Canon IR5000 - iR B/W Laser User manual

FY8-13GS-000
JULY 2000
iR5000/iR6000
REVISION 0
COPYRIGHT ©

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
INTRODUCTION
ii
2.Outline of the Manual
This Service Manual contains basic information needed to service the iR5000/iR6000 and
its accessories (i.e., side paper deck, shift tray) in the field, conducted for the purpose of
maintaining its product quality and a specific level of performance. A separate Service
Manual is made available for each of its accessories (except for the side paper deck and shift
tray); for details, refer to the appropriate manual.
This Service Manual consists of the following chapters:
1. System Unit
Chapter 1 Introduction: features, specifications, names of parts, func-
tions, operation, system configuration, rou-
tine maintenance by the user
Chapter 2 Main Controller: functional construction, outline of electrical
circuitry, principles of operation of the image
processing system, power supply
Chapter 3 Installation: site conditions and installation procedure,
relocation of the machine, installation of ac-
cessories
2. Reader Unit
Chapter 1 Basic Operation: functional construction, outline of electrical
circuitry, basic sequence of operations
Chapter 2 Original Exposure System: principles of operation of the exposure sys-
tem, timing of operation, disassembly/assem-
bly and adjustment
Chapter 3 Image Processing System: principles of operation of the image process-
ing system, timing of operation, disassembly/
assembly and adjustment
3. Printer Unit
Chapter 1 Introduction: safety of the laser, image formation, auxiliary
processes
Chapter 2 Sequence of Operations: basic operations, outline of electrical cir-
cuitry, basic sequence of operations
Chapter 3 Laser Exposure System: principles of operation of the laser exposure
system, timing of operation, disassembly/
assembly and adjustment
Chapter 4 Image Formation System: principles of operation of the image forma-
tion system, timing of operation, disassem-
bly/assembly and adjustment
Chapter 5 Pickup/Feeding System: principles of operation of the pickup/feeding
system, timing of operation, disassembly/
assembly and adjustment

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
INTRODUCTION
iii
Chapter 6 Fixing System: principles of operation of the fixing system,
timing of operation, and disassembly/assem-
bly and adjustment
Chapter 7 Externals and Controls: principles of operation of the externals/con-
trols, timing of operation, disassembly/as-
sembly and adjustment
Chapter 8 Paper Deck: principles of operation, timing of operation,
disassembly/assembly and adjustment
Chapter 9 Shift Tray: principles of operation, timing of operation,
disassembly/assembly adjustment
4. Troubleshooting
Chapter 1 Maintenance and Inspection: table of periodically replaced parts, table of
consumables/durables, scheduled servicing
chart
Chapter 2 Image Adjustment Basic Procedure:
basic procedure for image adjustment
Chapter 3 Standards and Adjustments: standards and adjustments
Chapter 4 Troubleshooting Image Faults/Malfunctions:
troubleshooting image faults/malfunctions
Chapter 5 Service Mode: how to use service mode, list of service
modes
Chapter 6 Self Diagnosis: codes, causes of errors, timing chart
Appendix: general timing chart, general circuit diagrams
The descriptions are updated from time to time to reflect product improvements, and ma-
jor changes are communicated in the form of Service Information bulletins.
All service persons are expected to familiarize themselves with the contents of this Ser-
vice Manual and Service Information bulletins and acquire a level of knowledge and skill
required to promptly respond to the needs of the field.

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
SYSTEM UNIT

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
S1
CONTENTS
Contents
CHAPTER 1 GENERAL DESCRIPTION
CHAPTER 2 MAIN CONTROLLER
1. Basic Operations ............................2-1S
1.1 Functional Construction ..........2-1S
1.2 Outline of Electrical Circuitry .2-2S
1.2.1 Outline ...............................2-2S
1.2.2 Main Controller PCB.........2-2S
1.2.3 Hard Disk Drive.................2-2S
1.3 Start-Up Sequence ...................2-4S
1.3.1 Outline ...............................2-4S
1.3.2 Start-Up Sequence .............2-5S
1.4 Inputs to and Outputs from
the Major PCBs........................2-7S
1.4.1 Wiring Diagram of the
Major PCBs .......................2-7S
2. Digital Image Processing ................2-8S
2.1 Outline ......................................2-8S
2.2 Input Image Processing ............2-9S
2.2.1 Image Data from the Reader
Unit ....................................2-9S
2.2.2 Enlargement/Reduction
(main scanning direction) ...2-9S
2.2.3 Edge Emphasis ...................2-9S
2.2.4 Editing ................................2-9S
2.2.5 Density Conversion (LUT) 2-9S
2.2.6 Binary Processing (error
diffusion; T-BIC) ...............2-9S
2.2.7 Binary Processing
(dither screen) ..................2-10S
1. Features ..........................................1-1S
1.0.1 High Speed, High Image
Quality ...............................1-1S
1.0.2 Hard Disk ..........................1-1S
1.0.3 Stackless, Duplexing
Mechanism .........................1-1S
1.0.4 Large-CapacityPaper
Source ................................1-1S
1.0.5 Variety of Delivery
Processing
(with accessories) ...............1-1S
2. Specifications ..................................1-2S
2.1 Copier .......................................1-2S
2.1.1 Type ...................................1-2S
2.1.2 Method ...............................1-2S
2.1.3 Functions ...........................1-3S
2.1.4 Others ................................1-8S
2.2 Paper Deck-G1 .......................1-11S
......................................................1-11S
2.3 Shift Tray-B1 .........................1-12S
3. Names of Parts .............................1-13S
3.1 ExternalView .........................1-13S
3.2 Cross Section .........................1-15S
4. Using the Machine........................1-17S
4.1 Turning On the Power
Switches .................................1-17S
4.2 Control Panel ..........................1-18S
4.3 Extension Mode .....................1-19S
4.4 User Mode .............................1-20S
5. System Construction .....................1-24S
5.1 Functional Construction .........1-24S
5.2 OutlineofElectrical
Circuitry .................................1-25S
5.2.1 ConstructionofElectrical
Circuitry...........................1-25S
5.3 Inputs to and Outputs from
the Major PCBs......................1-26S
5.3.1 Wiring Diagram of the
Major PCBs .....................1-26S
6. Routine Maintenance by
the User ........................................1-27S
6.1 Cleaning .................................1-27S
6.2 Inspection ...............................1-30S
6.2.1 Making a Check ...............1-30S

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
S2
CONTENTS
1. Selecting the Site............................3-1S
2. Unpacking and Installation ............3-3S
2.1 Before Starting the Work .........3-3S
2.2 Installation ...............................3-4S
2.3 Unpacking ................................3-5S
2.4 Mounting the Scanner..............3-6S
2.5 Mounting the Fixing
Assembly .................................3-7S
2.6 Checking the Charging
Assemblies ...............................3-9S
2.7 Mounting the Developing
Assembly ...............................3-12S
2.8 Mounting the Pickup
Assembly ...............................3-13S
2.9 Mounting the Deck Locking
Plate (left deck) .......................3-14S
2.3 Controlling the Image
Memory ..................................2-11S
2.3.1 Compression/Decompression,
Rotation,Enlargement/
Reduction .........................2-11S
2.3.2 SDRAM ..........................2-11S
2.3.3 Hard Disk Drive (HDD) ..2-11S
2.4 Output Image Processing .......2-11S
2.4.1 Smoothing ........................2-11S
2.4.2 Thickening
(PDL output only) ............2-11S
2.4.3 Binary-Binary Density
Conversion (read image
output only) ......................2-11S
3. Soft Counter .................................2-12S
4. Controlling the Power Supply ......2-14S
4.1 Outline ....................................2-14S
4.2 Power Supply Mode ..............2-14S
4.3 Standby Mode
(normaloperation) ..................2-14S
4.4 Power Save Mode ..................2-14S
4.5 Low Power Mode ..................2-15S
4.5.1 Shift from Standby Mode
(standby →low-power) ...2-15S
4.5.2 Shift to Standby Mode
(low power →standby) ...2-15S
4.6 Sleep Mode ............................2-15S
4.6.1 Shift from Standby Mode
(standby →sleep) ............2-15S
4.6.2 Shift from Low Power
Mode (low power
mode →sleep) .................2-15S
4.6.3 Return to Standby Mode
(sleep →standby) ............2-15S
4.7 Off Mode ...............................2-16S
4.7.1 Shift from Standby Mode
(standby →off mode) .....2-16S
4.7.2 Shift from Low Power
Mode (low power
mode →off mode) ...........2-16S
4.7.3 Return to Standby Mode
(off mode →standby) .....2-16S
4.8 Power Off Mode ....................2-16S
CHAPTER 3 INSTALLATION 2.10 Supplying Toner .....................3-15S
2.11 Setting the Cassette .................3-16S
2.12 Changing the Paper Size for
the Front Deck (right/left) .......3-17S
2.13 Checking Images/Operations
and User Mode .......................3-18S
2.14 CheckingtheEnvironment
Switch ....................................3-20S
2.15 Installing the Machine ............3-21S
3. Relocating the Machine .................3-22S
4. Mounting the Delivery Roll ..........3-23S
5. Mounting the Original Holder ......3-24S
6. Installing the Control Card IV ......3-25S
7. Installing the NE Controller-A1 ....3-26S
7.1 Installation ..............................3-26S

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
READER UNIT

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
R1
CONTENTS
Contents
CHAPTER 1 BASIC OPERATION
CHAPTER 2 ORIGINAL EXPOSURE SYSTEM
1. Functional Construction ................ 1-1R
2. Outline of Electrical Circuitry....... 1-2R
2.1 Outline .................................... 1-2R
2.2 Reader Controller PCB ........... 1-2R
3. Basic Sequence of Operations....... 1-3R
3.1 Basic Sequence of Operations
at Power-On ............................ 1-3R
3.2 Basic Sequence of Operations
in Book Mode ......................... 1-3R
4. Inputs to and Outputs from the
Major PCBs ................................... 1-4R
4.1 Wiring of Major PCBs ............ 1-4R
4.2 Inputs to and Outputs from the
Reader Controller PCB ........... 1-5R
1. Outline of Operations.................... 2-1R
1.1 Outline .................................... 2-1R
1.2 Sequence of Operations
(original exposure) .................. 2-3R
1.2.1 Book Mode, 1 Original,
Copyboard Closed ............ 2-3R
1.2.2 Book Mode, 1 Original,
Copyboard Cover Open .... 2-4R
1.3 Enlargement/Reduction
(zoom) ..................................... 2-5R
1.3.1 Changing the Reproduction
Ratio in Main Scanning
Direction ........................... 2-5R
1.3.2 Changing the Reproduction
Ratio in Sub Scanning
Direction ........................... 2-5R
2. Scanner Drive System ................... 2-6R
2.1 Outline ..................................... 2-6R
2.2 Controlling the Scanner
Motor ...................................... 2-7R
2.2.1 Controlling the Motor
When Scanning an Image .. 2-7R
2.2.2 Reversing the Scanner
After Scanning in Main
ReadingDirection ............. 2-8R
3. Controlling the Scanning
Lamp (LA2)................................... 2-9R
3.1 Outline ..................................... 2-9R
3.2 Scanning Lamp ........................ 2-9R
3.3 Turning On/Off the Lamp ........ 2-9R
3.4 Detecting an Error ................. 2-10R
4. Detecting the Size of Originals .... 2-11R
4.1 Outline ................................... 2-11R
4.2 Points of Detection ................ 2-11R
4.3 Outline of Detection .............. 2-11R
4.4 Outline of Detection
Operation ............................... 2-12R
4.4.1 Book Mode, 1 Original,
Copyboard Cover Open .. 2-12R
4.4.2 Book Mode, 1 Original,
Copyboard Cover Close . 2-13R
5. Scanning Lamp ........................... 2-15R
5.1 Removing the Scanning
Lamp ..................................... 2-15R
5.2 Points to Note When Replacing
the Scanning Lamp ................ 2-16R
5.3 After Replacing the Scanning
Lamp ..................................... 2-16R
6. Scanner Drive Block.................... 2-17R
6.1 Scanner Motor ....................... 2-17R
6.1.1 Removing the Scanner
Motor .............................. 2-17R
6.1.2 Mounting the Scanner
Motor .............................. 2-18R
6.2 Scanner System Drive
Cable ..................................... 2-19R

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
R2
CONTENTS
6.2.1 Removing the Scanner
System Drive Cable ........ 2-19R
6.2.2 Routing the Scanner
Drive Cable ..................... 2-21R
6.2.3 Positioning the No. 1/2
Mirror Base ..................... 2-22R
7. Others .......................................... 2-24R
7.1 Removing the Original Size
Sensor ................................... 2-24R
7.2 Removing the HP Sensor ...... 2-25R
7.3 Removing the Copyboard
Sensor ................................... 2-26R
8. PCBs ........................................... 2-27R
8.1 Removing the Fuse PCB ....... 2-27R
8.2 Removing the Inverter PCB .. 2-28R
1. Outline........................................... 3-1R
2. Analog Image Processing.............. 3-2R
2.1 Outline .................................... 3-2R
2.2 Driving the CCD ..................... 3-2R
2.3 Gain Correction and Offset
Correction of the CCD Output 3-3R
2.4 A/D Conversion of the CCD
Output ..................................... 3-3R
3. Digital Image Processing ............... 3-4R
3.1 Outline ..................................... 3-4R
3.2 Shading Correction .................. 3-4R
3.2.1 Outline .............................. 3-4R
3.2.2 ShadingAdjustment .......... 3-5R
3.2.3 Shading Correction ........... 3-5R
3.2.4 Edge Gain Correction
(ADF in use) ..................... 3-6R
3.3 Auto DensityAdjustment
(AE) ........................................ 3-7R
CHAPTER 3 IMAGE PROCESSING SYSTEM
3.3.1 Outline .............................. 3-7R
3.3.2 ABC Circuit ...................... 3-7R
3.4 Related Service Mode .............. 3-8R
4. External Covers ............................. 3-9R
4.1 Removing the Reader Front
Cover ....................................... 3-9R
4.2 Removing the Reader Rear
Cover ..................................... 3-11R
5. CCD/AP PCB ............................. 3-12R
5.1 Removing the CCD Unit ....... 3-12R
5.2 When Replacing the CCD/
AP PCB ................................ 3-13R
6. Reader Controller PCB ................ 3-14R
6.1 Removing the Reader
Controller PCB ...................... 3-14R
6.2 When Replacing the Reader
Controller PCB ...................... 3-14R

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PRINTERUNIT

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
P1
CONTENTS
Contents
CHAPTER 1 GENERAL DESCRIPTION
1. Safety..............................................1-1P
1.1 Safety of Laser Light ...............1-1P
1.2 Regulations Under the Center
for Devices and Radiological
Health .......................................1-1P
1. Basic Operations ............................2-1P
1.1 Functional Construction ..........2-1P
1.2 Outline of Electrical Circuitry ...2-2P
1.2.1 Outline ...............................2-2P
1.2.2 DC Controller PCB ...........2-2P
1.3 Sequence of Basic Operations...2-4P
1.3.1 Basic Sequence of
Operations at Power-On ....2-4P
1.4 Controlling the Main Motor
(M2) .........................................2-6P
1.3 Handling the Laser Unit ...........1-3P
1.4 Safety of Toner .........................1-6P
2. ImageFormation.............................1-7P
2.1 Outline ......................................1-7P
CHAPTER 2 SEQUENCE OF OPERATIONS
1.4.1 Outline ...............................2-6P
1.5 Inputs to and Outputs from
the Major PCBs........................2-7P
1.5.1 Wiring Diagram of Major
PCBs..................................2-7P
1.5.2 Inputs to the DC
Controller PCB ..................2-8P
1.5.3 Inputs to the DC
Controller PCB ................2-14P
CHAPTER 3 LASER EXPOSURE SYSTEM
1. Outline of Operations .....................3-1P
1.1 Outline .....................................3-1P
1.2 Basic Sequence of Operations
(laser exposure system)...........3-3P
2. Generating Sync Signals ................3-4P
2.1 Outline .....................................3-4P
2.2 Flow of Sync Signals ...............3-5P
3. Laser Driver Circuit .......................3-6P
3.1 Controlling the Laser ...............3-6P
4. Controlling the Laser Scanner
Motor..............................................3-9P
4.1 Outline ......................................3-9P
5. Disassembly and Assembly ..........3-10P
5.1 Scanner Unit...........................3-11P

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P2
CONTENTS
CHAPTER 4 IMAGE FORMATION SYSTEM
1. Outline of Processes .......................4-1P
1.1 Outline .....................................4-1P
1.2 Basic Sequence of Operations
(image formation system) .........4-3P
2. PotentialControl .............................4-5P
2.1 Outline ......................................4-5P
2.1.1 Controlling Potential for
Printing/Copying ................4-6P
2.2 Determining Primary
Current ...................................4-11P
2.3 Determining the Laser
Output ....................................4-12P
2.4 Determining the Developing
Bias ........................................4-13P
2.5 APC Correction ......................4-14P
2.6 DensityAdjustment in Each
Mode ......................................4-16P
2.6.1 DensityAdjustment
During Copying ...............4-16P
2.6.2 DensityAdjustment
During Printing ................4-17P
3. Controlling Charging ....................4-18P
3.1 Controlling Pre-Exposure
LED ........................................4-18P
3.1.1 Outline .............................4-18P
3.2 Controlling Primary
Charging .................................4-19P
3.2.1 Outline .............................4-19P
3.2.2 Primary ChargingAssembly
Cleaning Mechanism .......4-20P
3.2.3 Others ..............................4-21P
3.3 Dust-Collecting Roller Bias...4-22P
3.3.1 Outline .............................4-22P
3.4 Controlling the Pre-Transfer
Charging .................................4-23P
3.4.1 Outline .............................4-23P
3.4.2 Controlling the Output to
Suit the Environment
(fuzzy control) ..................4-24P
3.4.3 Cleaning Mechanism for
the Pre-Transfer Charging
Assembly .........................4-25P
3.4.4 Others ..............................4-26P
3.5 Controlling Transfer
Charging .................................4-27P
3.5.1 Outline .............................4-27P
3.5.2 Controlling the Output to
Suit the Environment
(fuzzy control) ..................4-28P
3.5.3 Cleaning Mechanism for
the Transfer Charging
Assembly .........................4-29P
3.5.4 Others ..............................4-30P
3.6 Controlling Separation
Charging .................................4-32P
3.6.1 Outline .............................4-32P
3.6.2 Correctingthe Output to
Suitthe Environmentand
the Density of the Original
Used .................................4-34P
3.6.3 Others ..............................4-35P
4. Hopper/Developing Assembly ......4-36P
4.1 Outline ....................................4-36P
4.2 Controlling the Drive to the
Hopper/Developing
Assembly ...............................4-37P
4.3 Controlling the Developing
Bias ........................................4-39P
4.4 Detecting the Level of Toner
and Controlling the Supply
of Toner ..................................4-41P
4.4.1 Sequence of Operations
(toner supply) ...................4-42P
5. Drum Cleaner Unit .......................4-43P
5.1 Outline ....................................4-43P
5.2 Detecting theWasteToner ......4-44P
6. Controlling the Drum Heater ........4-46P
6.1 Outline ....................................4-46P
7. Disassembly and Assembly ..........4-49P
7.1 Pre-Exposure Lamp Unit ........4-50P
7.1.1 Removing the Pre-
Exposure Lamp Unit ........4-50P
7.2 Photosensitive Drum ..............4-51P

COPYRIGHT © 2000 CANON INC.2000 2000 2000 2000 CANON iR5000/iR6000 REV.0 JULY 2000
P3
CONTENTS
7.2.1 Removing the Drum
Unit ..................................4-51P
7.2.2 Replacing the Drum
Heater ...............................4-52P
7.2.3 Mounting the Photosensitive
Drum ................................4-53P
7.2.4 Setting the DIP Switch
for the Drum Heater
Control PCB ....................4-53P
7.3 Process Unit ...........................4-54P
7.3.1 Removing the Process
Unit ..................................4-54P
7.3.2 Mounting the Process
Unit ..................................4-56P
7.4 Potential Sensor/Potential
Control PCB...........................4-57P
7.4.1 RemovingthePotential
Sensor/Potential Control
PCB .................................4-57P
7.4.2 Adjusting the Potential
Sensor ..............................4-59P
7.5 Primary ChargingAssembly ..4-61P
7.5.1 Removing the Primary
Charging Assembly ..........4-61P
7.6 Pre-Transfer Charging
Assembly ...............................4-62P
7.6.1 Removing the Pre-Transfer
Charging Assembly..........4-62P
7.7 Transfer/Separation Charging
Assembly ...............................4-63P
7.7.1 Removing the Transfer/
Separation Charging
Assembly .........................4-63P
7.7.2 Mounting the Transfer/
Separation Charging
Assembly .........................4-63P
7.8 Charging Wire ........................4-66P
7.8.1 Outline .............................4-66P
7.8.2 Removing the Wire
Cleaner of the Primary
Charging Assembly ..........4-66P
7.8.3 Routing the Charging
Wire .................................4-66P
7.8.4 Routing the Grid for the Primary
Charging Assembly ..........4-69P
7.8.5 Adjusting the Height of the
Charging Wire..................4-71P
7.8.6 Cleaning the Primary
Anti-Stray Sheet ...............4-72P
7.9 Developing Assembly ............4-73P
7.9.1 Removing the Developing
Assembly from the
Machine ...........................4-73P
7.9.2 Removing the Blade Unit
.........................................4-74P
7.9.3 Mounting the Blade .........4-75P
7.9.4 Removing the Developing
Cylinder/MagneticSeal ....4-75P
7.9.5 Cleaning the Developing
Anti-Stray Sheet ...............4-77P
7.10 Hopper Assembly....................4-78P
7.10.1 Removing the Hopper
Assembly from the
Machine ...........................4-78P
7.11 Drum Cleaner ..........................4-79P
7.11.1 Construction .....................4-79P
7.11.2 RemovingtheCleaning
Blade ................................4-79P
7.11.3 Mounting the Cleaning
Blade ................................4-80P
7.11.4 Mounting the Side Seal ....4-82P
7.11.5 Cleaning the Cleaner Side
Scraper .............................4-83P
7.12 Separation Claw/Separation
Claw Drive Assembly ............4-84P
7.12.1 Removing from the Drum
Unit ......................................4-84P

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P4
CONTENTS
1. Outline ............................................5-1P
1.1 Specifications and
Construction .............................5-1P
1.2 Arrangement of Roller and
Sensors.....................................5-2P
2. Pickup Assembly ............................5-4P
2.1 Pickup Control System .............5-4P
2.1.1 Outline ...............................5-6P
2.1.2 Sequence of Operations
(pickup) .............................. 5-7P
2.1.3 Pickup Retry Operation ......5-9P
2.1.4 Others ..............................5-10P
2.2 Lifter Movement .....................5-11P
2.2.1 Outline .............................5-11P
2.2.2 LifterLimiterControl
Circuit(right/leftdeck) .....5-13P
2.2.3 DetectingthePresence/
Absence of Paper .............5-14P
2.2.4 DetectingtheLevelof
Paper ................................5-14P
2.3 Identifying the Size of Paper
in the Cassette .........................5-17P
2.3.1 Right/Left Deck ................5-17P
2.3.2 Cassette 3/4 ...................... 5-17P
2.3.3 Markings on the Width
Guide Rail ........................5-19P
2.3.4 Paper Sizes .......................5-20P
2.4 Manual Feed Tray Pickup
Assembly ...............................5-23P
2.4.1 Pickup Operation .............5-23P
2.4.2 Detecting the Size of Paper
on the Manual Feed Tray .5-24P
3. Controlling the Registration
Clutch ...........................................5-25P
3.1 Outline ....................................5-25P
3.2 Control System .......................5-25P
4. Double-Sided Prints .....................5-26P
4.1 Control System .......................5-26P
4.1.1 Sending Paper to the
ReversingAssembly After
Printing on the First Side .5-26P
4.1.2 Sending Paper from the Revers-
ing Assembly to the Duplexing/
Feeding Assembly ...........5-27P
4.1.3 Outline .............................5-28P
4.2 Sequence of Operations
(printing) ................................5-29P
4.3 Through-Path Operation .........5-30P
4.3.1 Outline .............................5-30P
4.3.2 Outline of Operations .......5-31P
4.4 Detecting Horizontal
Registration Position ..............5-35P
4.4.1 Outline .............................5-35P
4.4.2 Operation .........................5-36P
5. Controlling the PickupAssembly .5-37P
5.1 Pickup Assembly Motors .......5-37P
6. Controlling the Delivery
Assembly......................................5-38P
6.1 ReversalDeliveryOperation ....5-38P
7. ControllingtheCassetteHeater.....5-40P
8. Detecting Jams ..............................5-42P
8.1 Outline ....................................5-42P
8.1.1 Arrangement of Jam
Sensors ............................5-42P
8.1.2 Types of Jams ..................5-43P
8.2 Sequence of Operations
(jam detection) ......................5-44P
8.2.1 Delay Jam ........................5-44P
8.2.2 Stationary Jams................5-46P
8.2.3 Jam History......................5-47P
9. Disassembly and Assembly ..........5-48P
9.1 Manual Feed Tray Assembly...5-49P
9.1.1 Removing the Right
Upper Cover ....................5-49P
9.1.2 Opening of the Right
Upper Cover ....................5-49P
9.1.3 Removing the Manual Feed
Pull-Out Roller Unit ........5-50P
9.1.4 Removing the Feeding
Roller ...............................5-50P
9.1.5 Removing the Separation
Roller ...............................5-50P
CHAPTER 5 PICK-UP/FEEDING SYSTEM

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9.1.6 Adjusting the Pressure of
the Separation Roller ........5-51P
9.1.7 Removing the Manual feed
Tray Paper Sensor ............5-52P
9.1.8 Attaching the Side Guide
Timing Belt in the Manual
Feed Tray Assembly ........5-53P
9.1.9 Removing the Manual
Feed Pull-Out Roller ........5-53P
9.2 Deck Pickup Assembly ..........5-54P
9.2.1 Removing the Right Deck
Pickup Assembly ............. 5-54P
9.2.2 Removing the Left Deck
Pickup Assembly .............5-54P
9.2.3 Removing the Cassette 3
Pickup Assembly .............5-55P
9.2.4 Removing the Cassette 4
Pickup Assembly .............5-55P
9.2.5 Removing the Pickup
Roller ...............................5-55P
9.2.6 Removing the Feeding
Roller ...............................5-56P
9.2.7 Orientation of the Feeding
Roller of the Deck/Cassette
Pickup Assembly .............5-57P
9.2.8 Removing the Separation
Roller ...............................5-57P
9.2.9 Adjusting the Separation
Roller Pressure .................5-59P
9.2.10 Orientation of the
Separation Roller ..............5-59P
9.2.11 Adjusting the Left/Right
Registration for the
Front Deck .......................5-60P
9.2.12 Adjusting the Registration
for the Cassette 3/4 ...........5-60P
9.2.13 Removing the Lifter
Motor M20 (M21) of the
Cassette 3 (4) ...................5-61P
9.2.14 Adjusting the Position of
the Lifter Motor M20
(M21) of the Cassette 3
(cassette 4) .......................5-61P
9.2.15 Adjusting the Position of
the Cassette 3/4 Pickup
Solenoid (SL3, 4) .............5-63P
9.3 Vertical Path Roller
Assembly ...............................5-64P
9.3.1 Removing theVertical
Path Roller 1 ....................5-64P
9.3.2 Removing theVertical
Path Roller 2 ....................5-64P
9.3.3 Removing theVertical
Path Roller 3/4 .................5-65P
9.4 Registration Feeding
Assembly ...............................5-66P
9.4.1 Removingthe
Registration Clutch ...........5-66P
9.4.2 Removingthe
RegistrationRoller ...........5-66P
9.5 FeedingAssembly ..................5-68P
9.5.1 Removing the Feeding
Belt ...................................5-68P
9.5.2 Removing the Fixing/
Feeding Unit Releasing
Lever Switch .................... 5-69P
9.6 Duplex Unit ............................5-70P
9.6.1 Removing the Duplex
Unit ..................................5-70P
9.6.2 Removing the Reversing
Flapper Solenoid ..............5-70P
9.6.3 Removing the Reversal
Motor ...............................5-70P
9.6.4 Mounting the Reversal
Motor ...............................5-71P
9.6.5 Removing the Duplexing
Feeding Left Motor ..........5-72P
9.6.6 Removing the Duplex
Feeding Right Motor ........5-72P
9.6.7 Removing the Horizontal
Registration Motor ...........5-73P
9.6.8 Removing the Duplex
Pre-Registration Sensor ...5-73P
9.6.9 Removing the Duplex
Paper Sensor ....................5-74P
9.6.10 Removingthe Reversal
Sensor 1 ...........................5-75P

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9.6.11 Removingthe Reversal
Sensor 2 ...........................5-75P
9.6.12 Removing the Left Deck
Feed Paper Sensor ...........5-76P
9.6.13 Removing the Horizontal
Registration Sensor ..........5-77P
9.6.14 Removing the Duplex
Driver PCB ......................5-77P
9.6.15 Removing the Horizontal
RegistrationUnit ..............5-78P
9.6.16 Removing the Duplex
Feeding Fan .....................5-78P
9.6.17 Mounting the Reversing
Flapper Solenoid ..............5-79P
CHAPTER 6 FIXING SYSTEM
1. Outline of Operation ......................6-1P
1.1 Outline .....................................6-1P
1.2 Basic Sequence of Operations
(fixing system) .........................6-4P
2. Fixing Drive System.......................6-5P
2.1 Outline ......................................6-5P
2.2 Controlling the Drive of the
Fixing Roller ............................6-6P
2.3 Controlling the Drive of the
CleaningWeb ...........................6-7P
2.4 Controlling the Drive of the
FixingAssembly Inlet Guide ....6-8P
2.5 Controlling the Reciprocating
Mechanisms of the
Thermistor ................................6-9P
2.6 Controlling the Reciprocating
Mechanism of the Upper
Separation Claw .....................6-10P
3. Controlling the Fixing
Temperature ..................................6-11P
3.1 Outline ....................................6-11P
3.2 Temperature Control ...............6-12P
3.2.1 Normal Sequence .............6-13P
3.2.2 Temperature Control by
Mode ................................6-15P
3.3 Detecting Errors .....................6-18P
4. Disassembly and Assembly ..........6-20P
4.1 FixingAssembly ....................6-21P
4.1.1 Removing the Fixing/
Feeding Unit ....................6-21P
4.1.2 Removing the Fixing
Assembly .........................6-22P
4.2 Fixing Roller Cleaning
Assembly ...............................6-24P
4.2.1 Removing the Fixing
Web ..................................6-24P
4.2.2 Mounting the Fixing
Web ..................................6-25P
4.2.3 Adjusting the Fixing Web
Solenoid (SL9) .................6-26P
4.3 Fixing Heater and the Control
Parts .......................................6-27P
4.3.1 Removing the Main/Sub
Heater ...............................6-27P
4.3.2 Mounting the Main/Sub
Heater ...............................6-28P
4.3.3 RemovingtheThermal
Switch ..............................6-28P
4.3.4 Removing the Main
Thermistor ........................6-29P
4.3.5 Removing the Sub
Thermistor ........................6-31P
4.4 Fixing RollerAssembly..........6-32P
4.4.1 Removing the Fixing
Upper Roller ....................6-32P
4.4.2 Mounting the Fixing
Upper Roller ....................6-33P
4.4.3 Removing the Fixing
Lower Roller .................... 6-33P
4.4.4 Adjusting the Nip .............6-34P
4.5 Fixing SeparationAssembly...6-35P
4.5.1 Removing the Upper
Separation Claw ...............6-35P

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CONTENTS
4.5.2 Removing the Lower
Separation Claw ...............6-35P
4.6 DeliveryAssembly .................6-36P
4.6.1 RemovingtheExternal
Delivery Roller .................6-36P
4.6.2 Removing the Internal
Delivery Roller .................6-37P
4.6.3 Adjusting the Position
of the Delivery Flapper
Solenoid (SL5) .................6-38P
4.7 Paper Sensor ..........................6-39P
4.7.1 Removing the Claw Jam
Sensor ..............................6-39P
4.7.2 Removing the Internal
Delivery Sensor ...............6-39P
4.7.3 Removing the Delivery
Jam Sensor .......................6-40P
4.7.4 RemovingtheExternal
Delivery Sensor ...............6-41P
4.8 FixingAssembly Inlet Guide
Assembly ...............................6-42P
4.8.1 Adjusting the Position of
the FixingAssembly Inlet
Guide Solenoid (SL1) ......6-42P
4.8.2 Adjusting the Position of
the FixingAssembly Inlet
Guide ...............................6-42P
CHAPTER 7 EXTERNALS AND CONTROLS
1. Control Panel..................................7-1P
1.1 Outline .....................................7-1P
2. Fans ................................................7-2P
2.1 Arrangement, Functions, and
Error Codes ..............................7-2P
2.2 Operation ..................................7-4P
2.2.1 Controlling the Speed .........7-4P
2.2.2 Sequence of Operations .....7-4P
3. Power Supply .................................7-5P
3.1 Power Supply...........................7-5P
3.1.1 Outline ...............................7-5P
3.1.2 Distribution of Power
Among Switches ................7-6P
3.1.3 Output of Power Supplies ...7-8P
3.2 Rated Outputs of the DC
Power Supply...........................7-9P
3.3 Protection Mechanism ............7-10P
4. Others ...........................................7-12P
4.1 Silent Mode ............................7-12P
5. Disassembly and Assembly ..........7-13P
5.1.1 External Covers ................7-14P
5.1.2 Removing the Front
Cover ...............................7-15P
5.2 Arrangement of Electrical
Parts (rear of the machine) ......7-16P
5.3 Control Panel ..........................7-18P
5.3.1 Removing the Control
Panel ................................7-18P
5.3.2 Removing the Control
Panel Control PCB and
Keypad PCB .................... 7-18P
5.3.3 Removing the Touch
Panel ................................7-20P
5.4 PCBs ......................................7-21P
5.4.1 DC Controller PCB ..........7-21P
5.4.2 Main Controller Box and
the Main Controller PCB .7-22P
5.4.3 Power Supply PCB ..........7-23P
5.4.4 High-Voltage Power
Supply PCB .....................7-24P
5.4.5 Accessories Power
Supply PCB .....................7-25P
5.4.6 AC Driver PCB ...............7-25P
5.4.7 Motor Driver PCB ...........7-26P
5.4.8 Anti-Rush Current PCB ...7-26P
5.4.9 Serial Number PCB .........7-27P
5.5 Fans ........................................7-28P
5.5.1 Exhaust Fan .....................7-28P
5.5.2 Feeding Fan .....................7-28P
5.5.3 HDD Fan .........................7-29P
5.5.4 DC Power Supply Fan .....7-29P
5.6 Drive System ..........................7-30P

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CONTENTS
5.6.1 Left Deck Drive
Assembly .........................7-30P
5.6.2 Vertical Path Duplex/Right
Deck Drive Assembly ......7-30P
5.6.3 Main Motor Drive
Assembly .........................7-31P
5.6.4 Manual Feed Pickup
Drive Assembly ...............7-31P
5.6.5 Waste Toner Drive
Assembly .........................7-32P
5.6.6 Left Deck Pull-Out Roller
Drive Assembly ...............7-32P
5.6.7 Drum Drive Assembly .....7-32P
5.6.8 WasteToner Bottle
Assembly, Lifter Drive
Assembly,Vertical Path
Drive Assembly, and
Cassette Pickup Drive
Assembly .........................7-33P
5.6.9 Left Deck Lifter Drive
Assembly .........................7-35P
5.7 Motor .....................................7-36P
5.7.1 Vertical Path Lower
Motor (M27) ....................7-36P
5.7.2 Main Motor (M2) ............7-36P
5.7.3 Vertical Path Duplex Motor
(M25), Vertical Path Upper
Motor (M26), Deck Right
Motor (M11), Lifter Right
Motor (M5), and Cassette
Pickup Motor (M12) ........7-37P
5.7.4 Pre-Registration Motor
(M17) and Drum Motor
(M1) .................................7-38P
5.8 Solenoid .................................7-40P
5.8.1 Right Deck Pickup Roller
Releasing Solenoid
(SL6) ................................7-40P
5.8.2 Adjusting the Position of
the Right Deck Pickup
Solenoid (SL6) .................7-40P
5.8.3 Right Deck Pickup Roller
Releasing Solenoid
(SL7) ................................7-41P
5.8.4 Adjusting the Position of
the Left Deck Pickup
Solenoid (SL7) .................7-41P
5.9 Clutches ..................................7-42P
5.9.1 Manual Feed Pickup
Clutch/Developing
Clutch ...............................7-42P
5.10 Sensors...................................7-43P
5.10.1 Cassette 3/4 Paper Size
(width/length) Sensor ......7-43P
5.11 HDD .......................................7-44P
5.12 Others .....................................7-46P
5.12.1 DC Controller PCB
Base .................................7-46P
5.12.2 Relay ................................7-46P
5.12.3 Power Supply
Transformer .....................7-47P
CHAPTER 8 PAPER DECK
1. Paper Deck .....................................8-1P
1.1 Inputs to and Outputs from the
Deck Driver..............................8-1P
1.1.1 Inputs to the Driver (1/2) ...8-1P
1.1.2 Outputs from the Deck
Driver (2/2) ........................8-2P
1.1.3 Outputs form the Deck
Driver (1/1) ........................8-3P
1.2 Pickup ......................................8-4P
1.2.1 Outline ...............................8-4P
1.2.2 Pickup Operation ...............8-4P
1.2.3 Sequence of Operations
(pickup from the deck) ......8-6P
1.3 Detecting Paper in the Deck ....8-7P
1.3.1 DetectingthePresence/
Absence of Power ..............8-7P
1.3.2 Switching the Deck Paper
Size ....................................8-7P
1.3.3 DetectingtheLevelof
Paper in the Deck ...............8-8P

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1.4 DeckLifter ...............................8-9P
1.4.1 DetectingthePresence/
Absence of Paper ...............8-9P
1.4.2 Indicating the Level of Paper
on the Deck Front Cover ..8-11P
1.5 Opening/Closing the
Compartment ..........................8-12P
1.5.1 Opening/Closing the
Compartment ....................8-12P
1.5.2 Sequence of Operations
(opening/closingthe
compartment) ...................8-13P
1.6 Controlling the Deck ..............8-14P
1.6.1 Controlling the Deck
Main Motor (M101) ........8-14P
1.6.2 Controlling the Deck
Lifter Motor (M102) ........8-15P
2. Detecting Jams ..............................8-17P
2.1 Outline ....................................8-17P
3. Disassembly and Assembly ..........8-19P
3.1 External Covers ......................8-20P
3.1.1 Removing the Front
Cover ...............................8-20P
3.1.2 Removing the Rear
Cover ...............................8-23P
3.1.3 Removing the Right
Cover ...............................8-23P
3.1.4 Removing the Upper
Cover ..............................8-24P
3.2 General Descriptions ..............8-25P
3.2.1 Disconnecting the Deck
from the Host Machine ....8-25P
3.2.2 Removingthe
Compartment ....................8-27P
3.2.3 Changing the Deck Paper
Size Configuration ...........8-29P
3.2.4 Adjusting the Deck
Registration ......................8-30P
3.2.5 Adjusting the Roll
Position ............................8-30P
3.3 Drive Mechanisms .................8-31P
3.3.1 Removing the Deck
Pickup Clutch (CL102) ....8-31P
3.3.2 Removing the Deck Main
Motor (M101) ..................8-31P
3.3.3 Removing the Deck Lifter
Motor (M102) ..................8-32P
3.3.4 RemovingtheLifterCable
(front of the deck) ............8-33P
3.3.5 RemovingtheLifterCable
(rear of the deck) .............8-35P
3.3.6 Routing the Lifter Cable ...8-37P
3.4 Feeding Mechanisms .............8-38P
3.4.1 Removing the Deck
Pickup Unit ......................8-38P
3.4.2 Removing the Deck
Pickup Roller ...................8-38P
3.4.3 Orientation of the Deck
Pickup Roller ...................8-39P
3.4.4 Removing the Deck
Pickup/Feed Roller ...........8-39P
3.4.5 Orientation of the Deck
Pickup/Feed Roller ...........8-40P
3.4.6 Removing the Deck
Separation Roller ..............8-40P
3.4.7 Adjusting the Pressure
of the Deck Separation
Roller ...............................8-41P
3.4.8 Position of the Deck
Pickup Roller Releasing
Solenoid (SL101) .............8-42P
3.5 Electrical Mechanisms ............8-43P
3.5.1 Removing the Deck
Driver PCB ......................8-43P
3.5.2 Removing the Open
Switch PCB .....................8-43P

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CONTENTS
CHAPTER 9 SHIFT TRAY
1. Specifications .................................9-1P
2. Names of Parts ...............................9-2P
3. Outline of the Electrical Circuit .....9-3P
3.1 Shift Tray Driver PCB .............9-3P
3.2 Inputs to and Outputs from
the Shift Tray Driver PCB ........9-4P
4. Outline of Operations .....................9-5P
4.1 Shifting .....................................9-5P
4.2 Stacking ....................................9-5P
4.3 Detecting paper .........................9-6P
4.4 Delivery ....................................9-6P
5. Maintenance and Inspection ............9-7P
5.1 Adjusting the Limit Sensor
Position ....................................9-7P
5.1.1 Related Service Mode ........9-7P
5.1.2 MakingAdjustments ..........9-7P
6. Disassembly and Assembly ............9-9P
6.1 Removing the Shift Tray
Driver PCB ............................9-10P
6.2 Removing the Tray Drive
Unit ........................................9-12P