Page 2 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 3: Table Of Contents
CONTENTS Contents CHAPTER 1 MAINTENANCE AND INSPECTION 1. Periodical Servicing Chart ....1-1 3.3 Printer Unit ........ 1-8 1.1 Reader Unit ........ 1-1 3.4 Side Paper Deck ......1-9 1.2 Printer Unit ........ 1-1 4. Points to Note for Periodical 1.3 Cleaning the photosensitive Servicing ........
Page 4 CONTENTS 4.14.1 New Fixing Web ....2-37 3.4 Mounting the Developing Blade ........2-22 4.14.2 Existing Fixing Web .... 2-37 3.4.1 Removing the Blade Unit ... 2-22 4.15 Position of the Side Paper 3.4.2 Mounting the Blade .... 2-22 Deck Pickup Roller Releasing 3.5 Replacing the Potential Sensor/ Solenoid ........
Page 5 CONTENTS 8.5 Conversion Table for the 9.2 Emergency Measure for a Fault Potential Control System ..2-55 in the Environment Sensor ..2-60 8.6 Emergency Measures for a 10. Checking the Photointerrupters ..2-61 Fault in the Potential Sensor ..2-59 10.1 Using a Meter ......
Page 6 CONTENTS 6.1 COPIER ........4-76 4.3 SORTER ........4-58 5. FUNCTION (operation/inspection 6.2 FEEDER ........4-92 mode) ..........4-59 6.3 SORTER ........4-92 5.1 COPIER ........4-59 6.4 BOARD ........4-93 5.2 FEEDER ........4-75 7. TEST (test print mode) ....4-94 6.
Page 7: Chapter 1 Maintenance And Inspection
CHAPTER 1 MAINTENANCE AND INSPECTION CHAPTER 1 MAINTENANCE AND INSPECTION 1. Periodical Servicing Chart Do not use solvents or oils other than those indicated. 1.1 Reader Unit × : Clean : Replace : Lubricate : Adjust : Inspect Intervals Unit Part Upon every...
Page 8 CHAPTER 1 MAINTENANCE AND INSPECTION Intervals Unit Part Upon every every every every Remarks installation 250,000 500,000 750,000 1,000,000 Charging Charging wire Replace with assembly cleaner charging wire (primary, pre- simulta- transfer, trans- neously. fer/separation) Grid wire (primary) Charging assembly shielding plate (each charging assembly)
Page 9 CHAPTER 1 MAINTENANCE AND INSPECTION Intervals Unit Part Upon every every every every Remarks installation 250,000 500,000 750,000 1,000,000 Developing Anti stray- assembly toner sheet Cleaner Side scraper Toner dish (rear, front) Fixing Inlet guide assembly Oil dish Thermistor Sub thermistor Thermal switch Delivery Separation...
Page 10: Cleaning The Photosensitive Drum
CHAPTER 1 MAINTENANCE AND INSPECTION 1.3 Cleaning the photosensitive drum Do not rotate the magnet roll during work. Otherwise, waste CK-0429 toner may fall through the cleaner assembly. 1) Slide out the process unit. (Be sure to place the drum protective sheet over the fixing/feeding unit.) 2) Take out the photosensitive drum.
Page 11: Periodically Replaced Parts
CHAPTER 1 MAINTENANCE AND INSPECTION 2. Periodically Replaced Parts Some parts of the machine must be replaced on a periodical basis to ensure a specific level of machine performance. (Once they fail, the consequences are likely to be consider- able.) Whenever possible, schedule the replacement to coincide with a scheduled visit to the user’s.
Page 12: Printer Unit
CHAPTER 1 MAINTENANCE AND INSPECTION 2.3 Printer Unit As of June 2000 Part name Part No. Q’ty Life Remarks Primary, pre-transfer, transfer, FB4-3687 500,000* separation charging wire Primary grid wire FY1-0883 500,000 Primary charging wire FF5-6883 500,000 Strengthened polish cleaner 1 type (blue) Primary charging wire FF2-6884...
Page 13: Consumables And Durables
CHAPTER 1 MAINTENANCE AND INSPECTION 3. Consumables and Durables Some parts of the machine are likely to require replacement because of wear or damage once or more over the period of machine warranty. Replace them when they fail. 3.1 Guide to Timing of Replacement You can check the timing of replacement for durables in service mode: COPIER>COUNTER>DRBL-1.
Page 14 CHAPTER 1 MAINTENANCE AND INSPECTION 3.3 Printer Unit As of June 2000 Part name Part No. Q’ty Life Remarks Pickup/feeding roller FB1-8581 120,000 (manual feed roller) Separation roller FB5-0873 120,000 (manual feed tray) Pickup roller FF5-1220 250,000 Each holder uses 2 pc. Pickup/feeding roller FF5-9779 250,000...
Page 15 CHAPTER 1 MAINTENANCE AND INSPECTION 3.4 Side Paper Deck As of June 2000 Part name Part No. Q’ty Life Remarks Pickup roller (front) FF5-1220 250,000 Pickup roller (rear) FF5-1221 250,000 Feeding roller FF5-9779 250,000 Separation roller FB2-7777-020 250,000 T01-304-01...
Page 16 CHAPTER 1 MAINTENANCE AND INSPECTION 4. Points to Note for Periodical Servicing Unless otherwise instructed, clean with lint-free paper and alcohol. • Make a thorough check of the block (front, rear) for melting by leakage, deformation by heat, cracking, discoloration (yellowing). If a fault is found, replace the part with a new one immediately.
Page 17 CHAPTER 1 IMAGE ADJUSTMENT BASIC PROCEDURE 5. Image Adjustment Basic Procedure 5.1 Making Pre-Checks <Pre-Checks> Points to Note When Making Checks on the Printer Side Clean the following: 1. Primary charging assembly grid wire 2. Primary charging wire The machine's potential control mechanism is designed for both 3.
Page 18 CHAPTER 1 IMAGE ADJUSTMENT BASIC PROCEDURE 5.2 Making Checks on the Printer Unit (1/2) <Checking Images> <Checking the Density Slope> <Checking fro Fogging> Checking Halftone Images REF. Are there vertical Generate a halftone image. Generate a blank print. *1:VD target value lines in the image? COPIER >DISPLAY >DPOT >VDT (for copier image) COPIER >DISPLAY >DPOT >VDT-P (for printer image)
Page 19 CHAPTER 1 IMAGE ADJUSTMENT BASIC PROCEDURE 5.3 Making Checks on the Printer Unit (2/2) <Checking the Solid Black Density> Generate a solid black print. <Checking the Halftone Density> Is the density too low or too high (too Generate a halftone image. light or too dark)? Check the following readings in service mode: COPIER>DISPLAY>DPOT>VDM (for copier image)
Page 20 CHAPTER 1 IMAGE ADJUSTMENT BASIC PROCEDURE 5.4 Making Checks on the Reader Unit <Checking the Solid Black Density> <Making Image Initial Checks> <Checking the Density Slope> <Checking for Fogging> Make a copy of Make a copy of Execute shading adjustment in service Is there a difference Are there vertical the NA3 Chart in text mode.
Page 21: Chapter 2 Standards And Adjustments
CHAPTER 2 STANDARDS AND ADJUSTMENTS CHAPTER 2 STANDARDS AND ADJUSTMENTS 1. Image Adjustments 1.1 Standards of Image Position The image margin/non-image width of a print made in Direct must be as follows: 2.5±1.5mm +1.5mm - 1.0mm F02-101-01 Image Leading Edge Margin F02-101-02 Left/Right Image Margin 2.5mm±1.5 +1.5mm...
Page 22: Checking The Image Position
CHAPTER 2 STANDARDS AND ADJUSTMENTS 1.2 Checking the Image Position Make prints using the following as the source of paper (10 prints each), and check to see that the image margin and the non-image width are as indicated: • Each cassette •...
Page 23: Left/Right Front Deck
CHAPTER 2 STANDARDS AND ADJUSTMENTS 1.3.2 Left/Right Front Deck 1) Loosen the four screws [2] and the two fixing screws [3] of the cassette front cover [1]. F02-103-03 2) Move the cassette guide assembly (front) [4] to the front or the rear to make adjustments.
Page 24: Duplex Feeding Unit
CHAPTER 2 STANDARDS AND ADJUSTMENTS 1.3.4 Duplex Feeding Unit 1) Adjust the image margin as indicated using service mode: COPIER>ADJUST>Feed- ADJ>ADJ-REFE. Edge of paper Decreasing the ADF-REFE setting Increasing the ADJ-REFE setting (A decrease by ‘ 23’ will (An increase by ‘ 23’ will increase ecrease the margin by 1 mm.) the margin by 1 mm.) 2.5mm±2.0...
Page 25: Adjusting The Image Leading Edge Margin
CHAPTER 2 STANDARDS AND ADJUSTMENTS 1.4 Adjusting the Image Leading Edge Margin 1) Adjust the image margin in service mode so that it is as indicated: COPIER>ADJUST>Feed-ADJ>REGIST. Decreasing the REGIST setting (A decrease by ‘10’ will increase the margin by 1 mm.) Edge of paper Increasing the REGIST setting (An increase by ‘10’...
Page 26 CHAPTER 2 STANDARDS AND ADJUSTMENTS 1.6 Adjusting the Leading Edge Non-Image Width 1) Adjust the non-image width in service mode so that it is as indicated: COPIER>ADJUST>ADJ-XY>ADJ-X. Decreasing the ADJ-X setting (A decrease by '12' will decrease the width by 1 mm.) Image leading edge Increasing the ADJ-X setting (An increase by '12' will increase the width by 1 mm.)
Page 27: Cable
CHAPTER 2 STANDARDS AND ADJUSTMENTS 2. Scanning System 2.1 Replacing the Scanner Drive Cable 2.1.1 Removing the Scanner System Drive Cable Obtain the following before starting to replace the scanner drive cable: • mirror positioning tool (FY9-3040-000) 1) Remove the ADF. 2) Remove the copyboard glass.
Page 28 CHAPTER 2 STANDARDS AND ADJUSTMENTS 8) Remove the two cable fixing screws [11] of the No. 1 mirror base [10]. 9) Remove the two springs [12] used to secure the cable in place. 10) Remove the cable fixing plate [13] and each pulley cable.
Page 29 CHAPTER 2 STANDARDS AND ADJUSTMENTS 2.1.2 Routing the Scanner Drive Cable Route the scanner cable to each pulley and hook mirror base in the order indicated: 1) Loosen the screw on the cable fixing plate. 2) Fit the ball of the cable into the hole of the drive pulley, and wind the cable (4 times in- ward, 5 times outward);...
Page 30: Adjusting The Position Of The
CHAPTER 2 STANDARDS AND ADJUSTMENTS When mounting the reader up- per frame, be sure to go through the following steps: 1) Fit the eight claws [1] of the reader frame correctly into the cut-offs in the reader upper frame. 2) Secure the positions [2] of the four left/ right claws using screws.
Page 31 CHAPTER 2 STANDARDS AND ADJUSTMENTS 2) Insert the pins of the mirror positioning tool (front [2]/rear [3]) into each of the holes [1]: No. 1 mirror base, No. 2 mir- ror base, and rail. The position of the No. 2 mirror base is adjusted by sliding the cable fixing plate to the front and the rear.
Page 32: After Replacing The Scanning
CHAPTER 2 STANDARDS AND ADJUSTMENTS 2.3 After Replacing the Scanning Lamp Execute ‘CCD auto adjustment’ in service mode, and record the updated CCD adjustment data on the service label. 1. CCD Auto Adjustment COPIER>FUNCTION>CCD> CCD-ADJ 2. CCD Adjustment Data all items under COPIER>ADJUST>CCD 2-12...
Page 33: Primary Charging Assembly
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3. Image Formation System 3.1 Routing the Grid Wire of the Primary Charging Assembly 1) Loosen the two mounting screws used to secure the left and right shielding Screws plates in place. 2) Loosen the three mounting screws used to secure the motor unit in place at the front.
Page 34 CHAPTER 2 STANDARDS AND ADJUSTMENTS 5) Cut the twisted charging wire (excess) Stud A with nippers. 6) Hook the loop on stud A. 7) After routing the wire for 31 runs, lead it through section B, and give it a half turn;...
Page 35: Routing The Charging Wire
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3.2 Routing the Charging Wire of Charging Assemblies 3.2.1 Routing the Charging Wire All charging wires (except the grid wire) are routed more or less in the same way; the fol- lowing cites the primary charging assembly: 1) Remove the shielding plate (left, right) of the charging assembly.
Page 36: Charging Wire
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3) Free a length of about 5 cm of charging wire from the charging wire reel (0.06 mm in diameter), and form a loop at its end with a diameter of about 2 mm. To form a loop, wind the charg- ing wire around a hex key once, REF.
Page 37 CHAPTER 2 STANDARDS AND ADJUSTMENTS 7) Cut off the excess of the charging wire with nippers. 8) Pick the end of the charging wire ten- sion spring with tweezers, and hook it on the charging power supply electrode. In the case of the pre-transfer charging assembly, hook the spring on the pin at the front.
Page 38 CHAPTER 2 STANDARDS AND ADJUSTMENTS 3.2.2 Adjusting the Height of the Charging Wire Charging assembly Height of charging wire Tolerance Primary ±1mm 7.5 +1.5 7.5 +1.5 - 0 mm - 0 mm Pre-transfer No height adjusting mechanism 10.06±0.3 mm Transfer 9.5±0.5mm ±2mm Separation...
Page 39: Removing The Cleaning Blade
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3.3 Mounting the Drum Cleaning Blade 3.3.1 Removing the Cleaning Blade 1) Slide out the process unit from the ma- chine. (See the Printer Manual : Chap.4 > 7.3 "Process Unit".) 2) Remove the primary charging assembly. 3) Disconnect the connector [1] of the AC line of the drum heater.
Page 40: Mounting The Cleaning Blade
CHAPTER 2 STANDARDS AND ADJUSTMENTS 6) Disconnect the connector [6], and re- move the two screws [7]; then, detach the pre-exposure LED assembly [8]. F02-203-11 7) Loosen the five mounting screws [9], and detach the blade support plate from the cleaning blade. F02-203-12 3.3.2 Mounting the Cleaning Blade When mounting the cleaning blade, be sure that the side with the marking [1] will be the...
Page 41 CHAPTER 2 STANDARDS AND ADJUSTMENTS 2) Tighten the five mounting screws [2] lightly, stopping to turn them when re- sistance is felt. 3) Turn the screws tightened lightly in step 2) about 20° to 30° in the order indi- cated, tightening them fully. Order of tightening F02-203-14 After mounting the cleaning...
Page 42: Mounting The Developing Blade
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3.4 Mounting the Developing Blade 3.4.1 Removing the Blade Unit 1) Take the developing assembly out of the machine. 2) Remove the two mounting screws [1], and detach the developing assembly cover [2]. F02-203-15 3) Place a newspaper on the floor or a desk, and pour out the toner onto the newspaper from the developing assem- bly.
Page 43: Replacing The Potential Sensor/Potential Control Pcb
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3.5 Replacing the Potential Sensor/Potential Control PCB 3.5.1 Removing the Potential Sensor/Potential Control PCB Be sure to replace the potential sensor and the potential control PCB at the same time. 1) Open the front cover, and slide out the hopper unit.
Page 44 CHAPTER 2 STANDARDS AND ADJUSTMENTS 7) Remove the two screws [9], and detach [10] the potential control PCB together with the mounting base [10]. F02-203-20 8) Remove the four screws [11] and three [11] connectors [12], and detach the poten- tial control PCB [13].
Page 45: Adjusting The Potential Sensor
CHAPTER 2 STANDARDS AND ADJUSTMENTS 3.5.2 Adjusting the Potential Sensor The potential sensor and the po- tential control PCB are adjusted in a pair, requiring simultaneous replacement. 1) Start service mode, and set ‘0’ to the following to disable potential control: COPIER>OPTION>BODY>PO-CNT.
Page 46 CHAPTER 2 STANDARDS AND ADJUSTMENTS 6) Insert the door switch actuator into the door switch assembly. 7) Connect the power plug to the power outlet, and turn on the main power switch. 8) Execute the following in service mode: COPIER>FUNCTION>DPC>OFST. 9) Record the setting of <OFST>...
Page 47: Pickup/Feeding System
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4. Pickup/Feeding System 4.1 Orientation of the Deck/Cassette Pickup Roller The pickup roller may be mounted by reversing the steps used to remove it; however, be sure to keep the following in mind: • The pickup rollers used at the front and the rear of the machine are not interchangeable. •...
Page 48: Orientation Of The Deck/Cassette Separation Roller
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.2 Orientation of the Deck/Cassette Separation Roller When replacing the separation roller, be sure it is oriented as follows: Cassette 3/4, Right Pickup Assembly Left Deck Pickup Assembly Narrower groove Wider groove Narrower groove (rear of machine) (front of machine) Wider groove F02-402-01...
Page 49: Orientation Of The Pickup Roller Of The Side Paper Deck
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.4 Orientation of the Pickup Roller of the Side Paper Deck The pickup roller may be mounted by reversing the steps used to remove it; however, be sure to keep the following in mind: • The pickup rollers used at the front and the rear of the machine are not interchangeable.
Page 50: Orientation Of The Feeding Roller Of The Side Paper Deck
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.5 Orientation of the Feeding Roller of the Side Paper Deck When mounting the feeding roller assembly [1] to the side paper deck, be sure that the belt pulley [2] is toward the front of the machine. When mounting the feeding roller [3] to the feeding roller shaft [4], be sure that the round marking [5] is toward the rear of the ma- chine.
Page 51: Adjusting The Pressure Of The Separation Roller Of The Deck/Cassette
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.6 Adjusting the Pressure of the Separation Roller of the Deck/Cassette If double feeding or pickup failure occurs during pickup, change the position of the pres- sure spring of the separation roller: • If double feeding occurs, move the hook of the spring in the direction of B. •...
Page 52: Adjusting The Pressure Of The Separation Roller Of The Manual Feed Tray
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.7 Adjusting the Pressure of the Separation Roller of the Manual Feed Tray If double feeding or pickup failure occurs during pickup, adjust the position of the pres- sure spring of the separation roller. 1) Remove the right upper cover. 2) Remove the upper guide [1].
Page 53: Adjusting The Fixing Inlet Guide Solenoid (Sl1)
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.8 Adjusting the Fixing Inlet Guide Solenoid (SL1) Adjust the position of the solenoid using the two screws [1] so that the guide will be posi- tioned as indicated when the solenoid turns on. Upper roller Lower roller Inlet guide Solenoid...
Page 54: Adjusting The Position Of The Pickup Solenoid (Sl3, Sl4) Of The Cassette 3/4
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.9 Adjusting the Position of the Pickup Solenoid (SL3, SL4) of the Cassette 3/4 Adjust the position of the solenoid using the two screws [3] so that the distance from the bottom of the pickup assembly to A of the roller arm is 36±0.5 mm when [1] and [2] are op- erated.
Page 55: Adjusting The Position Of The Delivery Flapper Solenoid (Sl5)
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.10 Adjusting the Position of the Delivery Flapper Solenoid (SL5) Adjust the position of the mounting screw [2] using the screw [2] so that the drive lever [1] is pushed fully when the solenoid turns on (i.e., when the plunger is drawn). F02-410-01 4.11 Adjusting the Position of the Right Deck Pickup Solenoid (SL6)
Page 56: Adjusting The Position Of The Left Deck Pickup Solenoid (Sl7)
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.12 Adjusting the Position of the Left Deck Pickup Solenoid (SL7) Before removing the left deck pickup solenoid from the support plate [1], take note of its position with reference to the fixing screw [2] of the solenoid. Or, mark the position for the solenoid by drawing a line on the support plate with a scriber.
Page 57: Adjusting The Position Of The Fixing Web Solenoid (Sl9)
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.14 Adjusting the Position of the Fixing Web Solenoid (SL9) 4.14.1 New Fixing Web Adjust the position for the solenoid using the screw [2] so that the distance of travel of the drive lever [1] is 8.6 mm. 8.6mm F02-414-01 4.14.2 Existing Fixing Web...
Page 58: Position Of The Side Paper Deck Pickup Roller Releasing Solenoid
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.15 Position of the Side Paper Deck Pickup Roller Releasing Solenoid Before removing the deck pickup roller releasing solenoid [1] from the support plate, take note of the position of the two fixing screws [2] of the solenoid with reference to the index on the support plate.
Page 59: Attaching The Drive Belt
CHAPTER 2 STANDARDS AND ADJUSTMENTS 4.17 Attaching the Drive Belt Attach the drive belt on the pulley and the rollers as indicated. Main drive belt Paper feed drive belt F02-417-01 2-39...
Page 60: Fixing System
CHAPTER 2 STANDARDS AND ADJUSTMENTS 5. Fixing System 5.1 Points to Note When Mounting the Fixing Heater 1) Do not touch the surface of the heater. 2) For both heaters, be sure that the side with the longer harness is toward the front. 3) Mount the main heater [1] to the right side and the sub heater [2] to the left side (view- ing from the front of the fixing assembly).
Page 61: Adjusting The Lower Roller Pressure (Nip)
CHAPTER 2 STANDARDS AND ADJUSTMENTS 5.3 Adjusting the Lower Roller Pressure (nip) 5.3.1 Taking Measurements Wait for 15 min after the machine ends its warm-up; then, make 20 A4 copies before starting the work: 1) Place A4 or LTR paper, and select A4 or Feeding LTR in the control panel.
Page 62: Laser Exposure System
CHAPTER 2 STANDARDS AND ADJUSTMENTS 6. Laser Exposure System 6.1 When Replacing the Scanner Unit If the temperature of the fixing assembly is 150°C or higher when the scanner unit is re- placed, force potential control in service mode: 1) Make the following selections in service mode: COPIER>FUNCTION>DPC>DPC. 2) Turn off and then on the main power switch.
Page 63: Electrical Parts
CHAPTER 2 STANDARDS AND ADJUSTMENTS 7. Electrical Parts 7.1 When Replacing the CCD Unit 1) Replace the CCD unit. 2) After assembling the machine, connect the power plug to the power outlet, and turn on the main power switch. 3) Execute the following modes: CCD auto adjustment: COPIER>FUNCTION>CCD>CCD-ADJ CCD edge gain correction position auto adjustment: COPIER>FUNCTION>CCD>EGGN-POS...
Page 64: When Replacing The Main Controller Pcb
CHAPTER 2 STANDARDS AND ADJUSTMENTS 7.3 When Replacing the Main Controller PCB 1) Replace the main controller PCB. 2) Remove the counter memory PCB from the existing PCB, and mount it to the new PCB. 3) After assembling the machine, connect the power plug to the power outlet, and turn on the main power switch.
Page 65: When Replacing The Dc Controller Pcb
CHAPTER 2 STANDARDS AND ADJUSTMENTS 7.5 When Replacing the DC Controller PCB 1) Print out the data of user mode/service mode. 2) Replace the DC controller PCB. 3) Remove the EEPROMs (6 pc.) from the existing PCB, and mount them to the new PCB. 4) After assembling the machine, connect the power plug to the power outlet, and turn on the main power switch.
Page 66: When Replacing The High-Voltage Pcb
CHAPTER 2 STANDARDS AND ADJUSTMENTS 7.6 When Replacing the High-Voltage PCB 1) Replace the high-voltage PCB. 2) After assembling the machine, connect the power plug, and turn on the main power switch. 3) Enter the values recorded on the label attached to the new high-voltage PCB in the fol- lowing service mode items: COPIER>ADJUST>DEVELOP>HVT-DE COPIER>ADJUST>HV-TR>HVT-TR...
Page 67: Checking The Surface Potential Control System
CHAPTER 2 STANDARDS AND ADJUSTMENTS 8. Checking the Surface Potential Control System 8.1 Outline In the event of an image fault, it is important to find out if the cause is within the static latent image formation block (including the photosensitive drum and the potential control system) or is with the developing/transfer mechanism;...
Page 68: Zero Level Check
CHAPTER 2 STANDARDS AND ADJUSTMENTS 8.3 Zero Level Check A "zero level check" is a check made to find out whether the control system of the DC controller PCB identifies 0 V when the drum surface potential is 0 V. A zero level check may be made in either of two ways, so as to find out whether a circuit on the the DC controller PCB or the potential measurement circuit is normal: 1) Method 1:...
Page 69 CHAPTER 2 STANDARDS AND ADJUSTMENTS 4) Open the front cover, and slide out the pickup feeding unit to the front. 5) Remove the three screws [3], and detach the front switch cover [4]. F02-803-02 6) Free the cable of the potential control PCB from the cable clamp, and disconnect the connector (4-pin) [5] connected to the DC controller PCB.
Page 70: Method 2
CHAPTER 2 STANDARDS AND ADJUSTMENTS 11) Connect the connector of the cable (of the potential control PCB). 12) Mount the front switch cover, and close the front cover. 13) Mount the rear upper cover. 14) Turn on the main power switch. 8.3.2 Method 2 1) Disable potential control so that the machine will be in non-auto control mode.
Page 71 CHAPTER 2 STANDARDS AND ADJUSTMENTS Be sure to fit the clip [3] fully away from the sensor window, not letting it coming into contact with the cover of the sensor. 7) Insert the door switch tool into the door switch assembly. 8) Turn on the main power switch.
Page 72 CHAPTER 2 STANDARDS AND ADJUSTMENTS Blank Page 2-52...
Page 73: Checking The Potential System
CHAPTER 2 STANDARDS AND ADJUSTMENTS 8.4 Checking the Potential System START Disable potential control: COPIER> OPTION>BODY>PD-CNT=0 Checking the Primary Output Checking the Laser Output Is the image better? Enable potential control: COPIER> Disable potential control: COPIER> OPTION>BODY>PO-CNT=1. OPTION>BODY>PO-CNT=0 Turn off the main power switch. Make the following selections in Measure the voltage PR-CNT during copying Forced execution...
Page 74 CHAPTER 2 STANDARDS AND ADJUSTMENTS Checking the Developing Bias Output Checking the Transfer Output Is the toner Enable potential control: COPIER> image on the photosensitive OPTION>BODY>PO-CNT=1 Replace the photosensitive drum before transfer drum. normal? Measure the voltage DEV-DC-CNT during printing of J102A-8 on the DC Disable potential control: COPIER>...
Page 75: Conversion Table For The Potential Control System
CHAPTER 2 STANDARDS AND ADJUSTMENTS 8.5 Conversion Table for the Potential Control System Control[V] Primary[µA] Developing bias[V] Pre-transfer[µA] Transfer[µA] Separation[µA] 3.00 1,400 3.05 1,391 3.10 1,382 3.15 1,373 3.20 1,365 3.25 1,356 3.30 1,347 3.35 1,338 3.40 1,330 3.45 1,321 3.50 1,312 3.55...
Page 76 CHAPTER 2 STANDARDS AND ADJUSTMENTS Control[V] Primary[µA] Developing bias[V] Pre-transfer[µA] Transfer[µA] Separation[µA] 5.00 1,050 5.05 1,041 5.10 1,032 5.15 1,023 5.20 1,015 5.25 1,006 5.30 5.35 5.40 5.45 -101 5.50 -103 5.55 -105 5.60 -107 5.65 -109 5.70 -111 -102 5.75 -113 -106...
Page 77 CHAPTER 2 STANDARDS AND ADJUSTMENTS Control[V] Primary[µA] Developing bias[V] Pre-transfer[µA] Transfer[µA] Separation[µA] 7.00 -165 -200 7.05 -167 -203 7.10 -169 -207 7.15 -171 -211 7.20 -173 -215 7.25 -175 -218 7.30 -177 -222 7.35 -179 -226 7.40 -181 -230 7.45 -183 -233 7.50...
Page 78 CHAPTER 2 STANDARDS AND ADJUSTMENTS Control[V] Primary[µA] Developing bias[V] Pre-transfer[µA] Transfer[µA] Separation[µA] 9.00 -247 -350 9.05 -249 -353 9.10 -251 -357 9.15 -253 -361 9.20 -255 -365 9.25 -257 -368 9.30 -259 -372 9.35 -261 -376 9.40 -264 -380 9.45 -266 -383 9.50...
Page 79: Emergency Measures For A Fault In The Potential Sensor
CHAPTER 2 STANDARDS AND ADJUSTMENTS 8.6 Emergency Measures for a Fault in the Potential Sensor If transfer separation fails because of a fault in the potential sensor, try using the follow- ing service mode items to get around the problem; keep in mind, however, that this is no more than a temporary measure used until the replacement of the potential sensor: 1.
Page 80: Checking The Environment Sensor
CHAPTER 2 STANDARDS AND ADJUSTMENTS 9. Checking the Environment Sensor 9.1 Procedure Check the environment sensor using the environment sensor tool to see that it operates normally. 1) Make the following selections in service mode, and obtain the following data: COPIER>DISPLAY>ANALOG.
Page 81 CHAPTER 2 STANDARDS AND ADJUSTMENTS 10. Checking the Photointerrupters The machine’s photointerrupters may be checked by means of a meter or service mode. 10.1 Using a Meter Set the meter range to 300 VDC. Connect the - probe of the meter to the GND terminal of the PCB to check. Connect the + probe of the meter to the terminals indicated.
Page 82 CHAPTER 2 STANDARDS AND ADJUSTMENTS Printer Unit (service mode: COPIER>I/O>DC-CON) Sensor Connector No. Checks Voltage I/O address display display D>J113-A14 Open and close the right lower cover. Cover Open Right lower cover open/closed sensor --- Closed D>J103-B14 Open and close the manual feed tray. Tray Open Manual feed tray open/closed sensor IO-P03-13 Closed...
Page 83 CHAPTER 2 STANDARDS AND ADJUSTMENTS Sensor Connector No. Checks Voltage I/O address display display PS20 D>J115-A11 Put paper over the point of Paper Present Left deck re-try sensor IO-P02-2 detection. Absent PS21 D>J110-A8 Put paper over the point of Paper Present Cassette 3 re-try sensor IO-P02-0...
Page 84 CHAPTER 2 STANDARDS AND ADJUSTMENTS Sensor Connector No. Checks Voltage I/O address display display PS38 D>J107-B16 Put paper over the point of Paper Present Reversal sensor 2 IO-P02-7 detection. Absent PS45 D>J106-B5 Put paper over the Present Fixing web length sensor IO-P02-12 sensor.
Page 85: Chapter 3 Arrangement And Functions Of
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.1 Clutches F03-101-01 1.1.1 Reader Unit The reader unit does not have a clutch. 1.1.2 Printer Unit Symbol Name Notation Function Clutch Drives the developing cylinder. Drives the registration roller.
Page 86: Solenoids And Switches
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.2 Solenoids and Switches MSW2 MSW3 MSW1 F03-102-01...
Page 87: Reader Unit
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.2.1 Reader Unit The reader unit does not have a solenoid or a switch. 1.2.2 Printer Unit Symbol Name Notation Function Solenoid Drives the fixing assembly inlet guide. Drives the manual feed pickup mechanism. Drives the cassette 3 pickup mechanism.
Page 88: Motors
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.3 Motors F03-103-01...
Page 89: Reader Unit
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.3.1 Reader Unit Symbol Name Notation Function Motor Scanner motor 1.3.2 Printer Unit Symbol Name Notation Function Motor Drum motor Main motor Left deck lifter motor Right deck lifter motor Primary charging wire cleaning motor Pre-transfer charging wire cleaning motor Transfer/separation charging wire cleaning motor Hopper stirring motor...
Page 90: Fans
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.4 Fans F03-104-01...
Page 91: Reader Unit
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.4.1 Reader Unit The reader unit does not have a fan. 1.4.2 Printer unit Symbol Name Notation Function Feeding fan Primary charging cooling fan Heat discharging fan Controller cooling fan De-curling fan DC power supply fan HDD fan Duplex feeding fan...
Page 92: Sensors
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.5 Sensors PS23 PS25 PS48 PS47 PS26 PS50 PS13 PS49 PS21 SVR4 PS17 PS15 SVR2 PS27 SVR5 PS14 PS22 SVR3 PS18 PS16 PS43 PS39 PS40 PS24 PS28 PS32 PS19 PS11 PS12 PS20 PS10 F03-105-01...
Page 93 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS SVR1 PS30 PS34 PS31 PS38 PS33 PS37 PS29 PS35 PS45 PS36 PS46 F03-105-02...
Page 94: Reader Unit
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.5.1 Reader Unit Symbol Name Notation Function Photointerrupter PS39 Scanner HP sensor PS40 Copyboard cover sensor SIZE Photosensor PS43 Original sensor 1.5.2 Printer Unit Symbol Name Notation Function Photointerrupter Right lower cover open/closed sensor Manual feed tray open/closed sensor Claw jam sensor Right deck open/closed sensor...
Page 95 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS Symbol Name Notation Function Photointerrupter PS31 Duplex horizontal registration sensor PS32 Right deck feed paper sensor PS33 Left deck feed paper sensor PS34 Duplexing paper sensor PS35 Internal delivery sensor PS36 External delivery sensor PS37 Reversal sensor 1 PS38...
Page 96: Lamps, Heaters, And Others
CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.6 Lamps, Heaters, and Others THM2 THM1 ELCB F03-106-01 3-12...
Page 97 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.6.1 Reader Unit Name Notation Function Lamp Scanning lamp Heater Lens heater (standard in 100-V model) Mirror heater (standard in 100-V model) 1.6.2 Printer Unit Name Notation Function Lamp LA1 Pre-exposure lamp (LED) Heater Fixing main heater Fixing sub heater...
Page 98 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.7 PCBs F03-107-01 3-14...
Page 99 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.7.1 Reader Unit Ref. Name Function Reader controller PCB Controls the reader unit/ADF. CCD/AP PCB Drives the CCD/processes analog images. Inverter PCB Controls the scanning lamp. Fuse PCB Controls the mirror/lens heater. (standard in 100-V model) 1.7.2 Printer unit Ref.
Page 100 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.8 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB Of the VRs, LEDs, and switches found on the machine, those used in the field are dis- cussed: 1. Some LEDs have leakage current and emit dim light when off; this is a normal condition and must be kept in mind: 2.
Page 101 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.8.2 DC Controller PCB J117 J120 J116 J121 J123 J302 J114 J201 A1 A9 A1 A20 J115 J102 J107 J112 J104 J105 B9 B1 F03-108-02 The shorting connectors of J303 are set as follows; be sure to transfer the shorting con- nectors to the new PCB upon replacement: 100V 120V...
Page 102 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.8.3 Reader Controller PCB J5021 J5009 J5015 J5013 SW5001 J5014 J5005 J5007 J5012 J5006 J5002 J5008 J5001 J5004 F03-108-04 SW5001-1 SW5001-2 Inch series. Not used. OFF: AB series Not used. 1.8.4 Power Supply PCB 10 1 PN4004 PN4003...
Page 103 CHAPTER 3 ARRANGEMENT AND FUNCTIONS OF ELECTRICAL PARTS 1.8.5 HVT PCB J4504 J4506 J4507 J4508 VR4501 13 1 J4502 J4503 J4501 F03-108-06 1.8.6 Drum Heater Control PCB SW2001 J2001 F03-108-07 SW2001-1 SW2001-2 controlled to 47°C Not used. OFF: controlled to 43°C (default) Not used For details of drum heater control, see 6.
Page 105: Chapter 4 Service Mode
CHAPTER 4 SERVICE MODE CHAPTER 4 SERVICE MODE 1. Organization of Service Mode 1.1 Outline The screens in service mode are grouped into three: Initial screen, Level 1/Level 2 screen, and Level 3 screen. User screen ( )(2,8)( ) Reset key Initial screen Reset key Select an item.
Page 106: Starting Service Mode And Making Selections
CHAPTER 4 SERVICE MODE The machine’s service mode is divided into the following seven types: COPIER FEEDER DISPLAY Control display mode SORTER I/O display mode BOARD ADJUST Adjustment mode FUNCTION Operation/inspection mode OPTION Settings mode TEST Test print mode COUNTER Counter mode F04-101-02 1.2 Starting Service Mode and Making Selections...
Page 107: Ending Service Mode
CHAPTER 4 SERVICE MODE 1.3 Ending Service Mode Press the Reset key once to return to the service mode Initial screen (F05-102-01). Press the Reset key twice to end service mode and to return to the User (standard) screen. If you used ADJUST, FUNCTION, or OPTION in service mode, be sure to turn off and then on the power switch after ending service mode.
Page 108: Basic Operations
CHAPTER 4 SERVICE MODE 1.5 Basic Operations 1.5.1 Initial Screen COPIER Initial item FEEDER Touch to select an item SORTER BOARD F04-105-01 1.5.2 Level 1/Level 2 Screen Level 1 item Touch to select an item VERSION USER DPOT ACC-STS ANALOG Level 2 items CST-STS SENSOR...
Page 109: Level 3 Screen
CHAPTER 4 SERVICE MODE 1.5.3 Level 3 Screen Page number < 1/2 > < READY > <VERSION> DC-CON Level 2 item ready to accept a servicing/ READY: R-CON copying operation. paper jam exists. PANEL JAM: service operation under way. SERVICE: FEEDER initial rotation or the like under WAITING:...
Page 110: Display (Control/Display Mode)
CHAPTER 4 SERVICE MODE 2. DISPLAY (control/display mode) 2.1 COPIER The following screen appears in response to COPIER>DISPLAY; for the items, see the pages that follow: VERSION USER DPOT ACC-STS ANALOG CST-STS SENSOR MISC ALARM-1 HV-STS F04-201-01...
Page 111 CHAPTER 4 SERVICE MODE COPIER>DISPLAY <VERSION> Indicates the PCB ROM versions of the machine and accessories. Indication<xx, yy> xx: version number yy:R & D control number. DC-CON Indicates the ROM version of the DC controller PCB. R-CON Indicates the ROM version of the reader controller PCB. PANEL Indicates the ROM version of the control panel CPU PCB.
Page 112 COUNTER Indicates the type of control of the software counter. (00: 100 V, 01: USA, Europe) MODEL Indicates the identification of the model. (0: iR5000, 1: iR6000) <ACC-STS> Indicates the connection of accessories. FEEDER Indicates the connection of the ADF. (0: not connected, 1: connected) SORTER Indicates the state (connection) of the finisher and the puncher unit.
Page 113 CHAPTER 4 SERVICE MODE COPIER>DISPLAY Indicates the size of the memory mounted to the main controller. (64 MB, 128 MB) Indicates the connection of a network board. (0: none, 1: Etherboard, 2: To- ken-Ring, 3: both) LIPS-RAM Indicates the size of the memory mounted on the LIPS board. (xx MB) LIPS Indicates the connection of the LIPS board.
Page 114 CHAPTER 4 SERVICE MODE COPIER>DISPLAY <CST-STS> Indicates the paper size of the cassette and the manual feeder. WIDTH-C3 Indicates the paper width of the cassette 3 in terms of paper size. WIDTH-C4 Indicates the paper width of the cassette 4 in terms of paper size. (100-V model only) WIDTH-MF Indicates the paper width of the manual feeder in terms of paper size.
Page 115 CHAPTER 4 SERVICE MODE COPIER>DISPLAY <JAM> Indicates jam data. < JAM > < 1/7 > < READY > AAA BBBB CCCC DDDD E FFff G HHHHHH IIIII AAA BBBB CCCC DDDD E FFff G HHHHHH IIIII AAA BBBB CCCC DDDD E FFff G HHHHHH IIIII AAA BBBB CCCC DDDD E FFff G HHHHHH IIIII AAA BBBB CCCC DDDD E FFff G HHHHHH IIIII AAA BBBB CCCC DDDD E FFff G HHHHHH IIIII...
Page 116 CHAPTER 4 SERVICE MODE COPIER>DISPLAY FF: Types of Jams G: Source of Paper Code Type Code Description 00xx none right front deck 01xx delay jam left front deck 02xx stationary jam cassette 3 0Axx stationary jam at power-on cassette 4 0Bxx front cover open jam not used...
Page 117 CHAPTER 4 SERVICE MODE COPIER>DISPLAY <ERR> Indicates error data. < 1/7 > < READY > < ERR > AAA BBBB CCCC DDDD EEEE FFff G AAA BBBB CCCC DDDD EEEE FFff G AAA BBBB CCCC DDDD EEEE FFff G AAA BBBB CCCC DDDD EEEE FFff G AAA BBBB CCCC DDDD EEEE FFff G AAA BBBB CCCC DDDD EEEE FFff G AAA BBBB CCCC DDDD EEEE FFff G...
Page 118 CHAPTER 4 SERVICE MODE COPIER>DISPLAY <HV-STS> Indicates the measurements taken of the voltage/current system. PRIMARY Indicates the level of primary charging current. PRE-TR Indicates the level of current for pre-transfer (post) charging. Indicates the level of transfer charging current. Indicates the level of separation charging current. BIAS Indicates the level of developing bias DC.
Page 119 CHAPTER 4 SERVICE MODE COPIER>DISPLAY <DPOT> Indicates the photosensitive drum surface potential control data. DPOT-K Indicates the surface potential of the photosensitive drum. (unit: V) VL1T Indicates the target value of the light-area potential (VL1) for copying. VL1M Indicates the measurement taken of the light-area potential (VL1) for copy- ing.
Page 120 CHAPTER 4 SERVICE MODE PLMT-P Indicates the primary charging current control mechanism for printer (PDL) images. (0: normal, 1: error) LLMT Indicates the laser power voltage control mechanism for copying. (0: nor- mal, 1: error) PLMT Indicates the primary charging current control mechanism for copying. (0: normal, 1: error) BIAS-P Indicates the result of potential control for the developing bias for copying.
Page 121 CHAPTER 4 SERVICE MODE <ALARM-1> Indicates alarm data. < ALRM-1 > < 1/1 > < READY > BODY SORTER ww xx yy zz F04-201-04 4-17...
Page 122 CHAPTER 4 SERVICE MODE Item Description Remarks BODY Indicates alarms associated with the 01: right front deck lifter copying machine. fault 02: left front deck lifter fault 03: cassette 3 lifter fault 04: cassette 4 lifter fault 05: paper deck lifter fault 10: primary charging assembly leakage 11: transfer charging...
Page 123 CHAPTER 4 SERVICE MODE FEEDER>DISPLAY 2.2 FEEDER FEEDSIZE Indicates the size of an original detected by the ADF. 4-19...
Page 124: I/O (I/O Display Mode)
CHAPTER 4 SERVICE MODE 3. I/O (I/O display mode) The following screen appears in response to COPIER>I/O; for the items, see the pages that follow: Input/output port of DC controller PCB DC-CON R-CON Input/output port of reader controller PCB Input/output port of ADF controller PCB FEEDER SORTER Input/output port of finisher controller PCB...
Page 125 CHAPTER 4 SERVICE MODE COPIER>I/O 3.1 DC-CON Indicates the input/output ports of the DC controller PCB. <DC-CON (1/8)> Address Notation Description Remarks IO-P01 PS23 manual feed paper sensor signal 0: paper present PS29 registration paper sensor signal 1: paper present PS19 right deck re-try sensor signal 1: paper present...
Page 126 CHAPTER 4 SERVICE MODE COPIER>I/O <DC-CON (2/8)> Address Notation Description Remarks PS10 left deck lifter sensor signal 1: paper present PS12 left deck limit sensor signal 1: limit PS17 cassette 3 lifter sensor signal 1: paper present PS18 cassette 4 lifter sensor signal 1: paper present cassette 4 universal detection 0: universal...
Page 127 CHAPTER 4 SERVICE MODE COPIER>I/O <DC-CON (3/8)> Address Notation Description Remarks PS49 left deck paper level sensor (upper) signal 1: paper present SSR error signal 1: error not used PS48 right deck paper level sensor (lower) signal 1: paper present PS50 left deck paper level sensor (lower ) signal 1: paper present...
Page 128 CHAPTER 4 SERVICE MODE COPIER>I/O <DC-CON (4/8)> Address Notation Description Remarks high-voltage transfer error signal high-voltage primary error signal not used IO-P08 developing clutch drive signal 1: ON registration roller clutch drive signal 0: ON manual feed pickup clutch drive signal 1: ON not used not used...
Page 129 CHAPTER 4 SERVICE MODE COPIER>I/O <DC-CON (5/8)> Address Notation Description Remarks primary charging wire cleaning motor (CW) signal 1: ON pre-transfer charging wire cleaning motor (CW) 1: ON signal pre-transfer charging wire cleaning motor 1: ON (CCW) signal transfer/separation charging wire cleaning motor (CW) signal 1: ON transfer/separation charging wire cleaning motor (CCW) signal 1: ON...
Page 130 CHAPTER 4 SERVICE MODE COPIER>I/O <DC-CON (6/8)> Address Notation Description Remarks not used not used not used not used pre-exposure LED ON signal 1: ON potential sensor ON signal 1: ON fixing 12 V supply signal 0: supplied IO-P16 DDI-PPRDY DDI-CTS not used not used...
Page 131 CHAPTER 4 SERVICE MODE COPIER>I/O <DC-CON (7/8)> Address Notation Description Remarks delivery motor clock signal IO-P20 registration roller clutch ON signal not used not used not used not used pre-registration motor clock signal not used duplexing feed right motor clock signal IO-P21 serial 0-TXD serial 1-TXD...
Page 132 CHAPTER 4 SERVICE MODE COPIER>I/O <DC-CON (8/8)> Address Notation Description Remarks pulse count INT DMA-END-INT DMA-REQ-INT IO-P25 SW101 deck open detection switch signal 0: closed PS102 deck paper absent sensor signal 1: paper present PS103 deck lifter upper limit sensor signal 1: upper limit PS101 deck pickup sensor signal...
Page 133 CHAPTER 4 SERVICE MODE COPIER>I/O 3.2 R-CON Indicates the input/output ports of the reader controller PCB. <R-CON (1/2)> Address Notation Description Remarks IO-P1 scanner motor clock signal when 1→0, ON scanner motor CCW/CW switch signal 0: CCW, 1: CW scanner motor HOLD/OFF switch signal 0: current hold, 1: current OFF scanner motor driver reset signal...
Page 134 CHAPTER 4 SERVICE MODE COPIER>I/O <R-CON (2/2)> Address Notation Description Remarks PCB check mode (for factory) 0: check mode scanning lamp (LOW/HI) switch signal not used CS output to EEPROM 1: CP PS39 scanner HP sensor signal 1: HP ADF-ITOP (image leading edge) signal 0: ADF original image leading edge interrupt PS40...
Page 135: Mn-Con
CHAPTER 4 SERVICE MODE COPIER>I/O 3.3 MN-CON Indicates the input/output ports of the main controller PCB. <MN-CON (1/2)> Address Notation Description Remarks P001 GPDATA not used (1 fixed) not used (1 fixed) not used (1 fixed) not used (1 fixed) P002 SPRTST signal, printer start-up signal 0: reader image start...
Page 136 CHAPTER 4 SERVICE MODE COPIER>I/O <MN-CON (2/2)> Address Notation Description Remarks delivery count 1: counter pickup count 1: counter serial EEPROM DIN access port to EEPROM serial EEPROM SCK access port to EEPROM serial EEPROM CS access port to EEPROM PCI (PDL) soft reset 0: LIPS board forced reset not used...
Page 137: Feeder
CHAPTER 4 SERVICE MODE COPIER>I/O 3.4 FEEDER Indicates the input/output ports of the ADF controller PCB. <FEEDER (1/3)> Address Notation Description Remarks IO-P01 feed motor drive clock not used feed motor clock LB pickup motor clock LB not used delivery reversal motor clock LB large/small identification sensor signal 1: paper present (large) A4R/LTRR identification sensor signal...
Page 138 CHAPTER 4 SERVICE MODE COPIER>I/O <FEEDER (2/3)> Address Notation Description Remarks D/A load signal not used not used not used not used IO-P06 EEPROM data input cooling fan lock signal 1: locked cooling fan not used post-separation sensor signal (IRQ0) registration 1 sensor signal (IRQ1) read sensor signal...
Page 139 CHAPTER 4 SERVICE MODE COPIER>I/O <FEEDER (3/3)> Address Notation Description Remarks not used not used not used not used not used not used not used IO-P11 LED4 LED ON signal 0: ON LED3 LED ON signal 0: ON LED2 LED ON signal 0: ON LED1 LED ON signal...
Page 140: Sorter
CHAPTER 4 SERVICE MODE 3.5 SORTER Indicates the input/output ports of the finisher controller PCB. <Sorter (1/3)> 3.5.1 Finisher Block Address Notation Description Remarks IO-P01 not used (output) not used No. 2 feed motor phase A output No. 2 feed motor phase B output stapler shift motor phase B output stapler shift motor phase A output alignment motor phase B output...
Page 141 CHAPTER 4 SERVICE MODE Address Notation Description Remarks IO-P05 inlet feed motor phase A output (output) inlet feed motor phase B output not used not used not used not used not used not used 8-15 not used IO-P06 stapler tray paper detection signal 0: paper present (input) punch motor clock detection signal...
Page 142 CHAPTER 4 SERVICE MODE Address Notation Description Remarks not used not used 8-15 not used IO-P10 0-15 not used IO-P11 0-15 not used IO-P12 stapler connection detection signal 0: connected (input) stapler cartridge detection 0: cartridge present staple ready signal staple absent detection signal 0: staple present not used...
Page 143 CHAPTER 4 SERVICE MODE Address Notation Description Remarks IO-P17 PI15 joint detection signal 1: connected (input) PI16 cover open/closed detection signal 1: closed saddle unit connection detection signal tray upper limit detecting switch signal 1: upper limit tray safety switch signal 0: safe cover open/closed detecting switch signal 0: closed...
Page 144 CHAPTER 4 SERVICE MODE Address Notation Description Remarks IO-P21 belt escape solenoid drive signal 1: ON (output) buffer outlet solenoid drive signal 1: ON not used buffer inlet solenoid drive signal 1: ON flapper solenoid drive signal 1: ON paddle solenoid drive signal 1: ON solenoid timer output escape solenoid drive signal...
Page 145: Saddle Stitcher Unit
CHAPTER 4 SERVICE MODE 3.5.2 Saddle Stitcher Unit Address Notation Description Remarks IO-P23 stitcher motor (rear) CW drive output 0: CW (output) stitcher motor (rear) CCW drive output 0: CCW stitcher motor (front) CW drive output 0: CW stitcher motor (front) CCW drive output 0: CCW paper fold motor CW drive output 0: CW...
Page 146 CHAPTER 4 SERVICE MODE Address Notation Description Remarks IO-P27 PI7S paper positioning HP detection signal 0: HP (input) PI16S stitcher IN detection signal 0: in PUSH SW2 ON/OFF PI17S vertical path paper detection signal 1: paper present PI12S crescent roller phase detection signal 0: HP PI13S guide home position detection signal...
Page 147 CHAPTER 4 SERVICE MODE Address Notation Description Remarks not used not used 8-15 not used IO-P32 0-15 not used IO-P33 MS4S staple absent detection signal 2 1: staple absent (input) MS6S staple absent detection signal 1 1: staple absent MS1S inlet cover open detecting switch signal 0: closed MS2S...
Page 148: Adjust (Adjustment Mode)
CHAPTER 4 SERVICE MODE 4. ADJUST (adjustment mode) 4.1 COPIER The following screen appears in response to COPIER>ADJUST; for the items, see the pages that follow: BLANK V-CONT ADJ-XY FEED-ADJ LASER HV-PRI CST-ADJ HV-TR DEVELOP HV-SP MISC DENS F04-401-01 4-44...
Page 149 CHAPTER 4 SERVICE MODE COPIER>ADJUST <AE> Executing AE Adjustment If you have cleared the RAM on the reader controller PCB, enter the settings indicated on the service label. AE-TBL Use it to adjust the density of characters for image density adjustment. Range of 1 to 9 Default: 5 adjustment...
Page 150 CHAPTER 4 SERVICE MODE COPIER>ADJUST <ADJ-XY> Executing Image Read Start Position Adjustment If you have cleared the RAM on the reader controller PCB, enter the settings indicated on the service label. ADJ-X Use it to adjust the scanner image leading edge position. Range of 250 to 290 (A change of ‘1’...
Page 151 CHAPTER 4 SERVICE MODE COPIER>ADJUST ADJ-S Use it to adjust the scanner home position. Range of 55 to 70 (A change of ‘1’ causes a shift of 0.1 mm.) adjustment Caution • Execute this mode if the copyboard glass is soiled so that the standard white plate will be read avoiding the soiled area.
Page 152 CHAPTER 4 SERVICE MODE COPIER>ADJUST <CCD> Making CCD- and Shading-Related Adjustments If faulty images are noted after executing COPIER>FUNCTION>CCD>CCD-ADJ, enter the settings indicated on the service label. SH-TRGT Use it to enter the white level target value for shading correction. SH-RATIO Use it to enter the data on the white label ratio (standard white paper and standard white plate) for shading correction.
Page 153 CHAPTER 4 SERVICE MODE COPIER>ADJUST <DEVELOP> Adjusting the Developing Bias Output BIAS Use it to enter the adjustment value for the development bias. Range of 0 to 600 (A higher setting makes images lighter.) adjustment Caution • If you have cleared the RAM on the DC controller PCB, enter the set- tings indicated on the service label.
Page 154 CHAPTER 4 SERVICE MODE COPIER>ADJUST <DENS> Making Fine Adjustments for Copy Density Auto Correction If you have cleared the RAM on the DC controller PCB, enter the settings indicated on the service label. DENS-ADJ Use it to correct the density of images (copier/printer). If images are foggy or high-density areas are faint, correct the F-value table.
Page 155 CHAPTER 4 SERVICE MODE COPIER>ADJUST <V-CONT> Adjusting the Potential Control System • Normally, the machine’s potential control is not executed if the temperature of the fix- ing assembly is 150°C or higher. If you have adjusted any of the following potential control-related modes, be sure to execute potential control by making the following selections: COPIER>OPTION>BODY>PO-CNT-S.
Page 156 CHAPTER 4 SERVICE MODE COPIER>ADJUST <HV-PR1> Adjusting the Output of the Primary Charging Assembly If you have cleared the RAM on the DC controller PCB, enter the settings indicated on the service label. PRIMARY Use it to enter the adjustment value of the primary current for non-potential control.
Page 157 CHAPTER 4 SERVICE MODE COPIER>ADJUST H-PRE-TR Use it to enter the offset value for the pre-transfer high-voltage output of the DC controller PCB. Caution If you have replaced the DC controller PCB or cleared the RAM on the DC controller PCB, enter the settings indicated on the label attached to the new DC controller PCB.
Page 158 CHAPTER 4 SERVICE MODE COPIER>ADJUST D-HV-SP Use it to enter the offset value for the separation high-voltage output of the DC controller PCB. Caution If you have replaced the DC controller PCB or cleared the RAM on the DC controller PCB, enter the settings indicated on the label attached to the new DC controller PCB.
Page 159 CHAPTER 4 SERVICE MODE COPIER>ADJUST <CST-ADJ> Making Cassette-/Manual Feed-Related Adjustments If you have cleared the RAM on the DC controller PCB, enter the settings indicated on the service label. C3-STMTR Enter the paper width basic value (STMTR) for the cassette 3. Caution If you have replaced the paper width detecting VR, execute FUNCTION>CST in service mode.
Page 160 CHAPTER 4 SERVICE MODE COPIER>ADJUST C4-LVOL Use it to enter the stacking capacity of the cassette 4 (50 sheets). C4-HVOL Use it to enter the stacking capacity of the cassette 4 (275 sheets). <MISC> Making Other Adjustments If you have cleared the RAM on the DC controller PCB, enter the settings indicated on the service label.
Page 161: Feeder
CHAPTER 4 SERVICE MODE COPIER>ADJUST 4.2 FEEDER DOCST Use it to adjust the original leading edge registration when the ADF is se- lected as the source of paper. • A higher setting decreases the leading edge margin. • The data will be stored on the ADF controller PCB. Range of -10 to +10 (unit: 0.5 mm) adjustment...
Page 162: Sorter
CHAPTER 4 SERVICE MODE SORTER>ADJUST 4.3 SORTER PNCH-HLE Use it to adjust the position of the punch holes (paper feeding direction) when the puncher unit is used. • A higher setting moves the punch holes toward the leading edge (middle) of the sheet. Range of -4 to +2 (unit;...
Page 163: Function (Operation/Inspection Mode)
CHAPTER 4 SERVICE MODE 5. FUNCTION (operation/inspection mode) 5.1 COPIER The following screen appears in response to COPIER>FUNCTION; for the items, see the pages that follow: INSTALL FIXING SYSTEM PANEL LASER PART-CHK CLEAR MISC-R MISC-P HRD-DISK CLEANING SENS-ADJ F04-501-01 4-59...
Page 164 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <INSTALL> Modes for Installation TONER-S Use it to supply toner from the hopper to the developing assembly and to stir the toner inside the developing assembly. Caution • Make sure that the developing assembly is properly mounted before pressing the OK key.
Page 165 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <CCD> Executing Auto Adjustment for CCD-/Shading-Related Items CCD-ADJ Use it to execute CCD auto adjustment. Caution • Execute this mode if you have replaced the CCD unit, scanning lamp, inverter PCB, or copyboard glass (standard white plate). •...
Page 166 CHAPTER 4 SERVICE MODE COPIER>FUNCTION SHDG-POS Use it to enter the data for optimum position auto adjustment in reference to the standard white plate for shading correction. Caution Do not use this mode item. It is for use at the factory only. SH-PS-ST Use it to execute optimum position auto adjustment in reference to the standard white plate for shading correction.
Page 167 CHAPTER 4 SERVICE MODE COPIER>FUNCTION 5) When the following has been updated, enter the new settings: COPIER>ADJUST>CCD-EGGN-ST and -EGGN-END. Edge gain correction plate Copyboard glass Reading glass (front) F04-501-03 4-63...
Page 168 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <LASER> Using Laser-Related Operations POWER Turning On the Laser Using the Mode 1) Select the mode item, and press the OK key. • The laser turns on. • The laser turns off automatically in 30 sec. (To turn it off earlier, press the Stop key.) <DPC>...
Page 169 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <CST> Executing Size Auto Adjustment for the Cassette/Manual Feed Tray C3-STMTR C3-A4R C4-STMTR C4-A4R Use it to store the paper width basic value for the cassette 3/4. STMTR width: 139.5 mm, A4R width: 210 mm Caution For fine adjustment after storing the basic value, make the following selec- tions: ADJUST>CST-ADJ>C3-STMTR, C3-A4R, C4-STMTR, C4-A4R.
Page 170 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <CLEANING> Executing Cleaning Operations WIRE0-CLN Use it to execute automatic cleaning of the charging wire five times (5 round trips) consecutively. Caution If you have replaced the primary charging wire or the transfer charging wire, execute this mode item.
Page 171 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <PANEL> Checking the Control Panel LCD-CHK Use it to check for missing dots on the touch panel. Using the Mode 1) Select the mode item, and press the OK key. • The entire face of the touch panel turns on in white and blue repeatedly. 2) Press the Stop key to stop the operation.
Page 172 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <INPUT KEY/DISPLAY> Screen display Screen display counter check BILL start START copy COPY mail box scan OTHER reset RESET 0 to 9 0 - 9 energy saver STAND BY stop STOP clear CLEAR interrupt INTERRUPT additional functions USER guide T04-501-01...
Page 173 CHAPTER 4 SERVICE MODE COPIER>FUNCTION Use it to select the motor to check. Using the Mode 1) Select the mode item. 2) Using the keypad, enter the code of the motor to check (T04-501-03). 3) Press the OK key. MTR-ON Use it to check the operation of the motor.
Page 174 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <Code/Motor Name> Code Name Code Name drum motor (M1) left deck pickup motor (M24) main motor (M2) cassette 3/4 pickup motor (M12) fixing motor (M19) vertical path duplexing feed motor (M25) laser scanner motor (M15) vertical path lower motor (M27) hopper stirring motor (M9) vertical path upper motor (M26)
Page 175 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <CLEAR> Cleaning the RAM, Jam History, and Error Code History The data is cleared only when the main power switch has been turned off and then on; be sure to turn it off and then on at the end. Use it to clear error codes.
Page 176 CHAPTER 4 SERVICE MODE COPIER>FUNCTION PWD-CLR Use it to clear the password set for ‘system administrator’ in user mode. Using the Mode 1) Select the mode item, and press the OK key. 2) Turn off and then on the main power switch. CNT-MCON Use it to clear the counter for servicing located on the main controller PCB.
Page 177 CHAPTER 4 SERVICE MODE COPIER>FUNCTION KEY-HIST Use it to print out the history of key inputs made on the control panel. Using the Mode 1) Select the mode item, and press the OK key. • The machine will print out the history of key inputs. HIST-PRT Use it to print out the history of jams and errors in service mode.
Page 178 CHAPTER 4 SERVICE MODE COPIER>FUNCTION <SENS-AJD> Use it to check the operation of sensors. STCK-LMT Use it to adjust the position of the full sensor (PS104, PS105) of the shift tray. • If either of the full sensors (or both) detects paper, the machine will in- dicate ‘ON’.
Page 179: Feeder
CHAPTER 4 SERVICE MODE COPIER>FUNCTION 5.2 FEEDER SENS-INT Use it to adjust the sensitivity of each sensor of the ADF. Caution Be sure to clean the sensor before executing this mode. Using the Mode 1) Select the mode item, and press the OK key. •...
Page 180 CHAPTER 4 SERVICE MODE 6. OPTION (settings mode) 6.1 COPIER The following screen appears in response to COPIER>OPTION; for the items, see the pages that follow: BODY USER TEMPO F04-601-01 4-76...
Page 181 CHAPTER 4 SERVICE MODE COPIER>OPTION BODY Use it to make machine settings. PO-CNT Use it to turn on/off potential control. Settings 0: off, 1: on (default) PO-CNTMD Use it to select a potential control mode. Settings 0: one at time of power-up (default) 1: 10 mins and 60 mins after power-up (reduced mode) 2: 10 mins and 60 mins after power-up (normal mode) W-CLN-P...
Page 182 CHAPTER 4 SERVICE MODE COPIER>OPTION FUZZY Use it to turn on/off fuzzy control and to make environment settings. • The selection will affect pre-transfer, transfer, and separation charging currents. • Selecting 1 through 3 will make the operation independent of the envi- ronment sensor.
Page 183 Use it to reduce the warm-up time if the room temperature is likely to be about 18°C or higher when the machine is first turned on. In the case of the iR5000 Series, the multiple rotation initial, standby, and print start temperatures are reduced by 15°C.
Page 184 CHAPTER 4 SERVICE MODE COPIER>OPTION COTDPC-D For factory use. Settings 0 to 3 (default: 0) EVL-VDT Use it to switch the drum target potential (VDT) and the developing bias (Vdc) to reduce traces of black fixing separation claws caused by an excess deposit of toner in a low-humidity environment.
Page 185 CHAPTER 4 SERVICE MODE COPIER>OPTION TR-SP-C3 Use it to switch the transfer/separation output level when the cassette 3 is used as the source of paper to prevent various problems. Settings 0: normal (default), 1: to prevent re-transfer 2; to prevent separation fault, 3: to prevent transfer fault TR-SP-C4 Use it to switch the transfer/separation output level when the cassette 4 is used as the source of paper to prevent various problems.
Page 186 CHAPTER 4 SERVICE MODE COPIER>OPTION SLEEP Use it to turn on/off sleep mode. Settings 0: OFF, 1: ON (default) WEB-DISP Use it to turn on/off the fixing web length warning. • If OFF (no warning), the message will appear only when service mode is started.
Page 187 CHAPTER 4 SERVICE MODE COPIER>OPTION COUNTER5 Use it to change the type of soft counter 5 of the control panel to suit the needs of the user or the dealer. Settings 000 to 804 (T05-601-01; default, 000) COUNTER6 Use it to change the type of soft counter 6 of the control panel to suit the needs of the user or the dealer.
Page 188 CHAPTER 4 SERVICE MODE COPIER>OPTION CNT-DISP Use it to enable/disable the indication of a serial number in response to the Counter Check key. Settings 0: enable indication (default), 1: disable indication PH-D-EL Use it to select the number of lines for photo mode printing. Settings 0: 141 lines (default), 1: 134 lines COPY-JOB...
Page 189 CHAPTER 4 SERVICE MODE <Soft Counter Specifications> The soft counters are classified as follows according to input numbers: 100s: total 500s: scan 200s: copies 600s: box 300s: prints 700: reception prints 400s: copies + prints 800: report prints Legend counter effective for the machine full color mono: mono color (Y, M, C/R, G, B/sepia mono)
Page 190 CHAPTER 4 SERVICE MODE COPIER>OPTION Effective No. Counter type Effective No. Counter type copy (Mono 1) print (Bk/L) copy (Mono 2) print (Bk/S) copy (Bk 1) print (4C+Mono/L) copy (Bk 2) print (4C+Mono/S) copy (4C/L) print (4C+Mono/2) copy (4C/S) print (4C+Mono/1) copy (Mono/L) print (4C/L/double-sided) copy (Mono/S)
Page 191 CHAPTER 4 SERVICE MODE COPIER>OPTION Effective No. Counter type Effective No. Counter type Bk scan (total 1) box print (total 1) copy scan (Bk) box print (total 2) Bk scan (total 2) box print (L) Bk scan (L) box print (S) copy scan (Bk/L) reception print (total 1) Bk scan (S)
Page 192 CHAPTER 4 SERVICE MODE COPIER>OPTION Making Cassette-Related Settings U1-NAME U2-NAME U3-NAME U4-NAME Use it to turn on/off the paper name indication when a paper size group (U1 to U4) is detected. Settings 0: OFF (touch panel indicates ‘U1’ through ‘U4’; default) 1: ON (indicates paper name specified in CST-U1 through -U4) CST-U1 Use it to specify paper names used for paper size group U1.
Page 193 CHAPTER 4 SERVICE MODE COPIER>OPTION C1-DWSW C2-DWSW DK-DWSW C3-DWSW C4-DWSW Use it to turn on/off the thick paper control sequence. (C1: right deck, C2: left deck, C3/C4: cassette 3/4, DK: paper deck) Setting 0: OFF (default), 1: ON <Code/Paper Names> Code Notation Name Code...
Page 194 CHAPTER 4 SERVICE MODE COPIER>OPTION Use it to make accessories-related settings. COIN Use it to turn on/off the coin vendor indication. • The control card indicator used on the control panel may be used for the coin vendor. Settings 0: OFF (default), 1: ON (for count vendor) DK-P Use it to set a paper of the paper deck.
Page 195 CHAPTER 4 SERVICE MODE COPIER>OPTION F-HUM-D Use it to enter an approximate humidity level of the site of installation. • Uses the input humidity as the output of the humidity sensor. • Valid only if F-HUM-SW is set to '1'. Settings 30% to 99% (default: 35%) 4-91...
Page 196 CHAPTER 4 SERVICE MODE FEEDER>OPTION 6.2 FEEDER SIZE-SW Use it to turn on/off the mixed size detection mechanism for AB and Inch series originals. Settings 0: disable (default), 1: enable 6.3 SORTER BLNK-SW Use it to set the margin width (W) on both sides of the fold when the saddle stitcher is used.
Page 197 CHAPTER 4 SERVICE MODE BOARD>OPTION 6.4 BOARD MENU-1 Use it to enable level 1 indication for the printer settings menu. Settings 0: disable indication (default), 1: enable indication MENU-2 Use it to enable level 2 indication for the printer settings menu. Settings 0: disable indication (default), 1: enable indication MENU-3...
Page 198: Test (Test Print Mode)
CHAPTER 4 SERVICE MODE 7. TEST (test print mode) The following screen appears in response to COPIER>TEST; for the items, see the pages that follow: NETWORK F04-701-01 4-94...
Page 199 CHAPTER 4 SERVICE MODE COPIER>TEST Use it to select the type of test print and generate it. TYPE Enter the type number of the test print, and press the OK key to generate it. Caution Be user to return the input to ‘00’ after generating the test print. Settings 00: normal print, 01 through 08: see T04-701-01 TXPH...
Page 200 CHAPTER 4 SERVICE MODE COPIER>TEST NETWORK Use it to check the connections related to the network. PING Use it to check the connection between the machine and the network (for TCP/IP environment only). Caution Use this mode to check the connection to the network after installing the machine or when the connection to the network is found to be poor.
Page 201 CHAPTER 4 SERVICE MODE COPIER>TEST 6) Make the following selections in service mode: COPIER>TEST>NETWORK>PING; then, enter the loop back address* (127.0.0.1), and press the OK key and then the Start key. • If ‘NG’ is indicated, the machine has a problem with the TCP/IP set tings;...
Page 202 CHAPTER 4 SERVICE MODE 8. COUNTER (counter mode) The following screen appears in response to COPIER>COUNTER; for the items, see the pages that follow: TOTAL TOTAL PICK-UP PICK-UP PRDC-1 FEEDE FEEDER DRBL-1 MISC DRBL-2 F04-801-01 <Clearing the Counter Reading> 1) Select the item to clear (to highlight). 2) Press the Clear key on the control panel.
Page 203 CHAPTER 4 SERVICE MODE COPIER>COUNTER <Guide to Consumables Counter> The machine is equipped with consumables counters (PRDC-1, DRBL-1, DRBL-2), pro- viding references for parts replaced on a periodical basis or parts requiring replacement. PRM-WIRE / 00000027 / 00500000 / !! 000082 [4] [5] [1] Indicates the name of the part.
Page 204 CHAPTER 4 SERVICE MODE COPIER>COUNTER Level 2: PICK-UP Level 3: C1 right front deck (cassette 1) pickup counter left front deck (cassette 2) pickup counter cassette 3 pickup counter cassette 4 pickup counter manual feed tray pickup counter paper deck pickup counter 2-SIDE duplexing 2nd side pickup counter Level 2: FEEDER...
Page 205 CHAPTER 4 SERVICE MODE COPIER>COUNTER level 2: DRBL-1 Level 3: PRM-UNIT primary charging assembly counter PO-UNIT pre-transfer charging assembly counter PO-SCRPR pre-transfer (post-) charging assembly scraper counter T/S-UNIT transfer/separation charging assembly counter CLN-BLD cleaner blade counter SP-CLAW cleaner separation claw counter DVG-CYL developing cylinder counter DVG-ROLL...
Page 206 CHAPTER 4 SERVICE MODE COPIER>COUNTER Level 2: DRBL-2 Level 3: DF-PU-RL ADF pickup roller counter DF-SP-PL ADF separation plate counter DF-SP-PD ADF separation pad counter DF-FD-RL ADF feed roller counter LNT-TAPE ADF dust-collecting tape counter PD-PU-RL paper deck pickup roller counter PD-SP-RL paper deck separation roller counter PD-FD-RL...
Page 207 CHAPTER 5 SELF DIAGNOSIS CHAPTER 5 SELF DIAGNOSIS 1. Error Codes 1.1 List of Error Codes The machine is equipped with a mechanism to run self diagnosis to find out its condition (particularly of its sensors): CPU on the main controller PCB and the CPU on the DC con- troller PCB.
Page 208 CHAPTER 5 SELF DIAGNOSIS E002 Main Cause The main thermistor (TH1) has poor contact or an open circuit. The thermal switch (TP1) has an open circuit. The SSR is faulty. The DC controller is faulty. Mode of Detection 0000 The temperature of the upper fixing roller does not reach 100°C within 2 min after it has exceeded 70°C.
Page 209 CHAPTER 5 SELF DIAGNOSIS E010 Main Cause The main motor (M2) is faulty. The DC controller PCB is faulty. Mode of Detection 0000 The clock pulses do not arrive for 2 secs or more after the main motor drive signal (MMFG) has been generated. E012 Main Cause The drum motor (M1) is faulty.
Page 210 CHAPTER 5 SELF DIAGNOSIS E032 Main Cause The copy data controller or the remote diagnostic device is faulty. The Main controller PCB is faulty. Mode of Detection 0001 Although once connected, the copy data controller or the remote diagnostic device has become disconnected. E061 Main Cause The laser shutter is faulty.
Page 211 CHAPTER 5 SELF DIAGNOSIS E110 Main Cause The laser scanner motor (M15) is faulty. The wiring is faulty (short circuit, open circuit). The DC controller PCB is faulty. Mode of Detection 0001 • After the laser scanner motor drive signal has been generated, the motor ready signal (LMRDY*) does not arrive for 15 secs or more.
Page 212 CHAPTER 5 SELF DIAGNOSIS E202 Main Cause The scanner HP sensor (PS39) is faulty. The scanner motor (M3) is faulty. The reader controller PCB is faulty. Mode of Detection 0001 The scanner HP sensor does not turn off even when the scanner has been moved 40 mm forward after the main power switch has been turned on or the Start key has been pressed.
Page 213 CHAPTER 5 SELF DIAGNOSIS E240 Main Cause The main controller PCB. The DC controller PCB is faulty. Mode of Detection 0000 An error has occurred in the communication between the main controller PCB and the CPU of the DC controller PCB. E243 Main Cause The control panel CPU PCB is faulty.
Page 214 CHAPTER 5 SELF DIAGNOSIS E601 Main Cause The wiring is faulty (short circuit, open circuit). The hard disk drive is faulty. The DC controller PCB is faulty. The main controller PCB is faulty. Mode of Detection 0000 The main controller PCB has detected an error in control data while an image was transmitted between the main controller PCB and the hard disk drive.
Page 215 CHAPTER 5 SELF DIAGNOSIS E710 Main Cause The DC controller PCB is faulty. The reader controller PCB is faulty. The main controller PCB is faulty. Mode of Detection 0001 When the main power is turned on, the IPC (IC5021) on the reader controller PCB cannot be initialized.
Page 216 CHAPTER 5 SELF DIAGNOSIS E713 Main Cause The connector is not connected properly. The finisher accessories power supply PCB is faulty. The finisher controller PCB is faulty. The DC control- ler PCB is faulty. Mode of Detection 0000 The communications IC (IPC) on the finisher controller has gone out of order.
Page 217 CHAPTER 5 SELF DIAGNOSIS E740 Main cause The LAN card is faulty. The main controller PCB is faulty. Mode of Detection 0001 An error is detected on the LAN card at power-on (with the card inserted). 0002 A MAC address is found to be faulty. 0003 The LAN card register cannot be read.
Page 218 CHAPTER 5 SELF DIAGNOSIS E805 Main Cause The wiring is faulty (short circuit, open circuit). The feed fan (FM1) is faulty. The heat discharge fan (FM3) is faulty. The DC controller PCB is faulty. Mode of Detection 0001 While the heat discharge fan is being driven, the clock signal (FM3CLK) does not arrive for 5 secs or more.
Page 219 CHAPTER 5 SELF DIAGNOSIS 1.2 Self Diagnosis of the ADF When the machine's self diagnosis mechanism has turned on, the condition can be reset by turning off and then on the host machine's power switch. If the machine must remain out of order, prints may still be made by disconnecting the machine's lattice connector, and placing an original on the host machine's copyboard glass.
Page 220 CHAPTER 5 SELF DIAGNOSIS E512 Main Cause The delivery motor clock sensor (PI10) is faulty. The delivery motor (M2) is faulty. The finisher controller PCB is faulty. Mode of Detection 0001 When operation starts, as many clocks as needed do not arrive from the delivery motor clock sensor.
Page 221 CHAPTER 5 SELF DIAGNOSIS E590 Main Cause The punch home position sensor (PI3P) is faulty. The punch motor (M1P) is faulty. The punch driver PCB is faulty. Mode of Detection 0001 The puncher does not leave home position when the punch motor has been driven for 200 msecs.
Page 222 CHAPTER 5 SELF DIAGNOSIS E5F3 Main Cause The alignment home position sensor (PI5S) is faulty. The alignment motor (M5S) is faulty. The saddle stitcher controller PCB is faulty. Mode of Detection 0001 The alignment plate home position sensor does not turn on when the alignment motor has been driven for 0.5 sec (initially, driven for about 1.7 sec).
Page 223 CHAPTER 5 SELF DIAGNOSIS E5F9 Main Cause The inlet door switch (MS1S) is faulty. The front door switch (MS2S) is faulty. The delivery door switch (MS3S) is faulty. The saddle stitch control- ler PCB is faulty. Mode of Detection 0001 When the inlet cover, front cover, and the delivery cover are found to be closed, the inlet door switch detects an open condition for 1 sec or more from the start of the initial rotation of the host machine or the start of printing.
Page 225 APPENDIX A. GENERAL TIMING CHART General Timing Chart I · A4, 2 Sheets, Single-Sided, Direct; Right Deck (face-down delivery) Originals placed Start key ON 1st original read 1st original delivered STBY 1st original separated/feed 2nd original delivered 2nd original separated/feed 2nd original read Original set sensor (PI5) Post-separation sensor (S3)
Page 226 General Timing Chart II · A4, 1 Sheet, Direct, Double-Sided; Right Deck Original placed Start key ON STBY Original separated/feed Original face read Original reversed Original back read Idle CCW/delivery Original set sensor (PI5) Post-separation sensor (S3) Registration 1 paper sensor (PS1) Read sensor (S2) Delivery reversal sensor (S1)
Page 227 APPENDIX B. LIST OF SIGNALS/ABBREVIATIONS The following is a list of the signals and abbreviations used in this chapter and the circuit diagrams. The abbreviations in parentheses are electrical signals, but are analog sig- nals, which cannot be expressed in terms of ‘1’ or ‘0’. Others are digital REF.
Page 228 APPENDIX DMON DRUM MOTOR DRIVE command DPDS DUPLEXING PAPER DETECTION signal DRGFPD DUPLEXING PRE-REGISTRATION PAPER DETECTION signal DRUM HT ON DRUM HEATER DRIVE CONTROL signal DSJAM DERIVERY JAM DETECTION signal DSRGPD DUPLEXING SIDE REGISTRATION PAPER DETECTION signal DTEP DEVELOPER TONER signal EXTERNAL DELIVERY signal FCBSD* FIXING WEB SOLENOID DRIVE command...
Page 229 APPENDIX LD-EN LASER ENABLE signal LDCLD* LEFT DECK PULL-OFF CLUTCH DRIVE command LDEL LEFT DECK LIMIT DETECTION signal LDEOP LEFT DECK OPEN/CLOSED DETECTION signal LDLM LEFT DECK LIFTER MOTOR DRIVE command LDLTP LEFT DECK LIFTER POSITION DETECTION signal LDPD LEFT DECK PAPER DETECTION signal LDPD1 LEFT DECK PAPER LEVEL DETECTION signal1 LDPD2...
Page 230 APPENDIX M16_A* DUPLEXING HORIZONTAL REGISTRATION MOTOR (A*) DRIVE command M16_B DUPLEXING HORIZONTAL REGISTRATION MOTOR (B) DRIVE command M16_B* DUPLEXING HORIZONTAL REGISTRATION MOTOR (B*) DRIVE command M17_A PRE-REGISTRATION MOTOR (A*) DRIVE command M17_A* PRE-REGISTRATION MOTOR (A) DRIVE command M17_B PRE-REGISTRATION MOTOR (B*) DRIVE command M17_B* PRE-REGISTRATION MOTOR (B) DRIVE command M18_A*...
Page 231 APPENDIX M3B* SCANNER MOTOR (B*) DRIVE command M9ON HOPPER MOTOR (TONER STIRRING) DRIVE command MFDS MANUAL FEED TRAY OPEN/CLOSED DETECTION signal MFLSD* MULTI FEED RELEASING SORENOID DRIVE command MFPCD* MULTI FEED ROLLER CLUTCH DRIVE command MFPD MANUAL FEED PAPER WIDTH DETECTION MULTIFEEDER PAPER DETECTION signal MMFG MAIN MOTOR DRIVE CLOCK signal...
Page 232 APPENDIX RVFSD2* REVERSING FLAPPER SORENOID DRIVE command RVS1 REVERSING signal1 RVS2 REVERSING signal2 SL1P* FIXING ASSEMBLY INLET GUIDE SOLENOID DRIVE command SL1R* FIXING ASSEMBLY INLET GUIDE SOLENOID DRIVE command SP-CNT SEPARATION CHARGING CURRENT CONTROL signal HOPPER TONER signal FIXING MAIN THERMISTOR signal FIXING SUB THERMISTOR signal THHUM1 MACHINE INSIDE HUMIDITY signal...
Page 233 C. General Circuit Diagram Standard 100V model only Scanning lamp (Xenon tube) Mirror heater Lens heater Scanner home Copyboard position sensor cover sensor PS39 Original size J5102 PS40 To ADF To ADF J5105 J5105A Inverter PCB J5057 detection 3 J5056 6 5 4 3 PCB18 J5101...
Page 235 D. PAPER DECK -G1 GENERAL CIRCUIT DIAGRAM To host machine J1BL 1 2 3 4 1 2 3 Deck driver PCB PCB1 1 2 3 4 5 6 7 8 9 10 10 11 12 13 10 11 12 1 2 3 NC NC 1 2 3 4 5 6 7 8 9 10 J17M...
Page 236 E. SHIFT TRAY GENERAL CIRCUIT DIAGRAM Limit sensor (front) Shift motor PS105 J208 1 2 3 J105 J106 Shift Tray Driver PCB PCB1 J104 J103 J102 J101 J207 J205 J204 J203 J123 J114 J205H <To host machine> <To host machine> PS104 J205F PS102...
Page 237: Copier
APPENDIX F. SPECIFICATIONS 1.1 Copier 1.1.1 Type Item Specifications Body Console Copyboard Fixed Light source Xenon tube Lens Lens array (F3.7) Photosensitive medium Amorphous silicon drum (80-dia.) A-101-01 1.1.2 Method Item Specifications Reproduction Indirect statophotography Charging Corona Exposure Laser Copy density adjustment Auto or manual Development Dry, 1-component toner production...
Page 238: Functions
Enlarge V 1: 4.000 Zoom 1: 0.250 to 4.00 (in 1% increments) Wait time iR5000: 5 min or less (at 20°C/168°F) iR6000: 6 min or less (at 20°C/168°F) First copy time 5.5 sec (stream reading, right deck, Direct, A4/LTR, non-AE, straight delivery) 3.8 sec (book mode, right deck pickup, Direct, A4/LTR,...
Page 239 Plain paper (64 to 80 g/m Left deck A4, B5, LTR Tracing paper A4, B5 Colored paper (Canon-recommended) Thick paper (90 to 200 g/m A4, B5, LTR Cassette 3 Plain paper (64 to 80 g/m A3, B4, A4, B5, A5R, A4R, B5R Cassette 4 279.4×431.8 mm (11"...
Page 240 (vertical feeding) Tracing paper A3, B4, A4, B5, A4R, B5R Transparency (Canon-recommedned) A4, A4R, LTR, LTRR Colored paper (Canon-recommended) B4, A4, A4R Postcard (vertical feeding only) Postcard, 2-in-1 postcard (vertical feeding only), 4-in-1 postcard (horizontal feeding only) Label sheet (Canon-recommended)
Page 241 A3, B4, A4, B5, A5R, A4R , B5R 279.4×431.8 mm (11"×17"), LGL, LTR, LTRR, STMT (vertical feeding) Double-sided • Colored paper (Canon-recommended) B4, A4, A4R Thick paper (90 to 200 g/m A3, B4, A4, B5, A4R, B5R, LTR, LTRR Manual feed tray •...
Page 242 APPENDIX Item Specifications Claw None Tray Paper deck 162 mm/16.4 in deep (approx.; about 1500 sheets of 80 g/ (right, left) paper) Cassette 3/4 55 mm/2.2 in deep (approx.; about 550 sheets of 80 g/m Delivery tray 250 sheets (approx.; of 80 g/m Hard disk 6.4 GB or 5.1 GB*1 Non-image...
Page 243: Others
282 Wh iR6000: 282 Wh (approx.; reference) (approx.; reference) Noise Continuous iR5000: 995 Wh (approx.; reference only) copying iR6000: 1008 Wh (approx.; reference only) By sound power level (impulse mode) During copying iR5000: 71 dB or less iR6000: 78 dB or less...
Page 244 APPENDIX Reproduction ratio Size Paper size copies/min (1-to-N) iR5000 iR6000 Direct A3 (297×420 mm) A4 (210×297 mm) B4 (257×364 mm) B5 (182×257 mm) A4R (297×210 mm) B5R (257×182 mm) A5R (210×149 mm) Reduce II A3→A5R (50%) A3→B5R (61.1%) B4→B5R (70.7%) A3→A4R...
Page 245 APPENDIX Reproduction ratio Size Paper size copies/min iR5000 iR6000 Direct 279.4×431.8 mm 279.4×431.8 mm (11"×17") (11"×17") LTRR LTRR STMTR STMTR Reduce 279.4×431.8 mm STMTR (50.0%) (11"×17")→STMTR 279.4×431.8 mm LTRR (64.7%) (11"×17")→LTRR 279.4×431.8 mm (73.3%) (11"×17")→LGL LGL→LTRR LTRR (78.6%) Enlarge IV STMTR*→...
Page 246: Paper Deck-G1
Copy paper type • Plain paper (64 to 80 g/m A4, B5, LTR • Tracing paper (SM-1) A4, B5 • Colored paper (Canon-recommended) Thick paper (90 to 200 g/m A4, B5, LTR Paper stack Height: 385 mm (approx.; about 3500 sheets)
Page 247: Shift Tray-B1
APPENDIX 1.3 Shift Tray-B1 Item Specifications Paper type Same as host machine Paper size Feeding Same as host machine Shifting LTR, LTRR, LGL, 279.4×431.8 mm (11"×17"), A4, A4R, A3 Paper stack Height: 60 mm /2.4 in (approx.; about 500 sheets of 64 g/m Stacking performance Delivery direction 50 mm or less...
Page 248: List Of Special Tools
APPENDIX G. List of Special Tools The following special tools will be needed in addition to the standard tools set: Name Toll No. Shape Rank Remarks Digital FY9-2002 Used when making multimeter electrical checks. Door switch TKN-0093 Mirror FY9-3009 Used when positioning positioning tool the No.
Page 249 APPENDIX Name Toll No. Shape Rank Remarks Environment FY9-3014 Used to check the sensor checking environment sensor. sensor Tester extension FY9-3038 Used when making electrical checks. Tester extension FY9-3039 Used when making pin (L-shaped) electrical checks. Rank: A: each service person is expected to carry one. B: each group of five persons is expected to carry one.
Page 250: List Of Solvents/Oils
APPENDIX H. List of Solvents/Oils Name Uses Composition Remarks Alcohol Cleaning: Fluorescent family • Do not bring near fire. e.g., glass, plastic, hydrocarbon, • Procure locally. rubber parts; alcohol, surface • Substitute: IPA (isopropyl alcohol) external covers. activating agent, water Solvent Cleaning: Fluorescent family...
Page 251 Prepared by Office Imaging Products Technical Support Division Office Imaging Products Quality Assurance Center CANON INC. Printed in Japan REVISION 0 (JULY 2000) (18723/22109) 5-1, Hakusan 7-chome, Toride-shi, Ibaraki 302-8501 Japan...
Page 252 This publication is printed on 100% reprocessed paper. PRINTED IN JAPAN (IMPRIME AU JAPON) 0800M1.25-1...

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Canon iR5000 Service Handbook

Chapter 1 Maintenance and Inspection

Chapter 2 Standards and Adjustments

Chapter 3 Arrangement and Functions of

Chapter 4 Service Mode

APPENDIX Functions

Chapter 5 Self Diagnosis

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