

When the cassette is slid into or out of the machine, the following takes place:
3.9.1 Moving Up the Lifter/Moving Down the Pickup Roller Shaft (cassette slid in)
1) Moving Down the Pickup Roller Shaft With the power on, when the cassette is slid into the machine, the pickup roller moves down until it comes into contact with the paper surface as follows: The cassette rear end pushes in the lever 1 of the pickup unit. When the cassette size detection mechanism goes ON, the main motor (M1) and the pickup solenoid (SL1) go ON to swing the pickup lever. I The pickup roller shaft is subject to the moment of the lever 1 and the pickup lever.
Pickup roller shaft Feeding roller
Lever 1 Cassette Pickup roller
F05-309-01 Movement of the Lever 1 When the Cassette Is Slid In 2) Moving Up the Lifter When the main power is turned on with the cassette set in the machine or the cassette is slid in while the machine is in standby state, the pickup roller shaft moves down to push down the lifter trigger lever. The cam is released when the pickup roller shaft pushes one side of the lifter trigger lever, and the drive from the main motor (M1) move sup the lifter. When the pickup roller remaining in contact with the paper surface moves up to a specific height, the movement of the levers cause the pickup roller shaft to return to the uppermost position to end the upward movement of the lifter.
5-19
Pickup roller shaft
Lifter trigger lever Cam

M1
F05-309-02 Moving Up the Lifter
3.9.2 Moving Up the Pickup Roller Shaft and Releasing the Separation Roller Pressure (cassette slid out)
When the cassette is slid out of the machine, the pickup roller shaft is mechanically moved up and the separation roller pressure is also released. 1) Moving Up the Pickup Roller Shaft and Releasing the Separation Roller Pressure When the cassette is slid out, the lever 1 rotates by the work of a spring. When the lever 1 rotates, the pickup roller shaft moves so that the pickup roller and the cassette will not interfere with each other.
Pickup roller shaft Feeding roller
Spring Lever 1
Pickup roller Cassette
F05-309-03 Moving Up the Pickup Roller Shaft 2) Releasing the Separation Roller Pressure The lever 1 is provided with a protrusion used to push down the separation roller assembly. When the cassette is slid out, the lever 1 rotates causing the separation roller to move down, thereby removing the pressure between the separation roller and the feeding roller.
5-20
Protrusion of lever 1
Separation roller
Cassette
F05-309-04 Releasing the Separation Roller b. Releasing the Lifter The lifter is released when the cassette is slid out while the machine is in standby state.
3.10
Detecting the Level of Paper
The level of paper inside the cassette is detected by the light-blocking plate of the lifter gear and a sensor in relation to the distance over which the lifter moves up. When paper starts to run out, the lifter gradually moves up; when paper fully runs out, the cassette paper sensor (Q1604 for cassette 1) identifies the condition as indicating the absence of paper.
Lifter
Light-blocking plate
F05-310-01
5-21
If the cassette is full of paper
If the cassette is empty of paper
Pickup roller Paper
Sensor 2 Sensor 1 Light-blocking plate Lifter

Note: The diagram is a view from the rear of the copying machine.
F05-310-02 Detecting the Level of Paper in the Cassette (upper cassette holder) The amount of paper inside the cassette is indicated on the control panel in terms of four levels (including the absence of paper).
Indication 3 bars 2 bars 1 bar no bar 0: 1: Level 100% to about 50% of capacity 50% to about 10% of capacity about 10% or less of capacity No paper Sensor 1 0 1 1 Sensor 2 0 0 1 -
light-blocking plate over the sensor. light-blocking plate not over the sensor.
T05-310-01
5-22
4 Identifying the Size of Paper

The size of paper inside the cassette may be set using the dial on the cassette. The ABsetting and the Inch-setting are switched over using the switch found next to the dial.
4.1 Identifying the Size

The dial on the cassette may be set to any of 16 stops. When the dial is set to an appropriate paper size and the cassette is slid into the machine, the four cassette size detecting switches recognize the size of the paper based on the resulting combination of indentations and protrusions of the size detecting cam.
4.2 AB-/Inch-Setting Switch

The AB-setting and the Inch-setting is switched over using the switch found next to the dial. When the cassette is slid into the machine, the cassette side detecting switch recognizes the paper configuration (AB or Inch)
[1]
[3] [2]
Ref. [1] [2] [3]
Name Dial AB-/Inch-setting switch Size detecting cam
F05-402-01
5-23
4.3 Paper Size

The width and the length of paper are identified by the CPU of the machine with reference to how the dial mounted to the cassette is set. The following diagram shows the rotary label attached to the dial, and the following table shows the paper sizes that are recognized by the machine:
STM T STMT-R
A5R
A5
LT
LGL
11 17
B5 R B4 U1 U2 U3
B5
A/B-setting rotary label
Inch-setting rotary label
F05-403-01 Rotary Label Note 1:U Cassette The following are special types of paper: U1...FOOLSCAP U8...K-LGL(R) OFFICIO A-OFFICIO E-OFFICIO B-OFFICIO A-LGL
U2...FOLIO U3...A-FLS U4...G-LTR U5...G-LTR(R) U6...G-LGL U7...X-LGL
Note 2:SP-1, -2 (SPECIAL 1, 2) A default size paper that suits t the needs of the user may be registered in user mode. A SPECIAL cassette icon may be indicated on the control panel for immediate access. For details, see the Users Manual.
5-24
U4 U5 U6 U7
U8
S P-3 4
SP-
SP-1 -2
SP
A4 R A3
A4
LT
R-
(AB-setting) Cassette name No cassette A5 A5R A4 A4R A3 B5 B5R B4 U1 (FLSO) U1 (OFICIO) U1 (A-OFI) U1 (E-OFI) U1 (B-OFI) U1 (A-LGL) U2 (FOLIO) U3 (A-FLS)
Combination of states of cassette size detection switches SW1 SW2 SW3 SW4 SW5 OFF OFF OFF OFF OFF OFF ON ON OFF ON OFF ON ON ON ON OFF ON ON ON OFF OFF ON OFF ON OFF OFF ON OFF ON ON OFF ON OFF OFF ON OFF ON OFF OFF OFF OFF ON ON OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF ON OFF OFF ON ON ON
Main scanning direction (mm) 210 148 297 210 297 257 182 257 216 216 220 220 216 220 210 206
Sub scanning direction(mm) 148 210 210 297 420 182 257 364 330 317 340 320 355 340 330 337
(Inch-setting) Cassette name No cassette STMT STMTR LTR (A-LTR) LTRR (A-LTRR) LGL 1117 U4 U5 U6 U7 U8
Combination of states of cassette size detection switches SW1 SW2 SW3 SW4 SW5 OFF OFF OFF OFF OFF ON ON ON OFF ON ON ON ON ON ON ON ON ON ON OFF ON ON ON ON OFF ON ON OFF ON OFF ON ON OFF ON OFF ON ON OFF ON ON ON ON OFF OFF ON ON ON OFF OFF OFF ON ON ON OFF OFF ON OFF ON OFF OFF ON OFF ON OFF ON ON OFF ON ON ON
Main scanning direction (mm) 216 140 279 280 216 220 216 279 267 203 203 268 190
Sub scanning direction(mm) 140 216 216 220 279 280 356 432 203 267 330 190 206
T05-403-01 List of Paper Sizes
5-25
5 Multifeeder
5.1 Outline
When the paper guide plate moves up, the paper on the multifeeder tray is butted against the pickup roller, and the pickup roller and the separation pad make sure that only one sheet of paper is picked up and fed into the machine. 1) The paper guide plate is operated by the drive of the main motor (M1) transmitted by the paper guide solenoid (SL5). 2) The pickup roller is operated by the drive of the main motor (M1) transmitted by the multifeeder clutch (CL2).
J102-B11 CL2 [7] J102-B1 [8] CL2D*
[1]
PS3 M1 PS4 [3] [4]
J102-A6 CL3D*
SL5
[6]
[2] [5]
F05-501-01
Ref. [1] [2] [3] [4] [5] [6] Name Multifeeder pickup roller Separation pad Paper guide plate Multifeeder tray Drive cam Spring cutch Ref. [7] [8] M1 CL2 SL5 Name Registration roller DC controller PCB Main motor Multifeeder clutch Multifeeder holding plate releasing solenoid
5-26
5.2 Identifying the Size of Paper in the Multifeeder

5.2.1 Detecting the Width of Paper
The width of paper is detected by a variable resistor operating in conjunction with the movement of the slide guide. The slide guide is set when the user adjusts the multifeeder tray to suit the paper placed on it.
5.2.2 Rear/Front Registration

The rear/front registration of the multifeeder may be adjusted by turning the screw on the slide guide. For details, see $. Standards and Adjustments in Chapter 7.
5.2.3 Identifying the Length of Paper

The length of paper is detected with reference to the period of time during which the preregistration sensor (PS4) remains ON while copies are being made. The maximum size of paper is 432 279 mm (1117).
Slide guide (rear)
Variable resistor
Multifeeder tray Slide guide (front)
F05-602-01 COPIER>ADJUST>CST-ADJ>MF-A4R Use it to adjust the paper width basic value of A4R paper for the manual feed tray. COPIER>ADJUST>CSRT-ADJ>MF-A6R Use it to adjust the paper width basic value of A6R for the manual feed tray. COPIER>ADJUST>CST-ADJ>MF-A4 Use it to adjust the paper width basic value of A4 paper for the manual feed tray.
5-27
6 Controlling the Registration Roller

6.1 Outline
The registration roller is driven by the registration motor (M9) so that the paper and the image on the photosensitive drum will match at a specific point. The timing at which the registration roller rotates may be adjusted in service mode (ADJUST>FEED-ADJ>REGIST).
6.2 Control System

Registration rollers
Registration drive signal (RGCD*) M9 J106-A6
DC controller PCB
F05-602-01 COPIER>ADJUST>FEED-ADJ>REGIST Use it to adjust the timing at which the registration roller is started.
5-28
7 Double-Sided Printing
7.1 Through-Path Operation
In this sequence of operations, paper after fixing is fed to the delivery assembly and then to the duplex feeding assembly using the reversing flapper. the machine re-arranges the order of images in its memory for printing. As many as two sheets may exist at a time between the registration sensor and the duplex paper sensor. COPIER>ADJUST>FEED-ADJ>ADJ-REFE Use it to adjust the image write start position in main scanning direction for re-pickup. (-100 to 100 mm)
5-29
7.2 Outline of Operations

For instance, through-path operations take place as follows when one set of double-sided prints are made of six originals:
1) The 1st sheet is picked up from the cassette. 2) The 2nd side is printed on the 1st sheet. 3) The 1st sheet is switched back in the delivery assembly, and is then sent to the duplex feeding assembly. 4) The 2nd sheet is picked up, and the 4th side is printed.
5) The 2nd sheet is switched back in the delivery assembly, and is then sent to the duplex feeding assembly. 6) The 1st side is printed on the back of the 1st sheet.
7) The 1st sheet is delivered. 8) The 2nd sheet is in the duplex feeding assembly. 9) The 3rd sheet is picked up, and the 6th side is printed.
F05-703-01
5-30
10) The 3rd sheet is switched back in the delivery assembly, and is then sent to the duplex feeding assembly. 11) The 3rd side is printed on the back of the 2nd sheet.
12) The 2nd sheet is delivered. 13) The 3rd sheet is in the duplex feeding assembly.
F05-703-02
5-31
7.3 Detecting the Horizontal Registration Position

7.3.1 Outline
In duplex printing, paper coming from the duplex feeding assembly is checked for horizontal registration, and the detected displacement in rear/front direction is made up for by adjusting the point of laser exposure. Paper position: Timing of detection: Drive: Position: Related service mode: Related error code: by duplex horizontal registration sensor (PS31) after duplex paper sensor (PS34) goes ON by duplex horizontal registration motor (M16) by pulse from duplex horizontal registration motor (1 pulse = about 0.16 mm) COPIER>ADJUST>FEED-ADJ>ADJ-REFE E051 (home position not detected within specific time) T05-703-01
PS10
M9
Copy paper
10 mm (approx.)
Detecting start position
Home position
F05-703-01
5-32
7.3.2 Operation
1) Timing of Detecting Home Position When the main power switch is turned on, During jam recovery, When the front cover is closed 2) Start Position Point of A4 detection When paper fed to the duplex feeding assembly reaches the duplex paper sensor (PS34), the horizontal registration motor (M16) goes ON, and the duplex horizontal registration sensor (PS31) starts paper edge detection. The detection takes place for 100 msec while the duplex feed right motor (M19) is at rest and each time a double-sided print is made. The detection start position is set at a point about 10 mm from the edge of paper whose movement is ideal with reference to the data on the paper width collected from the slide guide on the manual feed tray and the cassette size when the registration sensor goes ON. The detection of paper position is done with reference to the start position, and the displacement from the actual paper position is identified with reference to the drive pulses from the motor (1 pulse = about 0.16 mm).
Main power switch ON INTR/STBY Duplex feed right motor (M18) Registration sensor (PS29) Duplex paper sensor (PS34) Duplex horizontal registration motor (M16) Duplex horizontal registration sensor (PS31) H.P Duplex horizontal registration sensor (PS31) position S.P *1 Paper edge
*1: the edge of paper and the contact against the sensor are detected in the absence of the lightblocking plate. *2: the position of the edge of paper differs depending on the size of paper, hence different SP. HP: start position of the duplex horizontal sensor. SP: detection start position of the duplex horizontal registration sensor.
PRINT 100msec (approx.)
Reverse
Forward
Forward Reverse
10mm (approx.)
F05-703-02
5-33
8 Controlling the Pickup Assembly Motor

8.1 Pickup Assembly Motor
The pickup assembly motor system consists of six stepping motors of 2-phase magnetic excitation type. Each motor is supplied with power by the motor driver PCB, and is turned on/off and rotated clockwise or counterclockwise by pulse signals from the DC controller PCB. T05-801-01 shows the motors used in the pickup assembly and F05-801-01 shows a block diagram of the control circuit for the cassette 1/2 pickup motor:
Location Pickup system Vertical path system Duplex system Others Motor name Cassette 1/2 pickup motor Duplex motor Duplex registration motor Registration moter Delivery moter Notation (M2) (M6) (M3) (M9) (M5) Drive unit p. p. p. p. p. Error detection Motor error Jam occurred Same as above Same as above Same as above Same as above
T05-801-01
DC controller PCB +24V J104 A7 CPU (IC5025) J2101 A14 A10 A8 A9 A10 A13 A12 A9 A11 J2104 4 5 6 3 2 1 A +24V A* B +24V B* M12
Motor driver
F05-801-01
5-34
CH APTER 6 FIXING SYSTEM
CHAPTER 6 FIXING SYSTEM
1 Outline of Operations
1.1 Outline
The following are major functions of the fixing system.
Item Fixing method Fixing heater Control temperature Temperature detection Function SURF method Main heater: flat heater Sub heater: flat heater As selected in service mode [1] Main thermistor (temperature control, error detection) [2] Sub thermistor (error detection) [3] Thermal switch (error detection) [1] Sequence at power-on [2] Sequence for site of installation [3] Sequence for ambient temperature Cleaning roller [1] Temperature control error detection by thermistor [2] Overheating detection by thermal switch Equipped with rotation detection mechanism
Fixing temperature control
Cleaning method Error detection Fixing film
T06-101-01
6-1
The following are the major components for the fixing system:
DC controller PCB
Sub thermistor signal (S_TH2)
Fixing film signal (FILM_ROT_D)
Fixing film sensor (PS26)
Fixing film Main thermistor (TH1) Sub thermistor (TH2) Thermal switch (TP1) Fixing sub heater (H2)
Fixing main heater (H1) M4 Fixing motor Delivery roller Cleaning roller Main power supply PCB Lower fixing heater
F06-101-01
Fixing film sensor (PS26) Thermal switch (TP1) Fixing film
Fixing main heater (H1) Fixing sub heater (H2) Lower fixing roller Main thermistor (TH1) Sub thermistor (TH2) Cleaning roller
F06-101-02
6-2
Main thermistor signal (M_TH2)
Component Lower fixing roller Fixing motor Main sub heater
Notation M4 H1H2
Main thermistor Sub thermistor Thermal switch Fixing film sensor
TH1 TH2 TP1 PS26
Description Pressure roller 24VDC 230V model: 637W 120V model: 607W 100V model: 621W Temperature control, Error detection Error detection Set to 250 7C Fixing film rotation detection (reflection type sensor)
T06-101-02
6-3
2 Fixing Drive System

2.1 Outline
The fixing drive system is controlled for the following: 1. Fixing roller drive 2. Fixing film rotation speed detection (control)
2.2 Controlling the Drive of the Fixing roller

F06-202-01 shows the construction of the control system used to control the drive of the fixing roller:
DC controller PCB
Fixing motor FSAR_ON* FSAR_LOCK* N.C FSRM_CLK FSRM_SPEED* M4
Main power supply PCB
GND
Lower fixing roller
24V
F06-202-01 The following signals are used: [1] Fixing motor drive signal; when 1, the motor goes ON. [2] Fixing motor drive lock signal; when the rotation speed of the fixing motor reaches a specific level, 0. [3] Fixing motor low-speed drive signal; when the operation speed of the fixing motor is controlled 1/4, 1. E014 (fixing motor speed error) Indicates that the fixing motor drive signal (M4) is generated but the drive lock signal is not detected within 1.3 sec thereafter.
6-4
2.3 Controlling the Fixing Film Speed

F06-203-01 shows the control signal used to control the speed of the fixing film. The speed of rotation is controlled according to the changes in the output of the fixing film sensor (PS26).
DC controller PCB
FILM_ROT_D
Fixing film sensor (PS26)
Fixing film
Lower fixing roller
F06-203-01 The following signals are used: [1] Film rotation detection signal; when the fixing film is rotating, alternates between 1 and 0. E007 (fixing film rotation error) Indicates that that detection temperature of the main thermistor is 100C or higher and, in addition, the fixing motor is rotating but the film rotation detection signal cannot be detected for 6 sec or more.
6-5
3 Controlling the Fixing Temperature

3.1 Outline
The following relates to the control of the fixing temperature: 1. Fixing heater temperature control 2. Thermistor error detection
Switch PCB Relay RL1
+5V
Heater relay circuit
Thermal switch (TP1)

Fixign main heater(H1) Fixing sub heater(H2)
Fixing main thermistor TH1 TH2 Fixign sub thermistor
A/D converter (200V) Hightemperature detection circuit
IC300
+5V
IC334
+5V
F06-301-01
6-6
3.2 Controlling the Temperature

The machine uses the following types of mechanisms to control its fixing temperature:
Operation Item Normal [1] Power-on sequence (wait-up control) Description If the reading of the main thermistor (TH1) is 100C or lower during return from sleep mode or at power-on, control is initiated aiming at 180C. [2] Start-up sequence When copying is started. [3] Normal temperature When the temperature is controlled based on an assumed control sequence temperature of the lower roller while paper is moving through the fixing assembly. [4] Sheet-to-sheet con- When the temperature is controlled to a lower fixing level trol sequence between sheets being fed continuously. [5] Duplex control seWhen the temperature is controlled to a lower level for the quence 2nd side of a double-sided copy. [6] Small-size paper When overheating is prevented on the heater ends otherwise sequence caused by small-size sheets fed continuously. In this mode, the copying speed will decrease. [7] Switching the fixing The target temperature for fixing control is lowered: 1 : -10C temperature COPIER>OPTION> 2 : -6C BODY>FIX-TEMP 3 : -3C 4 : +3C 5 : +6C
Service mode ON
T06-302-01
6-7
3.2.1 Fixing Control Table

The machine assumes a surface temperature for the lower fixing roller in relation to the reading by the main thermistor (TH1), and determines a target temperature level for the fixing heater to suit its assumption. For instance, the following control temperature levels will be used for normal temperature control sequence in relation to the assumed lower fixing roller temperature:
Assumed lower fixing roller temperature (C) _ 50 T<55 _ 55 T<60 _ 60 T<65 _ 65 T<70 _ 70 T<70 _ 75 T<80 _ 80 T<85 _ 85 T<90 _ 90 T<95 _ 95 T<100 _ 100 T Control temperature (C) 205 200 195 190 185 180 175 170 165 160 155
T06-302-02 In addition to the selected paper size, number of sheets fed, and type of paper, the machine uses this type of table to determine control temperature levels.
6-8
3.3 Detecting Faults

The fixing temperature control mechanism checks for the following faults: 1. Temperature control error by the main thermistor (TH1) 2. Sensor error by the sub thermistor (TH2) 3. Overheating error by the thermal switch (TP1) The following signals are used in relation to error detection: [1] Fixing temperature detection signal 1; generates a voltage of a level suited to the reading of the main thermistor. [2] Fixing temperature detection signal 2; generates a voltage of a level suited to the reading of the sub thermistor. [3] Sub heater drive signal; when 1, the sub heater turns on . [4] Sub heater temperature detection signal; when the sub heater is powered, 0. [5] Main heater drive signal; when 1, the main heater goes ON. [6] Main heater temperature detection signal; when the main heater is powered, 0. [7] Relay drive signals; when 1, the relay (RL1) on the main power supply PCB goes ON.
6-9
E000 Indicates either of the following: the main thermistor (TH1) has poor contact or an open circuit; the thermal switch (TP1) has an open circuit; the main/sub heater has an open circuit; the main power supply PCB is faulty; the DC controller PCB is fatly; the door switch is faulty. E001 Indicates either of the following: the main thermistor (TH1) has a short circuit; the sub thermistor (TH2) has a short circuit; the main power supply PCB is faulty; the DC controller PCB is faulty. E002 Indicates any of the following: the main thermistor (TH1) has poor contact or an open circuit; the thermal switch (TP1) has an open circuit; the fixing heater has an open circuit; the AC driver PCB is faulty; the DC controller PCB is faulty; the door switch is faulty. E003 Indicates either of the following: the main thermistor (TH1) has poor contact or an open circuit; the thermal switch (TP1) has an open circuit; the fixing heater has an open circuit; the main power supply PCB is faulty; the DC controller PCB is faulty; the door switch is faulty. In the case of E000 through E003, the code will not be reset when the main power switch is turned off, requiring the use of service mode (COPIER>FUNCTION>CLEAR>ERROR). However, if E001 or E003 is detected within 3 sec after the front door switch is identified to have been opened or closed, the code will be reset when the main power switch is turned off and then on. This consideration is to prevent a service call in response to an error detected when the switch operation is not fully stable (as immediately after turning off and then on the main power switch).
6-10
CHAPTER 7 EXTERNALS AND CONTROLS
1 Control Panel
1.1 Outline
The machines control panel consists of the following PCBs and a touch panel (LCD) capable of displaying at a resolution of 320240 dots:
Control panel Control panel inverter PCB LCD PCB (LCD) Control panel PCB (keys, LEDs)
Control Panel switch PCB LCD contrast adjustment PCB
Control panel power switch PCB Key input monitor:keypad function keys Buzzer sound control Control panel LED control CPU
Controller block Adjusts the contrast of the LCD.
F07-101-01 COPIER>FUNCTION>PANEL>LCD-CHK Use it to check for missing dots on the LCD. COPIER>FUNCTION>PANEL>LED-CHK Use it check the activation of the LEDs on the control panel. COPIER>FUNCTION>PANEL>LED-OFF Use it to check the de-activation of the LEDs on the control panel. COPIER>FUNCTION>PANEL>KEY-CHK Use it to check key inputs. COPIER>FUNCTION>PANEL>TOUCHCHK Use it to adjust the coordinates on the touch panel.
7-1
2 Fans
2.1 Arrangement, Functions, and Error Code
The names and the functions of the fans used in the machine and the error codes associated with the fans are as follows:
Notation Name FM1 FM2 FM3 FM4 FM5 Developing assembly fan Fixing fan Electric unit fan Curl removing fan 1 Curl removing fan 2 Function Cooling the developing assembly Cooling the fixing assembly. Cooling the power unit. Prevents curling of paper. Prevents curling of paper. 2-speed control (voltage) Yes (24/12 V) Yes (24/12 V) Yes (24/12 V) No (24 V) No (24 V) Error code E805-0001 E805-0002 E805-0003 E805-0004 E805-0005
The curl removing fans 1 and 2 may be enabled or disabled in service mode: COPIER>OPTION>BODY>DECRL-FN. T07-201-01
7-2
The arrangement and the direction of current are as follows:
FM3
FM2 FM1
FM4
FM5
F07-201-01
7-3
2.2 Operations
2.2.1 Controlling the Speed
Some of the fans used in the machine are 2-speed fans (F07-202-01) whose speed of rotation is switched over by their respective voltage switching circuits:
DC controller PCB
24V
12V 24V or 12V
Full-speed signal
CPU
Half-speed signal
Voltage switching circuit
Clock signal
Fan
F07-202-01
2.2.2 Sequence of Operations

Main power switch Control panel switch
Initial multiple rotation During printing
Control panel switch OFF

Jam Door open
Printer state Developing assembly fan Fixing assembly fan Electrical unit fan Curl removing fan 1/2 (FM4/FM5)
Warm-up
Standby
After printing Low-power
+1
:full-speed. :half-speed or at rest (half-speed if the polygon mirror motor M10 is ON; otherwise, at rest).
*1: Rotates for 30 sec after the leading edge sensor goes ON during printing; if the sensor goes ON once again during the 30-sec period, rotates for another 30 sec. The fan may be enabled or disabled in service mode: COPIER>OPTION>BODY>DECRL-FN>
F07-202-02
7-4
3 Power Supply
3.1 Power Supply
3.1.1 Outline
The machine is supplied with DC power by the DC power supply PCB; the function of each PCB and associated components are shown in T07-301-01 and the loads of each power supply are indicated in F07-301-01:
Name Main power supply PCB Composite power supply PCB Option PCB Switch PCB (SW1/SW2) Description Generates DC power from AC power. Protection against over-current. Generates high voltage. Supplies power to the side paper deck and the finisher. Switches on/off (SW1) power to the main paper supply; switches on/off (SW2) power to the cassette heater, mirror heater, and lens heater. Identifies the state (open/closed) of the front door; cuts off AC power to the fixing heater; cuts off 24V power to the main motor, fixing motor, and composite power supply PCB. Supplies power to the thermistor.
Door switch (SW3)
Thermistor power supply PCB (200 V)
T07-301-01
7-5
The following shows how power is distributed inside the machine:

Circuit Switch PCB breaker SW1 DADF Main reader unit power supply PCB Copy Data Controller -A1
24VU2
Reader controller PCB ADF Clutches

24VU3 Solenoids
SW2
24VU3
Arrestor ground
Polygon mirror motor Cassette pedestal Pre-exposure lamp

24VU1_SW SW3 24VU1
Fans Pickup PCB Fans (half-speed)
Arrestor PCB (100V) Cassette heater Mirror heater Lens heater Filter assembly
RL1 THSW Main heater Sub heater
Main motor Fixing motor

13V
13V DC controller PCB 5VA
Sensors Inverter BD PCB HD HD

5VA Control
3VA1 3VA2 3VB
5VA
panel
5VA 5VA
5VA 5VA
Triac Side paper deck Option power 24VA1 Finisher-J1/Saddle Finisher-G1 supply 24VA2 Side paper deck PCB
5VA
:DC Power :AC Power
F07-301-01
7-6
3.1.3 Outputs of the Power Supplies

The outputs of the machines power supplies are controlled by the main power switch (SW1), control panel power switch (SW826), or signals from the printer board. The following shows the states of power supplies from each power supply PCB based on combinations of printer board signals and in relation to the main power switch and the control panel switch:
Main paper switch (SW1) OFF*1 ON ON Control panel switch (SW826) or printer board signal OFF OFF ON Power supply output from power supply PCB None None All Power supply output from composite power supply PCB None 3VB*2 All Power supply output from accessories power supply PCB None None All
*1:If the environment switch (SW2) is ON, the cassette heater, mirror heater, and lens heater are supplied with power.
T07-301-02
Control panel PCB Control panel switch SW826 Main controller PCB
RMT1 RMT2 3VA1 3VA2 3VB
UI_SOFT_SW*
FU1
Main power switch AC/DC converter

13VU MPON APON 5VA
Main power supply PCB Main switch
Accessories power supply PCB

F3501
SW1
AC/DC converter
AC/DC converter
24VA1 24VA2
Switch PCB
24VU1 24VU2 24VU3
F07-301-03
7-7
3.2 Rated Outputs of the Main Power Supply PCB

Output Connector No. 24VU1 J200-1 J203-1 24VU1-SW J202-1 J202-3 J202-5 J200-3*1 24VU2 J203-2 24VU3 J204-1 J204-3 J204-7 J204-8 J204-9 J206-2
Output voltage tolerance Rated output voltage Rated output current Overcurrent protection activation level *1:input. *2:+7%, -5%, depending on output current.
5%*2 24V 9.0A 5.5 to 8.0A
T07-302-01
3.3 Rated Outputs of the Composite Power Supply PCB

Output Connector No. 2 3 J122-3 5 J122-4 7 Output voltage tolerance Rated output voltage Rated output current Overcurrent protection activation level +2%, -4% 3.4V 3.4A 5.0 to 8.0A 2% 3.4V 1.9A 5.0 to 8.0A +3%, -4% 5.1V 12.5 to 17.0V 4.7A 0.11A 5.5 to 8.0A 1.0 to 8.0A J124-10 J126J121-3 J121-13 J124-9 J1263VA1 J121-4 J121-5 3VA2 J121-1 J121-2 3VB J121-11 J121-12 5V J122-1 J122-2 13VU J126J126-
T07-303-01
Note:However, applies only when the AC input is from 85 to 135 V in the case of the 100V model and from 187 to 264 V in the case of the 230V model.
7-8
3.4 Rated Outputs of the Accessories Power Supply PCB

Output Connector No. 24VA1 J703-2 J704-6 24VU1-SW J702-1 J702-4
Output voltage tolerance Rated output voltage Rated output current Overcurrent protection activation level
+7%,-5% 24V 5.5A 5.5 to8.0A
T07-304-01
However, applies only when the AC input is from 85 to 135 V in the case of the 100V model and from 187 to 264 V in the case of the 230V model.
7-9
3.5 Protective Functions

Each power supply PCB of the machine is equipped with an overcurrent protective circuit, and the respective output will stop in response to the activation of each PCB. The output from each power supply PCB goes ON in response to the signals RMT1 and RMT2 from the main controller PCB; if an error in the high-voltage output occurs or the fuse blows, 3VB from the composite power supply PCB will stop to cut off the output of all power supplies.
7-10
4 Others
4.1 Silent Mode
In silent mode, the rotation of the laser scanner motor while in standby is controlled (1/2) to reduce the operating noise of the machine. When the Start key is pressed in silent mode, the laser scanner motor will take extra time before its rotation returns to normal, so that the first print time will be somewhat longer. The period of time before silent mode is started may be changed in user mode.
7-11
5.1 External Covers

The following covers may have to be removed when cleaning, inspecting, or repairing the inside of the machine: Those covers that can be remove by merely removing the mounting screws are omitted from the discussions (the number of mounting screws used are indicated).
[3] [4] [1] [5] [2] [6] [7] [14] [8]
REF.
[1] Reader for cover (2 screws) [2] Reader right cover (2 screws) [3] Reader left cover (2 screws) [4] Reader rear cover (5 screws) [5] Support cover (1 screw) [7] Support right cover (1 screw) [8] Rear cover (4 screws) [9] Front cover (2 L-shaped pins) [10] Delivery tray (2 screws) [11] Inside cover (6 screws) [12] Right front cover (2 screws) [13] Right lower cover (none if the Cassette Feeding Unit-W1 is installed) [14] Right rear cover (5 screws) [15] Left upper cover (2; none if the Finisher-J1 or the Inner 2-Way-A1 is Installed [17] Left lower cover (1 screw) [18] Waste toner cover (1 screw) [19] Rear cover (7 screws)
[9] [10] [13] [12]
F07-501-01
[19]
[15]
[17]
[11]
[18] [9] [16]
F07-501-02 7-12
5.1.1 Removing the Front Cover

1) Open the front cover [1], and shift up the L-shaped pin [2] of the hinge with your finger. 2) Pull out the shifted L-shaped pin [2] to the right, and detach the front cover [1].
[2]
[1]
F07-501-03
5.1.2 Removing the Inside Cover

1) Remove the front cover. (See 5.1.1.) 2) Remove the drum unit. (See p. $.) 3) Remove the developing assembly. (See p. $.) 4) Remove the cassette 1 (topmost cassette). 5) Remove the tab [1] of the registration roller. 6) Remove the grip ring [2], and detach the feeding lever [3] 7) Remove the six mounting screws [4], and detach the inside cover [5].
[4] [4]
[1] [4] [5]
[4]
[4]
[3] [2]
[4]
F07-501-04
7-13
5.1.3 Removing the Support Cover

1) 2) 3) 4) Open the support right cover (1 screw). Remove the left rear cover. Open the front cover. Remove the screw [1], and remove the support cover [2]. Take care not to break the claw (indicated by a circle) found behind the support cover.
[1]
[2]
F07-501-05
7-14
5.2 Control Panel

5.2.1 Removing the Control Panel
1) Remove the support cover. (See p. $.) 2) Remove the reader front cover. (2 screws) 3) Remove the two screws [1], and disconnect the connector [2].
[1]
[2]
[3]
[1]
F07-502-01 4) Shift the control panel [1] to the left, and detach it upward.
[1] (2)
(1)
F07-502-02
7-15
5.3 PCBs
5.3.1 DC controller PCB
1) Remove the rear cover. (7 screws) 2) Remove the five screws [1], and detach the connector guard plate [2]. 3) Disconnect all connectors of the harness. 4) Remove the eight screws [3]. 5) Disconnect the connector [4] connecting the main controller, and remove the DC controller PCB [5].
[3] [2] [1] [3]
[1]
[4]
[3]
[5]
F07-503-01
7-16
5.3.2 HDD Unit

When removing the HDD unit, be sure to take care against damage by static electricity. Further, be sure to avoid impact on the HDD unit. 1) Remove the rear cover. (7 screws) 2) Remove the 12 screws [1], and detach the controller cover [2].
[1]
[1] [1]
[2] [1]
F07-503-02 3) Disconnect the two connectors [1]. 4) Remove the eight screws [2], and detach the HDD unit [3].
[2] [3] [2]
[2] [1]
F07-503-03
7-17
5.3.3 Controller Box Unit

1) Remove the rear cover. (7 screws) 2) Detach the DC controller PCB. (See p. $.) 3) Remove the hard disk unit. (See p. $.) 4) Disconnect all connectors of the harness. 5) Remove the eight screws [1], and detach the controller box unit [2].
[2]
[1]
[1]
[1]
[1] [1]
F07-503-04
5.3.4 Reader Controller PCB

1) Remove the rear cover. (7 screws) 2) Remove the hard disk unit. (See p. $.) 3) Disconnect all connectors of the harness. 4) Remove the six screws [1]. 5) Disconnect the connector [2] connected to the main controller, and detach the reader controller PCB [3].
[1]
[3] [1]
[2]
F07-503-05
7-18
5.3.5 Main Controller PCB

1) Remove the rear cover. (7 screws) 2) Remove the DC controller PCB. (See p. $.) 3) Remove the reader controller PCB. (See p. $.) 4) Disconnect all connectors of the harness. 5) Remove the screw [1] (one each), and detach the two PCB guides [2]. 6) Remove the eight screws [3], and detach the main controller PCB [4].
[3]
[2]
[3]
[1] [2] [3]
[3]
[4]
F07-503-06
5.3.6 Composite Power Supply

1) Remove the rear cover. (7 screws) 2) Disconnect all connectors. 3) Remove the three screws [1], and lift the composite power supply [2], and detach it to the front.
[1]
(1) [1] (2) [2]
F07-503-07 7-19
5.3.7 Accessories Power Supply

1) Remove the rear cover. (7 screws) 2) Disconnect all connectors. 3) Disconnect the connector [1] connected to the main power supply. 4) Remove the two screws [2], and detach the accessories power supply [3].
[2]
[1] [3]
F07-503-08
5.3.8 Main Power Supply

1) Remove the accessories power supply. (See 5.3.7.) 2) Disconnect all connectors. 3) Disconnect the connector [1] connected to the composite power supply. 4) Remove the four screws [2], and detach the main power supply [3].
[2]
[3]
[2]
[1]
F07-503-09
7-20
5.4 Cassette Heater

5.4.1 Removing the Cassette Heater
1) Remove the support cover. (See p. $.) 2) Remove the reader front cover. (2 screws) 3) Remove the two screws [1], and disconnect the connector [2].
7-21
CHAPTER 8 PAPER DECK
1 Side Paper Deck

1.1 Inputs to and Outputs from the Deck Driver
1.1.1 Inputs to the Deck Driver (1/2)
Deck driver PCB
+5VR
Deck pickup sensor
J10-1 -2 PS101 -3 J5-1 -2 -3
J8-5 -4 -3 J4-4 -3 -2
J05-5 -4 DPPD -3
+5VR
When paper is detected, '1'.
Deck paper sensor

PS102
J04-7 -6 DPE* -5
+5VR
When paper is absent in the deck, '0'.
Deck lifter upper limit sensor
PS103
J6-1 -2 -3
J4-7 -6 -5
J04-10 -9 DLUL -8
+5VR
When the deck lifter is at the upper limit, '1'.
Deck lifter position sensor
PS104
J7-1 -2 -3
J4-10 -9 -8
J04-13 -12 DLPD -11

+5VR
When the lifter is at pickup position, '1'.
Deck set sensor
J24-1 -2 PS105 -3
J09-5 -4 DSET -3
+5VR
When the deck is set to the copier, '1'.
Deck feed sensor
J12-1 -2 PS106 -3
J8-10 -9 -8
J05-10 -9 DPFD -8
+5VR
When paper is detected, '1'.
Deck paper supply position sensor
J18-1 -2 PS107 -3
J17-3 -2 -1 J17-6 -5 -4
J08-3 -2 DPSP -1
+5VR
When the deck lifter is at paper supply position,'1'.
Deck paper level sensor
J19-1 -2 PS108 -3
J08-6 -5 DPLD -4
+5VR
When the absence of paper (1/2 level) is detected, '1'.
Deck open sensor
J25-1 -2 PS109 -3
J09-8 -7 DOPND* -6
When the compartment is inside the deck, '1'.
F08-101-01
8-1
1.1.2 Outputs from the Deck Driver (2/2)

Deck driver PCB SW100 Deck open switch Deck open indication Open switch PCB
J3-1 -2
J04-4 -3 -2 -1
DOPN* When SW100 is pressed to open the deck, '0'.

+5VR
LED100
-3 -4
DOLON* When the deck is being
opened/closed, '0'. (The LED remains ON or flashes while the deck lifter motor is rotating.)
+24VU J26-3 J10-1 -3 J08-8 -7 -2
SW101 Deck open detecting switch

NO
SW102
J21-2 -1
DOPD When the deck is opened, '1'. (SW101 is not pushed) DLLD When the deck lifter is at the lower limit, '1'. (SW102 is not pushed.)
Deck lifter lower NO limit detecting switch
+24VU.
Power supply
0VU J719
J02-3 -2 J03
Host machine
F08-101-02
8-2
1.1.3 Outputs from the Deck Driver (1/1)

Deck driver PCB
Deck main motor
M101
J01-1 DMMB -2 +24V -3 DMMB* -4 DMMA -5 +24V -6 DMMA*
See p. 8-14.
Deck lifter motor
M102
J22-1 -2
J17-9 -10
J08-9 -10
See p. 8-15.
24VU
Deck pickup clutch
J13-2 CL102 -1
J8-11 -12
J05-11 -12
DPUCD* When '0', ON.
Deck pickup SL101 roller releasing solenoid Deck open solenoid
J9-2 -1
J8-1 -2
24VU J05-1 -2 DPRSD* When '0', ON. 24VU J09-1 -2 DOPSD* When '0', ON.
J23-2 SL102 -1
F08-101-03
8-3
1.2 Pickup
1.2.1 Outline
The paper deck (hereafter, deck) is capable of accommodating 200 sheets of paper at a time (A4/LTR/B5; 80 g/m2), feeding paper to its host machine in response to control signals from the DC controller. The deck lifter is driven by the deck lifter motor (M2D), and paper is picked up and fed using the drive of the deck main motor (M1D).
1.2.2 Pickup Operation

The paper placed inside the deck is held up by the lifter, and is kept at a specific level (pickup position). When the Start key is pressed and, in response, the deck pickup clutch (CL2D) goes ON, the drive of the deck main motor (M1D) rotates the pickup roller to pick up paper. At this time, the pickup/feeding roller and the separation roller serve to make sure that only one sheet of paper is fed; thereafter, when the deck pickup sensor (PS1D) debts paper, the deck pickup roller releasing solenoid (SL1D) goes ON to cause the pickup roller to move away from the stack of paper. The deck feeding roller is designed to rotate when the deck feeding clutch (CL1D) goes ON; the paper that has been picked up by it is sent to the registration roller of the host machine and is arched for the removal of the skew. The registration roller controls the paper so that the leading edge of the paper will match the image on the photosensitive drum.
8-4
PS6D
Deck feed detection signal (P_OUT_SENS) Deck paper detection signal (FEED_SENS)
PS1D
Deck pickup clutch drive signal (PULL_CL_ON*) Deck pickup clutch drive signal (FEED_CL_ON*)
CL1D
Deck drive PCB
DC controller PCB
F08-102-01
CL2D M1D
Deck main motor drive signal
(host machine)
Deck pickup roller releasing solenoid drive signal (PICKUP_SL_ON*)

SL1D
8-5
1.2.3 Sequence of Operations (pickup from the deck)

Start Key ON
INTR SCAN PRINT LSTR STBY
Deck main motor (M1D) Deck pickup clutch (CL2D) Deck pickup roller releasing solenoid (SL1D) Deck pickup sensor (PS1D) Deck feed sensor (PS6D) Deck feeding clutch (CL1D)
F08-102-02
8-6
1.3 Detecting Paper in the Deck

1.3.1 Detecting the Presence/Absence of Paper
The presence/absence of paper inside the deck is detected by the deck paper sensor (PS2D) [1]. When the paper placed on the lifter [2] runs out and, as a result, the paper detecting lever [4] of the pickup roller assembly leaves the deck paper sensor, the host machine will indicate the absence of paper on its control panel.
[4] [1]
[3]
[2]
F08-103-01
[4] [1]
[2]
F08-103-02
1.3.2 Switching the Deck Paper Size

The paper size of the deck is switched at time of installation or as requested by the user: move the guide plate inside the deck to suit the new paper size, and store the new paper size in service mode (OPTION>ACC>DK-P).
8-7
1.3.3 Detecting the Level of Paper Inside the Deck

The deck uses the deck paper supply position sensor (PS7D), deck paper level sensor (PS8D), and deck paper sensor (PS2D) to find out the level of paper inside the compartment and indicates the result on the control panel of the host machine. T08-103-01 shows how detection and indication are done (based on the states of the sensors):
Paper level 100% to about 50% about 50% to about 10% about 10% or less No paper PS2D 1 1 1 0 PS7D 1 1 0 0 PS8D 1 0 0 0 Indication on control panel
1: light-blocking plate over the sensor. 0: light-blocking plate not over the sensor.
T08-103-01
8-8
1.4 Deck Lifter

1.4.1 Detecting the Presence/Absence of Paper
The lifter of the deck is connected to a reel by means of a cable, and is driven by the deck lifter motor (M2D). The lifter is moved up or down depending on the direction of the rotation of the motor. When the compartment is pushed inside the deck, the deck open detection switch (SW1D) is pushed and, in addition, when the deck open sensor (PS9D) detects the light-blocking plate, the lifter starts to move up; the lifter will stop when the deck lifter position sensor (PS4D) detects the top of the stack of paper placed on the lifter. If the lifter fails to stop after the sensor lever blocks the deck lifter position sensor for some reason, the deck lifter upper limit sensor (PS3D) will go ON to prevent damage to the deck otherwise occurring if the lifter was let to continue to move up. The lifter starts to move down, on the other hand, when the deck open switch (SW100D) is pressed; it stops when it leaves the sensor lever of the deck paper supply position senor (PS7D; i.e., at the falling edge of the sensor output). When paper is supplied with the lifter in this position, the lever of the deck paper supply sensor is pushed, and the lifter moves farther down until the stack of paper moves past the sensor lever. A this time, the lifter keeps repeating the descent each time paper is supplied unit the deck lifter lower limit detecting switch (SW2D) is pressed (maximum paper supply position).
8-9
[5] [8] [3] M1D [10]
[2] [7] [1]
[4] M2D [9]
[11]
[12]
[13] [6]
[14]
[15]
F08-104-01 [1] [2] [3] [4] [5] [6] Deck lifter upper limit sensor Deck lifter position sensors Deck paper supply position sensor Deck paper level sensor Deck open detecting switch Deck lifter lower limit detecting switch [7] Deck open switch [8] Deck main motor [9] Deck lifter motor [10] Pickup roller [11] Feeding roller [12] Separation roller [13] Deck lifter cable [14] Lifter [15] Copy paper
8-10
1.4.2 Indicating the Level of Paper on the Deck Front Cover

The drive of the deck lifter motor (M2D) [1] is transmitted through a coupling [2] and forwarded to the rack [4] by the drive belt [3]. The rack is equipped with a black belt [5] which moves in conjunction with the rack, moving up and down inside the window [7] in the deck front cover [6]. When the paper starts to run out and the lifter moves up to reach the pickup position, the area of the black belt in the window increases while the area of white (amount of paper) decreases, thereby indicating the level of paper.
[4]
[5]
[7] [6]
[3]
[1] M2D [2]
F08-104-02
8-11
1.5 Opening/Closing the Compartment

1.5.1 Opening/Closing the Compartment
When the deck open switch (SW100D) is pressed, the deck open solenoid (SL2D) goes ON to release the lock of the compartment; the work of a spring then pushes the compartment several centimeters toward the front. At the same time, the deck lifter motor (M2D) starts to rotate and the lifter inside the compartment starts to move down. When the compartment is pushed manually inside the deck, the deck open sensor (PS9D) detects the light-blocking plate of the compartment, and the lifter moves up to pickup position. When the deck lifter motor rotates in response to the opening/closing of the deck, the deck open indicator (LED100D) on the open switch PCB will go ON or flash.
J20 -1 J20 -4 J5A -4 J5A -1
SW100D
Deck open signal (DECK_OPEN_SW) Deck open indicator LED ON sginal (LEDSW_LEDON)
PS3D Deck lifter upper limit detection
LED100D
Open switch PCB (compartment)
signal (LIFT_M_UPLMT)
PS9D
J5A -9 J6 -7 J7 -3
Deck open detection signal (DECK_OPEN_SENS) Deck open detection signal (DOPD*)
SW1D
Deck lifter
Deck driver PCB
DC controller PCB
SL2D SW2D
Deck open solenoid drive J6 signal -2 (DECK_LOCKOFF_SL_ON*) Deck lifter lower limit J4 -7 detection signal (DLLD) Deck lifter motor drive signal
J4 -9,10
M2D
9 (10 ::
LIFT_M_UP LIFT_M_DOWN
(host machine)
F08-105-01
8-12
1.5.2 Sequence of Operations (opening/closing the compartment)

Deck open switch ON ON Compartment set Flashes OFF
Deck open indicator (LED100D) Deck lifter motor (M2D) Deck paper supply position sensor (PS7D) Deck lifter lower limit detecting switch (SW2D) Deck open solenoid (SL2D) Deck open detecting switch (SW1D) Deck open sensor (PS9D) Deck liter position sensor (PS4D) Deck lifter decent
Compartment open
Deck lifter ascent
Varies depending on the amount of paper.
F08-105-02
8-13
1.6 Controlling the Deck Motor

1.6.1 Controlling the Deck Main Motor (M1D)
The deck main motor is a stepping motor controlled by the DC controller of the host machine. F08-106-01 shows the circuit used to drive the deck main motor, and it has the following functions: [1] Turning on/off the deck main motor. [2] Switching the rotation speed of the deck main motor. a. Turning On/Off the Motor The deck main motor is turned on/off by controlling the output of the following pulse signals from the host machine: FEED_M_A, FEED_M_A*, FEED_M_B, FEED_M_B*. b. Switching the Motor Rotation Speed The deck is equipped with an automatic pickup/feed speed switching mechanism to suit the speed of its host machines expected in the future. The speed is switched in response to motor clock signals (M-CLK) sent from the DC controller of the host machine to the deck driver PCB.
Side deck driver PCB +24V +5V
Motor drive current switching circuit

FEED_M_A*
DC controller PCB Motor rotation control circuit
FEED_M_A
FEED_M_B
M1D
FEED_M_B*
Deck main motor
F08-106-01
8-14
1.6.2 Controlling the Deck Lifter Motor (M2D)

The deck lifter motor control circuit is located on the side deck drive PCB. (F08-106-02 is its block diagram.) The combination circuit found in the diagram consists of various logic circuits, and rotates the deck lifter motor clockwise or counterclockwise depending on the combination of the states of the deck lifter motor DOWN signal (LIFT_M_DOWN) and the deck lifter UP signal (LIFT_M_UP) from the DC controller of the host machine. If the deck lifter position sensor (PS4D) does not detect the lifter within a specific period of time in the presence of the deck lifter UP signal for some reason, an alarm code (05) will be indicated in service mode (DISPLAY>ALARM1>BODY). [1] Conditions for Moving Up the Lifter The deck is connected to the host machine. The deck set signal (DECK_MOUNT_SENS) goes 1 The compartment is closed. The deck open detention signal (DECK_OPEN_SNS) goes 1. The compartment is closed. The deck open detecting switch (DECK_OPEN_SW) goes ON. The deck lifter upper limit detection signal (LIFT_M_UPLMT) goes 0 and, in addition, the deck lifter position detection signal (PAP_TOP_SENS) goes 0. The deck lifter motor DOWN signal (LIFT_M_DOWN) goes 0. The deck lifter UP signal (LIFIT_M_UP) goes 0. The above conditions cause the lifter to move up. [2] Conditions for Moving Down the Lifter The compartment is open. The deck open detection signal (DECK_OPEN_SENS) goes 0. The deck lower limit detection signal (LIFT_LOW_LIMIT) goes 0 and, in addition, the deck lifter position detection signal (PAP_TOP_SENS) goes 0. The deck lifter DOWN signal (LIFT_M_DOWN) goes 0. The deck lifter UP signal (LIFT_M_UP) goes 1. The above conditions cause the lifter to move down.
8-15
24V
24V
24V
Deck open detecting switch (SW1D)
Deck lifter motor UP drive signal
M2D
Deck lifter motor DOWN drive signal
Deck lifter motor Motor drive circuit Deck lifter upper limit detection signal (LIFT_UP_LIM)
Deck lifter drive signal (LIFT_UP_LIM) DC controller PCB
PS3D Deck lift upper limit sensor PS4D Deck lifter position sensor
Deck lifter position Combination signal (DLFPD) circuit Deck lifter UP signal (DECK_UP) Deck lifter lower limit signal (DLFLD)
Communication Deck motor error drive conver- signal (LIFT_M_ERR) sion IC
Deck lifter lower limit detecting switch (SW2D)
Deck open signal (DOPEN) Deck open switch (SW100D) Deck open detection signal (DECK_OPEN) PS9D Deck open sensor
Deck set signal (DMNTSD)
PS5D Deck set sensor
Deck paper supply position detection signal (DPLLD) Host machine Side deck driver PCB
PS7D Deck paper supply position sensor
Not: The communication conversion IC (IC4) in the diagram is used to convert serial signals into parallel signals and vice versa.
F08-106-02
8-16
2 Detecting Jams
2.1 Outline
The paper deck is equipped with the two sensor indicated in F08-201-01 to monitor the movement of paper. The presence/absence of a jam is detected with reference to the signals from the sensors by the DC controller PCB of the host machine at such times as stored in memory. When the DC controller of the host machine identifies a jam, it will deliver the sheets in front of the jam and then stop the machine; thereafter, it will indicate instructions on jam removal on the control panel.
PS6D PS1D
F08-201-01
Notation PS6D PS1D Name Deck feed sensor Deck pickup sensor Function Detect a delay jam. Detects a delay jam.
T08-201-01
8-17
The DC controller of the host machine identifies a jam in response to the following conditions: 1. Paper exists over the deck feed sensor (PS6D) when the host machine is turned on, ends its WAIT period, or remains at standby: deck pickup/vertical path delay jam.
Start key ON INTR SCAN Jam indicator ON PRINT
Deck pickup clutch (CL2D) Jam check Deck pickup sensor (PS1D) Deck feed sensor (PS6D) Deck main motor (M1D)
Normal
Error
F08-201-02
8-18
SYSTEM INSTALLATION
INSTALLATION
1 Selecting the Site of Installation

Select the site of installation against the following conditions; if possible, visit the users in advance of the delivery of the machine: 1. There must be a power outlet that may be used exclusively for the machine and rated as indicated (10%). 2. The temperature of the room must be between 7.5 and 30C and humidity, between 5% and 80%. Avoid areas near a water faucet, water boiler, humidifier, or refrigerator. 3. The site must not be near a source of fire or must not be subject to dust or ammonium gas. If the site is exposed to direct rays of the sun, provide curtains. 4. The level of ozone generated by the machine in operation will not affect the health of the individuals around it. Nevertheless, some may find the odor unpleasant, requiring good ventilation of the work place. 5. The floor of the site must be level so that the feet of the machine will remain in contact and the machine itself will remain level.
S-1
INSTALLATION
6. The site must be such that the machine will be at least 10 cm away from any wall, allowing adequate space for work.
10 cm min. 50 cm min. 50 cm min.
F03-100-01
10 cm min.
110 cm min.
50 cm min.
100 cm min.
F03-100-02 7. The site must be well ventilated. Do not install the machine near the air inlet of the room.
S -2
50 cm min.
INSTALLATION
2 Unpacking and Installation

2.1 Before Starting the Work
Keep the following in mind for the work: 1. If the machine is brought in from a cold to warm place, its pickup/feeding assembly can develop condensation, leading to image faults. Leave the machine alone for at least one hour, and start the work after the machine has become used to the room temperature. The term condensation refers to the symptom that occurs when a piece of metal is brought in from a cold to warm place, cooling the vapor in the air rapidly and turning it into droplets of water on the metal surface. 2. The machine weighs about 80 kg. Be sure to work in a group of two.
S-3
INSTALLATION
2.2 Unpacking and Removing the Fixing Materials

Work 1) Open the shipping box, and remove the plastic sheets. If you are installing the pedestal at the same time, unpack it. 2) While working in a group of two, hold the grips, and place it on the pedestal. (weight of body: about 80kg) Take care so that the main power switch will not be turned on when the machine is lifted. Checks/remarks
Grips
Grips
S -4
INSTALLATION
Work 3) Remove the packing tape of the machine. 4) Press the cassette release button, and take out each cassette to the front; then, remove all packing material from inside. 5) Connect the machine and the pedestal using a screw. Other types of pedestal may also be connected using a screw. 6) Slide the cassettes into the machine. 7) Open the cardboard box that comes with the machine, and take out the components and attachments;
Checks/remarks
Screw
check to make sure that none of the following is missing: Users Manual Drum unit Right lower cover Toner cartridge (100V model only) Cassette size label (inside cassettes) Cassette size plate (inside cassette) QR sheet (100V model only) Service Book (100V model only) Guidebook (model w/ printer function only) CD-ROM (model w/ printer function only)
S-5
INSTALLATION
2.3 Mounting the Scanner

Work 1) Remove the three screws and the three tags used to hold the scanner in place on the left cover of the reader unit. Keep the screws stored away for possible relocation of the machine. Checks/remarks
Tags
Stepped screws
2.4 Removing the Dummy Drum

Work 1) Open the front cover. 2) Shift down the feeder releasing lever to release the feeding assembly. 3) Turn the developing assembly locking lever counterclockwise to free the developing assembly. Checks/remarks
Developing assembly locking lever
Feeding releasing lever
S -6
INSTALLATION
Work 4) Remove the fixing screw from the dummy drum. The removed fixing screw will be used when mounting the drum unit. 5) Pull the dummy drum straight out to the font. The removed dummy drum will no longer be used.
Checks/remarks
Screw Dummy drum
2.5 Supplying the Toner

Work 1) Holding the grip of the developing assembly, pull the developing assembly to the front until it stops. Checks/remarks
Developing assembly
Grip
S-7
INSTALLATION
Work 2) Shake the toner cartridge several items. 3) Set the toner cartridge to the developing assembly, and push it down until the opening tab springs to view. The toner cartridge is locked to the developing assembly.
Checks/remarks
Toner cartridge
Open/close tab
4) While lightly holding down the toner cartridge with one hand, pull the open tab to the front until it stops (where the marking STOP is found). 5) Tap lightly on the top of the toner cartridge so that all toner will drop.
S -8
INSTALLATION
Work 6) Push in the black cover of the developing assembly back to its initial position. The toner cartridge will become disengaged. 7) Remove the toner cartridge. 8) Push in the developing assembly until it butts against the rear.
Checks/remarks
S-9
INSTALLATION
2.6 Mounting the Drum Unit

Work 1) Unpack the drum unit, and remove the two releasing members of the primary charging roller. 1. Do not touch the dump area of the photosensitive drum to avoid damage. 2. Take care not to expose the photosensitive drum to strong light. 3. Take care not to damage the stirrups found at the bottom of the drum unit. 2) Check to make sure that the developing assembly has been freed; then, insert the drum unit slowly along the rails. At this time, take extra care not to bring the developing assembly in contact with the developing cylinder or the like that are closely located. Checks/remarks
Primary charging roller releasing members
Rails
Drum unit
S -10
INSTALLATION
Work 3) Using the fixing screw removed from the dummy drum previously, secure the dump unit in place.
Checks/remarks
Drum unit
Screw
4) Fill out the date label, and attach it to the front cover of the drum unit. 5) Turn the developing assembly locking lever clockwise to lock the developing assembly in place. 6) Shift up the feeding releasing lever to lock the feeding assembly in place. 7) Close the front cover.
S-11
INSTALLATION
2.7 Stirring the Toner

Be sure to remove the packing material from inside the cassette before turning on the main power switch. Work 1) Connect the power plug to the power outlet. 2) Turn on the main power switch. Wait until the control panel indicates that the machine is ready for operation. 3) Start service mode. 4) Make the following selections: COPIER>FUNCTION>INSTALL>TONERS. 5) Press the OK key. The stirring operation will last for 240 sec (4 min), after which the operation stops automatically. 6) Press the Reset key twice to end service mode. Checks/remarks The power supply must be as rated. (The voltage may be 10% of the rating, but it must have the rated amperage.) Press the key, 2 and 8 at the same time, and the key once again. The following message will appear: CHECK THE DEVELOPER. In response, check to see if the developing assembly is properly locked in place. If you inadvertently stopped stirring of the toner in the middle, be sure to execute TONER-S once again.
Display I/O Adjust Function Option Test Counter
<INSTALL >
< 1/ 1 > <NO-PAPER>
TONER-S Check the Developer STRD-POS CARD 0 ( 0) { 1 - 2700}
+/-
OK
S -12
INSTALLATION
2.8 Setting the Cassette

Work 1) Press the cassette releasing button, and slide out the cassette to the front. 2) Check with the user to find out the size of paper to use, and set the size (A/B or Inch) using the selection switch of each cassette. Checks/remarks
Switch
3) Attach the label indicating the selected paper size (A/B or Inch) to the paper size dial.
Label
Protrusion
S-13
INSTALLATION
Work 4) Pick the lever of the side guide plate and the rear guide plate, and adjust it to the appropriate paper size index. The middle cassette cannot hold A3 or 1117 paper.
Checks/remarks
5) Set the paper size dial to suit the selected paper size.
Set the dial as indicated.
S -14
INSTALLATION
Work 6) Attach the size label to the cassete size plate, and fit the cassette size plate to each cassette. 7) Put paper into the cassettes, and slide them into the machine.
Checks/remarks
Cassette size plate Size labels
Cassette
S-15
INSTALLATION
2.9 Checking the Images/Operations

Work 1) To install the machine not using the 2cassette pedestal, mount the right lower cover. Skip this step if the machine is installed on a 2-cassette pedestal. Checks/remarks
Right lower cover
2) Using the NA-3 Chart as the original, make a print to check the images and the operation. 3) Make user mode settings (e.g., date, time) and service mode settings (COPIER>OPTION>USER) to suit the needs of the user.
Optimum Image In text mode, the white background must not be foggy. In text/photo mode, step edge No. 10 must be barely visible. The white background must be free of fogging. In photo mode, the white background must be free of fogging. (The moire, if any, along the step edges and the halftone area does not indicate a fault.) The non-image width must be as indicated: 2.51.5 mm. Checking the Operations During copying operation, check to make sure the operations are normal. During double-sided copying operation, check to make sure that paper is moved normally in the duplex unit. For pickup operation, check to make sure that pickup from each source of paper is normal. There must not be abnormal operating noise. Make copies at each default reproduction ratio, and check to make sure that the images are normal. Make copies in multiple sets, and check to make sure that copies are made specified numbers.
S -16
INSTALLATION
Work 4) If necessary in view of the site environment, turn on the cassette heater switch. 5) Move the machine to the site of installation; if it is placed on a pedestal, secure it in place using the four adjusters. 6) Clean the area around the machine, and fill out the Service Book.
Checks/remarks
Cassette heater switch
S-17
INSTALLATION
2.10
Connecting to the Network

Perform the following steps if the machine is equipped with printer functions:
1) Turn off the main power. 2) Connect the network cable to the machine, and turn on the main power. 3) Inform the users system administrator that the machine has been installed, and ask him/ her to make the network settings for the machine.
2.11
Checking the Network Connection

If the users network environment is TCP/IP, use the PING function to make sure that the network PCB has properly been installed and the network settings have properly been made. If the users network environment is IPX/SPX or AppleTalk, on the other hand, these checks are not needed.
2.11.1 Using the PING Function

1) Make the following selections to select PING: COPIER>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 PING is successful, OK will be indicated: otherwise, NG will be indicated.
<NETWORK> PING 0. < 1/1 > 0. 0. <READY > 0
IP address input Results (OK/NG)
+/-
OK
S -18
INSTALLATION
2.11.2 Making a Check Using a Remote Host Address

The connection to the network may be checked by executing PING using a remote host address (i.e., the IP address of a PC terminal connected to and operating on the TCP/IP network to which the machine is connected). 1) Inform the users system adminisrator that the network connection will be checked using PING. 2) Check with the users system administrator to find out the remote host address. 3) Enter the remote host address in the PING field. If OK is indicated, the connection to the network is correct. If NG is indicated, the connection to the network is not correct; investigate the cause as follows:
2.12
Troubleshooting the Network

If the connection to the network is not made, the following can be suspected; perform the steps under 2.12.1 to correct the faults: a. The connection between the network and the network PCB is faulty. b. The TCP/IP settings on the machine are faulty. c. The network PCB is faulty, or the PCB is mounted wrongly. d. The user network is faulty.
2.12.1 Checking the Connection of the Network Cable

1) Check to find out if the network cable is correctly connected to the network PCB. If the connection is correct, go to 2.12.2. If the connection is wrong, correct it, and make a check once again using the remote host address.
S-19
INSTALLATION
2.12.2 Making a Check Using a Loop-Back Address

A loop-back address is returned before it reaches the network PCB; therefore, executing PING using it will enable a check on the TCP/IP settings made on the machine. 1) Enter the loop-back address (127.0.0.1) in the PING field. If NG is indicated, check the TCP/IP settings of the machine once again, and execute PING once again. If OK is indicated, go to 2.12.3.
2.12.3 Making a Check Using a Local Host Address

The local host address is the IP address of the machine, and executing PING using it will enable a check on the network PCB (it is retuned after it reaches the network PCB). 1) Enter the IP address of the machine in the PING field. If NG is indicated, perform the following check/correction, and execute PING once again: a. If the IP address of the machine is wrong, check the IP address settings made on the machine once again, or find out if the IP address assigned to the machine is correct or not by consulting the users system administrator. b. If the network has faulty connection, check the connector of the network PC for connection. c. If the network PCB is faulty, replace the network PCB. If OK is indicated, suspect a problem in the users network environment; report to the users system administrator, and ask for corrective measures.
S -20
INSTALLATION
3 Relocating the Machine

3.1 Preparing for Relocation
If the machine must be relocated by truck or other means of transportation after it has been installed, perform the following: Do not lift the machine by holding its grips as when moving it over a step; otherwise, the machine will become separated from the pedestal. Be sure to lift the pedestal if the machine is connected to it. Work 1) Remove the fixing screw, and detach the drum unit. 2) Fix the scanner in place. 3) Tape the front cover, delivery assembly, and cassette in place. 4) Place a single sheet of A3 paper on the copyboard glass, and tape the copyboard cover (DADF) in place. Checks/remarks
S-21
INSTALLATION
3.2 Lifting the Machine Off the Pedestal

Work 1) Disconnect the lattice connector of the pedestal from the machine. 2) Slide out the two cassettes from the machine, and remove the screw used to connect the machine to the pedestal. Remove the screw likewise if the machine is installed to a different type of cassette pedestal. Checks/remarks
Screw
3) Open the right cover of the pedestal, and release the guide assembly connected to the machine (i.e., shift it down to the right). 4) While working in a group of two or more, hold the grips of the machine, and lift it straight up (pay attention to the pins of the pedestal). 5) Place the machine on the floor or on a desk.
Vertical path guide assembly
[2]
[1]
Right cover
S -22
INSTALLATION
4 Installing the Card Reader-C1

Work 1) Turn off the main power switch. 2) To facilitate the removal of the right rear cover, remove the screws from the rear cover.
Screws
Checks/remarks
3) Open the manual feed tray and the right lower cover. 4) Remove the five screws; and, while opening the right rear cover slightly, detach the right rear cover.
Right rear cover Screws
Screws
S-23
INSTALLATION
Work 5) Cut off the face plate at the top of the right rear cover with a nipper or the like.
Checks/remarks
Face plate
6) Lead out the connector of the card reader on the machine side, and mount the right rear cover.
Connector
7) Connect the connector on the card reader side and the connector on the machine side.
Card reader
Connectors
S -24
INSTALLATION
Work 8) While pushing the connector and the harness into the machine, put the boss of the right rear cover into the hole in the card reader support plate, and secure the card reader to the machine with a screw. Take care not to trap the connector or the harness. 9) Make the following selections in service mode: COPIER>FUNCTION>INSTALL>CARD; then, enter the card number (1 through 2700). Enter the number of the card (of all the cards used by the user) that have the lowest number. As many as 300 cards may be used having a number higher than the one entered.
Checks/remarks
Screw
Connector
Harness
S-25
INSTALLATION
5 Installing the Original Holder-D1

Work 1) Remove the two stickers from the right top of the machine. Using the two stepped screws (RS tightening; M410) that come with the machine, mount the original holder to the machine. If the work proves to be difficult, loosen the two stepped screws, and try again. 1. Be sure to use the stepped screws designed for the machine; ones for other types come together with the machine. 2. The original holder may be mounted to the left side of the machine. Checks/remarks
Stepped screws Original holder
S -26

Canon Ir2200 Ir2800 Ir3300 Service Manual

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Confidential

New Product Information

Yoshiaki Takase, General Manager OIP QA Division

New Product Information

January,25, 2001 Canon Inc. OIP QA Center OIP QA Division

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

Manual Transfer Separation Cleaning Fixing

CHAPTER 1 GENERAL DESCRIPTION

Reading Copying Printer output

Original type Maximum original size Reproduction ratio

A/B Inch AB Inch

CHAPTER 1 GENERAL DESCRIPTION

Item Single-sided copying mode

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

Maximum Standby Continuous Copying Standby

Ozone Dimensions (mm)

Weight Consumables Toner

CHAPTER 1 GENERAL DESCRIPTION

Reproduction mode Direct

Paper size A3 A5 A4 B4 B5 A4R B5R A5R

copies /min (1-to-N) E201 E202 16 22 33 14 28 -

Reduce II (50.0%) III (61.1%) IV (70.7%) V (81.6%) VI (86.5%)

A3 A5R A3 B5R B4 B5R A3 A4R B4 A4R B5R A5R A4 B5 A3 B4

A5R B5R B5R A4R A4R A5R B5 B4

Enlarge IV (200.0%) III (141.4%) II (122.4%) I (115.4%)

A5R A3 A4R A3 B5R B4 A4R B4 A5 B5 B4 A3 B5 A4

CHAPTER 1 GENERAL DESCRIPTION

Reproduction mode Direct

279.4431.8mm (11"17") 279.4431.8mm (11"17") 279.4431.8mm (11"17") copies/min

CHAPTER 1 GENERAL DESCRIPTION

1.2 Side Paper Deck-L1

CHAPTER 1 GENERAL DESCRIPTION

[1] [2] [3] [4] [5] [6] [7] [8]

F01-201-01 External View 1

CHAPTER 1 GENERAL DESCRIPTION

[1] [2] [3] [4]

F01-201-02 External View 2

CHAPTER 1 GENERAL DESCRIPTION

2.2 Cross Section

F01-202-01 Cross Section

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 1 GENERAL DESCRIPTION

Original Optical path Original illumination

Various networks or public telephone network

CCD PCB Original Exposure Block

Various accessory boards

Reader controller PCB

Main controller PCB Image Processing Block HDD

Lower feeding assembly Cassette 1 Cassette 2

3.2.1 Construction of the Electrical Circuit

3.2 Outline of the Electrical Circuitry

IC6501 Control (CPU) panel PCB

CHAPTER 1 GENERAL DESCRIPTION

IC120 (IPC communication 2)

DC loads Clutch Solenoid Motor Sensor Fan Etc.

BD Laser PCB drive PCB