Canon IR2200, IR2800, IR3300 E019

2001 CANON INC. 2000 2000 2000 2000 CANON iR2200/iR2800/iR3300 REV.0 MAR. 2001

CHAPTER 6 SELF DIAGNOSIS

6-9 T

E019

0000 The waste toner case is full of waste toner.

Main cause The waste toner case is full. The waste toner case full detection mechanism

is soiled. The waste toner sensor is faulty. The DC controller PCB is faulty.

Caution To clear the error, dispose of the waste toner, and turn off and then on the

main power switch.

Action If the error is still indicated after disposing of the waste toner, perform the

following:

1. Waste toner case full detection mechanism

Remove the waste toner case, and turn off and then on the main power

switch. Is 'E019' absent?

YES: The waste toner case full detection assembly is soiled with toner.

Clean both inside and outside of area A of the waste toner case

with alcohol. Make sure that no dirt remains inside and outside the

area around the round recess.

2. Waste toner full sensor, DC Controller PCB

Try replacing the waste toner case full sensor. Is the problem corrected?

YES: End.

NO: Replace the DC controller PCB.

Contents

Main Page 1 Symbols Used 2 Outline of the Manual Page Page Page CHAPTER 1 GENERAL DESCRIPTION CHAPTER 2 MAIN CONTROLLER CHAPTER 3 INSTALLATION Page 1-1 S 1 Specifications T01-101-02 1.1 Main Body 1.1.1 Type T01-101-01 1.1.3 Functions T01-101-03 1-3 S T01-101-04 1-4 S T01-101-05 1-5 S 1.1.4 Others T01-101-06 1-6 S Delivery by copier, Auto paper select ON, Auto density, Non-sort, Cassette T01-101-07 1-7 S 1-8 S 1.2 Side Paper Deck-L1 T01-102-01 2 Names of Parts 2.1 External View Page 1-11 S 2.2 Cross Section F01-202-01 Page CHAPTER 1 GENERAL DESCRIPTION 1-13 S 3 System Configuration Fixing Separation Transfer F01-301-01 3.2 Outline of the Electrical Circuitry F01-302-01 3.2.1 Construction of the Electrical Circuit CHAPTER 1 GENERAL DESCRIPTION 1-15 S 3.3 Inputs to and Outputs from the Major PCBs F01-303-01 3.3.1 Wiring Diagram of the Major PCBs Note: The in the diagram indicates connection between PCBs, NOT the flow of signals. 3.4 Configuration with Accessories 3.4.1 Accessories for Original/Paper Feeding 1-17 S 3.4.2 Accessory Boards F01-304-02 Page 1 Basic Construction 1.1 Functional Construction 1.2 Outline of the Electrical Circuitry 1.2.1 Outline 1.2.2 Main Controller PCB 1.2.3 HDD 2-3 S 1.3 Start-Up Sequence 1.3.1 Outline 1.3.2 Start-Up Sequence Page CHAPTER 2 MAIN CONTROLLER 2-7 S 2 Digital Image Processing F02-201-01 2.2 Input Image Processing 2.2.1 Image Data from the Reader Unit 2.2.2 Enlargement/Reduction (main scanning direction) 2.2.3 Edge Emphasis 2.2.4 Editing 2.3 Image Memory Control 2.4 Output Image Processing 2.4.1 Smoothing 2.4.2 Binary-Binary Density Conversion (read image output only) 3 Soft Counters Page Page Page 4 Controlling the Power Supply 4.2 Power Supply Modes 4.3 Standby Mode (normal operation) 4.4 Sleep Mode 1 4.4.1 Shift from Standby Mode to Sleep Mode 1 4.4.2 Shift from Sleep Mode 1 to Standby Mode 4.5 Sleep Mode 2 4.5.1 Shift from Standby Mode to Sleep Mode 2 4.5.2 Shift from Sleep Mode 2 to Standby Mode 4.5.3 Shift from Sleep Mode 2 to Sleep Mode 1 4.6 Turning Off the Power 5 New Functions F02-501-01 5.1 Hard Disk Spool Network PCB Main controller PCB 5.2 SMB Printing iR2200 iR2800 iR3300 5.3 LPD Banner Page 1 Selecting the Site of Installation Page 2 Unpacking and Installation 2.1 Before Starting the Work 2.2 Unpacking and Removing the Fixing Materials Page 2.3 Mounting the Scanner 2.4 Removing the Dummy Drum 2.5 Supplying the Toner Page Page 2.6 Mounting the Drum Unit Page 2.7 Stirring the Toner 2.8 Setting the Cassette Page Page 2.9 Checking the Images/Operations Page 2.10 Connecting to the Network 2.11 Checking the Network Connection 2.11.1 Using the PING Function 2.11.2 Making a Check Using a Remote Host Address 2.12 Troubleshooting the Network 2.12.1 Checking the Connection of the Network Cable 2.12.2 Making a Check Using a Loop-Back Address 2.12.3 Making a Check Using a Local Host Address 3 Relocating the Machine 3.1 Preparing for Relocation 3.2 Lifting the Machine Off the Pedestal 4 Installing the Card Reader-C1 Page Page 5 Installing the Document Tray-D2 6 Replacing the Drum Unit Page Page Page Page CHAPTER 1 BASIC OPERATION CHAPTER 2 ORIGINAL EXPOSURE SYSTEM CHAPTER 3 IMAGE PROCESSING SYSTEM Page 1 Outline of Electrical Circuitry 1.2 Reader Controller PCB 2 Basic Sequence of Operations 2.1 Basic Sequence of Operations at Power-On 2.2 Basic Sequence of Operations in Book Mode 1-3 R 3 Inputs to and Outputs from the Major PCBs F01-301-01 3.1 Wiring of Major PCBs Page Page Page CHAPTER 2 ORIGINAL EXPOSURE SYSTEM 2-3 R 1.2 Sequence of Operations (original exposure) F02-102-02 1.2.1 Book Mode, 1 Original, Copyboard Closed *1: original size detection.*2: shading correction. CHAPTER 2 ORIGINAL EXPOSURE SYSTEM 1.2.2 Book Mode, 1 Original, Copyboard Cover Open F02-102-04 *1: original size detection.*2: shading correction. F02-102-03 1.3 Enlargement/Reduction (zoom) 1.3.1 Changing the Reproduction Ratio in Main Scanning Direction 1.3.2 Changing the Reproduction Ratio in Sub Scanning Direction 2 Scanner Drive System 2.2 Controlling the Scanner Motor 2.2.1 Controlling the Motor When Scanning an Image 2.2.2 Reversing the Scanner After Scanning in Main Reading Direction 3 Controlling the Scanning Lamp (LA2) 3.2 Scanning Lamp 3.3 Turning On/Off the Lamp 3.4 Detecting an Error 4 Detecting the Size of Originals 4.2 Points of Detection 4.3 Outline of Detection 4.4 Outline of Detection Operation 4.4.1 Book Mode, 1 Original, Copyboard Cover Open 4.4.2 Book Mode, 1 Original, Copyboard Cover Close Page Page 5.1 Exposure Lamp 5.1.1 Removing the Exposure Lamp 5.1.2 After Replacing the Scanning Lamp 5.2 Scanner Drive Assembly 5.2.1 Removing the Scanner Motor 5.2.2 Mounting the Motor Unit 5.2.3 Removing the Scanner Drive Cable 5.2.4 Routing the Scanner Drive Cable 5.2.5 Adjusting the Position of the No. 1/No. 2 Mirror Base Page 5.3 Sensors 5.3.1 Removing the Original Detection Unit 5.3.2 Removing the HP Sensor 5.3.3 Removing the Original Cover Sensor 5.4 PCBs 5.4.1 Removing the Inverter PCB Page Page 2 Analog Image Processing 2.2 Dr iving the CCD 2.3 Gain Correction and Offset Correction of the CCD Output 2.4 A/D Conversion of the CCD Output 3 Digital Image Processing 3.2 Shading Correction 3.2.1 Outline 3.2.2 Shading Adjustment 3.2.3 Shading Correction 3.2.4 Edge Gain Correction (ADF in use) 3.3 Auto Density Adjustment (AE) 3.3.1 Outline 3.3.2 ABC Circuit 3.4 Related Service Mode 4 Disassembly and Assembly 4.1 External Covers 4.1.1 External Covers 4.1.2 Removing the Reader Right Cover 4.1.3 Removing the Copyboard Glass 4.1.4 After Mounting the Copyboard Glass 4.2 CCDs 4.2.1 Removing the CCD Unit 4.2.2 Points to Note When Replacing the CCD Unit 4.3 Frames 4.3.1 Removing the Left ADF Base Unit 4.3.2 Removing the Reader Upper Frame 4.3.3 Mounting the Reader Upper Frame 4.4 PCBs Page CHAPTER 1 INTRODUCTION CHAPTER 2 SEQUENCE OF OPERATIONS CHAPTER 3 LASER EXPOSURE SYSTEM CHAPTER 4 IMAGE FORMATION SYSTEM Page CHAPTER 5 PICKUP/FEEDING SYSTEM CHAPTER 6 FIXING SYSTEM CHAPTER 7 EXTERNALS AND CONTROLS CHAPTER 8 PAPER DECK-L1 CHAPTER 9 CASSETTE FEEDING UNIT-W1 CHAPTER 10 INNER 2WAY TRAY-A1 CHAPTER 11 ENVELOPE FEEDER ATTACHMENT-B1 Page 1 Safety 1.1 Safety of Laser Light 1.2 CDRH Ordinances Page 1.3 Handling the Laser System 1.4 Safety of Toner 2 Image Formation System Page Page 2-1 P 1 Basic Operations F02-101-01 1.1 Functional Construction CHAPTER 2 SEQUENCE OF OPERATIONS 2-2 P 1.2 Outline for the Electrical Circuitry 1.2.1 Outline 1.2.2 DC Controller PCB T02-102-01 Control Functions 2-3 P 1.3 Basic Sequence of Operations 1.3.1 Basic Sequence of Operations at Power-On If the reading of the main thermistor (TH1) is less than 100C If the reading of the main thermistor (TH1) is 100C or more. *1: The scanning lamp goes OFF at the end of shading. T02-103-01 2-4 P T02-103-01 2-5 P 1.4 Controlling the Main Motor (M2) F02-104-01 Control Circuit Block Diagram 1.4.1 Outline CHAPTER 2 SEQUENCE OF OPERATIONS 2-6 P 1.5 Inputs to and Outputs from the Major PCBs F02-105-01 1.5.1 Wiring Diagram of the Major PCBs Page Page Page 1.2 Sequence of Operations (laser exposure system) 2 Generating Sync Signals 2.2 Flow of Sync signals 3 Laser Driver Circuit 3.1 Controlling the Laser Unit CHAPTER 3 LASER EXPOSURE SYSTEM 3-6 P F03-301-01 4 Controlling the Laser Scanner Motor Page 5.1 Laser Scanner Assembly 5.1.1 Removing the Laser Unit Page 4-1 P 1 Outline of Processes T04-101-01 T04-101-01 shows the functions of and the methods used in the image formation system: Page 4-3 P 1.2 Basic Sequence of Operations (image formation system) F04-102-01 1 Original, 2 Prints 4-4 P 2 Controlling the Primary Charging Roller Bias PW-CPU DC controller PCB Memo F04-201-01 2.2 Turning On/Off the Bias 2.2.1 DC Bias 2.2.2 AC Bias 2.3 Controlling the Current Voltage/Current to a Specific Level 2.3.1 Controlling the DC Bias to a Specific Level 2.4 Temperature Correction of the DC Bias 2.5 Humidity Correction of the AC Bias 2.6 Controlling the Detection of the Photosensitive Drum Re- sistance (APVC control) Page 4-9 P 3 Controlling the Transfer Charging Roller Bias PW-CPU DC controller PCB F04-301-01 Composite power supply PCB 3.2 Turning On/Off the Bias 3.3 Controlling the Detection of the Transfer Charging Roller Resistance (ATVC control) 3.4 Controlling the Output by Operating Mode 3.4.1 Types of Modes 4-12 P F04-304-01 3.4.2 Turning On/Off the Cleaning Bias 3.5 Controlling the Output 4-14 P 4 Controlling the Separation Static Eliminator Bias PW-CPU DC controller PCB F04-401-01 Composite power supply PCB Page 4-16 P 5 Controlling the Transfer Guide Bias F04-501-01 5.1 Transfer Guide Bias 6 Primary Charging Roller Cleaning Mechanism 6.1 Outline 7 Developing Assembly 7.1 Outline 4-19 P 7.2 Controlling the Developing Bias PW-CPU DC controller PCB Memo 7.2.1 Outline 7.2.2 Controlling the DC Developing Bias 7.2.3 Controlling the AC Developing Bias 7.2.4 Controlling the Level of the DC Developing Bias 4-21 P 7.3 Detecting the Level of Toner F04-703-01 Check point NG 8 Drum Cleaner 8.1 Outline 4-23 P F04-801-02 8.2 Monitoring the Waste Toner Case 8.3 Locking of the Waste Toner Feedscrew 9 Disassembly and Assembly 9.1 Pre-Exposure Lamp Unit 9.1.1 Removing the Pre-Exposure Lamp Unit 9.2 Photosensitive Drum 9.2.1 Removing the Drum Unit 9.2.2 Cleaning the Photosensitive Drum 9.3 Transfer Charging Roller 9.3.1 Removing the Transfer Charging Roller 9.4 Charging Roller Solenoid 9.4.1 Removing the Charging Roller Solenoid (SL6) Page 9.5 Developing Assembly 9.5.1 Removing the Developing Assembly 9.5.2 Removing the Grip Assembly 9.5.3 Removing the Toner Sensor 9.5.4 Removing the Developing Assembly Upper Cover 9.5.5 Removing the Blade Base Unit 9.5.6 Removing the Developing Cylinder Page Page 9.5.7 Positioning the Developing Assembly Magnetic Seal 9.5.8 Mounting the Developing Assembly Blade A A 9.6 Removing the Paper Lint 9.6.1 Removing the Paper Lint 9.6.2 When Removing the Paper Lint 9.7 Waste Toner Case 9.7.1 Replacing the Waste Toner Case 9.7.2 Cleaning the Waste Toner Case Page 5-1 P 1.1 Specifications and Construction T05-101-01 T05-101-01 shows the major functions and the construction of the pickup/feeding system: 5-2 P 1.2 Arrangement of Rollers F05-101-01 The following rollers are mainly used to move paper: 1.3 Arrangement of Motors, Clutches, and Solenoids 5-4 P 1.4 Arrangement of Sensors T05-102-01 F05-103-01 The following sensors are used to monitor the movement of paper: 2.1 Sequence of Operations (jam detection) 2.1.1 Delay Jam Page 2.1.2 Stationary Jam 2.1.3 Jam History 5-8 P 3 Pickup Assembly 3.1 Pickup Control System F05-301-01 3.2 Outline 3.3 Sequence of Operations (pickup) 3.4 Operation of the Cassette Lifter 3.4.1 Operation of the Lifter During Printing 3.4.2 Releasing the Lifter 3.5 Cassette Pickup Operation 3.5.1 Rotating the Pickup Roller 3.5.2 Switching the Pickup Roller Drive 3.5.3 Pickup Roller Shaft Reference Page 3.6 Moving Up/Down the Pickup Roller 3.7 Pickup Retry Operation 3.7.1 Conditions for Detecting a Delay 3.7.2 Paper Retraction 3.8 Operation Other Than Cassette Pickup (standby) 3.8.1 Moving Up the Lifter/Moving Down the Pickup Roller Shaft (cassette slid in) Page Page Page 3.9 Detecting the Level of Paper Page 4 Identifying the Size of Paper 4.1 Identifying the Size 4.2 AB-/Inch-Setting Switch 4.3 Paper Size 5-26 P 4.4 Paper Size List T05-403-01 List of Paper Sizes 5 Multifeeder 5.1 Outline 5.2 Identifying the Size of Paper in the Multifeeder 5.2.1 Detecting the Width of Paper 5.2.2 Rear/Front Registration 5.2.3 Identifying the Length of Paper 6 Controlling the Registration Roller 6.1 Outline 6.2 Control System 7 Double-Sided Printing 7.1 Through-Path Operation 7.2 Outline of Operations 5-32 P F05-703-02 7.3 Detecting the Horizontal Registration Position 7.3.1 Outline 7.3.2 Operation 5-35 P 8 Controlling the Pickup Assembly Motor F05-801-01 8.1 Pickup Assembly Motor T05-801-01 9 Disassembly and Assembly 9.1 Pickup Assembly 9.1.1 Removing the Pickup Assembly 9.1.2 Removing the Pickup/Feeding/Separation Rollers 9.1.3 Removing the Pickup Solenoid 9.1.4 Removing the Frame Lid A 9.1.5 Removing the Pickup Motor 9.1.6 Remove the Vertical Path Cultch 9.1.7 Removing the Horizontal Registration Sensor Shift Motor 9.1.8 Checking the Image Rear Front Position 9.1.9 Adjusting the Cassette Rear Front Registration Page 9.2 Multifeeder Tray Assembly 9.2.1 Removing the Multifeeder Tray Assembly 9.2.2 Removing the Pickup Cover 9.2.3 Removing the Multifeeder Tray Pickup Roller 9.2.4 Removing the Separation Pad 9.2.5 Attaching the Timing Belt of the Multifeeder Tray 9.2.6 Checking the Image Rear Front Position 9.2.7 Adjusting the Registration for the Multifeeder Rear Front Page 9.3 Feeding Assembly 9.3.1 Removing the Feeding Assembly 9.3.2 Mounting the Feeding Assembly 9.4 Registration Roller Assembly 9.4.1 Removing the Registration Roller Page Page Page 6-1 P The fixing system has the following major functions: T06-101-01 CHAPTER 6 FIXING SYSTEM 6-2 P The following diagram shows the major components of the fixing system: F06-101-01 6-3 P F06-101-02 T06-101-02 2 Fixing Drive System 2.2 Controlling the Fixing Roller Drive 2.3 Controlling the Fixing Film Speed 6-6 P 3 Controlling the Fixing Temperature F06-301-01 6-7 P 3.2 Temperature Control T06-302-01 The machines fixing temperature is controlled using the following means: 3.2.1 Fixing Temperature Control 3.3 Detecting Errors Page 4 Disassembly and Assembly 4.1 Fixing Assembly 4.1.1 Removing the Delivery Cover 4.1.2 Removing the Riser Guide 4.1.3 Removing the Fixing Assembly 4.1.4 Removing the Fixing Stepped Gear 4.1.5 Removing the Fixing Film Unit 4.1.6 Removing the Roller Bushing, Conducting Rubber, and Fixing Roller Page 4.1.7 Removing the Cleaning Roller Unit 4.1.8 Removing the Lower Guide Ribs 4.1.9 Removing the Fixing Drive Unit 4.1.10 Mounting the Locking Cam Unit Page 1 Control Panel 2 Fans 2.1 Arrangement, Functions, and Error Codes Page 7-4 P 2.2 Operation F07-202-02 2.2.1 2-Speed Control F07-202-01 2.2.2 Sequence of Operations 3 Power Supply 3.1 Power Supply 3.1.1 Outline CHAPTER 7 EXTERNALS AND CONTROLS 7-6 P The machine distributes power as follows: M F07-301-01 7-7 P 3.1.2 Power Outputs F07-301-02 7-8 P 3.2 Rated Outputs of the Main Power Supply PCB T07-302-01 3.3 Rated Output of the Composite Power Supply PCB T07-303-01 7-9 P 3.4 Rated Outputs of the Accessories Power Supply PCB T07-304-01 3.5 Protective Functions 4 Others 4.1 Silent Mode Page 5.1 External Covers 5.1.1 Removing the Front Cover 5.1.2 Removing the Inside Cover 5.1.3 Removing the Support Cover 5.2 Control Panel 5.2.1 Removing the Control Panel 5.3 PCBs 5.3.1 Removing the DC Controller PCB 5.3.2 Points to Note When Replacing the DC Controller PCB 5.3.3 Removing the Controller Cover 5.3.4 Removing the HDD 5.3.5 Removing the HDD Unit 5.3.6 Removing the Controller Box Unit 5.3.7 Removing the Reader Controller PCB 5.3.8 When Replacing the Reader Controller PCB 5.3.9 Removing the Main Controller PCB 5.3.10When Replacing the Main Controller PCB 5.3.11Removing the Composite Power Supply 5.3.12Removing the Accessories Power Supply 5.3.13Removing the Main Power Supply Page 1.1 Pickup 1.1.1 Outline 1.1.2 Pickup Operation 8-2 P F08-101-01 8-3 P 1.1.3 Sequence of Pickup Operations (deck) F08-101-02 1.2 Detecting Paper in the Deck 1.2.1 Detecting the Presence/Absence of Paper 1.2.2 Switching the Deck Paper Size 1.2.3 Detecting the Level of Paper in the Deck 1.3 Deck Lifter 1.3.1 Detecting the Presence/Absence of Paper Page 1.3.2 Indicating the Level of Paper (deck front cover) 8-9 P 1.4 Opening/Closing of the Compartment ( ) F08-104-01 1.4.1 Opening/Closing of the Compartment 8-10 P 1.4.2 Sequence of Operations (opening/closing of the compartment) F08-104-02 1.5 Controlling the Deck Motor 1.5.1 Controlling the Deck Main Motor (M1D) 1.5.2 Controlling the Deck Lifter Motor (M2D) 8-13 P F08-105-02 Page Page 3 Disassembly and Assembly 3.1 External Covers 3.1.1 Sliding Out the Compartment 3.1.2 Removing the Front Cover Page 3.1.3 Removing the Rear Cover 3.1.4 Removing the Right Cover 3.1.5 Removing the Front Upper Cover 3.1.6 Removing the Upper Cover 3.2 Paper Deck Body 3.2.1 Removing the Deck from the Host Machine [1] 3.2.2 Removing the Compartment Page 3.2.3 Changing the Deck Paper Size 3.2.4 After Changing the Deck Paper Size 3.2.5 Checking the Image Rear Front Position 3.2.6 Adjusting the Cassette Rear Front Registration 3.2.7 Adjusting the Registration for the Deck 3.2.8 Adjusting the Position of the Support Member 3.3 Drive System 3.3.1 Removing the Deck Pickup Clutch (CL2D) 3.3.2 Removing the Deck Feeding Clutch (CL1D) 3.3.3 Removing the Deck Main Motor (M1D) 3.3.4 Removing the Deck Lifter Motor (M2D) 3.3.5 Removing the Lifter Cable (deck front) Page 3.3.6 Removing the Lifter Cable (deck rear) Page 3.3.7 Routing the Lifter Cable 3.4 Feeding Mechanism 3.4.1 Removing the Deck Pickup Unit 3.4.2 Removing the Deck Pickup Roller 3.4.3 Mounting the Deck Pickup Roller 3.4.4 Removing the Deck Pickup/Feeding Roller 3.4.5 Orientation of the Deck Pickup/Feeding Roller 3.4.6 Removing the Deck Separation Roller 3.4.7 Adjusting the Deck Separation Roller Pressure 3.4.8 Position of the Deck Pickup Roller Releasing Solenoid (SL1D) 3.5 Electrical Mechanisms 3.5.1 Removing the Deck Drive PCB 3.5.2 Removing the Open Switch PCB Page 9-1 P 1.1 Specifications and Construction T09-101-01 T09-101-01 shows the major functions and the construction of the Cassette Feeding unit- W1: 9-2 P 1.2 Arrangement of Rollers F09-102-01 The following rollers are used to move paper inside the machine: 1.3 Arrangement of Motors, Clutches, and Solenoids 9-4 P 1.4 Arrangement of Sensors F09-104-01 The following sensors are used to monitor the movement of paper: 2.1 Sequence of Jam Detection 9-6 P 3 Pickup Assembly F09-301-01 3.1 Pickup Control System Page 4 Identifying the Size of Paper Page 5.1 External Covers 5.1.1 Removing the Pickup Cover 5.2 Pickup Assembly 5.2.1 Removing the Pickup Assembly Page 5.3 PCBs 5.3.1 Removing the Cassette Size Detection Unit 5.3.2 Removing the Pedestal Controller PCB 5.4 Drive Mechanisms 5.4.1 Removing the Main Motor Drive Unit 5.4.2 Removing the Pedestal Main Motor 5.4.3 Mounting the Pedestal Main Motor Page 1 Specifications 1.1 Type 1.2 Cross Section CHAPTER 10 INNER 2 WAY TRAY-A1 10-3 P 2 Outline F10-201-01 2.1 Arrangement of Rollers and Sensors 2.2 Delivery to the No. 2 Delivery Slot 2.3 Delivery to the No. 3 Delivery Slot Page CHAPTER 10 INNER 2 WAY TRAY-A1 10-7 P 2.4 Detecting Jams F10-204-01 2.4.1 Arrangement of Sensors The following shows the sensor used to detect jams in the Inner 2-Way-A1. 2.4.2 Delay Jam 2.4.3 Stationary Jam 2.4.4 Stationary Jam at Power-On 2.4.5 Door Open Jam 3 Disassembly and Assembly 3.1 External Covers 3.1.1 Removing the Inner 2-Way Delivery Unit Page Page Page Page 1 Envelope Feeder Attachment-B1 1.1.1 Host Machine 1.1.2 Names of Parts 11-2 P 1.2 Specifications T11-102-01 1.2.1 Envelope Cassette 1.2.2 Envelopes 1.2.3 Guaranteed Image Area 1.3 Pickup 1.3.1 Pickup Operations Page 5 Making Adjustments 5.1 Outline 5.1.1 Envelopes and Type of Spring 5.2 Replacing the Spring 5.2.1 Replacing the Spring 5.3 Changing the Size 5.3.1 Changing the Size Page Page CHAPTER 1 MAINTENANCE AND INSPECTION IMAGE ADJUSTMENT BASIC PROCEDURE CHAPTER 2 CHAPTER 3 STANDARDS AND ADJUSTMENTS CHAPTER 4 TROUBLESHOOTING IMAGE FAULTS/ MALFUNCTIONS Page CHAPTER 5 SURVICE MODE CHAPTER 6 SELF DIAGNOSIS CHAPTER 7 UPGRADING APPENDIX Page 1 Periodically Replaced Parts 2 Consumables and Durables 2.1 Checking the Time of Replacement 2.2 Reader Unit 2.3 Printer Unit 2.4 Side Paper Deck 2.5 Cassette Feeding Unit 2.6 Inner 2-Way Tray-A1 3 Periodical Servicing Procedure Page 1-6 T 4 Scheduled Servicing Chart T01-401-01 Do not use solvents or oils not indicated herein. 4.1 Reader Unit 1-7 T 4.2 Printer Unit CHAPTER 1 MAINTENANCE AND INSPECTION 1-8 T 5 Points to Note for Scheduled Servicing F01-500-01 6 Cleaning the Bottom of the Developing Assembly 6.1 Cleaning the Bottom of the Developing Assembly Page 2-1 T CHAPTER 2 IMAGE ADJUSTMENT BASIC PROCEDURE Making Initial Checks 1 2Checking the Scanner Side 2-2 T CHAPTER 2 IMAGE ADJUSTMENT BASIC PROCEDURE 3Checking the Printer Side (1/3) 4Checking the Printer Side (2/3) 5Checking the Printer Side (3/3) Page 1 Image Adjustments 1.1 Standards of Image Position 1.2 Checking the Image Position 1.3 Adjusting Left/Right lamge Margin 1.3.1 Adjusting the Registration for the Cassette Rear Front 1.3.2 Adjusting the Registration for the Multifeeder Rear Front 1.3.4 Duplex Feeding Unit 1.4 Adjusting the Image Leading Edge Margin 1.5 Adjusting the Left/Right Non-Image Width 1.6 Adjusting the Leading Edge Non-Image Width 2 Scanning System 2.1 After Replacing the Scanning Lamp 2.2 Mounting the Motor Unit 2.3 Routing the Scanner Drive Cable 2.4 Adjusting the Position of the No. 1/No. 2 Mirror Base Page 2.5 Mounting the Copyboard Glass 2.6 Mounting the Reader Upper Frame 2.7 Points to Note When Replacing the CCD Unit 2.8 When Replacing the Reader Controller PCB 3 Image Formation System 3.1 Positioning the Developing Assembly Magnetic Seal A A 3.3 Removing the Paper Lint 3.4 Cleaning the Waste Toner Case 4 Fixing System 4.1 Mounting the Locking Cam Unit 5 Paper Deck 5.1 Mounting the Front Cover 5.2 Adjusting the Paper Level Indicator 5.3 Adjusting the Position of the Support Member 5.4 Mounting the Deck Pickup Roller 5.5 Removing the Deck Pickup/Feeding Roller 5.6 Orientation of the Deck Pickup/Feeding Roller 5.7 Adjusting the Deck Separation Roller Pressure 5.8 Position of the Deck Pickup Roller Releasing Solenoid (SL1D) 5.9 Adjusting the Height of the Side Member 5.9.1 Before Making Adjustments 5.9.2 Making Adjustments 6 Cassette Feeding Unit-W1 6.1 Mounting the Pedestal Main Motor 7 Envelope Feeder Attachment 7.1 Envelopes and Type of Spring 7.2 Replacing the Spring 7.2.1 Replacing the Spring 7.3 Changing the Size 7.3.1 Changing the Size Page Page 1 Making Initial Checks 1.1 Checking the Site of Installation 1.2 Checking the Originals 1.3 Checking the ADF Platen, Copyboard cover, and Copyboard glass (standard white plate) Page 1.9 Others Page Page 3 Troubleshooting Image Faults 3.1 The copy is too light (halftone area only). 3.2 The copy is too light (including solid black). Page 3.3 The copy is too light (entire face, considerable). Page Page 3.6 The copy is foggy (entire face). 3.7 The copy is foggy (vertical). 3.8 The copy has a black line (vertical, fuzzy, thick). 3.9 The copy has a black line (vertical, fine). 3.10 The copy has a white spot (vertical). 3.11 The copy has a white line (vertical). 3.12 The copy has a white spot (horizontal). 3.13 The back of the copy is soiled/Soiled edge. 3.14 The copy has a fixing fault. Page 3.18 The copy is blurred. 3.19 The copy is foggy (horizontal). 3.20 The copy has inadequate sharpness. 3.21 The copy is completely blank. Page 3.22 The copy is completely black. 3.23 The copy has a block/white dot after replacement of the drum unit. 3.24 The copy has a black line (stream reading). 4 Troubleshooting Malfunctions 4.1 Power Supply System 4.1.1 The AC power is absent. 4.1.2 The DC power is absent. 4.2 Printer Unit 4.2.1 Pickup fails. 4.2.2 The lifter fails to move up (pickup from the cassette). 4.2.3 The vertical path roller fails to rotate. 4.2.4 The registration roller fails to rotate. 4.2.5 Pickup from the multifeeder tray fails (i.e., the pickup roller fails to ro- tate). 4.2.6 Pickup from the multifeeder tray fails (i.e., the multifeeder holding plate fails to move up). 4.2.7 The photosensitive drum fails to rotate. 4.2.8 The pre-exposure lamp fails to go ON. 4.3 Reader Unit 4.3.1 The No. 1 mirror base fails to move. 4.3.2 The scanning lamp fails to go ON. 4.4 Message Indication 4.4.1 The Add Toner message fails to go OFF. 4.4.2 The Control Card Set message fails to go OFF (when no card reader is installed). 4.4.3 The Add Paper message fails to go OFF. 4.4.4 The Close the Front Cover message fails to go OFF. 4.5 Paper Deck 4.5.1 Pickup fails. 4.5.2 The deck lifter fails to move up. 5 Troubleshooting Feeding Faults 5.1 Paper Jams 5.1.1 Pickup Assembly 5.1.2 Separation/Feeding Assembly 5.1.3 Fixing/Delivery Assembly, Duplex Reversing Assembly 5.1.4 Duplex Feeding Assembly 5.2 Faulty Feeding 5.2.1 Double Feeding 5.2.2 Wrinkles 6 Outline of Electrical Components 6.1 Introduction 6.1.1 Guide to the List 6.1.2 Checking the Photointerrupters 4-48 T 6.2 E201 (reader unit/printer unit) F04-602-01 6.2.1 Clutches 6.2.2 Solenoids, Switches 4-49 T 6.2.1 Clutches The reader unit does not have nay clutch. 6.2.2 Solenoids, Switches The reader unit does not have any solenoid or switch. 4-50 T 6.2.3 Motors (1/2) F04-602-02 4-51 T 6.2.3 Motors (1/2) Printer Unit (1/2) 4-52 T 6.2.3 Motors (2/2) F04-602-02 4-53 T 6.2.3 Motors (2/2) Printer Unit (2/2) 6.2.4 Fans 4-55 T 6.2.4 Fans 4-56 T 6.2.5 Sensors (1/3) 4-57 T 6.2.5 Sensors (1/3) Printer Unit (1/3) 4-58 T 6.2.5 Sensors (2/3) 4-59 T 6.2.5 Sensors (2/3) Printer Unit (2/3) 4-60 T 6.2.5 Sensors (3/3) 4-61 T 6.2.5 Sensors (3/3) 4-62 T 6.2.6 Lamps, Heaters, and Others F04-602-05 4-63 T 6.2.6 Lamps, Heaters, and Others 4-64 T 6.2.7 PCBs F04-602-06 4-65 T 6.3 Side Paper Deck-L1 4-67 T 6.3.1 Clutches 6.3.2 Solenoids and Switches 6.3.3 Motors 4-68 T 6.3.4 Sensors 6.3.5 PCBs F04-603-02 4-69 T 6.3.4 Sensors 6.3.5 PCBs 6.4 2-Cassette Feeding Unit-W1 4-71 T 6.4.1 Clutches 6.4.2 Solenoids and Switches 6.4.3 Motors Page 4-73 T 6.4.4 Sensors 6.4.5 PCBs 6.5 Inner 2-Way Tray-A1 4-75 T 6.5.1 Solenoids 6.5.2 motors 6.5.3 Sensors 6.6 Super G3 FAX Board-J1 4-77 T 6.6.1 Others 6.6.2 PCBs 6.7 Variable Resistors (VR), Light-Emitting Diodes, and Check Pins by PCB 6.7.1 Main Controller PCB 4-80 T 6.7.2 DC Controller PCB F04-607-03 F04-607-02 6.7.3 Reader Controller PCB Page Page 5-1 T 1 Outline of Service Mode F05-101-01 5-2 T The machines service mode consists of the following seven types: F05-102-01 1.2 Starting Service Mode and Making Selections 1.3 Ending Service Mode 1.4 Backing Up Service Mode [1] 5-4 T 1.5 Using Service Mode F05-105-02 1.5.1 Initial Screen F05-105-01 1.5.2 Level 1/Level 2 Item Screen 1.5.3 Level 3 Item Screen F05-105-04 F05-105-03 VERSION 1/ 2 READY DC-CON R-CON PANEL FEEDER SORTER NIB PS/PCL LIPS 2 DISPLAY Control Display Mode F05-201-01 2.1 COPIER The following screen will appear in response to COPIER>DISPLAY; the respective item follows: <VERSION> Page Page <USER> <ACC-STS> <ANALOG> <CST-STS> WIDTH-MF <JAM> ERR 1/ 7 READY 5-14 T COPIER>DISPLAY>JAM FF: Types of Jams T05-201-04 T05-201-02 T05-201-01 ff: Jam Sensors FFff: Sensor/Type (jams in Saddle Finisher-G1) T05-201-06 T05-201-05 FFff: Sensor/Type (jams in Finisher-J1) <ERR> ERR 1/ 7 READY <HV-STS> PRIMARY TR BIAS TR-V <SENSOR> <ALARM-2> Indicates alarm data. ALARM-2 1/ 7 READY F05-201-04 2.2 FEEDER FEEDSIZE 3 I/O, I/O Display mode 5-21 T 3.1 DC-CON Indicates the input/output ports of the DC controller PCBs. <DC-CON (1/7)> 5-22 T <DC-CON (2/7)> 5-23 T <DC-CON (3/7)> 5-24 T <DC-CON (4/7)> 5-25 T <DC-CON (5/7)> 5-26 T <DC-CON (6/7)> 5-27 T <DC-CON (7/7)> 5-28 T 3.2 R-CON Indicates the input/output ports of the reader controller PCB. <R-CON (1/3)> 5-29 T <R-CON (2/3)> 5-30 T <R-CON (3/3)> 5-31 T COPIER>I/O>MN-CON 3.3 MN-CON Indicates the input/output ports for the main controller PCB. <MN-CON (1/2)> 5-32 T COPIER>I/O>MN-COM <MN-CON (2/2)> 5-33 T COPIER>I/O>FEEDER 3.4 FEEDER Indicates the input/output ports of the ADF controller PCB. <FEEDER (1/2)> 5-34 T COPIER>I/O>FEEDER <FEEDER (2/2)> 5-35 T 3.5 SORTER Indicates the input/output ports for the finisher controller PCB. <SORTER (1/8)> 3.5.1 Finisher-J1 5-36 T <SORTER (2/8)> 5-37 T <SORTER (3/8)> 5-38 T <SORTER (4/8)> 3.5.2 Saddle Finisher-G1 5-39 T <SORTER (5/8)> 5-40 T <SORTER (6/8)> 5-41 T <SORTER (7/8)> 3.5.3 Puncher Unit (Saddle Finisher-G1) 5-42 T <SORTER (8/8)> Page CHAPTER 5 SERVICE MODE 5-44 T 4 ADJUST Adjustment Mode F05-401-01 4.1 COPIER The following screen will appear in response to COPIER>ADJUST: <AE> AE-TBL <ADJ-XY> ADJ-X ADJ-Y ADJ-S ADJ-Y-DF STRD-POS <CCD> <LASER> <DEVELOP> DE-DC DE-OFST <DENS> DENS-ADJ <BLANK> BLANK-T BLANK-B <HV-PRI> P-DC P-AC AGS-GAIN AGS-OFST OFST1-DC OFST1-AC P-AC2 P-AC3 <HV-TR> TR-N1 TR-N2 TR-OFST TR-SPP <FEED-ADJ> REGIST ADJ-REFE ARCH <CST-ADJ> <FIXING> FX-FL-TH FX-FL-SP <MISC> C1-ADJ-Y C2-ADJ-Y C3-ADJ-Y C4-ADJ-Y DK-ADJ-Y FRAME-X FRAME-Y IMG-DLY 4.2 FEEDER DOCST LA-SPEED 4.3 SORTER PNCH-HLE PNCH-Y 5-61 T 5 FUNCTION Operation/Inspection Mode F05-501-01 5.1 COPIER The following screen will appear in response to COPIER>FUNCTION; lists of items fol- low: <INSTALL> TONER-S STRD-POS CARD <CCD> CCD-ADJ SHDG-POS SH-PS-ST EGGN-POS <DENS> WHITE-ME PD-DENS PD-ME <DPC> D-GAMMA <CST> MF-A4R MF-A6R MF-A4 <FIXING> NIP-CHK <PANEL> LCD-CHK LED-CHK LED-OFF KEY-CHK <PART-CHK> CL CL-ON MTR MTR-ON SL SL-ON Codes and Clutches 5-74 T Codes and Motors T05-501-04 T05-501-03 Codes and Solenoids <CLEAR> ERR DC-CON R-CON SERVICE Page <MISC-R> SCANLAMP <MISC-P> P-PRINT KEY-HIST HIST-PRT USER-PRT C1-ADJ-Y C2-ADJ-Y C3-ADJ-Y MF-ADJ-Y DK-ADJ-Y LBL-PRNT PRE-EXP <SYSTEM> DOWNLOAD CHK-TYPE HD-CHECK HD-CLEAR 6 OPTION Machine Settings Mode 6.1 COPIER BODY MODEL-SZ FIX-CLN FIX-TEMP HUM-SW SCANSLCT TRANS-SW PRIAC-SW SENS-CNF CONFIG SHARP COTDPC-D DF-BLINE FIX-SMR USER COPY-LIM SLEEP SIZE-DET COUNTER1 COUNTER2 COUNTER3 COUNTER4 COUNTER5 COUNTER6 Page 5-89 T Soft Counter Specifications T05-601-01a 5-90 T T05-601-01b 5-91 T T05-601-01c CST 5-93 T COPIER>OPTION>CST ENV1 T05-601-02 Settings 21: COM10, 22: ISO-B5, 23: Monarch, 24: ISO-C5, 25: DL, 26: No. 4 ENV2 Settings 21: COM10, 22: ISO-B5, 23: Monarch, 24: ISO-C5, 25: DL, 26: No. 4 ACC COIN DK-P INT-FACE IMG-CONT 6.2 FEEDER SIZE-SW 6.3 SORTER BLNK-SW MD-SPRTN 6.4 BOARD 7 TEST Test Print Mode PG TYPE TXPH PG-PICK Type Input Numbers and Test Prints NETWORK PING NETWORK 1/ 1 READY PING Page 8 COUNTER Counter Mode Clearing the Counter Readings Dividing Papers Between Small-Size and Large-Size Guide to the Counters for Periodically Replaced Parts and Durables List of COUNTER Items Page Page Page 1 Self Diagnosis 6-2 T 1.1 Detail Codes (copier) E000 E001 E002 E003 E007 E010 E014 E019 E032 E051 E064 E100 E110 E202 E204 E220 E225 E240 E243 E248 E261 E302 E315 E601 E602 E604 E605 E606 E674 E677 E710 E711 E712 E713 E716 E717 E719 E732 E733 E737 E740 E741 E743 E744 E803 E805 E901 1.2 ADF Error Codes E420 E421 E422 1.3 Saddle Finisher-G1 Error Codes 1.3.1 Error Code of the Finisher Unit E501 E505 E510 E514 E530 E531 E532 E537 E540 E577 E590 E592 E593 E5F1 1.4 Finisher-J1 Error Codes E500 E514 E530 E531 E537 E577 E580 E585 Page 1 Upgrading 1.1.1 Download Mode 1.1.2 Making Pre-Checks Page Page 1.2 Data Control Page Page 1.3 Downloading the System Software, RUI, and Language Module 1.3.1 Making Connections 1.3.2 Downloading Page Page Page Page Page 1.3.3 After Downloading 1.4 Upgrading the BOOT ROM 1.4.1 Making Preparations 1.4.2 Connection 1.4.3 Preparing BOOT ROM Page Page Page 1.4.4 After Downloading 1.5 Formatting the HDD 1.5.1 Making Connections 1.5.2 Starting Formatting Page Page Page Page Page 1.5.3 Points to Note When Formatting the Hard Disk CHAPTER 7 UPGRADING 7-27 T 1.6 Downloader PCB T07-106-01 1.6.1 Purpose Used for upgrading the CPU mounted on the options PCB (For DADF-H1/Finisher-J1). 1.6.2 Downloader PCB Components 1.6.3 Download Procedure DADF-H1 Finisher -J1 Page Page Page 1.6.4 Disconnecting 1.7 Upgrading by Replacing the DIMM/ROM 2 Backing Up Data 2.2 Backing Up Data 2.2.1 Making Preparations 2.2.2 Making Connections 2.2.3 Backing Up Data Page Page Page Page 2.2.4 Downloading Backup Data Page Page Page 2.2.5 Managing Backup Data Page Page Page A-1 A. General Timing Chart General Timing Chart (printer unit) A4, 2 sheets, Single-sided, Direct, Cassette (reversal delivery) A-2 General Timing Chart (reader unit w/ ADF) ADF Reader Unit ADF Reader Unit B. General Circuit Diagram Counter PCB From FAX Unit To DADF-H1 Switch PCB C. Side Paper Deck-L1 General Circuit Diagram A-5 13 12 11 10 9 8 7 6 5 4 3 2 1 H Side deck drier PCB G D. 2-Cassette Feeding Unit-W1 General Circuit Diagram Pedestal controller PCB 12 11 10 9 8 7 6 5 4 3 2 1 H G F E. Inner 2-Way Tray-A1 General Circuit Diagram A-8 F. List of Special Tools The following special tools will be needed in addition to the standard tools set: Page A-10 G.List of Solvents/Oils