Canon iR6570 series User manual

Feb 21 2005
Service Manual
iR6570/5570 Series

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
1.1.1System Configuration with Input/Output Accessories................................................................................ 1- 1
1.1.2System Configuration with Printing/Transmission Accessories (230V) .................................................... 1- 2
1.1.3Functions and Printing/Transmission Accessories (230V) ......................................................................... 1- 3
1.2 Product Specifications....................................................................................................................................... 1- 4
1.2.1 Names of Parts ............................................................................................................................................ 1- 4
1.2.1.1 External view....................................................................................................................................... 1- 4
1.2.1.2 Cross-Section....................................................................................................................................... 1- 5
1.2.2 Using the Machine ...................................................................................................................................... 1- 8
1.2.2.1 Turning On the Power Switch ............................................................................................................. 1- 8
1.2.2.2 Turning Off the Power Switch ............................................................................................................ 1- 9
1.2.2.3 Control Panel ..................................................................................................................................... 1- 11
1.2.3 User Mode Items....................................................................................................................................... 1- 12
1.2.3.1 Common Settings .............................................................................................................................. 1- 12
1.2.3.2 Timer Settings ................................................................................................................................... 1- 14
1.2.3.3 Adjustment/Cleaning......................................................................................................................... 1- 15
1.2.3.4 Report Output .................................................................................................................................... 1- 15
1.2.3.5 System Control Settings .................................................................................................................... 1- 16
1.2.3.6 Copier Specifications......................................................................................................................... 1- 19
1.2.3.7 Transmission/Reception Settings ...................................................................................................... 1- 20
1.2.3.8 Box Settings....................................................................................................................................... 1- 22
1.2.3.9 Printer Settings .................................................................................................................................. 1- 23
1.2.3.10 Address Book Settings .................................................................................................................... 1- 24
1.2.3.11 Voice Guide Settings....................................................................................................................... 1- 27
1.2.4 Maintenance by the User........................................................................................................................... 1- 27
1.2.4.1 Cleaning............................................................................................................................................. 1- 27
1.2.4.2 Checks ............................................................................................................................................... 1- 29
1.2.5 Safety ........................................................................................................................................................ 1- 30
1.2.5.1 Safety of the Machine's Laser Unit ................................................................................................... 1- 30
1.2.5.2 CDRH Regulations............................................................................................................................ 1- 31
1.2.5.3 Handling the Machine's Laser Unit ................................................................................................... 1- 31
1.2.5.4 Safety of Toner.................................................................................................................................. 1- 32
1.2.6 Product Specifications .............................................................................................................................. 1- 32
1.2.6.1 Product Specifications....................................................................................................................... 1- 32
1.2.7 Function List ............................................................................................................................................. 1- 35
1.2.7.1 Paper Types ....................................................................................................................................... 1- 35
1.2.7.2 Printing Speed ................................................................................................................................... 1- 36
Chapter 2 Installation
2.1 Making Pre-Checks ........................................................................................................................................... 2- 1
2.1.1Selecting the Site ......................................................................................................................................... 2- 1

Contents
2.1.2Checking the Contents.................................................................................................................................2- 3
2.1.3Name of Parts ..............................................................................................................................................2- 6
2.2 Unpacking and Installation ................................................................................................................................2- 8
2.2.1Points to Note Before Starting the Work.....................................................................................................2- 8
2.2.2Unpacking....................................................................................................................................................2- 8
2.2.3Installing the Scanner ................................................................................................................................2- 10
2.2.4Installing the Fixing Assembly..................................................................................................................2- 10
2.2.5Checking the Corona Assembly and the Dust-proofing Glass ..................................................................2- 11
2.2.6Installing the Developing Assembly..........................................................................................................2- 13
2.2.7Installing the Pick-up Assembly................................................................................................................2- 14
2.2.8Installing the Deck Pressure Plate .............................................................................................................2- 15
2.2.9Setting Up the Toner Bottle.......................................................................................................................2- 16
2.2.10Connecting the Reader Communication Cable........................................................................................2- 16
2.2.11Checking the Environment Switch ..........................................................................................................2- 17
2.2.12Turning on the Main Power.....................................................................................................................2- 18
2.2.13Stirring the Toner.....................................................................................................................................2- 18
2.2.14Setting the Cassette..................................................................................................................................2- 18
2.2.15Index Paper Attachment ..........................................................................................................................2- 19
2.2.16Changing Paper Size of the Front Deck (Left/Right) ..............................................................................2- 19
2.2.17Checking Images/Operations, User Mode...............................................................................................2- 20
2.2.18Adjusting Side Registration.....................................................................................................................2- 21
2.2.19Adjusting Leading Edge Registration......................................................................................................2- 23
2.2.20Getting the Machine Ready for Installation.............................................................................................2- 23
2.3 Checking the Connection to the Network........................................................................................................2- 26
2.3.1Overview....................................................................................................................................................2- 26
2.3.2Ping Operating Procedure..........................................................................................................................2- 26
2.3.3Checking with Remote Host Address........................................................................................................2- 26
2.4 Troubleshooting the Network ..........................................................................................................................2- 28
2.4.1Overview....................................................................................................................................................2- 28
2.4.2Checking with Loopback Address.............................................................................................................2- 28
2.4.3Checking with Local Host Address ...........................................................................................................2- 28
2.5 Installing the Copy Tray ..................................................................................................................................2- 29
2.5.1Checking the Contents...............................................................................................................................2- 29
2.5.2Turning Off the Host Machine ..................................................................................................................2- 29
2.5.3Installation Procedure for the Copy Tray-L1.............................................................................................2- 30
2.6 Installing the Card Reader ...............................................................................................................................2- 33
2.6.1Installation Procedure for the Card Reader ...............................................................................................2- 33
2.6.2Checking the Contents...............................................................................................................................2- 33
2.6.3Turning Off the Host Machine ..................................................................................................................2- 34
2.6.4Installation Procedure ................................................................................................................................2- 35
2.7 Installing the NE Controller.............................................................................................................................2- 39
2.7.1Installing the NE Controller-A1 ................................................................................................................2- 39
2.8 Installing the Original Holder..........................................................................................................................2- 41
2.8.1Checking the Contents...............................................................................................................................2- 41
2.8.2Installation Procedure ................................................................................................................................2- 41
2.9 Installing the Cassette Heater ..........................................................................................................................2- 43
2.9.1Checking the Contents...............................................................................................................................2- 43
2.9.2Turning Off the Host Machine ..................................................................................................................2- 43
2.9.3Mounting the Cassette Heater....................................................................................................................2- 44

Contents
Chapter 3 Basic Operation
3.1 Construction ...................................................................................................................................................... 3- 1
3.1.1Functional Construction .............................................................................................................................. 3- 1
3.1.2Wiring Diagram of the Major PCBs............................................................................................................ 3- 1
3.1.3Controlling the Main Motor (M2) ............................................................................................................... 3- 2
3.2 Basic Sequence.................................................................................................................................................. 3- 4
3.2.1Basic Sequence of Operation (at power-on; 30-sec start-up mode)............................................................3-4
3.2.2Basic Sequence of Operation (at power-on; low-temperature start-up mode) ............................................ 3- 5
3.2.3Basic Sequence of Operation (at power-on; high-humidity start-up mode) ............................................... 3- 6
3.2.4Basic Sequence of Operation (at time of copying/printing)........................................................................ 3- 7
Chapter 4 Main Controller
4.1 Construction ...................................................................................................................................................... 4- 1
4.1.1Construction and Mechanisms .................................................................................................................... 4- 1
4.2 Construction of the Electrical Circuitry ............................................................................................................ 4- 3
4.2.1Main Controller PCB................................................................................................................................... 4- 3
4.2.2HDD ............................................................................................................................................................ 4- 4
4.3 Start-Up Sequence............................................................................................................................................. 4- 7
4.3.1Overview ..................................................................................................................................................... 4- 7
4.3.2Start-Up Sequence....................................................................................................................................... 4- 7
4.4 Shut-Down Sequence ...................................................................................................................................... 4- 10
4.4.1Overview ................................................................................................................................................... 4- 10
4.4.2Flow of Operation ..................................................................................................................................... 4- 10
4.5 Image Processing............................................................................................................................................. 4- 11
4.5.1Overview of the Image Flow..................................................................................................................... 4- 11
4.5.2Construction of the Image Processing Module ......................................................................................... 4- 11
4.5.3Reader Unit Input Image Processing......................................................................................................... 4- 12
4.5.4Compression/ Extension/ Editing Block .................................................................................................. 4- 13
4.5.5Printer unit Output Image Processing ....................................................................................................... 4- 14
4.6 Flow of Image Data......................................................................................................................................... 4- 15
4.6.1Flow of Image Data According to Copy Functions .................................................................................. 4- 15
4.6.2Flow of Image Data for the Box Function ................................................................................................ 4- 15
4.6.3Flow of Image Data for the SEND Function............................................................................................. 4- 16
4.6.4Flow of Image Data for the Fax Transmission.......................................................................................... 4- 17
4.6.5Flow of Image Data for the Fax Reception Function ................................................................................ 4- 17
4.6.6Flow of Image Data for the PDL Function................................................................................................ 4- 18
4.7 Parts Replacement Procedure.......................................................................................................................... 4- 20
4.7.1 Main Controller Box ................................................................................................................................. 4- 20
4.7.1.1 Removing the Rear Cover (upper) .................................................................................................... 4- 20
4.7.1.2 Removing the Main Controller Box.................................................................................................. 4- 20
4.7.2 Main Controller PCB ................................................................................................................................ 4- 21
4.7.2.1 Removing the Main Controller PCB ................................................................................................. 4- 21
4.7.2.2 After Replacing the Main Controller PCB ........................................................................................ 4- 23
4.7.3 SDRAM .................................................................................................................................................... 4- 23
4.7.3.1 Removing the SDRAM ..................................................................................................................... 4- 23
4.7.4 Boot ROM................................................................................................................................................. 4- 23
4.7.4.1 Removing the Boot ROM.................................................................................................................. 4- 23

Contents
4.7.5 HDD ..........................................................................................................................................................4- 24
4.7.5.1 Removing the HDD ...........................................................................................................................4- 24
4.7.5.2 After Replacing the HDD ..................................................................................................................4- 24
4.7.6 Controller Fan ...........................................................................................................................................4- 24
4.7.6.1 Removing the Controller Cooling Fan...............................................................................................4- 24
Chapter 5 Original Exposure System
5.1 Construction.......................................................................................................................................................5- 1
5.1.1Specifications, Controls, and Functions ......................................................................................................5- 1
5.1.2Major Components ......................................................................................................................................5- 2
5.1.3Construction of the Control System ............................................................................................................5- 4
5.1.4Reader Controller PCB ................................................................................................................................5- 5
5.2 Basic Sequence ..................................................................................................................................................5- 7
5.2.1Basic Sequence of Operations .....................................................................................................................5- 7
5.2.2Basic 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
5.3.1.1 Overview..............................................................................................................................................5- 9
5.3.1.2 Controlling the Scanner Motor ............................................................................................................5- 9
5.3.2 Enlargement/Reduction.............................................................................................................................5- 11
5.3.2.1 Changing the Magnification in Main Scanning Direction.................................................................5- 11
5.3.2.2 Changing the Magnification in Sub Scanning Direction ................................................................... 5- 11
5.3.3 Controlling the Scanning Lamp ................................................................................................................5- 13
5.3.3.1 Overview............................................................................................................................................5- 13
5.3.3.2 Scanning Lamp ..................................................................................................................................5- 13
5.3.3.3 Controlling the Activation .................................................................................................................5- 14
5.3.4 Detecting the Size of Originals .................................................................................................................5- 14
5.3.4.1 Overview............................................................................................................................................5- 14
5.3.4.2 Points of Measurement Used for Original Size Identification...........................................................5- 14
5.3.4.3 Overview of Operation ......................................................................................................................5- 16
5.3.5 Dirt Sensor Control ...................................................................................................................................5- 19
5.3.5.1 Dust Detection in Stream Reading Mode ..........................................................................................5- 19
5.3.5.2 White Plate Dust Detection Control ..................................................................................................5- 21
5.3.6 Image Processing.......................................................................................................................................5- 22
5.3.6.1 Overview............................................................................................................................................5- 22
5.3.6.2 CCD Drive .........................................................................................................................................5- 23
5.3.6.3 CCD Output Gain Correction, Offset Correction ..............................................................................5- 24
5.3.6.4 CCD Output A/D Conversion............................................................................................................5- 24
5.3.6.5 Outline of Shading Correction...........................................................................................................5- 24
5.3.6.6 Shading Adjustment...........................................................................................................................5- 24
5.3.6.7 Shading Correction ............................................................................................................................5- 25
5.4 Parts Replacement Procedure ..........................................................................................................................5- 26
5.4.1 CCD Unit...................................................................................................................................................5- 26
5.4.1.1 Removing the Copyboard Glass ........................................................................................................5- 26
5.4.1.2 Removing the CCD Unit Cover.........................................................................................................5- 26
5.4.1.3 Removing the Original Size Sensor Unit...........................................................................................5- 27
5.4.1.4 Removing the CCD Unit....................................................................................................................5- 27
5.4.1.5 When Replacing the CCD Unit .........................................................................................................5- 27

Contents
5.4.2 Copyboard glass........................................................................................................................................ 5- 27
5.4.2.1 Removing Copyboard Glass.............................................................................................................. 5- 27
5.4.2.2 When Replacing the Platen Board Glass........................................................................................... 5- 28
5.4.3 Scanning Lamp ......................................................................................................................................... 5- 28
5.4.3.1 Removing the Copyboard Glass........................................................................................................ 5- 28
5.4.3.2 Removing the Right Cover (upper) ................................................................................................... 5- 29
5.4.3.3 Removing the Reader Right Cover.................................................................................................... 5- 29
5.4.3.4 Removing the Left Cover (upper) ..................................................................................................... 5- 29
5.4.3.5 Removing the Reader Left Cover...................................................................................................... 5- 29
5.4.3.6 Removing the Reader Front Cover.................................................................................................... 5- 30
5.4.3.7 Removing the Reader Unit Rear Cover............................................................................................. 5- 30
5.4.3.8 Removing the CCD Unit Cover ........................................................................................................ 5- 31
5.4.3.9 Removing the Scanning Lamp .......................................................................................................... 5- 32
5.4.3.10 When Replacing the Scanning Lamp .............................................................................................. 5- 32
5.4.4 Reader Controller PCB ............................................................................................................................. 5- 33
5.4.4.1 Removing the Copyboard Glass........................................................................................................ 5- 33
5.4.4.2 Removing the CCD Unit Cover ........................................................................................................ 5- 33
5.4.4.3 Removing the Original Size Sensor Unit .......................................................................................... 5- 34
5.4.4.4 Removing the Reader Controller PCB .............................................................................................. 5- 34
5.4.4.5 After Replacing the Reader Controller PCB ..................................................................................... 5- 35
5.4.5 Interface PCB............................................................................................................................................ 5- 35
5.4.5.1 Removing the Reader Unit Rear Cover............................................................................................. 5- 35
5.4.5.2 Removing the Interface PCB............................................................................................................. 5- 36
5.4.6 Inverter PCB ............................................................................................................................................. 5- 37
5.4.6.1 Removing the Copyboard Glass........................................................................................................ 5- 37
5.4.6.2 Removing the CCD Unit Cover ........................................................................................................ 5- 38
5.4.6.3 Removing the Inverter PCB .............................................................................................................. 5- 38
5.4.6.4 When Replacing the Inverter PCB .................................................................................................... 5- 38
5.4.7 Scanner Motor........................................................................................................................................... 5- 39
5.4.7.1 Removing the Reader Unit Rear Cover............................................................................................. 5- 39
5.4.7.2 Removing the Scanner Motor............................................................................................................ 5- 40
5.4.7.3 Mounting the Scanner Motor............................................................................................................. 5- 40
5.4.8 ADF Open/Close Sensor........................................................................................................................... 5- 41
5.4.8.1 Removing the Reader Unit Rear Cover............................................................................................. 5- 41
5.4.8.2 Removing the ADF Open/Closed Sensor.......................................................................................... 5- 42
5.4.9 Scanner HP Sensor.................................................................................................................................... 5- 42
5.4.9.1 Removing the Reader Unit Rear Cover............................................................................................. 5- 42
5.4.9.2 Removing the Mirror Base Home Position Sensor ...........................................................................5-43
5.4.10 Original Size Sensor ............................................................................................................................... 5- 44
5.4.10.1 Removing the Copyboard Glass...................................................................................................... 5- 44
5.4.10.2 Removing the CCD Unit Cover ...................................................................................................... 5- 45
5.4.10.3 Removing the Original Size Sensor Unit ........................................................................................ 5- 45
5.4.10.4 Removing the Original Size Sensor ................................................................................................ 5- 45
5.4.11 Cooling Fan............................................................................................................................................. 5- 46
5.4.11.1 Removing the Reader Unit Rear Cover........................................................................................... 5- 46
5.4.11.2 Removing the Cooling Fan.............................................................................................................. 5- 46
5.4.12 Scanner Drive Cable ............................................................................................................................... 5- 47
5.4.12.1 Outline ............................................................................................................................................. 5- 47
5.4.12.2 Removing the Copyboard Glass...................................................................................................... 5- 47

Contents
5.4.12.3 Removing the Right Cover (upper) .................................................................................................5- 47
5.4.12.4 Removing the Reader Right Cover..................................................................................................5- 48
5.4.12.5 Removing the Left Cover (upper)....................................................................................................5- 48
5.4.12.6 Removing the Reader Left Cover ....................................................................................................5- 48
5.4.12.7 Removing the Reader Front Cover ..................................................................................................5- 48
5.4.12.8 Removing the Reader Unit Rear Cover ...........................................................................................5- 49
5.4.12.9 Removing the ADF..........................................................................................................................5- 50
5.4.12.10 Removing the Control Panel..........................................................................................................5- 50
5.4.12.11 Removing the Scanner Drive Cable...............................................................................................5- 51
5.4.12.12 Fitting the Scanner Drive Cable.....................................................................................................5- 54
5.4.12.13 Adjusting the Position of the No. 1/No. 2 Mirror Base .................................................................5- 56
Chapter 6 Laser Exposure
6.1 Construction.......................................................................................................................................................6- 1
6.1.1Overview......................................................................................................................................................6- 1
6.1.2Major Components ......................................................................................................................................6- 1
6.2 Basic Sequence ..................................................................................................................................................6- 3
6.2.1Basic Sequence of Operation (laser exposure) ............................................................................................6- 3
6.3 Various Controls................................................................................................................................................6- 4
6.3.1 Controlling the Laser Activation Timing....................................................................................................6- 4
6.3.1.1 Generating the Sync Signal..................................................................................................................6- 4
6.3.1.2 Flow of the Sync Signal.......................................................................................................................6- 4
6.3.2 Controlling the Intensity of Laser Light......................................................................................................6- 5
6.3.2.1 Controlling the Laser Intensity ............................................................................................................6- 5
6.3.2.2 APC Control ........................................................................................................................................6- 6
6.3.3 Controlling the Laser Scanner Motor..........................................................................................................6- 7
6.3.3.1 Controlling the Laser Scanner Motor ..................................................................................................6- 7
6.4 Parts Replacement Procedure ............................................................................................................................6- 9
6.4.1 Laser Scanner Unit ......................................................................................................................................6- 9
6.4.1.1 Removing the Laser Scanner Unit ....................................................................................................... 6- 9
6.4.1.2 When Replacing the Scanner Unit.......................................................................................................6- 9
Chapter 7 Image Formation
7.1 Construction.......................................................................................................................................................7- 1
7.1.1Overview......................................................................................................................................................7- 1
7.1.2Major Components ......................................................................................................................................7- 2
7.2 Image Formation Process ..................................................................................................................................7- 3
7.2.1Overview......................................................................................................................................................7- 3
7.3 Basic Sequence ..................................................................................................................................................7- 4
7.3.1At Power-On................................................................................................................................................7- 4
7.3.2At Time of Printing......................................................................................................................................7- 4
7.4 Potential Control................................................................................................................................................7- 6
7.4.1Overview......................................................................................................................................................7- 6
7.4.2Copier/Printer Potential Control ..................................................................................................................7- 6
7.4.3Determining the Primary Current ..............................................................................................................7- 10
7.4.4Determining the Laser Output ...................................................................................................................7- 10
7.4.5Determining the Developing Bias .............................................................................................................7- 11

Contents
7.4.6APC Correction ......................................................................................................................................... 7- 12
7.4.7Adjusting the Density in Various Modes .................................................................................................. 7- 13
7.5 Charging Mechanism ...................................................................................................................................... 7- 15
7.5.1 Controlling Pre-Exposure LED................................................................................................................. 7- 15
7.5.1.1 Pre-Exposure LED Control ............................................................................................................... 7- 15
7.5.2 Primary Charging Mechanism .................................................................................................................. 7- 15
7.5.2.1 Overview ........................................................................................................................................... 7- 15
7.5.2.2 Primary Charging Assembly Cleaning Mechanism .......................................................................... 7- 16
7.5.2.3 Others ................................................................................................................................................ 7- 17
7.5.3 Dust-Collecting Roller Bias...................................................................................................................... 7- 18
7.5.3.1 Overview ........................................................................................................................................... 7- 18
7.5.4 Pre-Transfer Charging Mechanism........................................................................................................... 7- 18
7.5.4.1 Outline ............................................................................................................................................... 7- 18
7.5.4.2 Controlling the Output to Suit the Environment (fuzzy control) ...................................................... 7- 19
7.5.4.3 Pre-Transfer Charging Assembly Cleaning Mechanism................................................................... 7- 20
7.5.4.4 Others ................................................................................................................................................ 7- 20
7.6 Drum Cleaner Unit .......................................................................................................................................... 7- 22
7.6.1Outline ....................................................................................................................................................... 7- 22
7.6.2Detecting the State (full) of the Waste Toner Case................................................................................... 7- 22
7.7 Developing Assembly ..................................................................................................................................... 7- 24
7.7.1Controlling the Developing Assembly Drive ............................................................................................ 7- 24
7.7.2Controlling the Developing Bias............................................................................................................... 7- 24
7.7.3Detecting the Toner Level and Controlling Toner Supply........................................................................ 7- 26
7.8 Transfer Mechanism........................................................................................................................................ 7- 28
7.8.1 Transfer Charging Mechanism.................................................................................................................. 7- 28
7.8.1.1 Outline ............................................................................................................................................... 7- 28
7.8.1.2 Controlling the Output to Suit the Environment (fuzzy control) ...................................................... 7- 28
7.8.1.3 Transfer Charging Assembly Cleaning Mechanism.......................................................................... 7- 29
7.8.1.4 Others ................................................................................................................................................ 7- 30
7.9 Separation Mechanism .................................................................................................................................... 7- 32
7.9.1 Separation Charging Mechanism.............................................................................................................. 7- 32
7.9.1.1 Outline ............................................................................................................................................... 7- 32
7.9.1.2 Correcting the Output to Suit the Environment and the Drum Surface Potential ............................. 7- 32
7.9.1.3 Others ................................................................................................................................................ 7- 33
7.10 Parts Replacement Procedure........................................................................................................................ 7- 35
7.10.1 Process Unit ............................................................................................................................................ 7- 35
7.10.1.1 Removing the Primary Fan Duct..................................................................................................... 7- 35
7.10.1.2 Removing the Developing Assembly.............................................................................................. 7- 35
7.10.1.3 Removing the Process Unit ............................................................................................................ 7- 36
7.10.1.4 Mounting the Process Unit .............................................................................................................. 7- 37
7.10.2 Pre-Exposure Lamp ................................................................................................................................ 7- 38
7.10.2.1 Removing the Primary Fan Duct..................................................................................................... 7- 38
7.10.2.2 Removing the Developing Assembly.............................................................................................. 7- 38
7.10.2.3 Removing the Process Unit ............................................................................................................ 7- 39
7.10.2.4 Removing the Primary Charging Assembly.................................................................................... 7- 40
7.10.2.5 Removing the Potential Sensor Assembly ...................................................................................... 7- 41
7.10.2.6 Removing the Pre-Exposure Lamp Unit ......................................................................................... 7- 41
7.10.2.7 Cleaning the Primary Anti-Stray Sheet ........................................................................................... 7- 41
7.10.3 Primary Charging Assembly................................................................................................................... 7- 42

Contents
7.10.3.1 Removing the Primary Fan Duct .....................................................................................................7- 42
7.10.3.2 Removing the Primary Charging Assembly ....................................................................................7- 42
7.10.4 Pre-Transfer Charging Assembly............................................................................................................ 7- 43
7.10.4.1 Removing the Primary Fan Duct .....................................................................................................7- 43
7.10.4.2 Removing the Pre-Transfer Charging Assembly.............................................................................7- 43
7.10.5 Photosensitive Drum ...............................................................................................................................7- 44
7.10.5.1 Points to Note When Handling the Photosensitive Drum................................................................ 7- 44
7.10.5.2 Removing the Primary Fan Duct .....................................................................................................7- 44
7.10.5.3 Removing the Developing Assembly ..............................................................................................7- 44
7.10.5.4 Removing the Process Unit .............................................................................................................7- 45
7.10.5.5 Removing the Primary Charging Assembly ....................................................................................7- 47
7.10.5.6 Removing the Pre-Transfer Charging Assembly.............................................................................7- 47
7.10.5.7 Removing the Potential Sensor Assembly.......................................................................................7- 47
7.10.5.8 Removing the Drum Unit ................................................................................................................7- 47
7.10.5.9 Cleaning the Photosensitive Drum ..................................................................................................7- 48
7.10.6 Drum Cleaner Unit ..................................................................................................................................7- 49
7.10.6.1 Construction.....................................................................................................................................7- 49
7.10.6.2 Removing the Primary Fan Duct .....................................................................................................7- 49
7.10.6.3 Removing the Developing Assembly ..............................................................................................7- 50
7.10.6.4 Sliding Out the Process Unit ........................................................................................................... 7- 51
7.10.6.5 Removing the Primary Charging Assembly ....................................................................................7- 52
7.10.6.6 Removing the Cleaning Blade .........................................................................................................7- 52
7.10.6.7 Mounting the Cleaning Blade..........................................................................................................7- 53
7.10.6.8 Mounting the Side Seal....................................................................................................................7- 53
7.10.6.9 Cleaning the Cleaner Side Scraper ..................................................................................................7- 54
7.10.7 Drum Motor.............................................................................................................................................7- 54
7.10.7.1 Removing the Rear Cover (upper)...................................................................................................7- 54
7.10.7.2 Removing the Rear Cover (lower)...................................................................................................7- 55
7.10.7.3 Removing the Main Controller Box ................................................................................................ 7- 55
7.10.7.4 Removing the Waste Toner Bottle Holder ...................................................................................... 7- 56
7.10.7.5 Removing the Drum Motor..............................................................................................................7- 57
7.10.8 Photosensitive Drum Heater....................................................................................................................7- 57
7.10.8.1 Points to Note When Handling the Photosensitive Drum................................................................ 7- 57
7.10.8.2 Removing the Primary Fan Duct .....................................................................................................7- 58
7.10.8.3 Removing the Developing Assembly ..............................................................................................7- 58
7.10.8.4 Removing the Process Unit .............................................................................................................7- 59
7.10.8.5 Removing the Primary Charging Assembly ....................................................................................7- 60
7.10.8.6 Removing the Pre-Transfer Charging Assembly.............................................................................7- 61
7.10.8.7 Removing the Potential Sensor Assembly.......................................................................................7- 61
7.10.8.8 Removing the Drum Unit ................................................................................................................7- 61
7.10.8.9 Replacing the Drum Heater .............................................................................................................7- 62
7.10.8.10 Mounting the Drum Heater...........................................................................................................7- 63
7.10.9 Hopper Assembly ....................................................................................................................................7- 63
7.10.9.1 Removing the Primary Fan Duct ....................................................................................................7- 63
7.10.9.2 Removing the Hopper Assembly.....................................................................................................7- 63
7.10.10 Hopper Supply Motor............................................................................................................................7- 64
7.10.10.1 Removing the Primary Fan Duct ...................................................................................................7- 64
7.10.10.2 Removing the Right Cover (upper) ...............................................................................................7- 65
7.10.10.3 Removing the Front Cover ............................................................................................................7- 65

Contents
7.10.10.4 Removing the Hopper Supply Motor ............................................................................................ 7- 65
7.10.11 Hopper Strring Motor ........................................................................................................................... 7- 66
7.10.11.1 Removing the Primary Fan Duct................................................................................................... 7- 66
7.10.11.2 Removing the Right Cover (upper) ............................................................................................... 7- 67
7.10.11.3 Removing the Hopper Stirring Motor ........................................................................................... 7- 67
7.10.12 Developing Assembly........................................................................................................................... 7- 68
7.10.12.1 Removing the Developing Assembly............................................................................................ 7- 68
7.10.12.2 Cleaning the Developing Anti-Stray Sheet ................................................................................... 7- 68
7.10.13 Developing Cylinder............................................................................................................................. 7- 69
7.10.13.1 Removing the Developing Assembly............................................................................................ 7- 69
7.10.13.2 Removing the Blade Unit .............................................................................................................. 7- 69
7.10.13.3 Removing the Developing Cylinder.............................................................................................. 7- 70
7.10.14 Developing Blade.................................................................................................................................. 7- 71
7.10.14.1 Removing the Developing Assembly............................................................................................ 7- 71
7.10.14.2 Removing the Blade Unit .............................................................................................................. 7- 72
7.10.14.3 Mounting the Blade ....................................................................................................................... 7- 72
7.10.15 Transfer/Separation Charging Assembly.............................................................................................. 7- 72
7.10.15.1 Removing the Transfer/Separation Charging Assembly............................................................... 7- 72
7.10.15.2 Mounting the Transfer/Separation Charging Assembly................................................................ 7- 73
7.10.16 Separation Claw/Separation Claw Drive Assembly ............................................................................. 7- 74
7.10.16.1 Removing the Primary Fan Duct................................................................................................... 7- 74
7.10.16.2 Removing the Developing Assembly............................................................................................ 7- 75
7.10.16.3 Removing the Process Unit ........................................................................................................... 7- 75
7.10.16.4 Removing the Separation Claw Holder ........................................................................................ 7- 77
7.10.17 Potential Sensor Unit ............................................................................................................................ 7- 77
7.10.17.1 Outline ........................................................................................................................................... 7- 77
7.10.17.2 Removing the Left Cover (upper) ................................................................................................. 7- 77
7.10.17.3 Removing the Left Cover (middle) ............................................................................................... 7- 77
7.10.17.4 Removing the Fixing Heater Power Supply Unit..........................................................................7-78
7.10.17.5 Removing the Potential Control PCB ........................................................................................... 7- 78
7.10.17.6 Removing the Primary Fan Duct .................................................................................................. 7- 78
7.10.17.7 Removing the Potential Sensor Assembly .................................................................................... 7- 79
7.10.18 Charging Wire....................................................................................................................................... 7- 79
7.10.18.1 Outline ........................................................................................................................................... 7- 79
7.10.18.2 Routing the Charging Wire ........................................................................................................... 7- 79
7.10.18.3 Routing the Grid for the Primary Charging Assembly.................................................................. 7- 81
7.10.18.4 Adjusting the Height of the Charging Wire .................................................................................. 7- 81
Chapter 8 Pickup/Feeding System
8.1 Construction ...................................................................................................................................................... 8- 1
8.1.1Specifications and construction................................................................................................................... 8- 1
8.1.2Arrangement of Rollers and Sensors........................................................................................................... 8- 1
8.1.3Outline of the Pickup Control System......................................................................................................... 8- 3
8.1.4Outline of the Pickup Assembly Motor Control System............................................................................. 8- 5
8.2 Basic Sequence.................................................................................................................................................. 8- 7
8.2.1Pickup from the Right Deck........................................................................................................................ 8- 7
8.2.2Pickup from the Cassette 3 .......................................................................................................................... 8- 7
8.2.3Pickup Retry Operation ............................................................................................................................... 8- 8

Contents
8.3 Detecting Jams.................................................................................................................................................8- 10
8.3.1 Jam Detection Outline ...............................................................................................................................8- 10
8.3.1.1 Outline ............................................................................................................................................... 8- 10
8.3.1.2 Jam History ........................................................................................................................................8- 11
8.3.2 Delay Jams ................................................................................................................................................8- 12
8.3.2.1 Cassette Pickup Assembly (right deck, left deck, cassette 3/4).........................................................8- 12
8.3.2.2 Other Delay Jam ................................................................................................................................8- 12
8.3.3 Stationary Jams .........................................................................................................................................8- 13
8.3.3.1 Common Delay Jams .........................................................................................................................8- 13
8.3.3.2 Power-On Stationary Jam .................................................................................................................. 8- 14
8.4 Cassette Pick-Up Unit......................................................................................................................................8- 16
8.4.1Lifter Operation (cassette 3/4) ...................................................................................................................8- 16
8.4.2Detecting the Presence/Absence of Paper .................................................................................................8- 17
8.4.3Outline of the Paper Level Detection Mechanism.....................................................................................8- 18
8.4.4Paper Level Detection (cassette 3/4) .........................................................................................................8- 18
8.4.5Identifying the Size of Paper (cassette 3/4) ...............................................................................................8- 19
8.4.6Markings on the Width Guide Rail............................................................................................................8- 20
8.4.7Paper Size .................................................................................................................................................. 8- 20
8.5 Manual Feed Pickup Unit ................................................................................................................................8- 24
8.5.1Pickup Operation .......................................................................................................................................8- 24
8.5.2Detecting the Size of Paper in the Manual Feed Tray ............................................................................... 8- 24
8.6 Deck................................................................................................................................................................. 8- 26
8.6.1Lifter Operation (right/left deck) ...............................................................................................................8- 26
8.6.2Lifter Limiter (right/left deck) Control Circuit..........................................................................................8- 27
8.6.3Detecting the Presence/Absence of Paper .................................................................................................8- 28
8.6.4Outline of Paper Level Detection ..............................................................................................................8- 29
8.6.5Paper Level Detection Operation (right/left deck) .................................................................................... 8- 29
8.6.6Identifying the Size of Paper (right/left deck) ...........................................................................................8- 30
8.7 Registration Unit..............................................................................................................................................8- 31
8.7.1Outline .......................................................................................................................................................8- 31
8.7.2Control System ..........................................................................................................................................8- 31
8.8 Duplex Feeding Unit........................................................................................................................................8- 32
8.8.1Moving the Paper to the Reversing Assembly After Printing on the 1st Side ..........................................8- 32
8.8.2Moving the Paper to the Duplexing Feed Assembly From the Reversing Assembly ...............................8- 32
8.8.3Outline .......................................................................................................................................................8- 33
8.8.4Sequence of Printing Operation.................................................................................................................8- 34
8.8.5Outline of Through-Path Operation...........................................................................................................8- 34
8.8.6Through-Path Operation ............................................................................................................................8- 35
8.8.7Outline of Horizontal Registration Position ..............................................................................................8- 39
8.8.8Horizontal Registration Position Detection Operation ..............................................................................8- 40
8.9 Delivery ...........................................................................................................................................................8- 42
8.9.1Reversal Delivery Operation .....................................................................................................................8- 42
8.10 Parts Replacement Procedure ........................................................................................................................ 8- 44
8.10.1 Pickup Roller...........................................................................................................................................8- 44
8.10.1.1 Removing the Right Deck/ Cassette Pickup Assembly................................................................... 8- 44
8.10.1.2 Removing the Left Deck Pickup Assembly.....................................................................................8- 44
8.10.1.3 Removing the Pickup Roller............................................................................................................8- 45
8.10.1.4 Orientation of the Deck/Cassette Pickup Roller..............................................................................8- 45
8.10.2 Cassette Pickup Assembly ......................................................................................................................8- 46

Contents
8.10.2.1 Removing the Right Deck/ Cassette Pickup Assembly................................................................... 8- 46
8.10.3 Cassette Pickup Motor ............................................................................................................................ 8- 46
8.10.3.1 Removing the Rear Cover (upper) .................................................................................................. 8- 46
8.10.3.2 Removing the Rear Cover (lower) .................................................................................................. 8- 47
8.10.3.3 Removing the Main Controller Box ................................................................................................ 8- 47
8.10.3.4 Removing the Right Cover (lower rear).......................................................................................... 8- 48
8.10.3.5 Removing the Waste Toner Bottle Holder ...................................................................................... 8- 48
8.10.3.6 Removing the Motor Driver PCB Base........................................................................................... 8- 49
8.10.3.7 Removing the Cassette Pickup Motor ............................................................................................. 8- 49
8.10.4 Cassette Lifter Motor .............................................................................................................................. 8- 49
8.10.4.1 Removing the cassette right cover................................................................................................... 8- 49
8.10.4.2 Removing the Lifter Motor M20 of the Cassette 3 ......................................................................... 8- 50
8.10.4.3 Removing the Lifter Motor M21 of the Cassette 4 ......................................................................... 8- 50
8.10.4.4 Adjusting the Position of the Lifter Motor M20 (M21) of the Cassette 3 (cassette 4).................... 8- 50
8.10.5 Left Deck Lifter Motor ........................................................................................................................... 8- 51
8.10.5.1 Removing the Rear Cover (lower) .................................................................................................. 8- 51
8.10.5.2 Removing the HVT PCB................................................................................................................. 8- 52
8.10.5.3 Removing the Left Deck Lifter Motor ............................................................................................ 8- 52
8.10.6 Right Deck Lifter Motor ......................................................................................................................... 8- 52
8.10.6.1 Removing the Rear Cover (upper) .................................................................................................. 8- 52
8.10.6.2 Removing the Rear Cover (lower) .................................................................................................. 8- 53
8.10.6.3 Removing the Main Controller Box ................................................................................................ 8- 53
8.10.6.4 Removing the Right Cover (lower rear).......................................................................................... 8- 54
8.10.6.5 Removing the Waste Toner Bottle Holder ...................................................................................... 8- 54
8.10.6.6 Removing the Motor Driver PCB Base........................................................................................... 8- 55
8.10.6.7 Removing the High-Voltage Power Supply PCB ........................................................................... 8- 56
8.10.6.8 Removing the Right Deck Lifter Motor .......................................................................................... 8- 56
8.10.7 Right Deck Pickup Assembly ................................................................................................................. 8- 57
8.10.7.1 Removing the Right Deck/ Cassette Pickup Assembly................................................................... 8- 57
8.10.8 Left Deck Pickup Assembly ................................................................................................................... 8- 57
8.10.8.1 Removing the Left Deck Pickup Assembly .................................................................................... 8- 57
8.10.9 Left Deck Pickup Motor ......................................................................................................................... 8- 58
8.10.9.1 Removing the Rear Cover (lower) .................................................................................................. 8- 58
8.10.9.2 Removing the High-Voltage Power Supply PCB ........................................................................... 8- 58
8.10.9.3 Removing the Left Deck Pickup Motor .......................................................................................... 8- 58
8.10.10 Right Deck Pickup Motor ..................................................................................................................... 8- 59
8.10.10.1 Removing the Rear Cover (upper) ................................................................................................ 8- 59
8.10.10.2 Removing the Rear Cover (lower) ................................................................................................ 8- 59
8.10.10.3 Removing the Main Controller Box .............................................................................................. 8- 59
8.10.10.4 Removing the Right Cover (lower rear)........................................................................................ 8- 60
8.10.10.5 Removing the Waste Toner Bottle Holder .................................................................................... 8- 61
8.10.10.6 Removing the Right Deck Pickup Motor ...................................................................................... 8- 61
8.10.11 Left Deck Pickup Solenoid ................................................................................................................... 8- 62
8.10.11.1 Removing the Rear Cover (lower) ................................................................................................ 8- 62
8.10.11.2 Removing the High-Voltage Power Supply PCB ......................................................................... 8- 62
8.10.11.3 Remove the Left Deck Pickup Solenoid ....................................................................................... 8- 62
8.10.12 Manual Feed Unit ................................................................................................................................. 8- 63
8.10.12.1 Removing the Manual Feed Unit .................................................................................................. 8- 63
8.10.13 Manual Feed Pull-Out Roller Unit........................................................................................................ 8- 63

Contents
8.10.13.1 Removing the Manual Feed Pull-Out Roller Unit .........................................................................8- 63
8.10.13.2 Removing the Manual Feed Pull-Out Roller .................................................................................8- 64
8.10.14 Manual Feed Roller...............................................................................................................................8- 64
8.10.14.1 Removing the Manual Feed Pull-Out Roller Unit .........................................................................8- 64
8.10.14.2 Removing the Manual Feeding Roller...........................................................................................8- 65
8.10.15 Manual Separation Roller......................................................................................................................8- 65
8.10.15.1 Removing the Manual Feed Pull-Out Roller Unit .........................................................................8- 65
8.10.15.2 Removing the Separation Roller....................................................................................................8- 66
8.10.15.3 Adjusting the Pressure of the Separation Roller of the Manual Feed Tray ...................................8- 66
8.10.16 Manual Feed Tray sensor ......................................................................................................................8- 67
8.10.16.1 Removing the Manual feed Tray Paper Sensor .............................................................................8- 67
8.10.17 Registration Roller ................................................................................................................................8- 68
8.10.17.1 Removing the Fixing Upper Unit ..................................................................................................8- 68
8.10.17.2 Removing the Transfer/Separation Corona Assembly ..................................................................8- 69
8.10.17.3 Removing the Registration Clutch................................................................................................. 8- 70
8.10.17.4 Removing the Registration Roller .................................................................................................8- 70
8.10.18 Pre-Registration Motor..........................................................................................................................8- 71
8.10.18.1 Removing the Rear Cover (upper).................................................................................................8- 71
8.10.18.2 Removing the Main Controller Box .............................................................................................. 8- 72
8.10.18.3 Removing the Pre-Registration Motor...........................................................................................8- 73
8.10.19 Registration Clutch................................................................................................................................8- 73
8.10.19.1 Removing the Fixing Feed Unit.....................................................................................................8- 73
8.10.19.2 Removing the Registration Clutch................................................................................................. 8- 75
8.10.20 Feeding Roller .......................................................................................................................................8- 75
8.10.20.1 Removing the Right Deck/ Cassette Pickup Assembly .................................................................8- 75
8.10.20.2 Removing the Left Pickup Assembly............................................................................................8- 76
8.10.20.3 Removing the Feeding Roller........................................................................................................8- 76
8.10.20.4 Orientation of the Feeding Roller of the Deck/Cassette Pickup Assembly...................................8- 77
8.10.21 Vertical Path Roller...............................................................................................................................8- 77
8.10.21.1 Removing the Right Deck/ Cassette Pickup Assembly .................................................................8- 77
8.10.21.2 Removing the Vertical Path Roller 1.............................................................................................8- 77
8.10.21.3 Removing the Vertical Path Roller 3/4..........................................................................................8- 78
8.10.22 Vertical Path Motor...............................................................................................................................8- 78
8.10.22.1 Removing the Rear Cover (upper).................................................................................................8- 78
8.10.22.2 Removing the Rear Cover (lower).................................................................................................8- 79
8.10.22.3 Removing the Main Controller Box .............................................................................................. 8- 79
8.10.22.4 Removing the Right Cover (lower rear) ........................................................................................8- 80
8.10.22.5 Removing the Waste Toner Bottle Holder ....................................................................................8- 80
8.10.22.6 Removing the Vertical Path Upper Motor.....................................................................................8- 81
8.10.23 Vertical Path Duplex Motor ..................................................................................................................8- 81
8.10.23.1 Removing the Rear Cover (upper).................................................................................................8- 81
8.10.23.2 Removing the Rear Cover (lower).................................................................................................8- 82
8.10.23.3 Removing the Main Controller Box .............................................................................................. 8- 82
8.10.23.4 Removing the Right Cover (lower rear) ........................................................................................8- 83
8.10.23.5 Removing the Waste Toner Bottle Holder ....................................................................................8- 83
8.10.23.6 Removing the Vertical Path Duplex Motor ...................................................................................8- 84
8.10.24 Vertical Path Lower Motor ...................................................................................................................8- 84
8.10.24.1 Removing the Rear Cover (upper).................................................................................................8- 84
8.10.24.2 Removing the Rear Cover (lower).................................................................................................8- 85

Contents
8.10.24.3 Removing the Main Controller Box .............................................................................................. 8- 85
8.10.24.4 Removing the Right Cover (lower rear)........................................................................................ 8- 86
8.10.24.5 Removing the Waste Toner Bottle Holder .................................................................................... 8- 86
8.10.24.6 Removing the Vertical Path Lower Motor .................................................................................... 8- 87
8.10.25 Fixing Feeding Unit Releasing Lever Sensor ....................................................................................... 8- 87
8.10.25.1 Removing the Fixing Feed Unit .................................................................................................... 8- 87
8.10.25.2 Removing the fixing Feed unit front cover .................................................................................. 8- 89
8.10.25.3 Removing the Fixing Feed Unit Releasing Lever Switch ............................................................. 8- 90
8.10.26 Feeding Belt .......................................................................................................................................... 8- 91
8.10.26.1 Removing the Fixing Feed Unit .................................................................................................... 8- 91
8.10.26.2 Removing the fixing Feed unit front cover .................................................................................. 8- 93
8.10.26.3 Removing the Feeding Belt........................................................................................................... 8- 94
8.10.27 Duplexing Unit...................................................................................................................................... 8- 95
8.10.27.1 Removing the Duplex Unit............................................................................................................ 8- 95
8.10.27.2 Removing the Reversing Flapper Solenoid................................................................................... 8- 95
8.10.27.3 Adjusting the Position of the Reversing Flapper Solenoid(SL8) .................................................. 8- 95
8.10.27.4 Removing the Reversal Motor....................................................................................................... 8- 95
8.10.27.5 Mounting the Reversal Motor ....................................................................................................... 8- 96
8.10.27.6 Removing the Duplexing Feeding Left Motor .............................................................................. 8- 97
8.10.27.7 Removing the Duplex Feeding Right Motor ................................................................................. 8- 97
8.10.27.8 Removing the Duplex Pre-Registration Sensor............................................................................. 8- 97
8.10.27.9 Removing the Reversal Sensor 1................................................................................................... 8- 98
8.10.27.10 Removing the Reversal Sensor 2................................................................................................. 8- 98
8.10.27.11 Removing the Left Deck Feed Paper Sensor............................................................................... 8- 98
8.10.27.12 Removing the Duplex Driver PCB.............................................................................................. 8- 99
8.10.27.13 Removing the Duplex Feeding Fan............................................................................................. 8- 99
8.10.27.14 Removing the Horizontal Registration Unit.............................................................................. 8- 100
8.10.28 Separation Roller ................................................................................................................................ 8- 101
8.10.28.1 Removing the Right Deck/ Cassette Pickup Assembly............................................................... 8- 101
8.10.28.2 Removing the Left Deck Pickup Assembly ................................................................................ 8- 102
8.10.28.3 Removing the Separation Roller ................................................................................................. 8- 102
8.10.28.4 Orientation of the Separation Roller............................................................................................ 8- 103
8.10.28.5 Adjusting the Pressure of the Separation Roller of the Deck/Cassette ....................................... 8- 104
Chapter 9 Fixing System
9.1 Construction ...................................................................................................................................................... 9- 1
9.1.1Specifications, Control Mechanisms, and Functions .................................................................................. 9- 1
9.1.2Major Components ...................................................................................................................................... 9- 2
9.1.3IH Fixing Method (outline) ......................................................................................................................... 9- 3
9.1.4Limiting th Rise in Temperature at the Roller Edges by Use of a Flux blocking Plate (shutter) ............... 9- 5
9.2 Basic Sequence.................................................................................................................................................. 9- 6
9.2.1Outline ......................................................................................................................................................... 9- 6
9.2.230-Sec Start-Up Mode................................................................................................................................. 9- 7
9.2.3Low-Temperature Environment Start-Up Mode......................................................................................... 9- 8
9.2.4High-Humidity Environment Start-Up Mode ............................................................................................. 9- 8
9.2.5Recovery Mode ........................................................................................................................................... 9- 9
9.2.6Standby Mode............................................................................................................................................ 9- 10
9.2.7Power Save Mode...................................................................................................................................... 9- 11

Contents
9.2.8Sleep Mode ...............................................................................................................................................9- 11
9.2.9Copying/Printing Mode ............................................................................................................................. 9- 12
9.2.10Down Sequence .......................................................................................................................................9- 13
9.2.11Enhanced Fixing Mode............................................................................................................................9- 13
9.2.12Heavy Paper Mode ..................................................................................................................................9- 14
9.2.13Transparency Mode .................................................................................................................................9- 15
9.2.14Bond Paper Mode ....................................................................................................................................9- 16
9.3 Various Control Mechanisms ..........................................................................................................................9- 17
9.3.1 Fixing Drive System..................................................................................................................................9- 17
9.3.1.1 Controlling the Drive of the Fixing Roller ........................................................................................ 9- 17
9.3.1.2 Controlling the Drive of the Fixing Inlet Guide ................................................................................9- 18
9.3.1.3 Controlling the Reciprocating Movement of the Thermistor ............................................................9- 19
9.3.1.4 Controlling the Reciprocating Mechanism of the Upper Separation Claw .......................................9- 20
9.3.1.5 Controlling the Drive of the Shutter ..................................................................................................9- 20
9.3.1.6 Controlling the Shutter Position ........................................................................................................9- 21
9.3.2 Cleaning ....................................................................................................................................................9- 24
9.3.2.1 Controlling the Drive of the Cleaning Web.......................................................................................9- 24
9.3.2.2 Controlling the Mechanism Used to Detect the Remaining Length of the Cleaning Web................9- 26
9.3.3 Detecting the Passage of Paper .................................................................................................................9- 28
9.3.3.1 Preventing Wrapping of Paper........................................................................................................... 9- 28
9.4 Protective Functions ........................................................................................................................................9- 30
9.4.1Detecting an Error Using the Thermistor .................................................................................................. 9- 30
9.4.2Detecting an Error Using the Thermal Switch ..........................................................................................9- 30
9.4.3Errors .........................................................................................................................................................9- 30
9.5 Parts Replacement Procedure ..........................................................................................................................9- 32
9.5.1 Fixing/Feeding Assembly .........................................................................................................................9- 32
9.5.1.1 Removing the Fixing Feed Unit.........................................................................................................9- 32
9.5.2 Fixing Unit ................................................................................................................................................ 9- 34
9.5.2.1 Removing the Fixing Upper Unit ......................................................................................................9- 34
9.5.3 Pressure Roller ..........................................................................................................................................9- 37
9.5.3.1 Removing the Pressure Roller ...........................................................................................................9- 37
9.5.4 Upper Fixing Roller .................................................................................................................................. 9- 38
9.5.4.1 Removing the Fixing Roller ..............................................................................................................9- 38
9.5.4.2 Points to Note When Mounting the Fixing Roller............................................................................. 9- 41
9.5.4.3 Applying Grease After Replacing the Fixing Roller .........................................................................9- 43
9.5.4.4 Adjusting the Nip Width.................................................................................................................... 9- 44
9.5.5 External Delivery Roller ...........................................................................................................................9- 44
9.5.5.1 Removing the Outside Delivery Roller ............................................................................................. 9- 44
9.5.6 Internal Delivery Roller ............................................................................................................................9- 45
9.5.6.1 Removing the Inside Delivery Roller ................................................................................................9- 45
9.5.6.2 Points to Note When Mounting the Inside Delivery Roller...............................................................9- 47
9.5.7 Main Thermistor........................................................................................................................................9- 47
9.5.7.1 Removing the Main Thermistor/Shutter Thermistor .........................................................................9- 47
9.5.7.2 Points to Note When Mounting the Thermistor/Shutter Thermistor .................................................9- 48
9.5.8 Sub Thermistor..........................................................................................................................................9- 49
9.5.8.1 Removing the Sub Thermistor...........................................................................................................9- 49
9.5.8.2 Point to Note When Mounting the Sub Thermistor...........................................................................9- 50
9.5.9 Thermal Switch .........................................................................................................................................9- 50
9.5.9.1 Removing the Thermal Switch ..........................................................................................................9- 50