Canon iR C6800 Series User manual

Apr 6 2004
Service Manual
iR C6800 Series
iR C6800C

Application
This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and
repair of products. This manual covers all localities where the products are sold. For this reason, there may be
information in this manual that does not apply to your locality.
Corrections
This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products.
When changes occur in applicable products or in the contents of this manual, Canon will release technical information
as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will
issue a new edition of this manual.
The following paragraph does not apply to any countries where such provisions are inconsistent with local law.
Trademarks
The product names and company names used in this manual are the registered trademarks of the individual companies.
Copyright
This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied,
reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc.
COPYRIGHT © 2001 CANON INC.
Printed in Japan
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction
Symbols Used
This documentation uses the following symbols to indicate special information:
Symbol Description
Indicates an item of a nonspecific nature, possibly classified as Note, Caution, or Warning.
Indicates an item requiring care to avoid electric shocks.
Indicates an item requiring care to avoid combustion (fire).
Indicates an item prohibiting disassembly to avoid electric shocks or problems.
Indicates an item requiring disconnection of the power plug from the electric outlet.
Indicates an item intended to provide notes assisting the understanding of the topic in question.
Indicates an item of reference assisting the understanding of the topic in question.
Provides a description of a service mode.
Provides a description of the nature of an error indication.
Memo
REF.

Introduction
The following rules apply throughout this Service Manual:
1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical
and mechanical systems with reference to the timing of operation.
In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol ,
the arrow indicates the direction of the electric signal.
The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the
delivery unit door, which results in supplying the machine with power.
2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to
indicate "Low".(The voltage value, however, differs from circuit to circuit.) In addition, the asterisk (*) as in
"DRMD*" indicates that the DRMD signal goes on when '0'.
In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the
operations of the microprocessors used in the machines are not discussed: they are explained in terms of from
sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads.
The descriptions in this Service Manual are subject to change without notice for product improvement or other
purposes, and major changes will be communicated in the form of Service Information bulletins.
All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant
Service Information bulletins and be able to identify and isolate faults in the machine."

Contents
Contents
Chapter 1 Introduction
1.1 System Construction........................................................................................................................................... 11
1.1.1 System Configuration with Pickup/Delivery Accessories .......................................................................... 11
1.1.2 System Configuration with Printing/Transmission Accessories................................................................. 12
1.1.3 Functions of Printing/Transmitting Accessories......................................................................................... 13
1.2 Product Specifications........................................................................................................................................ 14
1.2.1 Names of Parts ............................................................................................................................................. 14
1.2.2 Using the Machine ....................................................................................................................................... 18
1.2.3 User Mode Items........................................................................................................................................ 111
1.2.4 User Maintenance ...................................................................................................................................... 118
1.2.5 Safety ......................................................................................................................................................... 122
1.2.6 Product Specifications ............................................................................................................................... 124
1.2.7 Function List .............................................................................................................................................. 127
Chapter 2 Installation
2.1 Making PreChecks ............................................................................................................................................ 21
2.1.1 Selecting the Site of Installation.................................................................................................................. 21
2.1.2 Installation Environment............................................................................................................................. 23
2.1.3 Checking the Contents................................................................................................................................. 24
2.2 Unpacking and Installation................................................................................................................................. 26
2.2.1 Before Starting the Work ............................................................................................................................ 26
2.2.2 Unpacking the Machine............................................................................................................................... 26
2.2.3 Mounting the Pickup Assembly .................................................................................................................. 29
2.2.4 Mounting the Scanner System..................................................................................................................... 29
2.2.5 Locking the Primary Transfer Roller in Place........................................................................................... 210
2.2.6 Before Mounting the Developing Assembly............................................................................................. 210
2.2.7 Mounting the Color Developing Assemblies ............................................................................................ 214
2.2.8 Mounting the Black Developing Assembly .............................................................................................. 217
2.2.9 Mounting the Process Unit........................................................................................................................ 219
2.2.10 Mounting the Fixing Assembly............................................................................................................... 223
2.2.11 Fitting the Black Toner Bottle................................................................................................................. 224
2.2.12 Checking the Environment Switch.......................................................................................................... 225
2.2.13 Turning On the Main Power Switch........................................................................................................ 226
2.2.14 Setting Up the Paper Cassette ................................................................................................................. 226
2.2.15 Changing the Deck Paper Size (right, left).............................................................................................. 227
2.2.16 Fitting the Color Toner Cartridge............................................................................................................ 228
2.2.17 Supplying Black Toner............................................................................................................................ 229
2.2.18 Cleaning the Intermediate Transfer Belt ................................................................................................. 229
2.2.19 Supplying Color Toner............................................................................................................................ 229
2.2.20 Setting Auto Gradation Correction.......................................................................................................... 230
2.2.21 Checking the Image/Operation................................................................................................................ 230
2.2.22 Adjusting the Horizontal Registration..................................................................................................... 230
2.2.23 Adjusting the Leading Edge Registration ............................................................................................... 233
2.2.24 Securing the Machine in Place ................................................................................................................ 233
2.2.25 If Not Connected to a Network ............................................................................................................... 234

Contents
2.3 Checking the Connection to the Network.........................................................................................................235
2.3.1 Overview....................................................................................................................................................235
2.3.2 Using the PING Utility ..............................................................................................................................235
2.3.3 Using a Remote Host Address...................................................................................................................235
2.4 Troubleshooting the Network...........................................................................................................................236
2.4.1 Overview....................................................................................................................................................236
2.4.2 Checking the Connection of the Network Cable .......................................................................................236
2.4.3 Using a Loopback Address........................................................................................................................236
2.4.4 Using a Local Host Address ......................................................................................................................236
2.5 Relocating the Machine....................................................................................................................................237
2.5.1 Relocating the Machine .............................................................................................................................237
2.6 Installing the Card ReaderC1 ..........................................................................................................................238
2.6.1 Points to Note About Installation ..............................................................................................................238
2.6.2 Checking the Contents...............................................................................................................................238
2.6.3 Installation .................................................................................................................................................239
2.6.4 Using the Card Reader in Combination with NetSpot Accountant (hereafter, NSA) ...............................241
2.7 Installing the NE ControllerA1 .......................................................................................................................242
2.7.1 NE ControllerA1 Installation Procedure ..................................................................................................242
2.8 Installing the Original Tray ..............................................................................................................................251
2.8.1 Checking the Contents...............................................................................................................................251
2.8.2 Installation .................................................................................................................................................251
2.9 Installing the Key Switch UnitA1 ...................................................................................................................253
2.9.1 Checking the Contents...............................................................................................................................253
2.9.2 Installation .................................................................................................................................................253
Chapter 3 Basic Operation
3.1 Construction........................................................................................................................................................31
3.1.1 Functional Construction...............................................................................................................................31
3.1.2 Arrangement of the Major PCBs.................................................................................................................33
3.1.3 DC Controller ..............................................................................................................................................34
3.2 Basic Sequence ...................................................................................................................................................36
3.2.1 Basic Sequence of Operation at PowerOn .................................................................................................36
3.2.2 Basic Sequence of Control During Printing (fullcolor)..............................................................................38
3.2.3 Basic Sequence of Operation During Printing (mono color).......................................................................39
Chapter 4 Main Controller
4.1 Construction........................................................................................................................................................41
4.1.1 Functional Construction...............................................................................................................................41
4.2 Construction of the Electrical Circuitry..............................................................................................................43
4.2.1 Main Controller PCB (main) .......................................................................................................................43
4.2.2 Main Controller PCB (sub)..........................................................................................................................45
4.2.3 Expansion Bus PCB.....................................................................................................................................46
4.2.4 SRAM PCB .................................................................................................................................................46
4.2.5 HDD.............................................................................................................................................................47
4.3 StartUp Sequence ..............................................................................................................................................49
4.3.1 Overview......................................................................................................................................................49
4.3.2 StartUp Sequence .....................................................................................................................................410
4.4 Actions when HDD Error .................................................................................................................................412
4.4.1 E602 in Detail............................................................................................................................................412
4.4.2 E609 in Detail............................................................................................................................................416

Contents
4.5 Image Processing.............................................................................................................................................. 417
4.5.1 Overview of the Flow of Image Data........................................................................................................ 417
4.5.2 Construction of the Image Processing Modules........................................................................................ 418
4.5.3 Reader Input Image Processing................................................................................................................. 419
4.5.4 Compression/Decompression and Editing Blocks .................................................................................... 420
4.5.5 Printer Output Image Processing............................................................................................................... 421
4.6 Flow of Image Data.......................................................................................................................................... 422
4.6.1 Flow of Image Data (copier function)....................................................................................................... 422
4.6.2 Flow of Image Data (Box function) .......................................................................................................... 423
4.6.3 Flow of Image Data (SEND function) ...................................................................................................... 424
4.6.4 Flow of Image Data (fax transmission)..................................................................................................... 425
4.6.5 Image Data Flow for Fax Reception Functions......................................................................................... 426
4.6.6 Flow of Image Data (PDL function) ......................................................................................................... 427
4.7 Parts Replacement Procedure........................................................................................................................... 428
4.7.1 Controller Box ........................................................................................................................................... 428
4.7.2 Main Controller PCB (main) ..................................................................................................................... 431
4.7.3 Main Controller PCB (sub)........................................................................................................................ 435
4.7.4 Expansion Bus PCB................................................................................................................................... 436
4.7.5 SRAM PCB................................................................................................................................................ 438
4.7.6 UFR Board ................................................................................................................................................. 440
4.7.7 Ethernet Board ........................................................................................................................................... 441
4.7.8 HDD........................................................................................................................................................... 443
4.7.9 Controller Fan ............................................................................................................................................ 445
Chapter 5 Original Exposure System
5.1 Construction ....................................................................................................................................................... 51
5.1.1 Specifications, Control Mechanisms, and Functions .................................................................................. 51
5.1.2 Major Components...................................................................................................................................... 52
5.1.3 Construction of the Control System ............................................................................................................ 54
5.1.4 Reader Controller PCB................................................................................................................................ 54
5.2 Basic Sequence................................................................................................................................................... 56
5.2.1 Basic Sequence of Operation at PowerOn ................................................................................................. 56
5.2.2 Basic Sequence of Operation in Response to a Press on the Start Key.......................................................57
5.3 Various Control .................................................................................................................................................. 59
5.3.1 Controlling the Scanner Drive System ........................................................................................................ 59
5.3.2 Enlargement/Reduction.............................................................................................................................. 511
5.3.3 Controlling the Scanning Lamp................................................................................................................. 511
5.3.4 Detecting the Size of Originals.................................................................................................................. 512
5.3.5 Dirt Sensor Control.................................................................................................................................... 516
5.3.6 Image Processing ....................................................................................................................................... 520
5.4 Parts Replacement Procedure........................................................................................................................... 523
5.4.1 Copyboard Glass........................................................................................................................................ 523
5.4.2 Exposure Lamp .......................................................................................................................................... 523
5.4.3 Reader Controller PCB .............................................................................................................................. 527
5.4.4 Interface PCB............................................................................................................................................. 530
5.4.5 Inverter PCB .............................................................................................................................................. 532
5.4.6 CCD Unit ................................................................................................................................................... 533
5.4.7 Scanner Motor............................................................................................................................................ 535
5.4.8 ADF Open/Close Sensor............................................................................................................................ 537
5.4.9 Scanner HP Sensor..................................................................................................................................... 539
5.4.10 Original Sensor ........................................................................................................................................ 541
5.4.11 Cooling Fan.............................................................................................................................................. 542
5.4.12 Scanner Drive Cable ................................................................................................................................ 543

Contents
Chapter 6 Laser Exposure
6.1 Construction........................................................................................................................................................61
6.1.1 Specifications, Control Mechanisms, and Functions...................................................................................61
6.1.2 Major Components ......................................................................................................................................62
6.1.3 Construction of the Control System ............................................................................................................63
6.2 Basic Sequence ...................................................................................................................................................64
6.2.1 Basic Sequence of Operation.......................................................................................................................64
6.3 Various Control ..................................................................................................................................................65
6.3.1 Controlling the Laser Activation Timing.....................................................................................................65
6.3.2 Controlling the Intensity of Laser Light.......................................................................................................68
6.3.3 Controlling the Laser Scanner Motor...........................................................................................................69
6.3.4 Controlling the Laser Shutter .....................................................................................................................610
6.4 Parts Replacement Procedure ...........................................................................................................................611
6.4.1 Laser Scanner Unit.....................................................................................................................................611
Chapter 7 Image Formation
7.1 Construction........................................................................................................................................................71
7.1.1 Specifications of the Image Formation System...........................................................................................71
7.1.2 Major Components ......................................................................................................................................74
7.1.3 Charging System..........................................................................................................................................75
7.2 Image Formation Process ...................................................................................................................................77
7.2.1 Image Formation Process ............................................................................................................................77
7.3 Basic Sequence ...................................................................................................................................................79
7.3.1 At Time of PowerOn ..................................................................................................................................79
7.3.2 During Copying/Printing (normal speed)..................................................................................................710
7.3.3 During Copying/Printing (2/3 speed, 1/3 speed) .......................................................................................710
7.4 Image Stabilization Control..............................................................................................................................711
7.4.1 Overview of Image Stabilization Control..................................................................................................711
7.4.2 Timing of Image Stabilization Control......................................................................................................712
7.4.3 Potential Control........................................................................................................................................715
7.4.4 ATVC Control ...........................................................................................................................................719
7.4.5 ATR Control..............................................................................................................................................721
7.4.6 ACR Control (Auto Carrier Refresh Control) ...........................................................................................724
7.4.7 Dmax Control...........................................................................................................................................725
7.4.8 Dhalf Control............................................................................................................................................726
7.4.9 PASCAL control .......................................................................................................................................729
7.5 Charging Meachanism......................................................................................................................................732
7.5.1 Controlling the Primary Charging Bias .....................................................................................................732
7.5.2 Controlling the Primary Charging Assembly Cleaning Mechanism .........................................................733
7.5.3 Controlling the PreTransfer Charging Bias..............................................................................................734
7.5.4 Controlling the PreTransfer Charging Assembly Cleaning Mechanism..................................................734
7.5.5 PreExposure LED.....................................................................................................................................736
7.6 Developing Rotary............................................................................................................................................737
7.6.1 Overview of the Developing Rotary..........................................................................................................737
7.6.2 Controlling the Developing Rotary ...........................................................................................................738
7.7 Developing Unit................................................................................................................................................741
7.7.1 Construction of the Color Developing Assembly......................................................................................741
7.7.2 Controlling the Color Developing Assembly Drive Mechanism ..............................................................742
7.7.3 Controlling the Color Developing Bias .....................................................................................................743
7.7.4 Color Toner Supply ...................................................................................................................................744
7.7.5 Detecting the Level of Color Toner...........................................................................................................745
7.7.6 Construction of the Black Developing Assembly .....................................................................................748

Contents
7.7.7 Controlling the Black Developing Assembly Drive Mechanism.............................................................. 749
7.7.8 Black Toner Supply................................................................................................................................... 750
7.7.9 Controlling the Black Developing Bias..................................................................................................... 752
7.8 Transfer Device ................................................................................................................................................ 753
7.8.1 Overview of the Transfer Assembly ......................................................................................................... 753
7.8.2 Controlling the Transfer Bias.................................................................................................................... 754
7.8.3 Overview of the Primary Transfer Assembly............................................................................................ 756
7.8.4 Controlling the ITB Cleaner Shifting Mechanism .................................................................................... 757
7.8.5 Checking the ITB Cleaner Position........................................................................................................... 758
7.8.6 Overview of the Secondary Transfer Assembly........................................................................................ 759
7.8.7 Controlling the Movement of the Secondary Transfer Roller................................................................... 760
7.8.8 Checking the Location of the Secondary Transfer Roller......................................................................... 761
7.8.9 Detecting the ITB Home Position ............................................................................................................. 762
7.8.10 Separation................................................................................................................................................ 764
7.9 Photosensitive Drum Cleaning......................................................................................................................... 765
7.9.1 Overview of the Drum Cleaning Unit ....................................................................................................... 765
7.9.2 Controlling the Drum Cleaning Unit Drive Mechanism........................................................................... 766
7.10 Waste Toner Collection Mechanism.............................................................................................................. 767
7.10.1 Collection of Waste Toner ...................................................................................................................... 767
7.10.2 Detecting the State of the Waste Toner Bottle (full)............................................................................... 768
7.11 Parts Replacement Procedure......................................................................................................................... 771
7.11.1 Process Unit ............................................................................................................................................. 771
7.11.2 Preexposure LED Array ......................................................................................................................... 778
7.11.3 Primary Charging Assembly.................................................................................................................... 784
7.11.4 Primary Charging Assembly Cleaning Motor ......................................................................................... 786
7.11.5 Pretransfer Charging Assembly.............................................................................................................. 789
7.11.6 Pretransfer Charging Assembly Cleaning Motor ................................................................................... 790
7.11.7 Photosensitive Drum Cleaning Unit ........................................................................................................ 790
7.11.8 Photosensitive Drum................................................................................................................................ 796
7.11.9 Drum Motor ........................................................................................................................................... 7108
7.11.10 Drum Heater......................................................................................................................................... 7111
7.11.11 Drum Heater PCB ................................................................................................................................ 7123
7.11.12 Photosensitive Drum Cleaning Blade .................................................................................................. 7136
7.11.13 Photosensitive Drum Cleaner Edge Scraper........................................................................................ 7143
7.11.14 Hopper Assembly................................................................................................................................. 7149
7.11.15 Hopper Supply Motor .......................................................................................................................... 7151
7.11.16 Hopper Strring Motor .......................................................................................................................... 7154
7.11.17 Color Developing Assembly................................................................................................................ 7157
7.11.18 Black Developing Assembly................................................................................................................ 7169
7.11.19 Black Developing Cylinder.................................................................................................................. 7177
7.11.20 Black Developing Clutch..................................................................................................................... 7186
7.11.21 Color Toner Supply Clutch.................................................................................................................. 7189
7.11.22 Color Developing Clutch ..................................................................................................................... 7191
7.11.23 Cleaning Assembly ScoopUp Sheet................................................................................................... 7195
7.11.24 Secondary Transfer Unit...................................................................................................................... 7202
7.11.25 ITB Cleaning Unit................................................................................................................................ 7203
7.11.26 ITB Cleaner End Scraper..................................................................................................................... 7209
7.11.27 Intermediate Transfer Unit................................................................................................................... 7214
7.11.28 Intermediate Transfer Belt ................................................................................................................... 7219
7.11.29 ITB Home Position Sensor PCB.......................................................................................................... 7225
7.11.30 Secondary Transfer Roller Shift Motor ............................................................................................... 7225
7.11.31 Primary Transfer Roller ....................................................................................................................... 7226
7.11.32 Secondary Transfer Internal Roller...................................................................................................... 7234
7.11.33 Secondary Transfer Roller ................................................................................................................... 7240

Contents
7.11.34 ITB Cleaning Blade..............................................................................................................................7242
7.11.35 ITB Scoopup Sheet .............................................................................................................................7249
7.11.36 Intermediate Transfer Belt Static Eliminator .......................................................................................7254
7.11.37 Secondary Transfer Static Eliminator ..................................................................................................7260
7.11.38 Ptential Sensor Unit..............................................................................................................................7261
7.11.39 ATR Sensor Unit..................................................................................................................................7268
7.11.40 Patch Image Sensor ..............................................................................................................................7274
7.11.41 Idle Roller.............................................................................................................................................7280
7.11.42 Patch Image Reading Sensor Shutter Solenoid ....................................................................................7287
7.11.43 Charging Wire ......................................................................................................................................7293
Chapter 8 Pickup/Feeding System
8.1 Construction........................................................................................................................................................81
8.1.1 Specifications, Control Mechanisms, and Functions...................................................................................81
8.1.2 Major Divisions of the Machine..................................................................................................................82
8.1.3 Arrangement of Rollers ...............................................................................................................................83
8.1.4 Diagram of the Paper Path...........................................................................................................................85
8.1.5 Arrangement of Sensors ..............................................................................................................................86
8.1.6 Arrangement of Solenoids ...........................................................................................................................88
8.1.7 Arrangement of Drive Mechanisms.............................................................................................................89
8.2 Basic Sequence .................................................................................................................................................810
8.2.1 Basic Sequence of Operation (in response to a press on the Start key).....................................................810
8.2.2 Interval Acceleration .................................................................................................................................812
8.2.3 Stopping the Paper Before Registration ....................................................................................................816
8.3 Detecting Jams..................................................................................................................................................817
8.3.1 Delivery Jams.............................................................................................................................................817
8.3.2 Stationary Jams ..........................................................................................................................................819
8.3.3 Other Jams..................................................................................................................................................821
8.4 Cassette.............................................................................................................................................................822
8.4.1 Overview....................................................................................................................................................822
8.4.2 Identifying Paper Sizes..............................................................................................................................823
8.4.3 Setting the Universal Cassette ...................................................................................................................825
8.4.4 Checking the Level of Remaining Paper...................................................................................................826
8.5 Cassette PickUp Unit.......................................................................................................................................828
8.5.1 Overview....................................................................................................................................................828
8.5.2 Basic Sequence ..........................................................................................................................................829
8.5.3 Movement of the Lifter..............................................................................................................................830
8.6 Manual Feed Pickup Unit.................................................................................................................................831
8.6.1 Overview....................................................................................................................................................831
8.6.2 Basic Sequence ..........................................................................................................................................832
8.6.3 Identifying the Size of Paper .....................................................................................................................832
8.6.4 Identifying the Last Sheet..........................................................................................................................833
8.7 Deck..................................................................................................................................................................834
8.7.1 Overview....................................................................................................................................................834
8.7.2 Basic Sequence ..........................................................................................................................................835
8.7.3 Identifying the Size of Paper .....................................................................................................................836
8.7.4 Checking the Level of Remaining Paper...................................................................................................837
8.8 Registration Unit...............................................................................................................................................838
8.8.1 Overview....................................................................................................................................................838
8.9 Duplex Feeding Unit.........................................................................................................................................839
8.9.1 Overview....................................................................................................................................................839
8.9.2 Detecting the Horizontal Registration Position .........................................................................................843
8.9.3 A5, 5 Sheets in Circulation........................................................................................................................845
8.9.4 A3, 3 Sheets in Circulation........................................................................................................................847

Contents
8.10 Delivery.......................................................................................................................................................... 849
8.10.1 Overview ................................................................................................................................................. 849
8.10.2 FaceUp Delivery .................................................................................................................................... 849
8.10.3 FaceDown Delivery ............................................................................................................................... 850
8.11 Parts Replacement Procedure......................................................................................................................... 853
8.11.1 Cassette Pickup Unit ................................................................................................................................ 853
8.11.2 Cassette Pickup Motor ............................................................................................................................. 853
8.11.3 Cassette Lifter Motor ............................................................................................................................... 854
8.11.4 Left Deck Lifter Motor ............................................................................................................................ 855
8.11.5 Right Deck Lifter Motor .......................................................................................................................... 856
8.11.6 Left Deck Pickup Motor .......................................................................................................................... 858
8.11.7 Right Deck Pickup Motor ........................................................................................................................ 859
8.11.8 Vertical Path Motor.................................................................................................................................. 860
8.11.9 Right Deck PullOff Motor...................................................................................................................... 861
8.11.10 Cassette Paper Level Sensor (A/B)........................................................................................................ 862
8.11.11 Left Deck Paper Level Sensor ............................................................................................................... 864
8.11.12 Right Deck Pickup Assembly ................................................................................................................ 866
8.11.13 Left Deck Pickup Assembly .................................................................................................................. 867
8.11.14 Right Deck Pickup/Feed/Separation Roller........................................................................................... 868
8.11.15 Left Deck Pickup/Feed/Separation Roller ............................................................................................. 869
8.11.16 Cassette Pickup/Feed/Separation Roller................................................................................................ 870
8.11.17 Manual Feed Unit .................................................................................................................................. 871
8.11.18 Manual Feed Roller................................................................................................................................ 871
8.11.19 Manual Feed Separation Roller ............................................................................................................. 872
8.11.20 Manual Feed PreRegustration Motor ................................................................................................... 873
8.11.21 Horizontal Registration Assembly......................................................................................................... 877
8.11.22 Registration Motor ................................................................................................................................. 879
8.11.23 Horizontal Registration Motor............................................................................................................... 881
8.11.24 Duplex Reversal Motor.......................................................................................................................... 884
8.11.25 Duplex Left Motor ................................................................................................................................. 884
8.11.26 Duplex Middle Motor ............................................................................................................................ 886
8.11.27 Duplex Right Motor............................................................................................................................... 887
8.11.28 Outside Delivery Motor ......................................................................................................................... 888
Chapter 9 Fixing System
9.1 Construction ....................................................................................................................................................... 91
9.1.1 Specifications, Control Mechanisms, and Functions .................................................................................. 91
9.1.2 Major Components...................................................................................................................................... 92
9.1.3 Construction of the Control System ............................................................................................................ 95
9.2 Basic Sequence................................................................................................................................................... 96
9.2.1 Sequence of Operation at PowerOn........................................................................................................... 96
9.2.2 Basic Sequence of Operation (printing) ...................................................................................................... 97
9.3 Various Control Mechanisms............................................................................................................................. 99
9.3.1 Controlling the Speed of the Fixing Roller.................................................................................................. 99
9.3.2 Controlling the Fixing Roller Temperature ............................................................................................... 912
9.3.3 External Heat Roller Drive Control ........................................................................................................... 917
9.4 Fixing Cleaning Web Mechanisms .................................................................................................................. 919
9.4.1 Overview ................................................................................................................................................... 919
9.4.2 Web Retaining Mechanism ....................................................................................................................... 920
9.5 Protective Functions......................................................................................................................................... 922
9.5.1 Detecting Overheating Using Thermistors................................................................................................ 922
9.5.2 Cutting Off the Power Using Thermal Switches....................................................................................... 922
9.5.3 Errors......................................................................................................................................................... 922

Contents
9.6 Parts Replacement Procedure ...........................................................................................................................924
9.6.1 Fixing Unit .................................................................................................................................................924
9.6.2 Fixing Roller ..............................................................................................................................................925
9.6.3 Pressure Roller ...........................................................................................................................................929
9.6.4 External Heat Roller...................................................................................................................................932
9.6.5 Fixing Thermistor (Upper).........................................................................................................................936
9.6.6 Fixing Thermistor (Lower).........................................................................................................................938
9.6.7 External Heat Thermistor ...........................................................................................................................941
9.6.8 Fixing Thermal Switch...............................................................................................................................943
9.6.9 Fixing Locking Thermal Switch ................................................................................................................945
9.6.10 Thermal Switch ........................................................................................................................................948
9.6.11 Upper Fixing Heater.................................................................................................................................950
9.6.12 Lower Fixing Roller.................................................................................................................................952
9.6.13 Fixing Locking Heater .............................................................................................................................954
9.6.14 Fixing Web...............................................................................................................................................957
9.6.15 Fixing Motor ............................................................................................................................................960
9.6.16 External Heater Shift Motor.....................................................................................................................961
9.6.17 Upper Separation Claw ............................................................................................................................962
9.6.18 Lower Separation Claw............................................................................................................................962
Chapter 10 Externals and Controls
10.1 Control Panel ..................................................................................................................................................101
10.1.1 Overview..................................................................................................................................................101
10.1.2 LCD Processing.......................................................................................................................................102
10.1.3 LCD Contrast Adjustment .......................................................................................................................102
10.1.4 Control Panel CPU ..................................................................................................................................102
10.2 Counters..........................................................................................................................................................103
10.2.1 Overview..................................................................................................................................................103
10.2.2 Increasing the Count................................................................................................................................106
10.3 Fans.................................................................................................................................................................107
10.3.1 Overview..................................................................................................................................................107
10.3.2 Sequence of Operations ...........................................................................................................................109
10.4 Power Supply................................................................................................................................................1010
10.4.1 Power Supply .........................................................................................................................................1010
10.4.2 Rated Output of DC Power Supply PCB ...............................................................................................1014
10.4.3 Protection Function ................................................................................................................................1015
10.4.4 Backup Battery.......................................................................................................................................1017
10.5 Parts Replacement Procedure .......................................................................................................................1018
10.5.1 Hopper Drive Unit..................................................................................................................................1018
10.5.2 Power Cord Base....................................................................................................................................1021
10.5.3 Control Panel..........................................................................................................................................1023
10.5.4 DC Controller PCB ................................................................................................................................1025
10.5.5 Printer Power Supply PCB.....................................................................................................................1026
10.5.6 Leakage Breaker.....................................................................................................................................1027
10.5.7 Fixing Relay ...........................................................................................................................................1029
10.5.8 Relay PCB ..............................................................................................................................................1029
10.5.9 DC Relay ................................................................................................................................................1030
10.5.10 HV1 PCB..............................................................................................................................................1030
10.5.11 HV2 PCB..............................................................................................................................................1033
10.5.12 HV3 PCB..............................................................................................................................................1034
10.5.13 Fixing/Feed Driver PCB.......................................................................................................................1036
10.5.14 Pickup Driver PCB...............................................................................................................................1037
10.5.15 Switch PCB ..........................................................................................................................................1038

Contents
10.5.16 Primary Exhaust Fan............................................................................................................................ 1039
10.5.17 Fixing Heat Discharge Fan .................................................................................................................. 1042
10.5.18 Power Supply Cooing Fan ................................................................................................................... 1046
10.5.19 Delivery Cooling Fan 1........................................................................................................................ 1047
10.5.20 Delivery Cooling Fan 2........................................................................................................................ 1048
10.5.21 Ozone Filter ......................................................................................................................................... 1049
10.5.22 Toner Filter .......................................................................................................................................... 1050
10.5.23 Sub Toner Filter ................................................................................................................................... 1051
Chapter 11 Maintenance and Inspection
11.1 Periodically Replaced Parts............................................................................................................................ 111
11.1.1 Overview ................................................................................................................................................. 111
11.1.2 Reader Unit.............................................................................................................................................. 111
11.1.3 Printer Unit.............................................................................................................................................. 112
11.2 Durables and Consumables ............................................................................................................................ 113
11.2.1 Overview ................................................................................................................................................. 113
11.2.2 Reader Unit.............................................................................................................................................. 113
11.2.3 Printer Unit.............................................................................................................................................. 114
11.3 Scheduled Servicing Basic Procedure............................................................................................................ 115
11.3.1 Scheduled Servicing Basic Procedure..................................................................................................... 115
11.3.2 Scheduled Servicing (reader unit) ........................................................................................................... 116
11.3.3 Scheduled Servicing (printer unit) .......................................................................................................... 117
11.3.4 Shifting the Photosensitive Drum Phase ............................................................................................... 1113
11.4 Cleaning........................................................................................................................................................ 1121
11.4.1 Cleaning the Secondary Transfer Rear Guide....................................................................................... 1121
11.4.2 Cleaning the Registration Roller, Registration Guide, and Transparency Sensor ................................ 1122
Chapter 12 Standards and Adjustments
12.1 Image Adjustment Basic Procedure ............................................................................................................... 121
12.1.1 Image Adjustment Basic Procedure 1 ..................................................................................................... 121
12.1.2 Image Adjustment Basic Procedure 2 ..................................................................................................... 123
12.1.3 Image Adjustment Basic Procedure 3 ..................................................................................................... 124
12.1.4 Image Adjustment Basic Procedure 4 ..................................................................................................... 125
12.1.5 Image Adjustment Basic Procedure 5 ..................................................................................................... 126
12.1.6 Image Adjustment Basic Procedure 6 ..................................................................................................... 127
12.1.7 Potential Control Conversion Table........................................................................................................ 128
12.2 Image Adjustments....................................................................................................................................... 1216
12.2.1 Image Position....................................................................................................................................... 1216
12.2.2 Checking the Image Position................................................................................................................. 1216
12.2.3 Cassette.................................................................................................................................................. 1217
12.2.4 Manual Feed Tray ................................................................................................................................. 1218
12.2.5 Front Deck............................................................................................................................................. 1218
12.3 Scanning System .......................................................................................................................................... 1220
12.3.1 After Replacing the CCD Unit.............................................................................................................. 1220
12.3.2 After Replacing the Copyboard Glass................................................................................................... 1221
12.3.3 After Replacing the Reader Controller PCB or Initializing the RAM .................................................. 1221
12.4 Laser Exposure System ................................................................................................................................ 1223
12.4.1 After Replacing the Laser Scanner........................................................................................................ 1223
12.5 Image Formation System.............................................................................................................................. 1223
12.5.1 After Replacing the Black Developing Unit ......................................................................................... 1223
12.5.2 Points to Note When Mounting the Polarity Positioning Plate............................................................. 1223
12.5.3 Replacing the Color Developing Unit................................................................................................... 1224

Contents
12.5.4 Replacing the Starter of the Color Developing Unit .............................................................................1226
12.5.5 After Replacing the Primary Charging Assembly .................................................................................1229
12.5.6 After Replacing the Primary Charging Wire .........................................................................................1229
12.5.7 After Replacing the PreTransfer Charging Wire..................................................................................1229
12.5.8 After Replacing the PreTransfer Charging Wire..................................................................................1229
12.5.9 After Replacing the Waste Toner Box...................................................................................................1229
12.5.10 After Replacing the ITB Cleaning Blade.............................................................................................1229
12.5.11 After Repacking the Photosensitive Drum Cleaning Blade ................................................................1231
12.5.12 Replacing the Photosensitive Drum.....................................................................................................1232
12.5.13 Points to Note When Replacing the Drum Heater...............................................................................1233
12.5.14 Points to Note When Replacing the Drum Heater PCB ......................................................................1234
12.5.15 After Repacking the ITB ....................................................................................................................1235
12.5.16 After Replacing the Primary Transfer Roller ......................................................................................1235
12.6 Fixing System ...............................................................................................................................................1237
12.6.1 Points to Note When Mounting the Fixing Assembly...........................................................................1237
12.6.2 After Replacing the Fixing Roller .........................................................................................................1237
12.6.3 After Replacing the Fixing Web............................................................................................................1237
12.6.4 Position of the Fixing inlet Guide..........................................................................................................1238
12.6.5 Points to Note When Mounting the Pressure Roller..............................................................................1238
12.6.6 Adjusting the Nip Pressure of the Pressure Roller ...............................................................................1238
12.6.7 Adjusting the Position of the Feeding Web Solenoid (SL2) .................................................................1239
12.6.8 Points to Note About the Position of the Fixing Thermal Switch .........................................................1239
12.6.9 Points to Note When Mounting the Shift Thermal Switch....................................................................1239
12.6.10 Points to Note When Mounting the Outside Heating Roller Thermal Switch ....................................1240
12.6.11 Points to Note When Mounting the Fixing Upper Thermistor............................................................1240
12.6.12 Points to Note When Mounting the Fixing Lower Thermistor............................................................1240
12.6.13 Points to Note When Mounting the External Heat Thermistor ...........................................................1241
12.7 Electrical Components..................................................................................................................................1241
12.7.1 When Replacing the Reader Controller PCB ........................................................................................1241
12.7.2 After Replacing the DC Controller PCB ...............................................................................................1242
12.7.3 Points to Note When Mounting the DC Controller PCB/ DC Controller Box......................................1243
12.7.4 After Replacing the Main Controller PCB (main).................................................................................1244
12.7.5 After Repacking the SRAM Board........................................................................................................1244
12.7.6 After Replacing the HDD ......................................................................................................................1244
12.7.7 When Replacing the HV2 PCB .............................................................................................................1245
12.7.8 When Replacing the ATR Sensor/Patch Image Read Sensor................................................................1246
12.8 Pickup/Feeding System ................................................................................................................................1246
12.8.1 Adjusting the Horizontal Registration After Replacing the Pickup Cassette........................................1246
12.8.2 Adjusting the Manual Feed Pickup Horizontal Registration.................................................................1247
12.8.3 Adjusting the Front Deck Pickup Horizontal Registration....................................................................1247
12.8.4 Registering the Paper Width Basic Value .............................................................................................1249
Chapter 13 Correcting Faulty Images
13.1 Making lnitial Checks.....................................................................................................................................131
13.1.1 Checking the Site Environment...............................................................................................................131
13.1.2 Checking the Paper..................................................................................................................................131
13.1.3 Checking the Placement of Paper............................................................................................................131
13.1.4 Checking the Durables.............................................................................................................................131
13.1.5 Checking the Periodically Replaced Parts...............................................................................................131
13.1.6 Checking the Units and Functional Blocks .............................................................................................131
13.1.7 Others.......................................................................................................................................................133
13.2 Test Print.........................................................................................................................................................134
13.2.1 Overview..................................................................................................................................................134

Contents
13.2.2 Test Print TYPE ...................................................................................................................................... 134
13.2.3 Selecting Test Print TYPE ...................................................................................................................... 134
13.2.4 16Gradation (TYPE=4).......................................................................................................................... 135
13.2.5 Full Page Halftone (TYPE=5)................................................................................................................. 136
13.2.6 Grid (TYPE=6)........................................................................................................................................ 137
13.2.7 MCYBk Horizontal Stripes (TYPE=10)................................................................................................. 138
13.2.8 64Gradation (TYPE=12)........................................................................................................................ 139
13.2.9 Full Color 16Gradation (TYPE=14) ...................................................................................................... 139
13.3 Troubleshooting............................................................................................................................................ 1310
13.3.1 Symptoms .............................................................................................................................................. 1311
13.3.2 Image Faults........................................................................................................................................... 1316
13.3.3 Faulty Feeding ....................................................................................................................................... 1363
13.3.4 Malfunction............................................................................................................................................ 1365
13.3.5 Error Code.............................................................................................................................................. 1369
13.4 Outline of Electrical Components ................................................................................................................ 1377
13.4.1 Clutch/Solenoid...................................................................................................................................... 1377
13.4.2 Motor...................................................................................................................................................... 1379
13.4.3 Fan.......................................................................................................................................................... 1384
13.4.4 Sensor..................................................................................................................................................... 1387
13.4.5 Switch .................................................................................................................................................... 1395
13.4.6 Lamps, Heaters, and Others................................................................................................................... 1397
13.4.7 PCBs .................................................................................................................................................... 13100
13.4.8 Variable Resistors (VR), LightEmitting Diodes (LED), and Check Pins by PCB............................. 13103
Chapter 14 Self Diagnosis
14.1 Error Code Table............................................................................................................................................ 141
14.1.1 Error Code ............................................................................................................................................... 141
14.2 Error Codes (SEND) ...................................................................................................................................... 144
14.2.1 SelfDiagnostic Display .......................................................................................................................... 144
14.2.2 List of Error Codes without Messages .................................................................................................... 147
14.3 Error Code Details........................................................................................................................................ 1414
14.3.1 Error Code Description ......................................................................................................................... 1414
14.3.2 E000....................................................................................................................................................... 1414
14.3.3 E001....................................................................................................................................................... 1416
14.3.4 E002....................................................................................................................................................... 1416
14.3.5 E003....................................................................................................................................................... 1417
14.3.6 E004....................................................................................................................................................... 1418
14.3.7 E005....................................................................................................................................................... 1420
14.3.8 E006....................................................................................................................................................... 1420
14.3.9 E008....................................................................................................................................................... 1420
14.3.10 E009..................................................................................................................................................... 1421
14.3.11 E012..................................................................................................................................................... 1421
14.3.12 E013..................................................................................................................................................... 1421
14.3.13 E014..................................................................................................................................................... 1422
14.3.14 E020..................................................................................................................................................... 1422
14.3.15 E021..................................................................................................................................................... 1425
14.3.16 E023..................................................................................................................................................... 1425
14.3.17 E025..................................................................................................................................................... 1425
14.3.18 E032..................................................................................................................................................... 1426
14.3.19 E043..................................................................................................................................................... 1426
14.3.20 E051..................................................................................................................................................... 1426
14.3.21 E061..................................................................................................................................................... 1427
14.3.22 E070..................................................................................................................................................... 1427

Contents
14.3.23 E073.....................................................................................................................................................1428
14.3.24 E077.....................................................................................................................................................1428
14.3.25 E078.....................................................................................................................................................1428
14.3.26 E079.....................................................................................................................................................1428
14.3.27 E100.....................................................................................................................................................1429
14.3.28 E110.....................................................................................................................................................1429
14.3.29 E197.....................................................................................................................................................1430
14.3.30 E202.....................................................................................................................................................1430
14.3.31 E225.....................................................................................................................................................1430
14.3.32 E227.....................................................................................................................................................1431
14.3.33 E240.....................................................................................................................................................1431
14.3.34 E248.....................................................................................................................................................1431
14.3.35 E351.....................................................................................................................................................1432
14.3.36 E400.....................................................................................................................................................1432
14.3.37 E413.....................................................................................................................................................1432
14.3.38 E490.....................................................................................................................................................1433
14.3.39 E500.....................................................................................................................................................1433
14.3.40 E503.....................................................................................................................................................1433
14.3.41 E505.....................................................................................................................................................1434
14.3.42 E514.....................................................................................................................................................1434
14.3.43 E519.....................................................................................................................................................1435
14.3.44 E530.....................................................................................................................................................1435
14.3.45 E531.....................................................................................................................................................1436
14.3.46 E532.....................................................................................................................................................1436
14.3.47 E535.....................................................................................................................................................1437
14.3.48 E537.....................................................................................................................................................1437
14.3.49 E540.....................................................................................................................................................1438
14.3.50 E542.....................................................................................................................................................1438
14.3.51 E584.....................................................................................................................................................1439
14.3.52 E590.....................................................................................................................................................1439
14.3.53 E591.....................................................................................................................................................1440
14.3.54 E592.....................................................................................................................................................1440
14.3.55 E593.....................................................................................................................................................1441
14.3.56 E5F0.....................................................................................................................................................1441
14.3.57 E5F1.....................................................................................................................................................1441
14.3.58 E5F2.....................................................................................................................................................1442
14.3.59 E5F3.....................................................................................................................................................1442
14.3.60 E5F4.....................................................................................................................................................1442
14.3.61 E5F5.....................................................................................................................................................1443
14.3.62 E5F6.....................................................................................................................................................1443
14.3.63 E5F8.....................................................................................................................................................1444
14.3.64 E5F9.....................................................................................................................................................1444
14.3.65 E602.....................................................................................................................................................1445
14.3.66 E602 in Detail......................................................................................................................................1445
14.3.67 E604.....................................................................................................................................................1449
14.3.68 E609.....................................................................................................................................................1449
14.3.69 E674.....................................................................................................................................................1449
14.3.70 E677.....................................................................................................................................................1450
14.3.71 E710.....................................................................................................................................................1450
14.3.72 E711.....................................................................................................................................................1450
14.3.73 E713.....................................................................................................................................................1451
14.3.74 E717.....................................................................................................................................................1451
14.3.75 E719.....................................................................................................................................................1451
14.3.76 E730.....................................................................................................................................................1452

Contents
14.3.77 E731..................................................................................................................................................... 1453
14.3.78 E732..................................................................................................................................................... 1453
14.3.79 E733..................................................................................................................................................... 1454
14.3.80 E740..................................................................................................................................................... 1454
14.3.81 E743..................................................................................................................................................... 1454
14.3.82 E744..................................................................................................................................................... 1455
14.3.83 E745..................................................................................................................................................... 1455
14.3.84 E746..................................................................................................................................................... 1456
14.3.85 E747..................................................................................................................................................... 1456
14.3.86 E800..................................................................................................................................................... 1459
14.3.87 E804..................................................................................................................................................... 1459
14.3.88 E805..................................................................................................................................................... 1459
14.3.89 E820..................................................................................................................................................... 1460
14.3.90 E824..................................................................................................................................................... 1460
14.4 Jam Codes..................................................................................................................................................... 1461
14.4.1 Jam Code (printer unit).......................................................................................................................... 1461
14.4.2 Jam Code (finisherrelated)................................................................................................................... 1463
14.4.3 Jam Code (ADFrelated) ....................................................................................................................... 1464
14.5 Alarm Codes................................................................................................................................................. 1466
14.5.1 Alarm Code ........................................................................................................................................... 1466
Chapter 15 Service Mode
15.1 Outline............................................................................................................................................................ 151
15.1.1 Construction of Service Mode................................................................................................................. 151
15.1.2 Starting Service Mode and Making Selections ....................................................................................... 152
15.1.3 Ending Service Mode .............................................................................................................................. 153
15.1.4 BackUp................................................................................................................................................... 153
15.1.5 Initial Screen............................................................................................................................................ 154
15.1.6 2nd/3rd Item Screen ................................................................................................................................ 154
15.1.7 4th Item Screen........................................................................................................................................ 155
15.2 DISPLAY (Status Display Mode).................................................................................................................. 156
15.2.1 COPIER ................................................................................................................................................... 156
15.2.2 FEEDER ................................................................................................................................................ 1526
15.2.3 DISPLAY(Status Display Mode)Level2 ............................................................................................... 1528
15.3 I/O (I/O Display Mode)............................................................................................................................... 1534
15.3.1 Overview ............................................................................................................................................... 1534
15.3.2 <DCCON> ........................................................................................................................................... 1535
15.3.3 <RCON> .............................................................................................................................................. 1542
15.3.4 <FEEDER> ........................................................................................................................................... 1545
15.3.5 <SORTER> ........................................................................................................................................... 1547
15.3.6 <MNCON> .......................................................................................................................................... 1558
15.4 ADJUST (Adjustment Mode) ...................................................................................................................... 1560
15.4.1 COPIER ................................................................................................................................................. 1560
15.4.2 FEEDER ................................................................................................................................................ 1590
15.4.3 SORTER ................................................................................................................................................ 1591
15.4.4 ADJUST (Adjustment Mode)Level2.................................................................................................... 1591
15.5 FUNCTION (Operation/Inspection Mode)............................................................................................... 15108
15.5.1 COPIER ............................................................................................................................................... 15108
15.5.2 FEEDER .............................................................................................................................................. 15139
15.5.3 FUNCTION (operation/inspection mode):Level 2............................................................................. 15144
15.6 OPTION (Machine Settings Mode) .......................................................................................................... 15146
15.6.1 COPIER ............................................................................................................................................... 15146
15.6.2 FEEDER .............................................................................................................................................. 15174

Contents
15.6.3 SORTER...............................................................................................................................................15175
15.6.4 BOARD................................................................................................................................................15176
15.6.5 OPTION (mechanical specifications setting mode):Level 2...............................................................15176
15.7 TEST (Test Print Mode) ............................................................................................................................15211
15.7.1 COPIER................................................................................................................................................15211
15.8 COUNTER (Counter Mode)......................................................................................................................15217
15.8.1 COPIER................................................................................................................................................15217
Chapter 16 Upgrading
16.1 Outline ............................................................................................................................................................161
16.1.1 Outline of the Version Upgrade...............................................................................................................161
16.1.2 Outline of the Service Support Tool........................................................................................................162
16.1.3 Network Interface of the Machine with the SST in Use..........................................................................164
16.2 Making Preparations.......................................................................................................................................168
16.2.1 Registering the System software .............................................................................................................168
16.2.2 Making Connections..............................................................................................................................1611
16.3 Formatting the HDD.....................................................................................................................................1617
16.3.1 Formatting All Partitions .......................................................................................................................1617
16.3.2 Formatting Selected Partitions...............................................................................................................1618
16.3.3 Formatting the Procedure ......................................................................................................................1620
16.4 Downloading System Software ....................................................................................................................1627
16.4.1 Batch Downloading................................................................................................................................1627
16.4.2 Downloading the System Software ........................................................................................................1640
16.4.3 Downloading the RUI, and Language Module ......................................................................................1648
16.4.4 Downloading the BOOT Software.........................................................................................................1656
16.4.5 Downloading the Dcon and Rcon Software...........................................................................................1663
16.4.6 Downloading the G3 FAX Software......................................................................................................1670
16.5 Uploading and Downloading Backup Data ..................................................................................................1677
16.5.1 Outline ...................................................................................................................................................1677
16.5.2 Uploading Procedure .............................................................................................................................1678
16.5.3 Downloading Procedure ........................................................................................................................1684
Chapter 17 Service Tools
17.1 Special Tools ................................................................................................................................................. 171
17.2 Solvents and Oils ........................................................................................................................................... 173