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SERVICE HANDBOOK(temp)
iR C6800 Series
iR C6800CN
Feb 4 2004

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   Summary of Contents for Canon iR C6800 Series

  • Page 1 SERVICE HANDBOOK(temp) iR C6800 Series iR C6800CN Feb 4 2004...
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.
  • Page 7: Table Of Contents

    Contents Contents Chapter 1 Maintenance and Inspection 1.1 Periodically Replaced Parts..........................1- 2 1.1.1Overview ..............................1- 2 1.1.2Reader Unit..............................1- 2 1.1.3Printer Unit ..............................1- 2 1.2 Durables and Consumables ..........................1- 4 1.2.1Overview ..............................1- 4 1.2.2Reader Unit..............................1- 4 1.2.3Printer Unit ..............................
  • Page 8 Contents 2.4.7After Replacing the Pre-Transfer Charging Wire..................2- 43 2.4.8After Replacing the Waste Toner Box....................... 2- 43 2.4.9After Replacing the ITB Cleaner Blade..................... 2- 43 2.4.10After Repacking the Photosensitive Drum Cleaning Blade ..............2- 43 2.4.11After Replacing the Photosensitive Drum ....................2- 44 2.4.12After Repacking the ITB ........................
  • Page 9 Contents 3.10 Address Book Settings ..........................3-71 Chapter 4 Service Mode 4.1 Test Print ................................. 4- 74 4.1.1Overview ..............................4- 74 4.1.2Test Print TYPE ............................4- 74 4.1.3Selecting Test Print TYPE ........................4- 74 4.1.416-Gradation (TYPE=4)..........................4- 75 4.1.5Grid (TYPE=6)............................4- 75 4.1.6MCYBk Horizontal Stripes (TYPE=10) ....................
  • Page 11: Chapter 1 maintenance And Inspection

    Chapter 1 Chapter 1 Maintenance and Inspection...
  • Page 12: Periodically Replaced Parts

    Chapter 1   1.1 Periodically Replaced Parts 1.1.1 Overview 0002-9397 Some parts of the machine must be replaced on a periodical basis for the machine to maintain a specific level of performance. They must be replaced regardless of the presence/absence of external changes or damage, as the performance of the machine will be considerably affected once they fail.
  • Page 13 Chapter 1 as of February 2004 Ref. Parts name Parts No. Q'ty Interval Remarks Pre-transfer charging FB4-3687- 500,000 assembly images* Pre-transfer charging FL2-2427- 500,000 assembly wire cleaner 1 images* Pre-transfer charging FL2-2428- 500,000 assembly wire cleaner 2 images* FY1-0883- 500,000 Primary grid wire images* FK2-0013-...
  • Page 14: Durables And Consumables

    Chapter 1   1.2 Durables and Consumables 1.2.1 Overview 0005-8047 Some parts of the machine may have to be replaced once or more over the period of machine warranty because of wear or damage. Replace them as needed by referring to the table of estimated lives (expressed in terms of the number of prints they make).
  • Page 15 Chapter 1 as of February 2004 Ref. Parts name Parts No. Interval Remarks FC5-6298- 150,000 Fixing roller prints* FC5-6299- 150,000 Pressure roller prints* FC5-2285- 150,000 Outside heating roller prints* FL2-0422- 250,000 [10] Cleaner scoop-up sheet images*2 FC5-1788- 250,000 (one edge in [11] Cleaner blade images*2...
  • Page 16 Chapter 1   as of February 2004 Ref. Parts name Parts No. Interval Remarks FC5-5136- 500,000 [22] Edge scraper images*2 FM2-0446- [23] Color developing assembly 500,000 prints FC5-2286- [24] Fixing web 500,000 prints FB5-3613- [25] Fixing heat insulating bush 500,000 prints Delivery upper separation FM2-1672- [26]...
  • Page 17: Scheduled Servicing Basic Procedure

    Chapter 1 1.3 Scheduled Servicing Basic Procedure 1.3.1 Scheduled Servicing Basic Procedure 0003-4125 - As a rule, provide scheduled servicing every 150,000 prints. - Check with the Service Book before setting out for a scheduled service visit, and take parts for which replacement is expected.
  • Page 18: 2scheduled Servicing (reader Unit)

    Chapter 1   - If you need to dispose of the waste toner, be sure to do so in strict accordance with the regulations imposed by the local authorities. - Do not dispose of waste toner in a fire. Doing so may cause an explosion. 5) Clean the copyboard glass and the reading glass.
  • Page 19: 3scheduled Servicing (printer Unit)

    Chapter 1 Interva Unit Location Remarks Original Scanner rail clea exposure needed system lubr icat Original Scanner mirror clea 250,000 exposure (No. 1 through images system No. 3 mirrors) Original Reflecting plate clea 250,000 exposure images system The foreign values are estimates only, and are subject to change based on future data. 1.3.3 Scheduled Servicing (printer unit) 0003-4126  ...
  • Page 20 Chapter 1   T-1-5 Unit Location Item Interval Remarks Externals Ozone filter repla 250,000 and controls images Externals Toner filter repla 250,000 and controls images [1]Toner filter [2]Ozone filter Externals Dust- clean 250,000 and controls collecting prints filter (primary) inside of the right upper cover Laser Dust-colleting clean...
  • Page 21 Chapter 1 Unit Location Item Interval Remarks Charging Primary clean upon assembly charging wire installati repla 500,000 images Charging Primary grid clean upon assembly wire installati 250,000 images repla 500,000 images Charging Charging wire repla 500,000 assembly cleaner 1/2 images (primary changing assembly)
  • Page 22 Chapter 1   Unit Location Item Interval Remarks Photosensiti Drum heater clean 1,000,00 ve drum sliding area 0 images lubri cate Clean the terminal [1] of the slip ring using alcohol; then, apply a small amount of lubricant (FY9-6008). Black Developing chec upon...
  • Page 23 Chapter 1 Unit Location Item Interval Remarks Color Color toner clean 250,000 developing cartridge level images assembly sensor window Color Developing clean 250,000 developing cylinder images assembly bushing Color Bottle cover clean 250,000 developing images assembly Color Color toner clean 250,000 developing cartridge...
  • Page 24 Chapter 1   Unit Location Item Interval Remarks Intermediate Scoop-up clean 150,000 transfer sheet base, prints assembly thereunder area Intermediate Cleaner clean 150,000 transfer container, prints assembly hereunder area [1] Scoop-up sheet base, there [2] Cleaner container, hereund Secondary Secondary clean 150,000 transfer...
  • Page 25 Chapter 1 Unit Location Item Interval Remarks Hopper Toner clean 250,000 assembly receptacle/ prints supply mouth Fixing Fixing web chec upon assembly installati Fixing Fixing clean 150,000 assembly thermistor prints repla 500,000 prints 枚 Fixing Pressure clean 150,000 assembly thermistor prints repla 500,000...
  • Page 26 Chapter 1   note: The black developing cylinder need not be cleaned on a periodical basis. If you must clean the surface of the cylinder, be sure to dry wipe it with lint-free paper, NEVER using water or solvent. The foregoing values are estimates only, and are subject to change based on future data. 1-16...
  • Page 27: Cleaning

    Chapter 1 1.4 Cleaning 1.4.1 Cleaning the Photosensitive Drum 0004-1175 Do not rotate the magnetic roller during the work. Otherwise, waste toner can start to fall out of the cleaning assembly. 1) Remove the photosensitive drum. 2) Moisten lint-free paper [1] with 5 to 10cc of alcohol [2]; then, collect 0.2 to 0.3g of drum cleaning powder (CK- 0429) [3] on the lint-free paper.
  • Page 28: 2cleaning The Secondary Transfer Rear Guide

    Chapter 1   5 10cm F-1-2 4) When the alcohol has evaporated, dry wipe the surface of the drum with lint-free paper. If there is an uneven layer of cleaning powder, go back to step 3), and clean the surface by increasing the number of back-and-forth movements. 5) Rotate the drum for the width that has been cleaned (5 to 10cm), and repeat steps 2 through 4 until the entire surface has been cleaned.
  • Page 29: 3cleaning The Registration Roller, Registration Guide, And Transparency Sensor

    Chapter 1 F-1-3 1.4.3 Cleaning the Registration Roller, Registration Guide, and Transparency Sensor 0005-6999 1) Slide out the fixing/feeding assembly. 2) Push the leaf springs on both sides, and slide the fixing/feeding assembly farther out. 3) Remove the 3 screws [1], and turn overt the transparency upper sensor unit [2]. F-1-4 4) Remove the paper lint building up over the transparency sensor [1] using a blower brush.
  • Page 30 Chapter 1   F-1-5 5) Remove the 2 screws [1], and detach the grounding spring [2]. 6) Remove the screw [3]. F-1-6 7) Remove the 3 screws [1], and detach the registration roller upper stay [3] together with the grounding spring [4] while freeing the spring [2] off its hook.
  • Page 31 Chapter 1 F-1-8 10) Turn the upper registration roller [1] and the lower registration roller [2] to clean them with lint-free paper moistened with alcohol. F-1-9 1-21...
  • Page 32: Upgrading

    Chapter 1   1.5 Upgrading 1.5.1 Outline of the Version Upgrade 0005-6159 The version upgrade of this machine and the accessories can be done by downloading from a personal computer (PC) in which the service support tool (SST) is installed or by replacing DIMM-ROM. The table below shows a list of firmware and the associated way of upgrading.
  • Page 33 Chapter 1 iR XXXX PC for service work Initializing the HDD HDD setting information Downloading system software System software Flash ROM Uploading backup data Backup data Downloading backup data Back up RAM F-1-10 To use the SST, you must first set the machine to download mode. The machine's download mode consists of 2 types.
  • Page 34 Chapter 1   Main power on keypad, 2+8 on keypad, 1+7 switch ON Safe mode Boot ROM Boot program program SYSTEM program In service mode COPIER > FUNCTION > SYSTEM > DOWNLOAD normal mode program Download mode A Download mode B F-1-11 Use safe mode for the following: -after replacing the HDD.
  • Page 35: 3network Interface Of The Machine With The Sst In Use

    Chapter 1 T-1-7 Function Download mode Normal mode Safe mode (download mode B) (download mode A) Formatting the HDD BOOTDEV DOSDEV FSTDEV DOSDEV2 FSTPDEV DOSDEV3 PDLDEV DOSDEV4 DOSDEV5 Downloading system -System -System software -Language -Language -RUI -RUI -Boot -Boot -G3FAX -Dcon -Rcon Downloading/...
  • Page 36 Chapter 1   You need not change the user enviroment network settings before or after the SST. iR XXXX User network enviroment User enviromsnt network settings Ethernet I/F Service network settings Power OFF Power ON in response to 1+7 or 2+8 on keypad iR XXXX Service PC User enviroment network settings...
  • Page 37 Chapter 1 Copy Send Mail Box Options Auto-Color Select eady to copy Department*S Copy atio Paper Select Finisher Two-sided Text/Photo/Map Special Features Interrupt System Monitor I-Fax Memory X is on F-1-13 Attension when installed option board -Normal Power ON  The Ethernet interface is disabled if a TokenRing board is installed. -Power ON in response to 1+7 or 2+8 The Ethernet interface is enabled if a TokenRing board is installed, and the TokenRing board is disabled. ...
  • Page 38 Chapter 1   iR XXXX User network enviroment (TokenRIng) TokenRIng I/F enabled Ethernet I/F disabled Power OFF Power ON in response to 1+7 or 2+8 on keypad iR XXXX Service PC TokenRIng I/F disabled Ethernet I/F enabled SST in use F-1-14 1-28...
  • Page 39: Chapter 2 standards And Adjustments

    Chapter 2 Chapter 2 Standards and Adjustments 2-29...
  • Page 40: Image Adjustments

    Chapter 2   2.1 Image Adjustments 2.5+1.5mm/-1.5mm 2.1.1 Image Position 0003-8718 The margin and the non-image width of a printout made at 100% magnification must be as follows: - Leading Edge Margin F-2-4 4.0+1.5/-1.0mm [double-sided copy, 2nd side:4.0+1.5/-1.0mm] 2.1.2 Checking the Image Position 0003-8719 Make 10 prints using the following as the source of...
  • Page 41: 3cassette

    Chapter 2 margin is as indicated. COPIER > ADJUST > FEED-ADJ > RG-REFE decrease the setting of REGIST. - If not as indicated, make the following adjustments: (an increase by 10 will decrease the margin by 1 mm) 1) Press the cassette release button, and slide out the double-sided copy, 2nd side:4.0+1.5/-1.0mm cassette 3 or 4 to the front.
  • Page 42: 5front Deck

    Chapter 2   [2] through the opening of the left front stay; then, turn the adjusting screw to adjust the left/right margin. F-2-12 F-2-10 4) Check to make sure that the left/right margin of the printouts on paper from the left deck is as indicated. 2) Check to make sure that the left/right margin of the 5) As necessary, make the following adjustments: prints is as indicated.
  • Page 43 Chapter 2 F-2-16 - turn the screwdriver counterclockwise to decrease F-2-14 the left margin [1]. - turn the screwdriver clockwise to increase the left 10) Close the left deck; when the gap is gone, slide out margin [1]. the left deck once again, and tighten the 4 screws you A full turn of the screwdriver changes the left margin loosened in step 9).
  • Page 44 Chapter 2   11) Close the right deck. 2-34...
  • Page 45: Scanning System

    Chapter 2 2.2 Scanning System COPIER>ADJUST>CCD>W-PLT-Y COPIER>ADJUST>CCD>W-PLT-Z (to enter the standard white plate white level data X, 2.2.1 After Replacing the Y, Z) CCD Unit 0003-9936 If you have replaced the CCD unit, be sure to enter the settings indicated on the label attached to the CCD unit: COPIER>ADJUST>CCD>CCDU-RG (to enter the correction value for CCD-dependent RG...
  • Page 46 Chapter 2   mode: COPIER>ADJUST>CCD>FCCDU-RG/GB b-8 auto gradation adjustment target value a. standard white plate white level data COPIER>ADJUST>PASCAL>OFST-P-Y,M,C,K COPIER>ADJUST>CCD>W-PLT-X,Y,Z 2. ADF-Related Adjustments The machine uses the RAM on its reader controller to hold ADF-related service data; as such, you must make the appropriate adjustments for the ADF whenever you have replaced the reader controller or initialized the RAM.
  • Page 47 Chapter 2 F-2-21 2-37...
  • Page 48: Laser Exposure System

    Chapter 2   2.3 Laser Exposure System 2.3.1 After Replacing the Laser Scanner 0004-2103 1) Make the following selections in service mode, and press key: COPIER>FUNCTION>DPC>DPC. 2) Turn off and then on the main power switch. 2-38...
  • Page 49: Image Formation System

    Chapter 2 2.4 Image Formation System 2.4.1 After Replacing the Black Developing Unit 0004-2117 Be sure to perform the following whenever you have replaced the black developing assembly: F-2-23 1) Make the following selections in service mode (black toner supply): 5) Supply half the starter so that it is even in the FUNCTION>INSTALL>TONER-S.
  • Page 50 Chapter 2   F-2-29 F-2-26 When tightening the screw, take full care so that no shavings caused by turning the screw into the lid of 10) Fit the container lid you removed in step 2) back the developing assembly and the container will move on in the direction indicated in the figure.
  • Page 51: 3replacing The Starter Of The Color Developing Unit

    Chapter 2 developing assemblies, 4) Turn back over the developing unit, and turn the COPIER>FUNCTION>INSTALL>INISET-3 developing gear in the direction in which the cylinder 16) Execute the following service mode item: normally turns so that the agent will drop into the COPIER>FUNCTION>MISC-P>P-PRINT.
  • Page 52 Chapter 2   Engage the 4 hooks [1], and attach the developing assembly lid [3] using the 2 screws [2] you removed in step 2). F-2-35 10) Turn the developing gear in its normal direction 5 to 6 by hand to even out the starter inside it. 11) Pour the rest of the starter around the string screw F-2-38 inside the color developing unit.
  • Page 53: 4after Replacing The Primary Charging Assembly

    Chapter 2 developing assembly, 2.4.6 After Replacing the COPIER>FUNCTION>INSTALL>INISET-Y. Pre-Transfer Charging developing assembly, Wire COPIER>FUNCTION>INSTALL>INISET-M. 0004-2672 developing assembly, COPIER>FUNCTION>INSTALL>INISET-C. Execute the following in service mode (pre-transfer charging wire cleaning): 19) Execute the following in service mode: COPIER>FUNCTION>CLEANING>WIRE-CLN. COPIER>FUNCTION>MISC-P>P-PRINT. Then, put the generated printout in the service book case. If 2.4.7 After Replacing the there is any previous printout, dispose of it.
  • Page 54: 11after Replacing The Photosensitive Drum

    Chapter 2   blade, be sure to perform the following: 2.4.15 After Replacing the 1) Execute the following service mode item (primary Primary Transfer Static transfer ATVC roller idle rotation): Eliminator COPIER>FUNCTION>MISC-P>ITR-ROT. 0004-4238 If you have replaced the primary transfer static 2.4.11 After Replacing the eliminator, be sure to perform the following: Photosensitive Drum...
  • Page 55: Fixing System

    Chapter 2 2.5 Fixing System 2.5.4 Position of the Fixing inlet Guide 0004-2213 2.5.1 Points to Note When Do not loosen the screw on the inlet guide base Mounting Fixing [1], as you would have to adjust the position of the Assembly guide if you detached it.
  • Page 56: 7points To Note About The Position Of The Fixing Thermal Switch

    Chapter 2   2.5.7 Points to Note About the Position of the Fixing Thermal Switch 0004-5056 After mounting the thermal switch, make sure of the following: Front The surface of the thermal switch [1] must be parallel F-2-43 to the fixing roller. (Check to be sure by shining the thermal switch with a pen light.) Otherwise, re-mount 2.5.6 Adjusting...
  • Page 57: 9points To Note When Mounting The Outside Heating Roller Thermal Switch

    Chapter 2 F-2-50 2.5.10 Points to Note When Mounting Fixing Upper Thermistor 0005-5549 F-2-47 After mounting the thermistor, make sure of the following: The surface of the thermal switch [1] must be parallel F-2-48 to the fixing roller. (Check to be sure by shining the thermal switch with a pen light.) Otherwise, re-mount 2.5.9 Points to Note When Mounting the Outside...
  • Page 58: 12points To Note When Mounting The External Heat Thermistor

    Chapter 2   to the fixing roller. (Check to be sure by shining the thermal switch with a pen light.) Otherwise, re-mount F-2-56 F-2-53 F-2-54 2.5.12 Points to Note When Mounting the External Heat Thermistor 0005-5551 After mounting the thermistor, make sure of the following: The surface of the thermal switch [1] must be parallel to the fixing roller.
  • Page 59: Electrical Components

    Chapter 2 2.6 Electrical Components b. service label settings (label attached behind reader unit front cover) 2.6.1 When Replacing the b-1 image read start position adjustment (x direction; for fixed reading) Reader Controller PCB 0003-9937 COPIER>ADJUST>ADJ-XY>ADJ-X b-2 image read start position adjustment (Y direction; - Be sure to generate the latest P-PRINT printout fixed reading) before replacing the reader controller PCB.
  • Page 60: 2after Replacing The Dc Controller Pcb

    Chapter 2   a. ADF sensor sensitivity adjustment - COPIER>ADJUST>DEVELOP>(all items) FEEDER>FUNCTION>SENS-INT - COPIER>ADJUST>DENS>(all items) b. tray width adjustment - COPIER>ADJUST>V-CONT>(all items) AB system: FEEDER>FUNCTION>TRY-A4 and - COPIER>ADJUST>HV-PRI>(all items) FEEDER>FUNCTION>TRY-A5R - COPIER>ADJUST>HV-TR>(all items) inch system: FEEDER>FUNCTION>TRY-LTR - COPIER>ADJUST>FEED-ADJ>(all items) and FEEDER>FUNCTION>TRY-LTRR - COPIER>ADJUST>CST-ADJ>(all items) c.
  • Page 61: 4after Replacing The Main Controller Pcb (main)

    Chapter 2 F-2-60 F-2-59 Supplementary Information: If the harness [1] is away from the side plate [4] of the DC controller box, wrong detection (E070-0102) of the ITB home position tends to occur because of noise. 2.6.4 After Replacing the Main Controller (main)
  • Page 62: 6after Replacing The Hdd

    Chapter 2   “Turn Off and Then On the Power Switch on the 4) Enter the appropriate card No. Left” on its control panel, turn off and then on the Enter the lowest of the numbers of the cards used for power.
  • Page 63: When Replacing The Atr Sensor/patch Image Read Sensor

    Chapter 2 COPIER>ADJUSUT>HV-TR>1TR-CGAI COPIER>ADJUSUT>HV-TR>1TR-COFS COPIER>ADJUSUT>HV-TR>1TR-GAI2 COPIER>ADJUSUT>HV-TR>1TR-OFS2 1TR-GAIN XXX 1TR-OFST XXX 1TR-CGAI XXX 1TR-COFS XXX 1TR-GAI2 XXX 1TR-OFS2 XXX F-2-62 2) Generate a P-PRINT printout in service mode. 3) Put the generated P-PRINT printout [1] in the service book case, replacing any existing printout. F-2-63 2.6.8 When Replacing the ATR Sensor/Patch Image...
  • Page 64: Pickup/feeding System

    Chapter 2   2.7 Pickup/Feeding System 2.7.2 Adjusting the Manual Feed Pickup Horizontal 2.7.1 Adjusting Registration 0003-9955 Horizontal Registration Make copies using the manual feed tray as the source After Replacing of paper, and check to make sure that the left/right margin is as indicated.
  • Page 65 Chapter 2 1) Push the release button, and slide out the left deck. the left margin [1]. 2) Using a flat-bladed screwdriver, detach the left face - turn the screwdriver clockwise to increase the left cover [1]. margin [2]. A full turn of the screwdriver will change the left margin by 1.0 mm.
  • Page 66: 4registering The Paper Width Basic Value

    Chapter 2   F-2-70 F-2-72 4) Check to make sure that the left/right margin of 10) Close the right deck; when the gap is gone, slide printouts made on paper from the right deck is as out the right deck once again, and tighten the 4 screws indicated.
  • Page 67 Chapter 2 3) Register the A4 paper width basic value as follows: 3-1) Set the manual feed side guide to A4. 3-2) Make the following selections to register manual feed A4 width: CPOIER>FUNCTION>CST>MF-A4 3-3) Press the OK key to register the A4 width. 3-4) Record the A4 basic value indicated on the control panel on the service label.
  • Page 69: Chapter 3 user Mode Items

    Chapter 3 Chapter 3 User Mode Items 3-59...
  • Page 70: Common Settings

    Chapter 3   3.1 Common Settings 0002-9584 * Factory setting. T-3-1 Item Description initial function initial function: *copy, transmit/fax, box system initial screen: ON/*OFF priority on system device: *ON/OFF function after auto-clear *return, do not return buzzer ON/OFF input sound: *ON/OFF input invalid sound: ON/*OFF supply alert sound: ON/*OFF warning sound: *ON/OFF...
  • Page 71 Chapter 3 Item Description reception/fax: 1/2/*3 other: 1/2/*3 manual feed paper standard mode on (paper size select, paper type select), *off registration local print standard mode paper select: *auto, cassette 1 thorough 5 print quantity: *1 to 2000 sorter (if w/ finisher): non-sort, *sort, rotation sort, group, rotation group sorter (w/ finisher): non-sort, sort, *shift sort, group, shift group, rotation group, staple...
  • Page 72: Setting The Timers

    Chapter 3   3.2 Setting the Timers 0002-9585 * Factory setting. T-3-2 Mode Description date/time enable time zone, *daylight saving auto sleep time 10, 15, 20, 30, 40, 50, 1 hr, 90 min, 2, 3, 4 hr auto clear time 0=no;...
  • Page 73: Adjustment, Cleaning

    Chapter 3 3.3 Adjustment, Cleaning 0002-9586 * Factory setting. T-3-3 Item Description zoom fine adjustment XY individually; -1.0 to +1.0% (in 0.1%- increments), *0% center bind staple edging (if w/ start key saddle finisher) center bind position change (if size: A3, 11X17/B4/A4R, LTRR w/ saddle finisher) auto gradation correct full correction (read test print x 3 times);...
  • Page 74: Report

    Chapter 3   3.4 Report 0002-9587 * Factory setting. T-3-4 Item Description transmit (specifications) transmission result report: *only if error, on, off transmitted original display: *on, off communications control report auto print every 100 communications: *on, off timed as specified: on, *off *00:00 to 2:59 send/receive separate: yes, *no fax (specifications)
  • Page 75: System Control Settings

    Chapter 3 3.5 System Control Settings 0002-9588 * Factory setting T-3-5 Item Description system administrator info yes using ID, address group ID ON/*OFF communications control yes using e-mail, fax, box setup remote UI *ON/OFF address book limit ID No., access NO.: ON/*OFF device information setup device name, location transfer setup...
  • Page 76: Copier Settings

    Chapter 3   3.6 Copier Settings 0002-9589 * Factory setting. T-3-6 Item Description preference key 1 *no setting (magnification, sorter, page separation may be enabled) preference key 2 *no setting (magnification, sorter, page separation may be enabled) auto sort *ON/OFF copy wait time indication ON/*OFF auto vertical/horizontal rotation...
  • Page 77: Common Transmission Settings

    Chapter 3 3.7 Common Transmission Settings 0002-9590 * Factory setting. T-3-7 Item Description common transmission source register (99 max.) setup user abbreviation (various settings) FTP transmission (ON/*OFF) error file clear (*ON/OFF) transfer error file (print always, save and print, *off) retry (*3 times;...
  • Page 78 Chapter 3   Item Description auto redial (*ON/OFF) fax reception function ECM (*ON/OFF) setup fax reception function setup reception mode (*auto reception, fax/tel switch-over, modem dial-in) ring(ON/*OFF) remote reception (ON/*OFF) auto reception switch-over (ON/*OFF) 3-68...
  • Page 79: Box Settings

    Chapter 3 3.8 Box Settings 0002-9591 T-3-8 Item Description box function setup user box setup, register (99 max.) read-in setup (register, initialize) fax box setup, register (49 max.) 3-69...
  • Page 80: Printer Settings

    Chapter 3   3.9 Printer Settings 0002-9592 * Factory setting. T-3-9 Item Description setting copy count (1 to 2000: *1) double-sided (double-sided, *single-sided) blank paper save (*yes, no) pickup (A4, plain; no switch-over) print adjust (super smooth, toner density, toner save) layout (lengthwise bind margin;...
  • Page 81: Address Book Settings

    Chapter 3 3.10 Address Book Settings 0002-9593 T-3-10 Item Description address register various times address list name register register one-touch button register various items 3-71...
  • Page 83: Chapter 4 service Mode

    Chapter 4 Chapter 4 Service Mode 4-73...
  • Page 84: Test Print

    Chapter 4   4.1 Test Print 4.1.1 Overview 0001-6108 The machine offers the following 6 types of test prints (TYPE), each designed for identification of a specific type of image fault. The data for these test prints is prepared by the main controller: if the output of a test print is free of the fault in question, suspect a fault on the PDL input or the reader unit.
  • Page 85: 416-gradation (type=4)

    Chapter 4 4.1.4 16-Gradation (TYPE=4) 0001-6113 Use this test print to check gradation, fogging, white line, and uneven density at the front/rear. a. Gradation If the 16-gradation[1] is not properly produced, suspect a fault in the drum unit or the laser exposure system. b.
  • Page 86: 6mcybk Horizontal Stripes (type=10)

    Chapter 4   F-4-2 4.1.6 MCYBk Horizontal Stripes (TYPE=10) 0001-6118 Use this test print to check the density of dark areas of individual colors, balance among colors, and white lines associated with development. a. Solid Density of Individual Colors and Balance Among Colors - the density must not be appreciably low (too light).
  • Page 87: 764-gradation (type=12)

    Chapter 4 2.5 1.5mm 2.5 1.5mm F-4-3 4.1.7 64-Gradation (TYPE=12) 0001-6119 Use this test print to check the gradation of Y, M, C, and Bk at once. F-4-4 4.1.8 Full Color 16-Gradation (TYPE=14) 0001-6120 Use this test print to check the gray balance, gradation of individual colors (YMCBk), and fogging. a.
  • Page 88 Chapter 4   c. Fogging If fogging is found in the white area, suspect a fault in the developing system, a fault in the drum unit, and poor adjustment of the laser exposure system. 4 colors (YMCK) 3 colors (YMC) Light area White White...
  • Page 89: Chapter 5 outline Of Components

    Chapter 5 Chapter 5 Outline of Components 5-79...
  • Page 90: Clutch/solenoid

    Chapter 5   5.1 Clutch/Solenoid 5.1.1 Clutches and Solenoids 0004-9524 <Reader Unit> The reader unit does not use clutches or solenoids. <Printer Unit> T-5-1 Name Connector No Fixing/ Notation PART- feeding Parts No. driver DC controller Color developing assembly clutch FK2-0033 CL>1 J1109...
  • Page 91 Chapter 5 Name Connector No Fixing/ Notation PART- feeding Parts No. driver DC controller Deck (right) pickup solenoid FK2-0116 SL>6 J1113 Deck (left) pickup solenoid FK2-0116 SL>7 J1113 Cassette 3 pickup solenoid FK2-0116 SL>8 J1114 Cassette 4 pickup solenoid FK2-0116 SL>9 J1114 Developing rotary locking solenoid...
  • Page 92 Chapter 5   SL10 SL11 SL12 F-5-1 5-82...
  • Page 93: Motor

    Chapter 5 5.2 Motor 5.2.1 Motors 0004-9333 <Reader Unit> T-5-2 Name Description Notation Parts No. PART-CHK E code Scanner motor drives the No. 1/No. 2 mirror base M501 FK2-0237 E202 T-5-3 Connector No. Notation I/F PCB Reader controller PCB M501 J306/307 J203 F-5-2...
  • Page 94 Chapter 5   T-5-4 Name Description Notation Parts No. PART-CHK E code Polygon motor drives the laser scanner FM2-0394 (laser scanner MTR>1 E110 assembly) drives the photosensitive drum, photosensitive drum Drum/ITB motor cleaner, intermediate transfer unit FK2-0019 MTR>2 E012 supplies color toner; drives the black/color Developing motor developing assembly FK2-0021...
  • Page 95 Chapter 5 Name Description Notation Parts No. PART-CHK E code Right deck pull-off motor drives the vertical path 1 roller FL2-0583 MTR>14 Vertical path motor drive the vertical path 3/4 roller FL2-0583 MTR>15 Dives the right deck pickup assembly, vertical path Right deck pickup motor roller 2 FL2-0582...
  • Page 96 Chapter 5   Name Description Notation Parts No. PART-CHK E code Left deck lifter motor drives the left deck lifer FK2-0017 Cassette 3 lifer motor drives the upper cassette lifter FK2-0016 Cassette 4 lifter motor drives the lower cast lifter FK2-0016 T-5-5 Connector No.
  • Page 97 Chapter 5 Connector No. Notation Fixing/feeding Pickup driver PCB DC controller PCB assembly driver PCB J1108 J1108 J1106 J1108 J1308/1302 J1119 J1404/1403 J1116 J1404/1403 J1116 J1404/1403 J1116 J1404/1403 J1116 5-87...
  • Page 98 Chapter 5   F-5-3 5-88...
  • Page 99: Fan

    Chapter 5 5.3 Fan 5.3.1 Fans 0005-0020 <Reader Unit> T-5-6 Name Function Nota tion Parts No. PART-CHK E code Reader cooling fan cools the reader assembly FH5-1061 1:ON T-5-7 Connector No. Notati Interface PCB Reader controller PCB FM13 J313/J308 J202 FM13 F-5-4 <Printer Unit>...
  • Page 100 Chapter 5   T-5-8 Name Description Nota PART- tion Parts No. E alarm code primary charging suction fan draws air from outside the machine to the primary charging assembly FK2-0103 1:ON(half- FAN-ON>1 E824-000 speed) 1:ON(full- speed) Primary charging assembly discharges air from around the primary charging exhaust fan assembly FK2-0124...
  • Page 101 Chapter 5 Name Description Nota PART- tion Parts No. E alarm code Power supply cooling fan cools the DC power supply PCB FK2-0524 1:ON FAN-ON>9 E804-0007 Delivery cooling fan 2 cools paper being delivered outside the machine (only if equipped with a finisher) FK2-0124 1:ON(half- FAN-...
  • Page 102 Chapter 5   FM10 FM12 FM11 F-5-5 5-92...
  • Page 103: Sensor

    Chapter 5 5.4 Sensor 5.4.1 Sensors 0005-0022 <Reader Unit> T-5-10 Name Description Connector No. Notat Interface Reader Parts No. Jam/E code controller PS50 Scanner HP sensor detects scanner home position FK2-0149 J310/J308 J202 PS50 ADF open/closed sensor detects the state (open/closed) of the ADF FK2-0149 J310/J307 J203...
  • Page 104 Chapter 5   T-5-11 Name Description Connector No. atio Feed Parts No. Jam/E code driver controlle r PCB ITB HP sensor A detects the ITB home position FK2-0161 J1121 E070 Patch image read sensor checks the density of the toner on the ITB FH7-7601 J1121 Transparency sensor (front)
  • Page 105 Chapter 5 Name Description Connector No. atio Feed Parts No. Jam/E code driver controlle r PCB Fixing inlet sensor detects paper at the fixing inlet FK2-0149 J1124 xx15 (stationary only) Inside delivery sensor detects inside delivery paper FK2-0149 J1307/ J1119 xx0C (except J1303 stationary)
  • Page 106 Chapter 5   Name Description Connector No. atio Feed Parts No. Jam/E code driver controlle r PCB ITB cleaning HP sensor detects the ITB cleaner home position FK2-0149 J1108 Horizontal registration sensor detects duplexing horizontal registration FH7-7196 J1307/ J1119 E051 J1303 Color toner level sensor detects the remaining level of color toner...
  • Page 107 Chapter 5 Name Description Connector No. atio Feed Parts No. Jam/E code driver controlle r PCB Right deck paper sensor detects the presence/absence of paper in the right deck FK2-0149 J1113 Right deck lifter sensor detects the right deck lifter FK2-0149 J1113 Right deck paper level sensor...
  • Page 108 Chapter 5   Name Description Connector No. atio Feed Parts No. Jam/E code driver controlle r PCB Cassette 3 pickup sensor detects pickup from the cassette 3 FK2-0149 J1114 xx03 (except stationary) Cassette 3 limit sensor detects the cassette 3 limit FK2-0149 J1114 Cassette 3 paper sensor...
  • Page 109 Chapter 5 Name Description Connector No. atio Feed Parts No. Jam/E code driver controlle r PCB Vertical path 1 sensor detects paper in the pickup vertical path 1 FK2-0149 J1113 xx08 (except stationary) Vertical path 2 sensor detects paper in the pickup vertical path 2 FK2-0149 J1112 xx04...
  • Page 110 Chapter 5   PS28 PS29 PS32 PS29 PS14 PS10 PS22 PS12 PS18 PS15 PS19 PS30 PS25 PS41 PS47 PS43 PS40 PS23 PS42 F-5-7 5-100...
  • Page 111 Chapter 5 PS31 PS20 PS26 PS21 PS13 PS64 PS36 PS34 PS33 PS35 PS66 PS60 PS24 PS61 PS51 PS49 PS17 PS62 PS48 PS50 PS57 PS55 PS56 PS54 PS63 F-5-8 5-101...
  • Page 112 Chapter 5   PS65 PS37 PS39 PS38 PS46 PS44 PS52 PS45 PS53 PS58 PS59 F-5-9 5-102...
  • Page 113: Switch

    Chapter 5 5.5 Switch 5.5.1 Switches 0005-0068 <Reader Unit> The reader unit does not have any switch. <Printer Unit> T-5-12 Name Description atio Connect Parts No. COPIER>FUNCTION E code Main power switch turns on/off the main power FK2-0140 Environment switch turns on/off the drum heater, reader heater, cassette heater, deck heater FM2-0844...
  • Page 114 Chapter 5   Name Description atio Connect Parts No. COPIER>FUNCTION E code Fixing/feeding lock detects the state (locked/unlocked) of the feeder release lever switch FC5-2496 SW14 SW15 SW13 SW11 SW12 F-5-10 5-104...
  • Page 115: Lamps, Heaters, And Others

    Chapter 5 5.6 Lamps, Heaters, and Others 5.6.1 Heaters, Lamps, and Others 0004-3243 LED1 H501 H502 HDD1 ELB1 F-5-11 T-5-13 Name Description Notatio PART- Parts No. E code Fixing main heater main heater (controls the fixing roller temperature) FK2-0043(100V) E000、E001、E004 FK2-0048(120V) FK2-0053(230V) Fixing sub heater...
  • Page 116 Chapter 5   Name Description Notatio PART- Parts No. E code Shift heater shift heater (keeps the shift roller heated) FK2-0045(100V) E000、E001、E004 FK2-0050(120V) FK2-0055(230V) Outside heating roller fixing auxiliary heater (helps keep the fixing roller heater heated) FK2-0047(100V) E000、E001、E004 FK2-0052(120V) FK2-0057(230V) Drum heater prevents condensation on the drum...
  • Page 117 Chapter 5 Name Description Notatio PART- Parts No. E code scanning lamp illuminates originals FK2-0224 MISC- E225 R>SCANL T-5-14 Main Reader Inverter AC driver Notation controller controller controller J1803/1810 J1105 J1803/1810 J1105 J1804/1810 J1105 J1804/1810 J1105 J1805/1810 J1105 J1806/1810 J1105 H501 J1807 -----...
  • Page 118: Pcbs

    Chapter 5   5.7 PCBs 5.7.1 PCB 0004-9428 <Reader Unit> T-5-15 atio Name Parts No. Description Interface PCB FM2-1102 communicates with the printer unit, Reader controller PCB FM2-1101 controls the reader unit CCD/AP PCB FM2-0617 (CCD performs analog image processing unit) Inverter PCB FK2-0225...
  • Page 119 Chapter 5 Notat Name Parts No. Description Potential control PCB FM2- converts the potential sensor 0444(potential output sensor unit) Manual feed paper width FH7-7600 detects the width of paper from the manual feeder Laser driver PCB FM2-0394(laser controls the drive of the laser unit scanner) Potential sensor FM2-...
  • Page 120 Chapter 5   Notat Name Parts No. Description [19] Main controller PCB (sub) FM2-0535 connects the image signals from the reader units [20] Ethernet PCB FM2-0538 connects to the network [21] Main controller PCB (main) FG3-2857 processes image data for output to the printer unit [22] WM2-5208...
  • Page 121 Chapter 5 [10] [11] [16] [13] [12] [14] [15] [17] [32] [18] [31] [19] [30] [20] [29] [22] [21] [28] [23] [27] [24] [26] [25] F-5-13 5-111...
  • Page 123: Chapter 6 system Construction

    Chapter 6 Chapter 6 System Construction 6-113...
  • Page 124 Chapter 6   6.1 System Construction 6.1.1 System Configuration with Pickup/Delivery Accessories 0002-5061 The machine may be configured as follows with pickup/delivery accessories F-6-1 [1] Finisher-R1 [2] Saddle Finisher-R2 [3] Additionary Finisher Tray-A1 [4] Puncher Unit-L1 [5] Shift Tray-C1 [6] Delivery Tray-K1 [7] Side Paper Deck-U1 * If any of the accessories [1] through [3] is used, the accessories [5] and [6] cannot be used as part of the system.
  • Page 125 Chapter 6 F-6-2 [1] iR Security Kit [2] SEND Expansion Kit D1P/D1U (dongle for extended functions) [3] Image Conversion Board-A2 [4] USB Interface Board-A3, or TokenRing Board (optional for 120V model) [5] UFR Board (standard for N model) [6] Ethernet Board (standard) [7] Super G3 Fax Board-P1 (optional for 100V model) [8] PS Print Sever Unit-D1 [9] Color iR 256 MB Expansion RAM (optional for 100V)
  • Page 126: Function List

    Chapter 6   6.2 Function List 6.2.1 Print Speed 0002-5174 T-6-1 Cassette/deck Manual feeder Cassette/deck (single-sided) (singe-sided) (double-sided) Paper type Paper size Color Mono Color Mono Color Mono Plain paper mode (64 to 11"×17"(2 105 g/m2) 79mm×43 2mm) 12"×18"(3 05mm×45 8mm) 13"×19"(3 30mm×48...
  • Page 127 Chapter 6 Cassette/deck Manual feeder Cassette/deck (single-sided) (singe-sided) (double-sided) Paper type Paper size Color Mono Color Mono Color Mono Heavy paper mode 1 (105 to 163 g/m2) 11"×17"(2 79mm×43 2mm) 12"×18"(3 05mm×45 8mm) 13"×19"(3 30mm×48 2mm) B4, LGL A4R, LTRR, A4, LTR, Heavy paper mode 2 (164...
  • Page 128 Chapter 6   Cassette/deck Manual feeder Cassette/deck (single-sided) (singe-sided) (double-sided) Paper type Paper size Color Mono Color Mono Color Mono Heavy paper mode 3 (210 11"×17"(2 to 253 g/m2) 79mm×43 2mm) 12"×18"(3 05mm×45 8mm) 13"×19"(3 30mm×48 2mm) B4, LGL A4R, LTRR, A4, LTR, Transparency...
  • Page 129: Paper Type

    Chapter 6 6.2.2 Paper Type 0002-5154 T-6-2 Source of paper Paper type Paper size Deck (left/ Manual Cassette right) feeder Plain paper A3, B4, A4R, (64 to 105g/m2) 279mm×432mm( Eco paper 11"×17"), LGL, Recycled paper LTRR Heavy paper A4, B5, LTR (106 to 209g/m2) 305mm×457mm( 12"×18"),...
  • Page 130: Accessories

    Chapter 6   6.2.3 Accessories 0003-5843 The following accessories are offered for the machine: 1. Finisher-R1 2. Saddle Finisher-R2 3. Additional Finisher Tray-A1 (Japanese model only) 4. Puncher Unit-L1 5. Side paper Deck-U1 6. Shift Tray -C1 7. Image Conversion Board-A2 8.
  • Page 131 Feb 4 2004...

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