Canon GP605 User manual

COPYRIGHT © 1999 CANON INC. CANON GP605/GP605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
FY8-13FD-000
REVISION 0
JAN. 1999
SERVICE
MANUAL

COPYRIGHT © 1999 CANON INC. CANON GP605/GP605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
COPYRIGHT 1999 CANON INC.
Printed in Japan
Use of this manual should be strictly
supervised to avoid disclosure of confi-
dential information.
Imprimé au Japon
THE INFORMATION CONTAINED HEREIN IS PUBLISHED BY CANON, INC., JAPAN.
SPECIFICATIONS AND OTHER INFORMATION CONTAINED HEREIN MAY DIFFER SLIGHTLY FROM
ACTUAL MACHINE VALUES OR THOSE FOUND IN ADVERTISING AND OTHER PRINTED MATTER.
ANY QUESTIONS REGARDING INFORMATION CONTAINED HEREIN SHOULD BE DIRECTED TO
THE COPIER SERVICE DEPARTMENT OF THE COMPANY.
IMPORTANT
Prepared by
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DEPARTMENT 3
OFFICE IMAGING PRODUCTS TECHNICAL SUPPORT DIVISION
5-1, Hakusan 7-chome, Toride, Ibaraki, 302-8501 Japan
CANON INC.

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
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This Service Manual contains basic data and figures on the GP605/605V needed to
service the machine in the field. The copier is a multifunction machine designed to provide
printer functions as an option.
This Service Manual consists of the following chapters; refer to the Copier Basic
Series as necessary for common technologies:
CHAPTER 1 General Description introduces the copier’s features and specifications,
shows how to operate the printer unit, and explains how copies are made.
CHAPTER 2 Basic Operation provides outlines of the steps used to generate copies.
CHAPTER 3 Exposure System discusses the principles of operation used for the
mechanical/electrical operations of the copier’s exposure system. It also explains the
timing at which the various units involved are operated, and shows how they may be
disassembled/assembled and adjusted.
CHAPTER 4 Image Processing System discusses the principles of operation used for
the mechanical/electrical operations of the copier’s image processing system. It also
explains the timing at which the various units involved are operated, and shows how they
may be disassembled/assembled and adjusted.
CHAPTER 5 Laser Exposure System discusses the principles of operation used for
the mechanical/electrical operations of the copier’s laser exposure system. It also
explains the timing at which the various units involved are operated, and shows how they
may be disassembled/assembled and adjusted.
CHAPTER 6 Image Formation System discusses the principles of how images are
formed. It also explains the timing at which the various units involved in image formation
are operated, and shows how they may be disassembled/assembled and adjusted.
CHAPTER 7 Pick-Up/Feeding System discusses the principles of how the printer unit
picks up and moves paper inside it. It also explains the timing at which the various units
involved are operated, and shows how they may be disassembled/assembled and
adjusted.
CHAPTER 8 Fixing System discusses the principles of how the printer unit fuses toner
images to paper. It also explains the timing at which the various units involved are
operated, and shows how they may be disassembled/assembled and adjusted.
CHAPTER 9 Externals/Auxiliary Mechanisms shows the copier’s external parts, and
explains the principles used for the copier’s various control mechanisms in view of the
functions of electrical and mechanical units and in relation to their timing of operation. It
also shows how these units may be disassembled/assembled and adjusted.
CHAPTER 10 Side Paper Deck discusses the principles of operation used for the
series of operations between pickup and delivery performed by the paper deck. It also
explains the timing at which the various units involved are operated, and shows how they
may be disassembled/assembled and adjusted.
CHAPTER 11 Installation introduces requirements for the site of installation, and
shows how the printer unit may be installed using step-by-step instructions.
INTRODUCTION

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN . 1999 PRINTED IN JAPAN (IMPRIME AU JA PON)
ii
CHAPTER 12 Maintenance and Servicing provides tables of periodically replaced
parts and consumables/durables and scheduled servicing charts.
CHAPTER 13 Troubleshooting provides tables of maintenance/inspection, standards/
adjustments, and problem identification (image fault/malfunction).
APPENDIX contains a general timing chart and general circuit diagrams.
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.
This Service Manual is prepared so that a full understanding may be attained when it
is used side by side with the separately available Copier Basic Series. Refer to the
appropriate section of the document when prompted as follows:
EX. Volume 3>Chapter 6>VI.A.2. "Cleaning the Charging Wire"
The Copier Basic Series is a combination of descriptions on the existing technologies
used in Canon copiers. It consists of the following seven volumes, and is intended to
supplement the contents of Service Manuals:
Volume I Introduction
Fundamental Technology
Volume II Applied Technology Analog Copiers
Volume III Applied Technology Digital Copiers
Volume IV Applied Technology Color Copiers
Volume V Applied Technology Accessories
Volume VI Applied Technology Controllers
Volume VII Appendix Product Line and Accessories

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
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System Configuration
The GP605/605V may be configured as follows:
[1] Finisher-D1
[2] Printer Board
[3] Copy tray
[4] GP605/605V
[5] Side Paper Deck-C1
[1]
[2]
[3] [4] [5]
Figure 1

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN . 1999 PRINTED IN JAPAN (IMPRIME AU JA PON)
iv
[3]
[4]
ONOFF
1 2 3
4 5 6
7 8 9
0
C
ID
ON/OFF
COPY A MAIL BOX OPTIONS
1 2 3
4 5 6
7 8 9
0
Copying Error
COPY B
Copying Error Data DataError Error
C
ID
[2][1]
[1] Data lamp
[2] Power switch
[3] Main power switch
[4] Heater switch
Figure 2 Arrangement of the Switches
When Turning Off the Main Power Switch
Be sure to turn off the main power switch, and disconnect the power plug before starting
disassembly/assembly work with the following in mind:
1. When you turn off the main power switch for adding printer functions, any data
being processed at the time may be lost. Check to make sure that the data lamp on
the control panel is off before operating the main power switch.
After turning off the main power switch, disconnect the communication cable from
the printer board so that data will not be accepted during work.
2. Do not turn off the main power switch when downloading is taking place. Other-
wise, the machine may stop operating.
3. Some units remain powered even when the control panel power switch is turned
off. Be sure to turn off the main power switch, and disconnect the power plug
before starting disassembly/assembly work.
(If the heater switch is on, the cassette heater and the drum heater remain pow-
ered even when the main power switch is turned off.)
4. Not all power will be removed even when the front door is opened if both the control
panel power switch and the main power switch are on.

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
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CHAPTER 1 GENERAL DESCRIPTION
I. FEATURES.................................1-1
II. SPECIFICATIONS ......................1-2
A. Copier ....................................1-2
1. Type..................................1-2
2. System..............................1-2
3. Performance .....................1-3
4. Others ...............................1-7
B. Side Paper Deck-C1 ............1-10
III. NAMES OF PARTS ..................1-11
A. External View.......................1-11
B. Cross Section ......................1-14
IV. OPERATING THE COPIER......1-16
A. Turning on the Power Switch
.............................................1-16
B. Control Panel .......................1-17
C. Extension Mode ...................1-18
D. User Mode ...........................1-19
V. ROUTINE MAINTENANCE BY THE
USER ........................................1-21
VI. SAFETY ....................................1-22
A. Safety of Laser Light............1-22
B. CDRH Regulations ..............1-23
C. Handling the Laser Assembly
.............................................1-24
D. Safety of Toner ....................1-28
VII. IMAGE FORMATION................1-29
A. Outline..................................1-29
CONTENTS
CHAPTER 2 BASIC OPERATIONS
I. BASIC OPERATIONS.................2-1
A. Functional Construction.........2-1
B. Electrical Circuitry ..................2-2
1. Outline ..............................2-2
2. MFC PCB..........................2-2
3. Image Processor PCB ......2-2
4. DC Controller PCB ...........2-3
5. Control panel CPU PCB ...2-3
6. Original Orientation Detection
PCB...................................2-3
7. Image Server ....................2-3
C. Basic Sequence of Operations
...............................................2-5
1. Basic Sequence of Operations
(power-on) ........................2-5
D. Controlling the Main Motor (M1)
...............................................2-6
1. Outline ..............................2-6
E. Inputs to and Outputs from the
Major PCBs............................2-7
1. Wiring Diagram of Major
PCBs.................................2-7
2. Inputs to the DC Controller
PCB...................................2-8
3. Outputs from the DC
Controller PCB................2-14
CHAPTER 3 ORIGINAL EXPOSURE SYSTEM
I. OPERATIONS ............................3-1
A. Outline....................................3-1
B. Basic Sequence of Operations
...............................................3-3
C. Changing the Reproduction Ratio
...............................................3-4
II. SCANNER DRIVE SYSTEM ......3-5
A. Outline....................................3-5
B. Controlling the Scanner Motor
...............................................3-6
III. CONTROLLING THE SCANNING
LAMP ..........................................3-8

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
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A. Outline....................................3-8
B. Controlling the Temperature by a
Fluorescent Lamp Heater ....3-10
C. Controlling Pre-Heat Voltage
.............................................3-10
D. Initial Activation....................3-11
E. Detecting an Error................3-12
IV. DETECTING THE ORIGINAL SIZE
..................................................3-14
A. Outline..................................3-14
B. Detection by Original Sensors
.............................................3-14
C. Detection by the Feeder ......3-14
V. DISASSEMBLY/ASSEMBLY ....3-15
A. No. 1 Mirror Mount...............3-16
1. Removing the Scanning
Lamp/Scanning Lamp Heater
........................................3-16
2. Points to Note When
Replacing the Scanning Lamp
........................................3-19
3. After Replacing the Scanning
Lamp...............................3-19
B. Scanner Drive Assembly .....3-20
1. Removing the Scanner Motor
........................................3-20
2. Scanner Drive Cable ......3-21
C. PCBs....................................3-28
1. Removing the Light Intensity
Control PCB....................3-28
2. Removing the Inverter PCB
........................................3-29
D. Others ..................................3-31
1. Removing the Original Size
Sensor (1/2) ....................3-31
2. Removing the Original Size
Sensor (3/4) ....................3-32
3. Removing the Scanner Home
Position Sensor ..............3-33
4. Removing the Copyboard
Glass...............................3-33
5. Removing the Image Leading
Edge Sensor...................3-34
6. Removing the Standard White
Plate................................3-35
7. After Replacing the Standard
White Plate .....................3-36
CHAPTER 4 IMAGE PROCESSING SYSTEM
I. OUTLINE.....................................4-1
II. ANALOG IMAGE PROCESSING4-4
A. Outline....................................4-4
III. DIGITAL IMAGE PROCESSING 4-6
A. Outline....................................4-6
B. Image Procesing Functional
Block ......................................4-7
C. Shading Correction ................4-9
D. Line Conversion...................4-10
E. Editing ..................................4-11
F. Density Processing ..............4-12
1. Outline ............................4-12
2. Density Adjustment during
Printing............................4-14
G. Binary Processing................4-15
1. Dither Screen Method.....4-15
2. Random Error Diffusion (R-
ED) Method.....................4-16
H. Image Memory.....................4-17
I. Detecting the Orientation of
Originals...............................4-19
J. Black Pixel Count.................4-20
IV. DISASSEMBLY/ASSEMBLY ....4-21
A. CCD PCB.............................4-22
1. Removing the CCD PCB
........................................4-22
2. After Replacing the CCD Unit
........................................4-23
B. Image Processor PCB .........4-24
1. Removing the Image
Processor PCB ...............4-24
2. After Replacing the Image
Processor PCB ...............4-25
C. Hard Disk (image server).....4-26
1. Removing the Hard Disk
(image server).................4-26
2. After Replacing the Hard Disk
(image server).................4-26
D. Others ..................................4-27
1. Removing the System
Motherboard ...................4-27
2. Removing the Memory Board
........................................4-28
3. Removing the Various Printer
Boards ............................4-28
4. Removing the Original
Detection PCB ................4-29

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
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CHAPTER 5 LASER EXPOSURE SYSTEM
I. OPERATIONS ............................5-1
A. Outline....................................5-1
B. Basic Sequence of Operations
(laser exposure system) ........5-4
II. GENERATING THE BD SIGNAL 5-5
A. Outline....................................5-5
B. Flow of the BD Signal ............5-5
III. LASER DRIVER PCB .................5-7
A. Outline....................................5-7
B. Controlling the Laser Activation
...............................................5-8
C. Controlling the Laser Intensity
.............................................5-10
IV. Controlling the Laser Scanner Motor
..................................................5-12
A. Outline..................................5-12
V. DISASSEMBLY/ASSEMBLY ....5-13
A. Laser Unit.............................5-14
1. Removing the Laser Unit
........................................5-14
2. After Replacing the Laser Unit
........................................5-15
B. BD Unit.................................5-16
1. Removing the BD Unit ....5-16
CHAPTER 6 IMAGE FORMATION SYSTEM
I . PROCESSES..............................6-1
A. Outline....................................6-1
B. Basic Sequence of Operations
(image formation)...................6-3
II . POTENTIAL CONTROL .............6-5
A. Outline....................................6-5
B. Determining the Optimum Grid
Bias ........................................6-8
C. Grid Bias Corrective Control..6-8
D. Determining the Optimum Laser
Output ....................................6-9
E. Laser Output Corrective control
...............................................6-9
F. Determining the Optimum
Developing Bias...................6-10
G. Potential Control for
Transparency Mode.............6-11
H. Target Potential Correction in
Each Mode...........................6-12
1. Adjusting the Density during
Printing (PDL input) ........6-13
2. Potential Control during High
Humidity Mode................6-14
3. Density Adjustment during
Printing (scanner input) ..6-15
III . CONTROLLING THE CHARGING
MECHANISMS..........................6-16
A. Controlling the Primary Charging
Mechanism...........................6-16
1. Outline ............................6-16
2. Changing the Primary
Charging Level Setting ...6-17
3. Primary Charging Assembly
Cleaning Mechanism......6-18
4. Others .............................6-19
B. Dust-Collecting Roller Bias..6-20
1. Outline ............................6-20
C. Controlling the Pre-Transfer
Charging Mechanism...........6-21
1. Outline ............................6-21
2. Controlling the Output to Suit
the Environment (fuzzy
control)............................6-22
3. Pre-Transfer Charging
Assembly Cleaning
Mechanism .....................6-23
4. Others .............................6-24
D. Controlling the Transfer Guide
Bias ......................................6-25
1. Outline ............................6-25
2. Controlling the Output to Suit
the Environment .............6-26
E. Controlling the Transfer Charging
Mechanism...........................6-27
1. Outline ............................6-27
2. Controlling the Output to Suit
the Environment (fuzzy
control)............................6-28
3. Correcting the Output at the
Trailing Edge of Paper....6-29

COPYRIGHT © 1999 CANON INC. CANON GP605/605V REV.0 JAN. 1999 PRINTED IN JAPAN (IMPRIME AU JAPON)
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4. Transfer charging Assembly
Cleaning Mechanism......6-30
5. Others .............................6-31
F. Controlling Separation Charging
.............................................6-32
1. Outline ............................6-32
2. Correcting the Output to Suit
the Environment and the
Toner Deposit .................6-33
3. Correcting the Output upon
Detection of Leakage......6-34
4. Others .............................6-35
IV . DEVELOPING ASSEMBLY ......6-36
A. Outline..................................6-36
B. Controlling the Developing
Assembly .............................6-37
C. Controlling the Toner Cartridge
Drive Mechanism .................6-38
D. Controlling the Developing Bias
.............................................6-39
E. Detecting the Toner Level and
Controlling the Toner Supply
Mechanism...........................6-41
V . DRUM CLEANER UNIT............6-45
A. Outline..................................6-45
B. Detecting the Waste Toner (case
full condition)........................6-46
VI. CONTROLLING THE DRUM
HEATER....................................6-48
A. Outline..................................6-48
VII .DISASSEMBLY/ASSEMBLY ....6-49
A. Photosensitive Drum Unit ....6-50
1. Points to Note When Handling
the Photosensitive Drum 6-50
2. Removing the Photosensitive
Drum ...............................6-51
3. Replacing the Photosensitive
Drum Heater ...................6-53
4. Mounting the Photosensitive
Drum Unit........................6-54
B. Parts Associated with the
Process Unit.........................6-55
1. Removing the Pre-Exposure
Lamp Unit .......................6-55
2. Removing the Potential
Sensor Unit .....................6-56
3. Removing the Primary
Charging Assembly ........6-57
4. Removing the Pre-Transfer
Charging Assembly ........6-57
5. Removing the Dust-Collecting
Roller ..............................6-58
6. Removing the Transfer/
Separation Charging
Assembly ........................6-58
C. Charging Wire......................6-60
1. Outline ............................6-60
2. Removing the Wire Cleaner of
the Primary Charging
Assembly ........................6-60
3. Removing the Wire Cleaner of
the Transfer Separation
Charging Assembly ........6-61
4. Routing the Charging Wire
........................................6-62
5. Routing the Grid Wire for the
Primary Charging Assembly
........................................6-64
6. Adjusting the Height of the
Charging Wire.................6-65
D. Process Unit.........................6-66
1. Removing the Process Unit
........................................6-66
2. Mounting the Process Unit
........................................6-68
E. Developing Assembly ..........6-69
1. Removing the Developing
Assembly ........................6-69
2. Removing the Hopper.....6-70
3. Removing the Blade Unit
........................................6-71
4. Mounting the Blade.........6-72
5. Removing the Developing
Cylinder...........................6-72
F. Drum Cleaner Unit ...............6-75
1. Removing the Cleaning Blade
........................................6-75
2. Mounting the Cleaning Blade
........................................6-77
G. Separation Claw/Separation Claw
Drive Assembly....................6-79
CHAPTER 7 PICK-UP/FEEDING SYSTEM
I. OUTLINE.....................................7-1
A. Specifications and Construction
...............................................7-1
B. Arrangement of Rollers and
Sensors..................................7-2
II. PICKUP ASSEMBLY ..................7-3

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A. Control System ......................7-3
B. Sequence of Operations (pickup)
...............................................7-4
1. Right Deck ........................7-4
2. Pickup from the Cassette 2
..........................................7-5
C. Controlling the Pickup Motor (M2)
...............................................7-6
1. Outline ..............................7-6
D. Movement of the Lifter ...........7-7
1. Outline ..............................7-7
2. Lifter Limiter (deck right/left)
..........................................7-9
3. Detecting the Presence/
Absence of Paper ...........7-10
4. Detecting the Level of Paper
........................................7-10
E. Detecting the Cassette Paper
Size ......................................7-13
1. Cassette Deck Right/Left
........................................7-13
2. Cassette 3/4....................7-13
3. Markings on the Width Guide
Rail..................................7-14
4. Paper Size ......................7-15
F. Manual Feed Tray Pickup
Assembly .............................7-18
1. Pickup Operation ............7-18
2. Detecting the Paper Size
........................................7-19
III. CONTROLLING THE
REGISTRATION CLUTCH
..................................................7-20
A. Outline..................................7-20
B. Control System ....................7-20
C. Sequence of Operations
(registration brake)...............7-21
IV. MAKING DOUBLE-SIDED COPIES
..................................................7-22
A. Control System ....................7-22
1. Copying on the First Side
........................................7-22
2. Copying on the Second Side
........................................7-23
B. Sequence of Operations......7-24
C. Controlling the Reversal Motor
(M11)....................................7-25
1. Outline ............................7-25
D. Controlling the Duplexing Feeder
Motor (M12) .........................7-26
1. Outline ............................7-26
E. No-Stacking Operation ........7-27
1. Outline ............................7-27
2. Outline of Operations......7-28
F. Detecting the Horizontal
Registration Position............7-32
1. Outline ............................7-32
2. Operations ......................7-33
3. Controlling the Horizontal
Registration Motor (M15)
........................................7-34
V. CONTROLLING THE DELIVERY
ASSEMBLY...............................7-35
A. Reversal Delivery.................7-35
VI. CONTROLLING THE CASSETTE
HEATER....................................7-36
VII. DETECTING JAMS...................7-38
A. Outline..................................7-38
1. Arrangement of Jam Sensors
........................................7-38
2. Types of Jams ................7-39
B. Sequence of Operations (jam
detection) .............................7-40
1. Delay Jams .....................7-40
2. Stationary Jams..............7-43
VIII.DISASSEMBLY/ASSEMBLY ....7-44
A. Manual Tray Assembly ........7-45
1. Removing the Manual Tray
Unit..................................7-45
2. Removing the Pickup Roller
........................................7-46
3. Mounting the Pickup Roller
........................................7-46
4. Removing the Feeding Roller
........................................7-47
5. Orientation of the Feeding
Roller ..............................7-47
6. Removing the Separation
Roller ..............................7-48
7. Adjusting the Tension of the
Separation Roller............7-48
8. Removing the Manual Feed
Tray Paper Sensor .........7-49
9. Routing the Manual Feed Tray
Assembly Side Guide Timing
Belt..................................7-51
10. Position of the Pickup Roller
Releasing Solenoid of the
Manual Feed Tray ..........7-52
11. Removing the Manual Feed
Roller ..............................7-53
12. Mounting the Manual Feed
Roller ..............................7-54
B. Cassette Pickup Assembly ..7-55
1. Removing the Front Deck
(right) ..............................7-55
2. Removing the Pickup
Assembly of the Front Deck
(left).................................7-56

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3. Removing the Cassette 3
Pickup Assembly ............7-57
4. Removing the Cassette 4
Pickup Assembly ............7-57
5. Removing the Pickup Roller
........................................7-57
6. Removing the Feeding Roller
........................................7-59
7. Orientation of the Feeding
Roller of the Cassette Pickup
Assembly ........................7-59
8. Removing the Separation
Roller ..............................7-59
9. Adjusting the Pressure of the
Separation Roller............7-61
10. Orientation of the Separation
Roller ..............................7-61
11. Position of the Pickup Roller
Releasing Solenoid of the
Cassette (3/4) .................7-62
12. Adjusting the Registration of
the Front Deck (right/left)
........................................7-63
13. Adjusting the Registration of
the Cassette 3/4..............7-63
14. Removing the Lifter Motor
(M16/M17) of the Cassette (3/
4).....................................7-64
15. Adjusting the Position of the
Lifter Motor M16 (M17) for the
Cassette 3 (4) .................7-65
C. Vertical Path Roller Assembly
.............................................7-68
1. Removing the Vertical Path
Roller 1/3/4 .....................7-68
2. Removing the Vertical Path
Roller 2 ...........................7-69
D. Registration Feeding Assembly
.............................................7-71
1. Removing the Registration
Clutch/Registration Brake
Clutch..............................7-71
2. Removing the Registration
Brake Clutch ...................7-71
3. Removing the Registration
Roller ..............................7-72
4. Removing the Pre-
Registration Roller ..........7-73
E. Feeding Assembly ...............7-75
1. Removing the Feeding Belt
........................................7-75
2. Removing the Fixing Feeding
Unit Releasing lever Sensor
........................................7-77
F. Duplexing Unit .....................7-78
1. Removing the Duplexing Unit
........................................7-78
2. Removing the Front Cover of
the Duplexing Unit ..........7-78
3. Removing the Reversing
Flapper Solenoid ............7-79
4. Removing the Reversal Motor
........................................7-79
5. Removing the Lower Feeder
Motor...............................7-80
6. Removing the Horizontal
Registration Motor ..........7-80
7. Removing the Deck (left)
Draw-Out Clutch/Lower
Feeder Middle Clutch .....7-81
8. Removing the Lower Feeding
Right Clutch ....................7-82
9. Removing the Duplexing
Reversal Sensor .............7-83
10. Removing the U-Turn Sensor
........................................7-86
11. Removing the Pre-Confluence
Sensor ............................7-86
12. Removing the Post-
Confluence Sensor .........7-87
13. Removing the Front Deck
(lifter) Draw-Out Sensor..7-88
14. Removing the Horizontal
Registration sensor.........7-88
CHAPTER 8 FIXING SYSTEM
I. OPERATIONS ............................8-1
A. Outline....................................8-1
B. Basic Sequence of Operations
(fixing system)........................8-4
II. FIXING DRIVE SYSTEM ............8-5
A. Outline....................................8-5
B. Controlling the Fixing Roller Drive
Mechanism.............................8-6
C. Controlling the Cleaning Belt
Drive Mechanism ...................8-8
D. Controlling the Fixing Inlet Guide
Drive Mechanism ...................8-9

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E. Controlling the Thermistor
Reciprocating Mechanism ...8-10
F. Controlling the Upper Separation
Claw Reciprocating Mechanism
.............................................8-11
III. CONTROLLING THE FIXING
TEMPERATURE.......................8-12
A. Outline..................................8-12
B. Down Sequence Control......8-13
C. Controlling Temperature by Mode
.............................................8-14
1. Transparency Mode........8-15
2. Thick Paper Mode ..........8-16
3. Power Save Mode ..........8-17
D. Error Detection.....................8-18
IV. CONTROLLING THE FIXING
ROLLER BIAS ..........................8-24
A. Outline..................................8-24
V. DISASSEMBLY/ASSEMBLY ....8-25
A. Fixing Assembly...................8-26
1. Removing the Fixing
Assembly ........................8-26
B. Fixing Roller Cleaning Assembly
.............................................8-29
1. Removing the Fixing Cleaning
Belt..................................8-29
2. Mounting the Fixing Cleaning
Belt..................................8-31
C. Fixing Heater and Control Parts
.............................................8-32
1. Removing the Main/Sub
Heater .............................8-32
2. Mounting the Main/Sub Heater
8-33
3. Removing the Thermal Switch
........................................8-34
4. Removing the Main
Thermistor.......................8-35
5. Removing the Sub Thermistor
........................................8-36
D. Fixing Roller Assembly ........8-37
1. Removing the Upper Fixing
Roller ..............................8-37
2. Mounting the Upper Fixing
Roller ..............................8-39
3. Removing the Lower Fixing
Roller ..............................8-40
4. Adjusting the Nip ............8-40
E. Separation Claw Assembly..8-42
1. Removing the Upper
Separation Claw .............8-42
2. Removing the Lower
Separation Claw .............8-42
F. Delivery Assembly ...............8-43
1. Removing the External
Delivery Roller ................8-43
2. Removing the Internal
Delivery Roller ................8-43
3. Removing the Delivery Speed
Switch Clutch..................8-45
G. Paper Sensors .....................8-46
1. Removing the Claw Jam
Sensor ............................8-46
2. Removing the External
Delivery Roller ................8-46
3. Removing the Internal
Delivery Sensor ..............8-46
4. Removing the Reversal
Sensor ............................8-47
5. Removing the Fixing/Feeding
Unit Outlet Sensor ..........8-47
CHAPTER 9 EXTERNALS/AUXILIARY MECHANISMS
I. CONTROL PANEL......................9-1
A. Outline....................................9-1
II. DOWNLOADING ........................9-2
A. Outline....................................9-2
III. COUNTERS................................9-4
IV. FANS...........................................9-6
A. Arrangement, Functions, and
Error Codes............................9-6
B. Sequence of Operations........9-8
1. 2-Speed Control ...............9-8
2. Sequence of Operations...9-9
V. POWER SUPPLY .....................9-10
A. Outline of the Power Supply
.............................................9-10
B. Turning on the Power ..........9-12
1. Outline ............................9-12
2. Power Supply at Main Power
Switch-On .......................9-14
3. Power Supply at Main Power
Switch-On and Control Panel
Switch-On .......................9-15
C. Rated Outputs of the DC Power
Supply PCB..........................9-16
D. Protective Functions ............9-17
E. Backup Battery ....................9-18

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1. MFC PCB........................9-18
2. Image Processor PCB ....9-19
VI. OTHERS ...................................9-21
A. Sleep Mode..........................9-21
1. Outline ............................9-21
2. Operation ........................9-22
B. Low Power mode .................9-23
C. Silence Mode .......................9-24
D. Power Save Mode ...............9-24
VII. DISASSEMBLY/ASSEMBLY ....9-25
A. External Covers ...................9-26
1. Removing the Front Door
........................................9-27
2. Removing the Inside Upper
Cover ..............................9-28
3. Removing the Fixing/Feeding
Unit Cover.......................9-28
4. Removing the Rear Cover
........................................9-29
B. Control Panel .......................9-30
1. Removing the Control Panel
........................................9-30
2. Removing the Control Panel
Controller (CPU) PCB and the
Control Panel Inverter PCB
........................................9-31
3. Removing the Control Panel
PCB and the LCD Panel
........................................9-32
C. Fans .....................................9-34
1. Removing the Primary
Charging Assembly Fan
........................................9-34
2. Removing the Fixing Heat
Discharge Fan ................9-35
3. Removing the Scanner
Cooling Fan ....................9-35
4. Removing the Stream
Reading Fan ...................9-36
5. Removing the Laser Cooling
Fan..................................9-37
6. Removing the De-Curling Fan
........................................9-38
7. Removing the Feeding Fan
........................................9-39
8. Removing the Drum Fan
........................................9-40
9. Removing the Inverter Cooling
Fan..................................9-41
10. Removing the Pre-Transfer
Charging Assembly Fan
........................................9-42
11. Removing the Power Supply
Cooling Fan 1 .................9-43
12. Removing the Power Supply
Cooling Fan 2 .................9-44
13. Removing the Separation Fan
........................................9-45
14. Removing the Laser Scanner
Fan..................................9-46
D. Drive Assembly....................9-48
1. Removing the Left Pickup
Drive Assembly...............9-48
2. Removing the Pickup Drive
Assembly ........................9-49
3. Removing the Developing
Drive Assembly...............9-50
4. Removing the Vertical Path
Drive Assembly...............9-51
5. Removing the Waste Toner
Drive Assembly...............9-52
6. Removing the Multifeeder
Pickup Drive Assembly...9-53
7. Removing the Lifter Drive
Assembly (right deck) .....9-54
8. Removing the Lifter Drive
Assembly (for the left deck)
........................................9-55
9. Removing the Main Drive
Assembly ........................9-56
10. Removing the Drum Drive
Assembly ........................9-57
11. Removing the Cassette
Pickup Drive Assembly...9-60
12. Removing the Toner Cartridge
Drive Assembly...............9-61
E. Switches...............................9-62
1. Removing the Cover Switch
(door switch) Assembly
........................................9-62
2. Removing the Manual Feed
Tray Switch Assembly ....9-63
3. Removing the Drum Heater
Switch Assembly ............9-64
F. DC Controller PCB...............9-65
G. Power Supply Unit ...............9-66
H. High-Voltage Transformer (AC)
.............................................9-67
I. High-Voltage Transformer (DC)
.............................................9-67
J. Relay PCB ...........................9-69
K. MFC PCB.............................9-69
L. Routing the Belt ...................9-71

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CHAPTER 10 SIDE PAPER DECK
I. SIDE PAPER DECK .................10-1
A. Inputs to and Outputs from the
Side Deck Driver..................10-1
1. Inputs to the Side Deck Driver
(1/2).................................10-1
2. Inputs to the Side Deck Driver
Input (2/2) .......................10-2
3. Outputs from the Side Deck
Driver (1/1)......................10-3
B. Pickup ..................................10-4
1. Outline ............................10-4
2. Pickup Operation ............10-4
3. Sequence of Operations
(pickup from the deck) ....10-6
C. Deck Paper Detection..........10-7
1. Detecting the Presence/
Absence of Paper ...........10-7
2. Switching the Deck Paper
Size.................................10-7
3. Deck Paper Level Detection
........................................10-8
D. Deck Lifter............................10-9
1. Detecting the Presence/
Absence of Paper ...........10-9
2. Paper Level Indicator on the
Deck Front Cover .........10-11
E. Opening Closing the Deck
(compartment) ...................10-12
1. Opening/Closing the Deck
......................................10-12
2. Sequence of Operations
(opening/closing the deck)
......................................10-13
F. Controlling the Deck Motor
...........................................10-14
1. Controlling the Deck Main
Motor (M101) ................10-14
2. Controlling the Deck Lifter
Motor (M102) ................10-16
II. DETECTING JAMS.................10-18
A. Outline................................10-18
III. DISASSEMBLY/ASSEMBLY ..10-20
A. External Covers .................10-21
1. Removing the Front Cover
......................................10-21
2. Removing the Rear Cover
......................................10-24
3. Removing the Right Cover
......................................10-24
4. Removing the Upper Cover
......................................10-25
B. Deck Body..........................10-26
1. Detaching the Deck from the
Copier ...........................10-26
2. Removing the Compartment
......................................10-28
3. Changing the Deck Paper
Size...............................10-30
4. Adjusting the Deck
Registration...................10-31
5. Adjusting the Position of the
Roll................................10-31
C. Drive Mechanisms .............10-32
1. Removing the Deck Pickup
Clutch (CL102) .............10-32
2. Removing the Deck Feeding
Clutch (CL101) .............10-32
3. Removing the Deck Main
Motor (M101) ................10-33
4. Removing the Deck Lifter
Motor (M102) ................10-33
5. Removing the Lifter Cable
(front of the deck)..........10-34
6. Removing the Lifter Cable
(rear of the deck) ..........10-36
7. Routing the Lifter Cable
......................................10-38
D. Feeding System.................10-39
1. Removing the Deck Pickup
Unit................................10-39
2. Removing the Deck Pickup
Roller ............................10-39
3. Orientation of the Deck Pickup
Roller ............................10-40
4. Removing the Deck Pickup/
Feeding Roller ..............10-40
5. Orientation of the Deck
Pickup/Feeding Roller ..10-41
6. Removing the Deck
Separation Roller..........10-41
7. Adjusting the Pressure of the
Deck Separation Roller
......................................10-42
8. Positioning the Deck Pickup
Roller Releasing Solenoid
(SL101) .........................10-43
E. Electrical System ...............10-44
1. Removing the Side Deck
Driver PCB....................10-44
2. Removing the Open Switch
PCB...............................10-44

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CHAPTER 11 SIDE PAPER DECK
I . SELECTING THE SITE ............11-1
II . UNPACKING AND INSTALLATION
..................................................11-4
A. Unpacking............................11-5
B. Mounting the Scanner..........11-8
C. Mounting the Fixing Assembly
.............................................11-9
D. Mounting the Corona Assemblies
...........................................11-10
E. Checking the Developing
Assembly ...........................11-13
F. Mounting the Pick-Up Assembly
...........................................11-14
G. Supplying Toner.................11-15
H. Mounting the ADF..............11-16
I. Checking Images/Operations
(user mode)........................11-17
J. Changing the Size of the Front
Deck (right and left) ...........11-20
III . RELOCATING THE COPIER
................................................11-21
IV . INSTALLING THE CONTROL
CARD V...................................11-22
1. Removing the Control Panel
......................................11-22
2. Before Installing the Control
Card ..............................11-24
3. Installing the Control Card
......................................11-25
V . INSTALLING THE REMOTE
DIAGNOSTIC DEVICE II ........11-27
VI . INSTALLING THE COPY DATA
CONTROLLER-A1..................11-36
A. Setting the Board ...............11-36
B. Installing to the Copier .......11-39
C. Checking the Operation.....11-42
VII .INSTALLING THE CASSETTE
HEATER (FOR 120V MODEL:
CASSETTE HEATER UNIT 15)
................................................11-53
A. Installing to the Copier .......11-53
CHAPTER 12 MAINTENANCE AND SERVICING
I. PERIODICALLY REPLACED
PARTS ......................................12-1
II. DURABLES TABLE ..................12-2
A. Copier ..................................12-2
B. Side Paper Deck..................12-5
III. SCHEDULED SERVICING CHART
..................................................12-6
IV. SCHEDULED SERVICING ITEMS
..................................................12-8
A. Copier ..................................12-8
B. Work Steps ........................12-11
1. Work 1 ..........................12-11
2. Work 2 ..........................12-12
CHAPTER 13 TROBLESHOOTING
I . GUIDE TO TROUBLESHOOTING
TABLES ....................................13-1
A . Image Adjustment Basic
Procedure ............................13-3
B . Points to Note for Scheduled
Servicing ..............................13-6
II . STANDARDS AND ADJUSTMENTS
..................................................13-7
A. Adjusting Images .................13-7
1. Adjusting the Image Position
........................................13-7
2. Adjusting the Left/Right Image
Margin.............................13-8
3. Adjusting the Image Leading
Edge Margin .................13-12
4. Adjusting the Left/Right Non-
Image Width..................13-12
5. Adjusting the Image Leading
......................................13-13

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B. Scanner System ................13-14
1. Replacing the Scanner Drive
Cable ............................13-14
2. Adjusting the Scanner Mirror
Mount............................13-14
3. After Replacing the Scanning
Lamp.............................13-14
C. Image Formation System...13-15
1. Routing the Primary Charging
Assembly Grid Wire......13-15
2. Routing the Charging
Assembly Charging Wires
......................................13-15
3. Mounting the Drum Cleaning
Blade.............................13-15
4. Mounting the Developing
Blade.............................13-15
5. Replacing the Potential
Sensor/Potential Control PCB
......................................13-15
D. Pickup/Feeding System.....13-18
1. Orienting the Deck/Cassette
Pickup Roller.................13-18
2. Orienting the Deck/Cassette
Separation Roller..........13-19
3. Orienting the Deck/Cassette
Pickup Assembly Feeding
Roller ............................13-19
4. Orienting the Manual Feed
Tray/Side Paper Deck Pickup
Roller ............................13-20
5. Orienting the Manual Feed
Pickup Roller.................13-21
6. Orienting the Side Paper Deck
Feeding Roller ..............13-21
7. Adjusting the Pressure of the
Deck/Cassette Separation
Roller ............................13-22
8. Adjusting the Pressure of the
Manual Tray Pickup/Feeding
Roller ............................13-23
9. Mounting the Solenoids
......................................13-24
9-1.Position of the Fixing Inlet
Guide Solenoid (SL1) ...13-25
9-2.Position of the Fixing Cleaning
Belt Solenoid (SL2).......13-26
9-3.Position of the Delivery
Flapper Solenoid (SL3)
......................................13-27
9-4.Position of the Fixing/Feeding
Unit Locking Solenoid (SL4)
......................................13-27
9-5.Position of the Multifeeder
Pickup Latching Solenoid
(SL6) .............................13-28
9-6.Position of the Deck (right)
Pickup Solenoid (SL7)..13-29
9-7.Position of the Deck (left)
Pickup Solenoid (SL8)..13-30
9-8.Position of the Cassette 3/4
Pickup Solenoid (SL9/10)
......................................13-31
9-9.Position of the Side Paper
Deck Pickup Roller Releasing
Solenoid........................13-32
10. Routing the Manual Feed Tray
Assembly Side Guide Timing
Belt................................13-32
11. Routing the Drive Belt...13-33
E. Fixing System ....................13-34
1. Point to Note When Mounting
the Fixing Heater ..........13-34
2. Position of the Fixing
Assembly Inlet Guide....13-34
3. Adjusting the Lower Roller
Pressure (nip) ...............13-36
F. Laser Exposure System.....13-37
1 After Replacing the Laser Unit
......................................13-37
2 Checking the Laser Power
......................................13-38
G. Electrical Parts...................13-41
1 After Replacing the CCD Unit
......................................13-41
2 After Replacing the Image
Processor PCB .............13-42
3 After Replacing the MFC PCB
......................................13-43
4. After Replacing the Hard Disk
......................................13-44
5. After Replacing the DC
Controller PCB..............13-45
6. Checking the Surface
Potential Control System
......................................13-45
7. Checking the Potential
System..........................13-51
8. Potential Control System
Conversion Table .........13-53
9. Checking the Environment
Sensor ..........................13-57
10. Checking the
Photointerrupters ..........13-58
III . TROUBLESHOOTING IMAGE
FAULTS ..................................13-63
A. Making Initial Checks.........13-63
1. Checking the Site .........13-63
2. Checking the Originals
......................................13-63

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3. Copyboard Cover, Copyboard
Glass, and Standard White
Plate..............................13-64
4. Checking the Charging
Assemblies ...................13-64
5. Checking the Developing
Assembly ......................13-64
6. Checking Papers ..........13-64
7. Checking the Periodically
Replace Parts ...............13-64
8. Others ...........................13-64
B. Sample Image Faults.........13-65
C. Troubleshooting Image Faults
...........................................13-67
1. The copy is too light (halftone
area) .............................13-67
2. The copy is too light (solid
black area). ...................13-68
3. The copy is too light (entire
area, considerably). ......13-68
4. The copy has uneven density
(darker at front).............13-69
5. The copy has uneven density
(lighter at front). ............13-69
6. The copy is foggy (entire
area). ............................13-70
7. The copy is foggy (vertical).
......................................13-71
8. The copy has black lines
(feeding direction, fuzzy,
thick). ............................13-71
9. The copy has black lines
(feeding direction, fine).
......................................13-72
10. The copy has white spots
(vertical). .......................13-73
11. The copy has white lines
(vertical). .......................13-73
12. The copy has white spots
(horizontal)....................13-74
13. The back of the copy is soiled
......................................13-75
14. The copy has poor fixing.
......................................13-76
15. The copy has a displaced
leading edge (appreciably
excess margin). ............13-77
16. The copy has a displaced
leading edge (excess margin).
......................................13-77
17. The copy has a displaced
leading edge (no margin).
......................................13-77
18. The copy has a blurred image.
......................................13-78
19. The copy is foggy (horizontal).
......................................13-79
20. The copy has poor sharpness.
......................................13-80
21. The copy is blank..........13-81
22. The copy is solid black.
......................................13-82
IV . TROUBLESHOOTING
MALFUNCTIONS....................13-82
A. Troubleshooting Malfunctions
...........................................13-82
1. E000 .............................13-82
2. E001 .............................13-83
3. E002 .............................13-83
4. E003 .............................13-83
5. E004 .............................13-84
6. E005 .............................13-84
7. E010 .............................13-84
8. E012 .............................13-85
9. E013 .............................13-85
10. E014 .............................13-86
11. E015 .............................13-86
12. E019 .............................13-86
13. E020 .............................13-87
14. E025 .............................13-87
15. E030 .............................13-88
16. E031 .............................13-88
17. E032 .............................13-88
18. E043 .............................13-89
19. E051 .............................13-89
20. E060 .............................13-90
21. E063 .............................13-90
22. E065 .............................13-91
23. E066 .............................13-91
24. E067 .............................13-91
25. E068 .............................13-92
26. E069 .............................13-92
27. E100 .............................13-92
28. E102 .............................13-93
29. E110 .............................13-93
30. E111 .............................13-93
31. E121 .............................13-94
32. E202 .............................13-94
33. E204 .............................13-94
34. E211 .............................13-95
35. E215 .............................13-95
36. E218 .............................13-95
37. E219 .............................13-95
38. E220 .............................13-95
39. E222 .............................13-95
40. E226 .............................13-96
41. E240 .............................13-96
42. E241 .............................13-96
43. E243 .............................13-96
44. E251 .............................13-97