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Canon iR4570 Series Service Manual
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Canon iR4570 Series Service Manual

Canon iR4570 Series Service Manual

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Service Manual
iR4570/3570, 2870/2270 Series
iR3035
Sep 4 2007

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Summary of Contents for Canon iR4570 Series

  • Page 1 Service Manual iR4570/3570, 2870/2270 Series iR3035 Sep 4 2007...
  • Page 3 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 refer- ence 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 Contents Contents Chapter 1 Introduction 1.1 Product Specifications ..........................1- 1 1.1.1 Safety ..................................1- 1 1.1.1.1 Safety of the Laser Light ................................1- 1 1.1.1.2 CDRH Regulations................................... 1- 1 1.1.1.3 Handling the Laser Unit ................................1- 1 1.1.1.4 Safety of Toner ..................................1- 1 Chapter 2 Installation 2.1 Unpacking and Installation .........................2- 1 2.1.1 Connecting the Cable ..............................
  • Page 8 Contents 3.4.1 Overview ..................................3- 6 3.4.2 Flow of Operation..............................3- 6 3.5 Image Processing............................3- 6 3.5.1 Overview of the Image Flow ............................3- 6 3.5.2 Construction of the Image Processing Module ......................3- 7 3.5.3 Reader Unit Input Image Processing ........................3- 7 3.5.4 Compressio/ Extesion/ Editing Block ........................3- 8 3.5.5 Printer unit Output Image Processing ........................3- 8 3.6 Flow of Image Data ............................
  • Page 9 Contents 5.1.1 Specifications of the Image Formation System ....................... 5- 1 5.1.2 Major Components of the Image Formation System ....................5- 2 5.2 Image Formation Process ..........................5- 2 5.2.1 Image Formation Process (outline) ......................... 5- 2 5.2.2 Image Formation Process (image formation) ......................5- 3 5.3 Basic Sequence............................5- 3 5.3.1 Sequence of Operation (initial rotation) ........................
  • Page 10 Contents 5.12.2.2 Removing the Waste Toner Case ............................5- 14 5.12.2.3 Removing the Drum Unit..............................5- 14 5.12.3 Hopper Assembly..............................5- 15 5.12.3.1 Removing the Front Cover Unit............................5- 15 5.12.3.2 Removing the Waste Toner Case ............................5- 15 5.12.3.3 Removing the Toner Cartridge............................. 5- 16 5.12.3.4 Removing the Drum Unit..............................
  • Page 11 Contents 5.12.10.9 Removing the Left Cover..............................5- 37 5.12.10.10 Removing the Laser Unit ..............................5- 37 5.12.10.11 Removing the Hopper Assembly ............................5- 38 5.12.10.12 Removing the Toner Feedscrew Motor ..........................5- 39 5.12.11 Static Charge Eliminator ............................ 5- 39 5.12.11.1 Removing the Static Eliminator ............................
  • Page 12 Contents 6.8.2.2 Removing the Right Cover (lower front)..........................6- 33 6.8.3 Pickup Roller................................6- 33 6.8.3.1 Removing the Pickup Roller/Feed Roller/Separation Roller ....................6- 33 6.8.4 Sensor Mount.................................6- 34 6.8.4.1 Removing the Right Cover (rear) ............................6- 34 6.8.4.2 Removing the Right Door............................... 6- 34 6.8.4.3 Removing the Right Cover (lower front)..........................
  • Page 13 Contents 6.8.14.2 Removing the Right Door..............................6- 50 6.8.14.3 Removing the Manual Feed Unit............................6- 51 6.8.14.4 Removing the Manual Feed Tray Assembly ........................6- 52 6.8.15 Manual Feed Unit ..............................6- 52 6.8.15.1 Removing the Right Cover (rear) ............................6- 52 6.8.15.2 Removing the Right Door..............................
  • Page 14 Contents Chapter 7 Fixing System 7.1 Construction ............................... 7- 1 7.1.1 Specifications, Control Mechanisms, and Functions ....................7- 1 7.1.2 Major Components..............................7- 1 7.2 Basic Sequence ............................7- 1 7.2.1 Power-On Sequence..............................7- 1 7.2.2 Down Sequence...............................7- 2 7.3 Various Control Mechanisms ........................7- 2 7.3.1 Controlling the Speed of the Fixing Film ........................7- 2 7.3.1.1 Controlling the Fixing Film Speed in Response to Low Temperature..................
  • Page 15 Contents 7.5.5.6 Releasing the Locking Plate ..............................7- 21 7.5.5.7 Removing the Fixing Film Unit ............................... 7- 22 7.5.5.8 Removing the Inside Delivery Sensor............................ 7- 23 7.5.6 Fixing Film Sensor..............................7- 23 7.5.6.1 Removing the inside delivery cover unit (old) ........................7- 23 7.5.6.2 Removing the inside delivery cover unit (new) ........................
  • Page 16 Contents 8.1.12.3 Removing the Toner Cartridge............................. 8- 12 8.1.12.4 Removing the Drum Unit..............................8- 13 8.1.12.5 Removing the Developing Assembly ........................... 8- 13 8.1.12.6 Removing the Upper Tray ..............................8- 14 8.1.12.7 Removing the Toner Cartridge Cover ..........................8- 14 8.1.12.8 Removing the Pre-Exposure Lamp ............................
  • Page 17 Contents 9.1.9.2 FAQ on G3FAX Specifications..............................9- 7...
  • Page 18 Contents...
  • Page 19 Chapter 1 Introduction...
  • Page 21 Contents Contents 1.1 Product Specifications..............................1-1 1.1.1 Safety ......................................1-1 1.1.1.1 Safety of the Laser Light....................................1-1 1.1.1.2 CDRH Regulations......................................1-1 1.1.1.3 Handling the Laser Unit ....................................1-1 1.1.1.4 Safety of Toner........................................1-1...
  • Page 23 Chapter 1 1.1 Product Specifications 1.1.1 Safety 1.1.1.1 Safety of the Laser Light 0007-3174 Laser light can prove to be hazardous to the human body. The machine's laser unit is fully enclosed in a protective housing and external covers so that its light will not escape outside as long as the machine is used normally.
  • Page 24 Chapter 1 Toner on Clothing or Skin 1. If your clothing or skin has come into contact with toner, wipe it off with tissue; then, wash it off with water. 2. Do not use warm water, which will cause the toner to jell and fuse permanently with the fibers of the cloth. 3.
  • Page 25 Chapter 2 Installation...
  • Page 27 Contents Contents 2.1 Unpacking and Installation ............................2-1 2.1.1 Connecting the Cable ................................... 2-1 2.2 Installing the Reader Heater............................2-1 2.2.1 Checking the Parts ..................................2-1 2.2.2 Turning Off the Host Machine..............................2-1 2.2.3 Installation Procedure .................................. 2-1 2.3 Installing the Cassette Heater for the Cassette Pedestal ....................2-2 2.3.1 Checking the Contents .................................
  • Page 29 Chapter 2 2.1 Unpacking and Installation 2.2.2 Turning Off the Host Machine 0013-4841 2.1.1 Connecting the Cable How to Turn Off the Main Power 0010-2913 1) If you are installing a cassette pedestal, remove the lattice connector cov- When turning off the main power, be sure to go through the following steps er, and fit the lattice connector [1] of the cassette pedestal to the machine.
  • Page 30 Chapter 2 F-2-6 13) Put back the protective sheet. F-2-4 14) Mount the copyboard glass (for DADF) and the copyboard glass (for copyboard cover). 15) Mount the glass retainer (let, right) using 2 screws each. Points to Note When Routing the Harness 16) Connect the power cable.
  • Page 31 Chapter 2 Screw (binding; M4X4) * not used in this machine 2.3.4 Turning Off the Host Machine 0015-2453 How to Turn Off the Main Power When turning off the main power, be sure to go through the following steps to protect the hard disk: 1) Hold down the control panel power switch for 3 sec or more.
  • Page 32 Chapter 2 F-2-14 2) Detach the rear cover [1] of the cassette pedestal. - 4 screws [2] F-2-11 4) Mount the heater unit [1] with the screw (binding; M4X6) [2], and connect the connector [3]. F-2-15 3) Using nippers, cut off the face plate [2] of the rear cover [1] of the cassette pedestal.
  • Page 33 Chapter 2 2.3.7 Installation Procedure (Cassette Heater Unit36) 0016-8304 (Excluding iR 3045/3035/3030/3025) It is necessary to install the heater PCB and the environment heater outlet in the machine to activate the Cassette Heater Unit 36. 1) Pull out the cassette 3 and 4. 2) While removing the hook by inserting the part indicated as [1] from the front side of the host machine with a flat blade screwdriver, detach the connector cover [2].
  • Page 34 Chapter 2 5) Attach the connector cover [1]. tach it with 2 screws (TP; M3X6) [4]. 6) Attach the plastic film [2] (for protecting the AC cable) over the cable [3] to fit the end of the connector cover [A] and the end of the rear side of the host machine [B].
  • Page 35 Chapter 2 T-2-2 F-2-32 Part name Part number Part name Part number Heater unit FG6-9651-000 1pc. Cable protection bush WT2-5098-000 1pc. Power supply code base FG6-1117-000 1pc. Power supply label FS6-8725-000 1pc. Relay harness unit FG6-2957-000 1pc. Screw (RS tight; M4X8) XA9-0628-000 2pcs.
  • Page 36 Chapter 2 3) Remove the 3 screws [1], and then detach the right cover [2] of the paper deck. F-2-35 4) Remove the 6 screws [1], and then detach the rear cover [2] of the paper deck. F-2-38 7) Attach the cable protective bush [1] included with the package to the hole [2] on the top board of the paper deck.
  • Page 37 Chapter 2 F-2-41 11) Remove the screw [2] to remove the blanking plate [1] attached on the power cord mount of the paper deck. F-2-44 15) Wrap the harness [1] around the cable guide [2] on the power cord mount. (One and a half turn) F-2-42 12) Connect the AC inlet connector [1] included with the package.
  • Page 38 Chapter 2 the figure below. F-2-47 Be sure to tell the users not to place any things within the shaded area for not disturbing opening/closing the paper deck when connecting the power plug of the heater. [1] Host machine [2] Front side [3] Paper deck 2.5 Installing the Voice Guidance Kit 2.5.1 A point to keep in mind at installation...
  • Page 39 Chapter 2 [10] [11] [12] [13] [14] [15] [16] [17] [18] F-2-48 Speaker Unit (Upper) 1pc. Speaker Unit (Lower) 1pc. Cable (1300 mm) 1pc. [4]* Cable (1850 mm) 1pc. Cable Guide 7pc. Voice Board 1pc. (Use eithe 4 or 5 cable guide(S)) Voice Board instruction plate 1pc.
  • Page 40 Chapter 2 2.5.4 Installation Procedure 0015-0862 1. Installation Procedure 1) Detach the face cover [1] in the direction shown by the arrow. - 4 screws [2] (to remove) - 2 screws [3] (to loosen) F-2-49 2) Detach the blanking plate [1] (Do not use the detached blanking plate). - 2 screws [2] F-2-50 3) Attach the voice board instruction plate [2] to the voice board [1].
  • Page 41 Chapter 2 33MHz 66MHz 4) Fit the voice board [1] to the PCI Bus Expansion Kit-B1 [A], and fix it in place using the 2 screws [2] removed in step 2). Cautions in mounting Be sure that the PCB is perpendicular to the connector. [C] [B] F-2-52 5) Detach the face cover.
  • Page 42 Chapter 2 7) Mount the speaker unit (lower) [1]. - 1 screw (binding; M3X16) [2] - 1 screw (binding; M4X16) [3] F-2-54 8) Mount the speaker unit (upper) [1] on the speaker unit (lower), fix them with a screw (binding; M4X6) [2] from beneath. F-2-55 9) Detach the cover [1] on the cable guide.
  • Page 43 Chapter 2 F-2-57 B: When a card reader is mounted on the host machine The right side --- 1 place F-2-58 11) Connect the cable [2] into the speaker unit [1]. F-2-59 12) Run the cable [1] through the cable guide [2] and mount the cable guide cover [3]. There should no excessive bending of the cable.
  • Page 44 Chapter 2 F-2-60 B: When a card reader is mounted on the host machine The right side F-2-61 13) Attach the ferrite core [1] to the cable. Be sure that the length [2] is 50 mm or shorter. F-2-62 14) Connect the cable [1] to the terminal [2] of the voice board. F-2-63 15) Run the cable [1] through the code guide [2] and mount the code guide cover [3].
  • Page 45 Chapter 2 F-2-64 B: When a card reader is mounted on the host machine The rear F-2-65 16) Connect the power cable to the outlet. 17) Turn ON the main power switch. 18) Check if the voice board is recognized. Service mode Select COPIER >...
  • Page 46 Chapter 2 2.6 Installing the Voice Operation Kit 2.6.1 A point to keep in mind at installation 0015-1982 - In order to install this equipment, "Expansion Bus-B1" is required. - In case of installing this equipment, "Voice Guidance Kit-B1" cannot be installed. 2.6.2 Checking the Contents 0015-0864 <Voice Operation Kit-A1>...
  • Page 47 Chapter 2 [11]* Screw (binding; M4X40) 1pc. [12] Hex Screw 2pc. [13] Washer 2pc. [14] Wire Saddle 3pc. [15] Voice Guidance Kit Users Guide 1pc. [16] Voice Guidance Kit Users Guide CD 1pc. [17] Voice Operation Kit Users Guide 1pc. [18] Voice Operation Kit Users Guide CD 1pc.
  • Page 48 Chapter 2 2.6.4 Installation Procedure 0015-0866 1. Installation Procedure 1) Detach the face cover [1] in the direction shown by the arrow. - 4 screws [2] (to remove) - 2 screws [3] (to loosen) F-2-67 2) Detach the blanking plate [1] (Do not use the detached blanking plate). - 2 screws [2] F-2-68 3) Attach the board support plate [2] to the voice operation board [1].
  • Page 49 Chapter 2 Checking the Position of the Slide Switch (SW1) on the Voice Guidance Board The slide switch (SW1) on the Voice Guidance Board is provided as a means of switching frequencies (33 MHz/66 MHz) to suit the transfer speed of the PCI bus. It is important for the switch setting to suit the transfer speed so that the voice will be free of interruption.
  • Page 50 Chapter 2 F-2-71 7) Remove the two screws [1] from the speaker unit and then remove the speaker unit (lower) [2]. F-2-72 8) Mount the speaker unit (lower) [1]. - 1 screw (binding; M3X20) [2] - 1 screw (binding; M4X20) [3] F-2-73 9) Mount the speaker unit (upper) [1] to the speaker unit (lower) using the two screws [2] that have been removed in step 7) from underneath.
  • Page 51 Chapter 2 10) Detach the cover [1] of the cable guide. F-2-75 11) Peel off the released paper of the code guide [1] and affix it to the host machine as shown in the figure. A: When a card reader is not mounted on the host machine F-2-76 B: When a card reader is mounted on the host machine F-2-77...
  • Page 52 Chapter 2 F-2-79 14) Run the cable [1] through the code guide [2] and mount the code guide cover [3]. There should no excessive bending of the cable. A: When a card reader is not mounted on the host machine F-2-80 B: When a card reader is mounted on the host machine F-2-81...
  • Page 53 Chapter 2 F-2-82 16) Fix the 3 wire saddles [2] with the rear cover [1]. F-2-83 17) Fix it with 3 wire saddles [2] so that there is no bending of the cable [1]. F-2-84 18) Connect the power cable to the power plug. 19) Turn ON the main power switch.
  • Page 54 Chapter 2 F-2-85 2) Select the voice mode type (Voice Guide + Recognition/Voice Guide/Voice Recognition) on the control panel, and press [OK]. Voice Navigation Selection Select the voice navigation type. Voice Guide + Voice Guide Voice Recognition Recognition You can perform operations using voice commands, or listen to the voice guide and perform operations using keys.
  • Page 55 Chapter 3 Main Controller...
  • Page 57 Contents Contents 3.1 Construction ...................................3-1 3.1.1 Construction and Mechanisms ..............................3-1 3.2 Construction of the Electrical Circuitry .........................3-1 3.2.1 Main Controller PCB ................................... 3-1 3.2.2 HDD ......................................3-2 3.3 Start-Up Sequence................................3-4 3.3.1 Overview...................................... 3-4 3.3.2 Start-Up Sequence ..................................3-4 3.4 Shut-Down Sequence ..............................3-6 3.4.1 Overview......................................
  • Page 59 Chapter 3 3.1 Construction 3.1.1 Construction and Mechanisms 0006-6582 The machine's main controller block consists of the following and has the following functions: T-3-1 Item Description Main controller PCB Controls system operation, memory, printer unit output, image processing, printer unit image input processing, rendering, color LCD controller, card printer unit interface, fax image processing, etc.
  • Page 60 Chapter 3 J1014 J1004 J1016 J1028 J1003 J1029 IC1005 IC1010 J1018 J1017 J1024 IC1084 J1006 IC1008 J1013 IC1009 IC1004 IC1100 J1061 J1062 IC1003 BATTERY IC1001 J1010 IC1006 J1026 J1023 IC1002 J1022 J1060 J1030 J1005 J1020 J1059 J1027 J1021 F-3-2 T-3-2 Connector Description J1003...
  • Page 61 Chapter 3 Partition Description APL_MEAP Stores MEAP applications. APL_GEN Mode memory data, standard mode data History (e.g., print job history) iFax image data Fax image data Other IMG_MNG Stores file management table, profile. PDL_DEV Stores PDL font, etc. BOOTDEV Stores execution module, message data file, RUI content, etc. FSTCDEV Chasing (not used) FSTDEV...
  • Page 62 Chapter 3 RCON Reader unit DCON Main controller PCB DC controller PCB BOOT SYSTEM Language BOOTDEV BOOTDEV MEAP G3FAX F-3-4 3.3 Start-Up Sequence 3.3.1 Overview 0006-6702 The system software used to control the machine is stored on the HDD. When the machine is started, the CPU on the main controller PCB reads the system software from the HDD according to the instructions of the boot ROM boot program, and writes it to the image memory (SDRAM) of the controller PCB.
  • Page 63 Chapter 3 -Self Diagnosis Program (interval 1) The self-diagnosis program is run by the CPU on the main controller PCB when the main power switch is turned on. The program is used to check the condition of the image memory (SDRAM) and the HDD. The machine will indicate an error code if it finds a fault while running the program.
  • Page 64 Chapter 3 - While the Boot Program Is Being Run Image memory (SDRAM) System area Image data area System software Boot Self-diagnosis program program BootROM Main controller PCB : access to the program during execution. : flow of the system program. F-3-8 3.4 Shut-Down Sequence 3.4.1 Overview...
  • Page 65 Chapter 3 Other iR machine Original Copy Scan -SEND -FAX -PullScan -E-Mail -PDL Print Image data Print output -BOX F-3-10 3.5.2 Construction of the Image Processing Module 0006-6706 The machine's major image processing is executed by the main controller PCB. The following shows the construction of the modules associated with image processing: Reader unit Reader unit controller PCB...
  • Page 66 Chapter 3 Reader unit Main controller PCB Enlargement/reduction Edge emphasis -intensify-to-density conversion -density adjustment (F adjustment) -gamma correction Text mode Film photo mode Text/photo/film photo mode Binary processing (error diffusion) Binary processing (screen processing) To compression/expansion/editing block F-3-12 3.5.4 Compressio/ Extesion/ Editing Block 0006-6714 Here, image data is processed for compression, extension, and editing.
  • Page 67 Chapter 3 Main controller PCB Compression/expansion/editing block Binary density conversion Enlargement/reduction Smoothing For PDL data, Thickening when fine line processing is ON To DC controller PCB F-3-14 3.6 Flow of Image Data 3.6.1 Flow of Image Data According to Copy Functions 0006-6746 The following is the flow of image data when the Copy Function is in use: Printer unit...
  • Page 68 Chapter 3 Printer unit Main controller PCB Image processing block for printer unit SDRAM Data rotation Data compression F-3-16 3.6.3 Flow of Image Data for the SEND Function 0006-6749 The following is the flow of image data when the SEND function is in use. Printer unit Main controller PCB Image processing block for printer unit...
  • Page 69 Chapter 3 Reader unit Main controller PCB Image processing block for reader unit SDRAM Compression Compression Expansion Image processing block for fax Resolution conversion Super G3 Fax Board F-3-18 3.6.5 Flow of Image Data for the Fax Reception Function 0006-6751 The following is the flow of image data when the fax reception function is in use: Super G3 Fax Board Main controller PCB...
  • Page 70 Chapter 3 Ethernet Main controller PC Rendering processing block Compression/expansion F-3-22 /editing block Freeing the Flexible Cable To free the flexible cable [1], shift up the lock first as shown. Processing block for printer unit DC controller PCB F-3-20 3.7 Parts Replacement Procedure 3.7.1 Main Controller PCB 3.7.1.1 Removing the Rear Cover 0007-6401...
  • Page 71 Chapter 3 F-3-28 3.7.3 Boot ROM 3.7.3.1 Removing the Face Cover F-3-25 0007-6413 1) Remove the 4 screws [1]. 3.7.2 SDRAM 2) Loosen the 2 screws [2]. 3.7.2.1 Removing the Face Cover 0007-6411 1) Remove the 4 screws [1]. 2) Loosen the 2 screws [2]. F-3-29 3) Pull off the face cover [1] in upward direction.
  • Page 72 Chapter 3 F-3-31 F-3-34 3.7.4 HDD 3.7.4.3 Removing the HDD 3.7.4.1 Removing the Face Cover 0007-6410 1) Remove the 2 screws [1], and detach the HDD [2] in the direction of the arrow. 0007-6409 1) Remove the 4 screws [1]. 2) Loosen the 2 screws [2].
  • Page 73 Chapter 4 Laser Exposure...
  • Page 75 Contents Contents 4.1 Construction ...................................4-1 4.1.1 Specifications, Control Mechanism, and Functions ........................4-1 4.1.2 Major Components..................................4-1 4.1.3 Construction of the Control System............................. 4-2 4.2 Basic Sequence ................................4-3 4.2.1 Basic Sequence ................................... 4-3 4.3 Various Controls ................................4-4 4.3.1 Controlling the Laser Activation Timing............................. 4-4 4.3.1.1 Turning On and off the Laser Light ................................4-4 4.3.1.2 Main Scanning Synchronous Control ................................4-5 4.3.2 Controlling the Intensity of Laser Light ............................
  • Page 77 Chapter 4 4.1 Construction 4.1.1 Specifications, Control Mechanism, and Functions 0006-9404 Laser Light T-4-1 Number of laser beams Output 5mW (iR2270/2870/2230/2830) 10mW (iR3570/4570/3530) Wave length 785 nm - 800 nm (infrared light) Scanner Motor T-4-2 Type of motor DC brushless motor Number of revolutions 16000 rpm (approx.;...
  • Page 78 Chapter 4 T-4-5 Name Description [1] Laser unit Generates laser light [2] Polygon mirror Scans laser light in main scanning direction. [3] BD mirror Reflects laser light in the direction of the BD PCB. [4] BD PCB Generates the BD signal. 4.1.3 Construction of the Control System 0006-5971 The laser exposure system is primarily controlled by the DC controller PCB.
  • Page 79 Chapter 4 iR3570/iR3570F/iR4570/iR4570F VDO1 /VDO1 CNT0 CNT1 CNT2 /VDO2 VDO2 PWCHG STAND BY FG PULSE DETECT POLYGON FG +24V P ACC P DEC +3.3V F-4-3 [1]DC controller PCB [2]Laser driver PCB [3]Scanner motor PCB [4]BD PCB T-4-6 Single Description VDO1 Image data single input CNT0 Laser driver control signal...
  • Page 80 Chapter 4 STBY INTR PRINT STBY PVREQ Laser A BD detention/APC control ON BD detection/APC control ON APC control ON F-4-4 4.3 Various Controls 4.3.1 Controlling the Laser Activation Timing 4.3.1.1 Turning On and off the Laser Light 0006-5973 The laser light is turned on and off according to the combination of laser control signals (CNT0/1/2) from the DC controller PCB. T-4-7 Laser control signal Laser status...
  • Page 81 Chapter 4 DC-CON F-4-5 4.3.1.2 Main Scanning Synchronous Control 0006-5974 The synchronous control in the main scanning direction is performed in the synch circuit based on the BD synch signal. Using the BD signal generated based on the light from laser A, the DC controller PCB generates the BD synch signal for laser A and the BD synch signal for laser B. The image data written to line memory is read out by the readout enable signal (RE_A, RE_B) generated based on the BD synch signal (BD_A, BD_B) for output to the laser driver PCB.
  • Page 82 Chapter 4 4.3.2 Controlling the Intensity of Laser Light 4.3.2.1 APC Control 0006-5976 The laser light hitting the photodiode included in the laserdiode is monitored and is controlled so that it remains a specific level at all times. 4.3.3 Controlling the Laser Scanner Motor 4.3.3.1 Controlling the Laser Scanner Motor 0006-5978 The laser scanner motor is controlled with reference to the laser scanner motor revolution signal (FG signal).
  • Page 83 Chapter 4 F-4-10 4.4.1.2 Removing the Left Cover 0007-8349 1) Remove the 4 screws [1], and detach the left cover [2]. LOSED DOOR OPEN F-4-11 F-4-8 [1] Laser shutter 4.4.1.3 Removing the Laser Unit [2] Laser shutter link (operates in conjunction with front cover) 0007-8350 [3] Laser unit 1) Open the 2 wire saddles [1], and disconnect the 2 connectors [2].
  • Page 84 Chapter 4 F-4-13 3) Remove the screw [1], and detach the fixing [2]. F-4-14 4) Lift the front of the laser unit [1], and slide it to the front. F-4-15 When sliding out the laser scanner unit, be sure to take care not to touch the PCB mounted to the laser scanner unit.
  • Page 85 Chapter 5 Image Formation...
  • Page 87 Contents Contents 5.1 Construction ...................................5-1 5.1.1 Specifications of the Image Formation System ........................... 5-1 5.1.2 Major Components of the Image Formation System ........................5-2 5.2 Image Formation Process...............................5-2 5.2.1 Image Formation Process (outline) .............................. 5-2 5.2.2 Image Formation Process (image formation) ..........................5-3 5.3 Basic Sequence ................................5-3 5.3.1 Sequence of Operation (initial rotation) ............................
  • Page 88 Contents 5.12.1.4 Removing the Drum Unit ................................... 5-11 5.12.1.5 Removing the Developing Assembly ................................. 5-12 5.12.1.6 Removing the Upper Tray ..................................5-13 5.12.1.7 Removing the Toner Cartridge Cover ................................ 5-13 5.12.1.8 Removing the Pre-Exposure Lamp................................5-14 5.12.2 Drum Unit ....................................5-14 5.12.2.1 Removing the Front Cover Unit .................................
  • Page 89 Contents 5.12.10.2 Removing the Waste Toner Case ................................5-34 5.12.10.3 Removing the Toner Cartridge..................................5-35 5.12.10.4 Removing the Drum Unit..................................5-35 5.12.10.5 Removing the Developing Assembly................................5-36 5.12.10.6 Removing the Upper Tray..................................5-37 5.12.10.7 Removing the Toner Cartridge Cover...............................5-37 5.12.10.8 Removing the Pre-Exposure Lamp ................................5-37 5.12.10.9 Removing the Left Cover..................................5-37 5.12.10.10 Removing the Laser Unit ..................................5-37 5.12.10.11 Removing the Hopper Assembly ................................5-38...
  • Page 91 Chapter 5 5.1 Construction 5.1.1 Specifications of the Image Formation System 0006-6168 T-5-1 Drum Unit Specifications Photosensitive drum Drum type Drum diameter 30 mm Cleaning mechanism by cleaning blade Process speed 230 mm/sec (iR3570/4570/3530) 137 mm/sec (iR2270/2870/2230/2830) Primary charging Charging method by roller (AC + DC) Charging roller diameter 16 mm...
  • Page 92 Chapter 5 5.1.2 Major Components of the Image Formation System 0006-5981 F-5-1 [1] Toner cartridge [2] Sub hopper [3] Developing unit [4] Photosensitive drum [5] Transfer roller [6] Primary charging roller [7] Drum unit [8] Drum cleaning unit 5.2 Image Formation Process 5.2.1 Image Formation Process (outline) 0006-5983 F-5-2...
  • Page 93 Chapter 5 Item Description [2]Primary charging charges the surface of the photosensitive drum to a uniform negative potential. [3]Laser exposure forms a latent static image on the drum. [4]Development forms a visible image on the drum. [5]Transfer transfers images from the drum to paper. [6]Separation separates paper from the drum.
  • Page 94 Chapter 5 Multifeeder Registration Main motor (M-motor) Primary charging (PRI) Laser (LD) Developing AC (DEV_AC) Developing DC (DEV_DC) Developing clutch (DEV_CL) Transfer (TR) Static removal (SEP) F-5-5 In [1] above, a cleaning bias (-2600 V) is applied. 5.3.2 Sequence of Operation (copying) 0006-6868 The sequence of operation during copying is as follows: Registration...
  • Page 95 Chapter 5 T-5-7 [1] Drum film thickness detection control corrects the development contrast. [2] Developing contrast control determines the appropriate primary charging DC bias and developing DC bias. [3] ATVC control corrects the transfer bias. F-5-8 5.4.2 APVC Control 0006-5987 The term APVC stands for "auto primary voltage control,"...
  • Page 96 Chapter 5 F-5-9 5.6 Drum Cleaner Unit 5.6.1 Photosensitive Drum Cleaning 0007-5224 The cleaning blade is kept in contact with the surface of the photosensitive drum. It serves to scrape off the residual toner left behind from transfer to paper for collection in the waste toner box.
  • Page 97 Chapter 5 iR3570 / iR4570 F-5-10 iR2270 / iR2870 F-5-11 Points to Note on Handing the Toner Cartridge 1. Care should be taken not to bump the toner stop [1] against the covers or the like when and after removing the toner cartridge. Since the toner stop comes off easily, toner scattering may be resulted if it comes off by accident.
  • Page 98 Chapter 5 F-5-13 5.8.3 Controlling the Drive of the Toner Cartridge 0006-5996 When a request is made for a supply of toner, the toner cartridge drive motor rotates in the direction shown in the following figure; its drive is transmitted from the drive motor to the toner cartridge, thus rotating the toner cartridge.
  • Page 99 However, in the case of the iR3570/iR4570 Series machines, the drive of the main motor is controlled to 2 different speeds, and the toner inside the developing...
  • Page 100 Chapter 5 5.9.4 Separation Mechanism 5.9.4.1 Controlling the Static Eliminator Bias 0006-6001 Static Eliminator Bias 1st side: -2300 V 2nd side: -3000 V A DC bias is applied between sheets while an image is being formed. (It is applied until the ongoing job is over.) 5.10 Transfer Mechanism 5.10.1 Transfer Guide Bias 5.10.1.1 Transfer Guide Bias Control...
  • Page 101 Chapter 5 E190-0000 When the machine identifies the waste toner full sensor as being continuous- ly on for 2000 sheets, it will indicate a warning; if it then detects the activa- tion of the sensor for 100 sheets continuously, it will indicate 'E190-000'. (The count is increased coinciding with delivery.) 5.12 Parts Replacement Procedure 5.12.1 Pre-Exposure Lamp...
  • Page 102 Chapter 5 F-5-24 2) Remove the screw [1]. F-5-29 5.12.1.5 Removing the Developing Assembly F-5-25 0007-8344 3) Shift the locking lever [1] to the left to release the developing assembly. 1) Remove the screw [1]. F-5-26 F-5-30 4) Remove the screw [1]. 2) Shift the locking lever [1] to the left to release the developing assembly.
  • Page 103 Chapter 5 F-5-35 5.12.1.6 Removing the Upper Tray 0007-8345 1) Remove the 2 screws [1], and detach the upper tray [2]. F-5-32 4) Remove the developing assembly [1]. F-5-36 Reference: Lift the front of the upper tray [1], and detach it as if to slide it toward the front.
  • Page 104 Chapter 5 5.12.1.8 Removing the Pre-Exposure Lamp 0007-8347 1) Open the 2 wire saddles [1], and disconnect the 2 relay connectors [2]. F-5-43 5.12.2.2 Removing the Waste Toner Case F-5-39 0007-8030 1) Remove the waste toner case [1]. 2) While freeing the lock [1] toward the right, detach the pre-exposure lamp [2].
  • Page 105 Chapter 5 F-5-47 3) Shift the locking lever [1] to the left to release the developing assembly. F-5-51 5.12.3 Hopper Assembly F-5-48 5.12.3.1 Removing the Front Cover Unit 4) Remove the screw [1]. 0007-8006 1) Open the front cover [1]. F-5-49 5) Remove the drum unit [1].
  • Page 106 Chapter 5 F-5-58 F-5-54 5.12.3.4 Removing the Drum Unit Point to note after attaching the waste toner receptacle After attaching the waste toner receptacle, move the waste toner full detec- 0007-8352 1) Open the right door [1]. tion lever [1] up and down to make sure that the lever is moved smoothly. Faulty detection may be resulted if the lever is caught in something and is not moved smoothly.
  • Page 107 Chapter 5 5) Remove the drum unit [1]. F-5-63 Be sure to hold the drum unit as shown. F-5-67 4) Remove the developing assembly [1]. F-5-68 F-5-64 5.12.3.5 Removing the Developing Assembly Be sure to hold the developing assembly as shown. 0007-8353 1) Remove the screw [1].
  • Page 108 Chapter 5 5.12.3.8 Removing the Pre-Exposure Lamp 0007-8357 1) Open the 2 wire saddles [1], and disconnect the 2 relay connectors [2]. F-5-74 2) While freeing the lock [1] toward the right, detach the pre-exposure lamp [2]. F-5-70 5.12.3.6 Removing the Upper Tray 0007-8354 1) Remove the 2 screws [1], and detach the upper tray [2].
  • Page 109 Chapter 5 When sliding out the laser scanner unit, be sure to take care not to touch the PCB mounted to the laser scanner unit. (The PCB is equipped with a laser scanner intensity adjustment variable resistor, and contact with the PCB can change the adjustment setting.) 5.12.3.11 Removing the Hopper Assembly 0007-8360...
  • Page 110 Chapter 5 Point to note after attaching the waste toner receptacle When fitting the hopper assembly to the machine, be sure that the connectors After attaching the waste toner receptacle, move the waste toner full detec- [1] are securely connected. If the connectors [1] are not connected, the envi- tion lever [1] up and down to make sure that the lever is moved smoothly.
  • Page 111 Chapter 5 5.12.4.4 Removing the Drum Unit Be sure to hold the drum unit as shown. 0007-8387 1) Open the right door [1]. F-5-94 2) Remove the screw [1]. F-5-99 5.12.4.5 Removing the Developing Assembly 0007-8388 1) Remove the screw [1]. F-5-95 3) Shift the locking lever [1] to the left to release the developing assembly.
  • Page 112 Chapter 5 F-5-105 5.12.4.6 Removing the Upper Tray 0007-8389 1) Remove the 2 screws [1], and detach the upper tray [2]. F-5-102 4) Remove the developing assembly [1]. F-5-106 Reference: Lift the front of the upper tray [1], and detach it as if to slide it toward the front.
  • Page 113 Chapter 5 5.12.4.8 Removing the Pre-Exposure Lamp 0007-8391 1) Open the 2 wire saddles [1], and disconnect the 2 relay connectors [2]. F-5-113 F-5-109 2) While freeing the lock [1] toward the right, detach the pre-exposure lamp [2]. When you have disconnected the connector [1], be sure to take care so that it will not come into contact with the PCB that is mounted to the laser scanner unit.
  • Page 114 Chapter 5 When sliding out the laser scanner unit, be sure to take care not to touch the PCB mounted to the laser scanner unit. (The PCB is equipped with a laser When fitting the hopper assembly to the machine, be sure that the connectors scanner intensity adjustment variable resistor, and contact with the PCB can [1] are securely connected.
  • Page 115 Chapter 5 F-5-128 5) Remove the screw [1], and release the arm [2]. F-5-125 2) Check the phase of the gear [1] shown in the figure. F-5-129 6) Remove the bushing unit [2] from the sub hopper [1]. F-5-130 7) Disconnect the connector [1]. F-5-126 3) Remove the 3 screws [1].
  • Page 116 Chapter 5 5.12.5 Developing Assembly 5.12.5.3 Removing the Developing Assembly 0007-8034 1) Remove the screw [1]. 5.12.5.1 Removing the Front Cover Unit 0007-8022 1) Open the front cover [1]. F-5-137 2) Shift the locking lever [1] to the left to release the developing assembly. F-5-133 2) Remove the face cover rubber [1].
  • Page 117 Chapter 5 Be sure to hold the developing assembly as shown. F-5-143 2) Slide out the sleeve front guide [2] in the direction of the arrow while re- leasing the claw [1]. F-5-141 F-5-144 3) Unscrew a self-tapping screw [1] and a washer screw [2], and remove the angle When fitting the developing assembly, be sure to fit the lower right segment adjustment plate [3].
  • Page 118 Chapter 5 11) Remove a grip ring [1], a washer [2], a push-on roller [3], a sleeve holder (front) [4] and a bearing [5] from the developing cylinder. F-5-152 5.12.7 Transfer Charging Roller 5.12.7.1 Removing the Transfer Roller F-5-148 0007-8431 1) Open the right door [1].
  • Page 119 Chapter 5 F-5-160 F-5-156 5.12.8.2 Removing the Waste Toner Case Points to Note When Attaching the Transfer Roller 0007-8015 1) Remove the waste toner case [1]. Be sure that the top of the holder [1] is on the inside of the static eliminator [2].
  • Page 120 Chapter 5 5) Detach the front cover unit [4] by moving it in the direction of the ar- row. F-5-168 F-5-164 Points to Note on Handing the Toner Cartridge 1. Care should be taken not to bump the toner stop [1] against the covers 5.12.9.2 Removing the Waste Toner Case or the like when and after removing the toner cartridge.
  • Page 121 Chapter 5 F-5-172 F-5-176 4) Remove the screw [1]. 2) Shift the locking lever [1] to the left to release the developing assembly. F-5-177 F-5-173 3) Slide the developing assembly [1] slightly to the front; then, disconnect 5) Remove the drum unit [1]. the connector [2].
  • Page 122 Chapter 5 F-5-183 5.12.9.7 Removing the Toner Cartridge Cover 0007-8368 1) Remove the 2 screws [1]; then, detach the toner bottle cover [2]. F-5-180 When fitting the developing assembly, be sure to fit the lower right segment [2] of the developing assembly [1] in the rail [3] of the machine. Thereafter, slide the developing assembly so that [A] of the developing assembly match- es [B] of the rail.
  • Page 123 Chapter 5 F-5-187 F-5-190 5.12.9.9 Removing the Left Cover 3) Remove the screw [1], and detach the fixing [2]. 0007-8370 1) Remove the 4 screws [1], and detach the left cover [2]. F-5-191 4) Lift the front of the laser unit [1], and slide it to the front. F-5-188 5.12.9.10 Removing the Laser Unit 0007-8371...
  • Page 124 Chapter 5 2) Disconnect the 3 connectors [1] found at the front and the connector [2] found at the rear. F-5-198 5.12.10 Toner Feedscrew Motor F-5-194 5.12.10.1 Removing the Front Cover Unit 3) Open the 11 wire saddles [1], and pull out the harness [3] through the hole 0007-8019 1) Open the front cover [1].
  • Page 125 Chapter 5 moved smoothly. F-5-206 2) Remove the screw [1]. F-5-202 5.12.10.3 Removing the Toner Cartridge 0007-8375 1) Shift up the lever [1]. F-5-207 3) Shift the locking lever [1] to the left to release the developing assembly. F-5-203 2) Remove the toner cartridge [1]. F-5-208 4) Remove the screw [1].
  • Page 126 Chapter 5 F-5-211 5.12.10.5 Removing the Developing Assembly F-5-214 4) Remove the developing assembly [1]. 0007-8377 1) Remove the screw [1]. F-5-215 F-5-212 2) Shift the locking lever [1] to the left to release the developing assembly. Be sure to hold the developing assembly as shown. F-5-213 3) Slide the developing assembly [1] slightly to the front;...
  • Page 127 Chapter 5 5.12.10.8 Removing the Pre-Exposure Lamp 0007-8381 1) Open the 2 wire saddles [1], and disconnect the 2 relay connectors [2]. F-5-221 2) While freeing the lock [1] toward the right, detach the pre-exposure lamp [2]. F-5-217 5.12.10.6 Removing the Upper Tray 0007-8378 1) Remove the 2 screws [1], and detach the upper tray [2].
  • Page 128 Chapter 5 When sliding out the laser scanner unit, be sure to take care not to touch the PCB mounted to the laser scanner unit. (The PCB is equipped with a laser scanner intensity adjustment variable resistor, and contact with the PCB can change the adjustment setting.) 5.12.10.11 Removing the Hopper Assembly 0007-8384...
  • Page 129 Chapter 5 When fitting the hopper assembly to the machine, be sure that the connectors [1] are securely connected. If the connectors [1] are not connected, the envi- ronment heater will not be supplied with power, leading to image faults. F-5-237 2) Remove the screw [1].
  • Page 131 Chapter 6 Pickup/Feeding System...
  • Page 133 Contents Contents 6.1 Construction ...................................6-1 6.1.1 Specifications, Controls, and Functions............................6-1 6.1.2 Division into Blocks ..................................6-2 6.1.3 Arrangement of Rollers................................6-3 6.1.4 Diagram of Paper Paths (printer on its own) ..........................6-4 6.1.5 Diagram of Paper Paths (w/ 3 Way Unit-A1 /copy tray)......................6-4 6.1.6 Diagram of Paper Paths (w/ Finisher-S1/copy tray) ........................
  • Page 134 Contents 6.8.4 Sensor Mount ..................................... 6-34 6.8.4.1 Removing the Right Cover (rear) ................................. 6-34 6.8.4.2 Removing the Right Door..................................... 6-34 6.8.4.3 Removing the Right Cover (lower front)..............................6-35 6.8.4.4 Removing the Sensor Mounting Plate ................................6-35 6.8.4.5 Mounting the Sensor Mounting Plate ................................6-35 6.8.5 Cassette Pick-up Motor 1................................
  • Page 135 Contents 6.8.15 Manual Feed Unit ..................................6-52 6.8.15.1 Removing the Right Cover (rear)................................6-52 6.8.15.2 Removing the Right Door ...................................6-52 6.8.15.3 Removing the Manual Feed Unit ................................6-53 6.8.16 Manual Pickup Roller ................................6-54 6.8.16.1 Removing the Right Cover (rear)................................6-54 6.8.16.2 Removing the Right Door ...................................6-54 6.8.16.3 Removing the Manual Feed Unit ................................6-55 6.8.16.4 Removing the Manual Feed Pickup Roller ..............................6-55 6.8.17 Manual Pick-up Clutch ................................
  • Page 137 Chapter 6 6.1 Construction 6.1.1 Specifications, Controls, and Functions 0006-7400 The major specifications, controls, and functions of the pickup/feeding system are as follows: T-6-1 Item Description Paper compartment front loading Pickup method cassette separation retard manual feeder separation pad Paper reference center Paper volume cassette 1/2...
  • Page 138 Chapter 6 Item Description Delivery accessory 3 Way Unit-A1 (standard with iR4570/3570 model) Inner 2-Way Tray-D1 Copy Tray-J1 Finisher-S1 Buffer Path Unit-E1 Finisher-Q3 Saddle Finisher-Q4 Inner Puncher Kit-Q1/R1/S1/T1 Punch Unit-L1/M1/N1/P1 Pickup accessory Cassette Feeding Unit-Y2 Side Paper Deck-Q1 Envelope Cassette Attachment-C1 6.1.2 Division into Blocks 0006-7401 F-6-1...
  • Page 139 Chapter 6 6.1.3 Arrangement of Rollers 0006-7402 [25] [24] [23] [22] [21] [20] [19] [18] [17] [16] [15] [14] [13] [12] [11] [10] F-6-2 [1] Pickup roller (cassette 1) [2] Feeding roller (cassette 1) [3] Separation roller (cassette 1) [4] Pickup roller (cassette 2) [5] Feeding roller (cassette 2) [6] Separation roller (cassette 2) [7] Vertical path roller 2...
  • Page 140 Chapter 6 6.1.4 Diagram of Paper Paths (printer on its own) 0006-7403 F-6-3 [1] Pickup from cassette 1 [2] Pickup from cassette 2 [3] Pickup from cassette pedestal [4] Pickup from side paper deck [5] Pickup from manual feeder [6] Delivery from copy tray 1 6.1.5 Diagram of Paper Paths (w/ 3 Way Unit-A1 /copy tray) 0006-7404 F-6-4...
  • Page 141 Chapter 6 [2] Pickup from cassette 2 [3] Pickup from cassette pedestal (option) [4] Pickup from side paper deck (option) [5] Pickup from manual feeder [6] Delivery to copy tray 1 [7] Delivery to copy tray 2 (option) [8] Delivery to copy tray 3 (option) 6.1.6 Diagram of Paper Paths (w/ Finisher-S1/copy tray) 0006-7405 F-6-5...
  • Page 142 Chapter 6 6.1.7 Diagram of Paper Paths (w/ Finisher-Q3/Saddle Finisher-Q4) 0006-7406 F-6-6 [1] Pickup from cassette 1 [2] Pickup from cassette 2 [3] Pickup from cassette pedestal (option) [4] Pickup from paper deck (option) [5] Pickup from manual feeder [6] Delivery to Finisher-Q3/Saddle Finisher-Q4 (option) [7] No.2 delivery assembly (option) 6.1.8 Arrangement of Sensors 0006-7408...
  • Page 143 Chapter 6 [1] Cassette 1 paper level sensor B (PS4) [2] Cassette 1 paper level sensor A (PS3) [3] Cassette 2 paper level sensor B (PS6) [4] Cassette 2 paper level sensor A (PS5) [5] Cassette 2 paper sensor (PS2) [6] Cassette 2 retry sensor (PS11) [7] Cassette 1 paper sensor (PS1) [8] Cassette 1 retry sensor (PS10)
  • Page 144 Chapter 6 Print Start PRINT Cassette 1 pickup motor (M6) Cassette 1 pickup solenoid (SL1) Cassette 1 retry sensor (PS10) Main motor (M2) Registration sensor (PS9) Registration clutch (CL2) Fixing motor (M11) Fixing/delivery paper sensor (PS13) No.1 delivery motor (M4) Delivery sensor 1 (PS14) cassette 1 pickup motor rotation...
  • Page 145 Chapter 6 F-6-11 1. Increase in Speed for Pickup Operation The speed is 1.5 times as high as the process speed (no increase if for manual feed pickup/in the case of the 1st sheet from cassette 1, accelerates to about twice as fast).
  • Page 146 Chapter 6 1. Increase in Speed for Pickup Operation The speed is 1.5 times as high as the process speed (no increase if for manual feed pickup/in the case of the 1st sheet from cassette 1, accelerates to about twice as fast).
  • Page 147 Chapter 6 6.3.2 Stationary Jams 6.3.2.1 Common Stationary Jam 0007-2665 The sensor N does not go off within a specific length of time after the sensor has gone on. Start key ON or PRINT set INTR PRINT L + A L + A Jam Check Normal...
  • Page 148 Chapter 6 [3] [4] [10] F-6-16 [1] Cassette paper sensor [2] Pickup roller (roller A) [3] Feed roller (roller B) [4] Separation roller (roller C) [5] Pickup vertical path roller [6] Cassette retry paper sensor [7] Vertical path guide [8] Lower right cover [9] Holding plate [10] Lifter plate 6.4.2 Basic Sequence...
  • Page 149 Chapter 6 INCH SW4-ON=INCH F-6-18 [1] AB/Inch switch [2] Cassette size dial [3] Cassette size detection PCB T-6-7 AB-configuration Size (no cassette) Envelope ON/OFF SW4 is used to detect the state of the AB/Inch-configuration switch. The machine will assume the absence of a cassette if it detects a combination not found in the table. At this time, it does not move up the cassette lifter.
  • Page 150 Chapter 6 Inch-configuration LTRR 11X17 EXEC Envelope ON/OFF SW4 is used to detect the state of the AB/Inch-configuration switch. The machine will assume the absence of a cassette if it detects a combination not found in the table. At this time, it does not move up the cassette lifter.
  • Page 151 Chapter 6 F-6-19 [1] Flag [2] Cassette paper sensor [3] Lifter clutch [4] Cassette paper level sensor A [5] Cassette paper level sensor B [6] Paper level sensor flag [7] Lifter gear [8] Tray 6-15...
  • Page 152 Chapter 6 View from the Front of the Machine When full with paper Cassette paper Cassette paper level sensor B level sensor A Paper When half full with paper Paper Cassette paper Cassette paper level sensor A level sensor B OFF ON When there is little paper Paper...
  • Page 153 Chapter 6 (1) the pickup guide plate is locked in place at all times, and does not require drive for pickup operation. (2) multi-pickup roller is driven by the main motor (M2) through the manual feed pickup clutch (CL1). [10] F-6-21 [1] Upper guide [2] Stopper plate...
  • Page 154 Chapter 6 F-6-23 [1] Side guide (rear) [2] Stop arm [3] Center gear [4] Side guide (front) [5] Variable resistor (SVR1) [6] Manual feed tray 6.5.4 Paper Retaining Mechanism 0007-2189 The holding plate of the machine's cassette is fixed in position at all times, and does not move up/down at time of pickup, and must temporarily be released when paper is set between it and the manual feed pickup roller.
  • Page 155 Chapter 6 F-6-25 3. When the upper guide is closed once again, the holding plate becomes locked in position once again. F-6-26 6.6 Registration Unit 6.6.1 Overview 0007-2213 The registration roller is driven by the main motor (M2). In between the registration roller and the main motor is the registration clutch (SL2), servicing to turn on and off the registration roller so that the paper will be matched in relation to the image on the drum at correct registration.
  • Page 156 Chapter 6 DC controller PCB F-6-27 6.6.2 Checking Horizontal Registration 0007-2214 The machine does not have a mechanism to check horizontal registration for both 1st and 2nd sides of a print. The point of horizontal registration for the 2nd side may be adjusted in service mode (i.e., the image write start position).
  • Page 157 Chapter 6 Configuration of Components If Without a Delivery Accessory F-6-28 [1] Delivery roller [2] Delivery sensor 1 (PS14) [3] Reversing flapper [4] Duplexing feeding roller 1 [5] Duplexing feed sensor (PS17) [6] Duplexing feeding roller 1 Configuration of the Components If With a Delivery Accessory F-6-29 [1] Reversing roller [2] Reversal sensor (PS4A)
  • Page 158 Chapter 6 [3] Duplexing inlet sensor (PS3A) [4] Duplexing inlet roller [5] Duplexing feeding roller 1 [6] Duplexing feed sensor (PS17) [7] Duplexing feeding roller 2 6.7.2 Sequence of Image Formation 0007-2223 The machine goes thorough the following sequence to form images when making double-sided copies/prints: - Configuration Without an Accessory Installed A4/LTR 1-2 2-2 1-1 3-2 2-1...
  • Page 159 Chapter 6 F-6-33 The 1st sheet is picked up. F-6-34 An image is formed for the 2nd side of the 1st sheet. The 2nd sheet is picked up. F-6-35 The 1st sheet is turned over and moved to duplexing registration. An image is formed for the 2nd side of the 2nd sheet. 6-23...
  • Page 160 Chapter 6 F-6-36 The 1st sheet is moved for registration once again. The 2nd sheet is turned over and moved for duplexing registration. The 3rd sheet is picked up. F-6-37 An image is formed for the 1st side of the 1st sheet and for the 2nd side of the 3rd sheet. The 2nd sheet is moved for duplexing. F-6-38 The 1st sheet is delivered.
  • Page 161 Chapter 6 F-6-39 An image is formed for the 1st side of the 2nd sheet and for the 2nd side of the 4th sheet. The 3rd sheet is moved for duplexing. F-6-40 The 2nd sheet is delivered. The 4th sheet is reversed and is moved for duplexing registration. The 3rd sheet is picked for registration once again. The 5th sheet is picked up.
  • Page 162 Chapter 6 F-6-42 The 3rd sheet is delivered. The 5th sheet is turned over and moved for registration. The 4th sheet is moved for registration once again. F-6-43 An image is formed for the 1st side of the 4th sheet. The 5th sheet is moved for duplexing. F-6-44 The 4th sheet is delivered.
  • Page 163 Chapter 6 F-6-45 An image is formed for the 1st side of the 5th sheet. F-6-46 The 5th sheet is delivered. 6.7.4 Flow of Paper (w/ delivery option) 0007-3126 A4/LTR, 5 Sheets, Delivery to Tray 1/2 A number in a circle indicates the 1st side, while a number in a square indicates the 2nd side. F-6-47 The 1st sheet is picked up.
  • Page 164 Chapter 6 F-6-48 An image is formed for the 2nd side of the 1st sheet. The 2nd sheet is picked up. F-6-49 The 1st sheet is turned over, and is moved for duplexing registration. An image is formed for the 2nd side of the 2nd sheet. F-6-50 The 1st sheet is moved for registration once again.
  • Page 165 Chapter 6 F-6-51 An image is formed for the 1st side of the 1st sheet and the 2nd side of the 3rd sheet. The 2nd sheet is moved for duplexing. F-6-52 The 1st sheet is delivered. The 3rd sheet is turned over and is moved for duplexing registration. The 2nd sheet is moved for registration once again. The 4th sheet is picked up.
  • Page 166 Chapter 6 F-6-54 The 2nd sheet is delivered. The 4th sheet is turned over, and is moved for duplexing registration. The 3rd sheet is moved for registration once again. The 5th sheet is picked up. F-6-55 An image is formed for the 1st side of the 3rd sheet and for the 2nd side of the 5th sheet. The 5th sheet is moved for duplexing. F-6-56 The 3rd sheet is delivered.
  • Page 167 Chapter 6 F-6-57 An image is formed for the 1st side of the 4th sheet. The 5th sheet is moved for duplexing. F-6-58 The 4th sheet is delivered. The 5th sheet is moved for registration once again. F-6-59 An image is formed for the 1st side of the 5th sheet. 6-31...
  • Page 168 Chapter 6 F-6-63 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door. F-6-60 The 5th sheet is delivered. 6.8 Parts Replacement Procedure 6.8.1 Pick-up Unit 1 6.8.1.1 Removing the Right Cover (rear) 0007-6551 1) Open the pedestal right door [1].
  • Page 169 Chapter 6 F-6-69 6.8.2.2 Removing the Right Cover (lower front) 0007-6556 1) Open the pedestal right door [1]. (if equipped with a Cassette Feeding Unit-Y2) F-6-67 2) Open the lower right door [2]. 3) Remove the 2 screws [3], and detach the right cover (lower front) [4]. When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first.
  • Page 170 Chapter 6 The collar (roller core) of the machine's feed/separation roller is black. 6.8.4 Sensor Mount 6.8.4.1 Removing the Right Cover (rear) 0007-6558 1) Open the pedestal right door [1]. (if equipped with a 2-Cassette Pedestal- 2) Open the right lower door [2]. 3) Remove the 5 screws [3], and detach the right cover (rear) [4].
  • Page 171 Chapter 6 When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first. 6.8.4.3 Removing the Right Cover (lower front) 0007-6562 1) Open the right door [1] of the pedestal (if a 2-Cassette Pedestal-Y1 is in- stalled).
  • Page 172 Chapter 6 6.8.5 Cassette Pick-up Motor 1 6.8.5.1 Removing the Rear Cover 0007-6571 1) Remove the 13 screws [1] and then the other screw [2]; then, detach the rear cover [3]. If the left cover (lower) has already been detached, the screw [3] should also have been removed.
  • Page 173 Chapter 6 F-6-91 6.8.6 Cassette Pick-up Motor 2 F-6-93 6.8.6.1 Removing the Rear Cover 6.8.6.3 Removing the Pickup Motor Base 0007-6598 0007-6990 1) Remove the 13 screws [1] and then the other screw [2]; then, detach the 1) Free the harness [1] from the 2 wire saddles [2]. rear cover [3].
  • Page 174 Chapter 6 F-6-97 F-6-100 6.8.6.4 Removing the Cassette Pickup Motor 2 2) Remove the screw [1], and detach the fixing plate [2]. 0007-6601 1) Remove the 2 screws [1], and detach the cassette pickup motor 2 [2]. F-6-101 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door.
  • Page 175 Chapter 6 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate. F-6-107 2) Disconnect the connector from the cassette size sensor relay PCB.
  • Page 176 Chapter 6 F-6-114 3) Remove the joint shaft [1], and free the extension delivery unit [2] from F-6-111 the right door. 6.8.8 Cassette Retry Paper Sensor 6.8.8.1 Removing the Right Cover (rear) 0007-6611 1) Open the pedestal right door [1]. (if equipped with a 2-Cassette Pedestal- 2) Open the right lower door [2].
  • Page 177 Chapter 6 F-6-120 Pickup Unit 1 F-6-118 When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first. 6.8.8.3 Removing the Right Cover (lower front) 0007-6613 1) Open the pedestal right door [1]. (if equipped with a Cassette Feeding Unit-Y2) F-6-121 2) Open the lower right door [2].
  • Page 178 Chapter 6 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door. F-6-127 F-6-123 4) Disconnect the connector [1], and remove the reuse band [2]; then, remove 6.8.9 Cassette Paper Sensor the 2 screws (M4x8; RS tightening). 6.8.9.1 Removing the Right Cover (rear) 0007-6618 1) Open the pedestal right door [1].
  • Page 179 Chapter 6 3) Remove the bushing [4] and the 5 screws [5]; then, detach the sensor base When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first. 6.8.9.3 Removing the Right Cover (lower front) 0007-6620 1) Open the pedestal right door [1].
  • Page 180 Chapter 6 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate. F-6-137 2) Remove the screw [1], and detach the fixing plate [2].
  • Page 181 Chapter 6 F-6-147 F-6-144 6.8.11 Slide Resistor Pickup Unit 1 6.8.11.1 Removing the Right Cover (rear) 0007-6641 1) Open the pedestal right door [1]. (if equipped with a 2-Cassette Pedestal- 2) Open the right lower door [2]. 3) Remove the 5 screws [3], and detach the right cover (rear) [4]. F-6-145 Pickup Unit 2 2) Disconnect the connector [1], and remove the screw;...
  • Page 182 Chapter 6 F-6-150 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door. F-6-154 F-6-151 4) Disconnect the connector [1], and remove the reuse band [2]; then, remove When tightening the 2 screws used to fix the hinge in place, be sure to close the 2 screws (M4x8;...
  • Page 183 Chapter 6 F-6-161 F-6-157 6.8.11.5 Removing the Slide Resistor 4) Disconnect the connector [1]. 5) Remove the manual feed unit [3]. 0007-6651 1) Detach the manual feed tray upper cover [2]. - 4 screws [2] - 2 screws [1] Be sure to mark the horizontal registration position before detaching the manual feed tray upper cover.
  • Page 184 Chapter 6 F-6-168 5) While freeing the hinge assembly [2], detach the right door. F-6-164 6.8.12.2 Removing the Right Door 0007-6654 1) Open the right door. F-6-169 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate.
  • Page 185 Chapter 6 F-6-174 2) Remove the screw [1], and detach the fixing plate [2]. F-6-171 6.8.12.4 Removing the Cassette Pickup Solenoid 0007-6664 1) Remove the cassette pickup solenoid [3]. - 1 connector [1] - 1 screw [2] F-6-175 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door.
  • Page 186 Chapter 6 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate. F-6-181 2) Remove the cassette size sensor relay PCB [1].
  • Page 187 Chapter 6 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate. F-6-184 2) Remove the screw [1], and detach the fixing plate [2].
  • Page 188 Chapter 6 F-6-192 4) Disconnect the connector [1]. F-6-196 5) Remove the manual feed unit [3]. - 4 screws [2] 6.8.15 Manual Feed Unit 6.8.15.1 Removing the Right Cover (rear) 0007-6705 1) Open the pedestal right door [1]. (if equipped with a 2-Cassette Pedestal- 2) Open the right lower door [2].
  • Page 189 Chapter 6 F-6-199 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door. F-6-203 F-6-200 4) Disconnect the connector [1], and remove the reuse band [2]; then, remove When tightening the 2 screws used to fix the hinge in place, be sure to close the 2 screws (M4x8;...
  • Page 190 Chapter 6 6.8.16.2 Removing the Right Door 0007-6710 1) Open the right door. F-6-206 4) Disconnect the connector [1]. 5) Remove the manual feed unit [3]. - 4 screws [2] F-6-210 2) Remove the screw [1], and detach the fixing plate [2]. F-6-207 F-6-211 3) Remove the joint shaft [1], and free the extension delivery unit [2] from...
  • Page 191 Chapter 6 F-6-214 Attaching the Right Door F-6-217 1) Match the hinge [1] found at the bottom of the right door against the lug. 3) Detach the connector cover [1] (snap stopper). 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate.
  • Page 192 Chapter 6 F-6-224 2) Remove the screw [1], and detach the fixing plate [2]. F-6-221 2) Remove the manual feed pickup roller [3] together with the shaft. - 1 bushing [2] 3) Remove the manual feed pickup roller [3] from the shaft. - 1 plastic E-ring [4] Do not drop the parallel pin when removing the manual feed pickup roller.
  • Page 193 Chapter 6 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate. F-6-231 When connecting the 4 fastons, be sure that they are located as indicated by their specific location numbers.
  • Page 194 Chapter 6 6.8.18 Manual Separation Pad 4) Disconnect the connector [1], and remove the reuse band [2]; then, remove the 2 screws (M4x8; RS tightening). 6.8.18.1 Removing the Right Cover (rear) 0007-6714 1) Open the pedestal right door [1]. (if equipped with a 2-Cassette Pedestal- 2) Open the right lower door [2].
  • Page 195 Chapter 6 F-6-246 6.8.18.4 Removing the Manual Feed Pickup Roller F-6-242 0007-6717 2) Remove the manual feed pickup guide [1]. 1) Detach the manual feed pickup upper cover [1] (snap stopper). - 1 screw [2] F-6-247 F-6-243 2) Remove the manual feed pickup roller [3] together with the shaft. 3) Detach the connector cover [1] (snap stopper).
  • Page 196 Chapter 6 F-6-249 6.8.19 Registration Clutch 6.8.19.1 Removing the Rear Cover 0007-6720 1) Remove the 13 screws [1] and then the other screw [2]; then, detach the rear cover [3]. If the left cover (lower) has already been detached, the screw [3] should also have been removed.
  • Page 197 Chapter 6 F-6-257 3) Remove the joint shaft [1], and free the extension delivery unit [2] from F-6-254 the right door. Point to Note When Replacing the Feed/Separation Roller 1 The collar (roller core) of the machine's feed/separation roller is black. 6.8.21 Vertical Path Roller 6.8.21.1 Removing the Right Cover (rear) 0007-6736...
  • Page 198 Chapter 6 F-6-263 Pickup Unit 1 F-6-261 When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first. 6.8.21.3 Removing the Right Cover (lower front) 0007-6739 1) Open the pedestal right door [1]. (if equipped with a Cassette Feeding Unit-Y2) F-6-264 2) Open the lower right door [2].
  • Page 199 Chapter 6 F-6-269 2) Remove the screw [1], and detach the fixing plate [2]. F-6-266 2) Release the claw [A] of the bushing [1] at the front to move it toward the rear, and then remove the vertical path roller [2] upward. F-6-270 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door.
  • Page 200 Chapter 6 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate. F-6-277 6.8.23 Duplex Feed Sensor 6.8.23.1 Removing the Right Cover (rear)
  • Page 201 Chapter 6 F-6-280 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door. F-6-284 F-6-281 4) Disconnect the connector [1], and remove the reuse band [2]; then, remove When tightening the 2 screws used to fix the hinge in place, be sure to close the 2 screws (M4x8;...
  • Page 202 Chapter 6 F-6-290 3) Remove the joint shaft [1], and free the extension delivery unit [2] from F-6-286 the right door. 2) Remove the face cover rubber [1]. 3) Remove the binding screw [2]. 4) Remove the RS tightening screw [3]. 5) Detach the front cover unit [4] by moving it in the direction of the ar- row.
  • Page 203 Chapter 6 F-6-297 7) Pull out the Extension Delivery Kit [1] from the machine. F-6-294 When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first. F-6-298 6.8.24.5 Removing the Extension Delivery Kit 6.8.24.6 Removing the Delivery Assembly 1 0007-6767 1) Remove the self-tapping screw [1], and detach the upper inside cover [2].
  • Page 204 Chapter 6 F-6-303 6.8.25.4 Removing the Right Door 0007-6785 1) Open the right door. F-6-300 6.8.25.2 Removing the Front Cover Unit 0007-6781 1) Open the front cover [1]. F-6-304 2) Remove the screw [1], and detach the fixing plate [2]. F-6-301 2) Remove the face cover rubber [1].
  • Page 205 Chapter 6 F-6-307 5) While freeing the hinge assembly [2], detach the right door. F-6-310 6.8.25.6 Removing the Fixing Unit 0007-8721 1) Remove the screw [1], and detach the harness cover [2]. F-6-308 Attaching the Right Door F-6-311 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook 2) Disconcert the 3 connectors [1].
  • Page 206 Chapter 6 F-6-314 F-6-317 2) Disconnect the connector [1] of the harness, and free the harness from the cable clamp [2]. When mounting the harness cover [1], be sure to keep the harness [2] within the space [3] indicated in the figure so that the harness [2] will not come into contact with the gear [4].
  • Page 207 Chapter 7 Fixing System...
  • Page 209 Contents Contents 7.1 Construction ...................................7-1 7.1.1 Specifications, Control Mechanisms, and Functions ........................7-1 7.1.2 Major Components..................................7-1 7.2 Basic Sequence ................................7-1 7.2.1 Power-On Sequence..................................7-1 7.2.2 Down Sequence ................................... 7-2 7.3 Various Control Mechanisms............................7-2 7.3.1 Controlling the Speed of the Fixing Film ............................ 7-2 7.3.1.1 Controlling the Fixing Film Speed in Response to Low Temperature ......................7-2 7.3.1.2 Controlling the Fixing Film Speed..................................7-2 7.3.2 Controlling the Fixing Film Temperature............................
  • Page 210 Contents 7.5.5.1 Removing the inside delivery cover unit (old) ............................. 7-18 7.5.5.2 Removing the inside delivery cover unit (new)............................7-20 7.5.5.3 Removing the Grounding Plate..................................7-20 7.5.5.4 Removing the Fixing Film Cover ................................. 7-20 7.5.5.5 Removing the Left Side Plate ..................................7-21 7.5.5.6 Releasing the Locking Plate ..................................
  • Page 211 Chapter 7 7.1 Construction 7.1.1 Specifications, Control Mechanisms, and Functions 0006-6002 The machine's fixing system has the following major functions: T-7-1 Item Description Fixing method by fixing film + pressure roller Fixing heater plate-type heater Control temperature 180 deg C (at PSTBY) Fixing drive control by control of fixing film speed Fixing temperature detection by main thermistor...
  • Page 212 Chapter 7 3. Starts measuring the time passed after the machine reaches the target temperature T deg C. Target temperature T deg C = 200 deg C (iR3570/iR4570): 190 deg C (iR2270/iR2870) 4. Starts feeding in the case of printing in plain paper mode. 5.
  • Page 213 Chapter 7 9. when the start-up control temperature is reached, shifts to copying temperature control. 200ms 400ms 300ms 500ms F-7-3 A: start-up control B: copying temperature control C: 65 (%) power supply D: X (%) power supply E: Y (%) power supply 7.3.2.4 Copying Temperature Control 0006-6584 The machine uses this mechanism to control the temperature of the fixing heater to an optimum level while a recording medium is passing through the fixing film...
  • Page 214 Chapter 7 DC controller PCB PS13 Fixing delivery sensor F-7-4 When a delay jam of the fixing delivery sensor (PS13) occurs, the fixing motor is stopped immediately so as to prevent paper from wrapping around the fixing roller. The pressure of the fixing film and the pressure roller is released when a jam occurs so that jammed paper can be taken out easily. 7.4 Protective Functions 7.4.1 Protective Functions 0006-6009...
  • Page 215 Chapter 7 Error code Detail code Symptom Description E001 0000 The thermistor detects The thermistor detects 235 deg C for 200 msec or more overheating. continuously. 0001 A hardware circuit detects A hardware circuit detects overheating in relation to the overheating.
  • Page 216 Chapter 7 F-7-15 4) Detach the fixing unit [1] toward the front. F-7-12 When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first. F-7-16 7.5.1.3 Removing the Fixing Unit 0007-7884 1) Remove the screw [1], and detach the harness cover [2].
  • Page 217 Chapter 7 F-7-18 F-7-21 7.5.2 Pressure Roller Note 2 Procedure for attaching the guide Perform the following steps if the guide has come off the inside delivery cov- 7.5.2.1 Removing the inside delivery cover unit (old) er unit. 0007-7910 The difference between new and old inside delivery cover unit: 1) Attach the torsion spring [2] to the duplexing support feeder mount [1].
  • Page 218 Chapter 7 [d] [2] F-7-25 2) Attach the screw [1] and the stepped screw [2], and fix the inside delivery cover unit [3]. F-7-26 F-7-23 3) Hook the edge [1] of the torsion spring on the spring-hook area [2] of the 7.5.2.2 Removing the inside delivery cover unit (new) inside delivery cover.
  • Page 219 Chapter 7 F-7-28 7.5.2.3 Removing the Grounding Plate 0007-7911 1) Remove the 2 screws [1], and detach the grounding plate [2]. F-7-32 F-7-29 7.5.2.4 Removing the Fixing Film Cover 0007-7912 1) Remove the 3 screws [1], and remove the self-tapping screw [2]; then, de- tach the fixing film cover [3].
  • Page 220 Chapter 7 F-7-36 F-7-40 Do not touch the screw [1] used to keep the fixing assembly in place. Turning the screw will change the pressure of the fixing assembly, which cannot be adjusted in the field, necessitating the replacement of the fixing assembly. F-7-37 When mounting the left side plate, be sure that it is correctly positioned so that the locking lever and the teeth are correctly engaged.
  • Page 221 Chapter 7 F-7-44 F-7-49 3) Remove the screw [1], and free the AC harness [2]. 7.5.2.8 Removing the Inlet Guide 0007-7916 1) Slide the inlet guide [1] in the direction of the arrow to detach. F-7-45 F-7-50 4) Free the AC harness [1] from the edge saddle [2]. 7.5.2.9 Removing the Pressure Roller 0007-7918 1) Remove the E-ring [1], and detach the drive gear [2].
  • Page 222 Chapter 7 F-7-53 Be sure to pay attention to the position and the orientation of the insulating bush. F-7-56 1) Remove the screw [1] and the stepped screw [2], and detach the inside de- livery cover unit [3]. F-7-57 Note 1 Point to note when removing the inside delivery cover unit Remove the inside delivery cover unit while supporting the guide [1] in the arrow direction A and opening it in the arrow direction B in the figure.
  • Page 223 Chapter 7 F-7-59 2) Attach the guide [1] to the duplexing support feeder mount [2]. At this time, fit [b] into [a] and [d] into [c]. Make sure that the edge [e] of the tor- sion spring is outside the guide. [d] [2] F-7-61 Note 3...
  • Page 224 Chapter 7 7.5.3.2 Removing the inside delivery cover unit (new) 7.5.4 Fixing Film 0009-9172 The difference between new and old inside delivery cover unit: 7.5.4.1 Removing the inside delivery cover unit (old) New inside delivery cover unit has a grip ring [1] at hinge. In this case, de- tach the cover following the procedure below.
  • Page 225 Chapter 7 F-7-71 2) Attach the guide [1] to the duplexing support feeder mount [2]. At this time, fit [b] into [a] and [d] into [c]. Make sure that the edge [e] of the tor- sion spring is outside the guide. [d] [2] F-7-73 Note 3...
  • Page 226 Chapter 7 7.5.4.2 Removing the inside delivery cover unit (new) 0009-9174 The difference between new and old inside delivery cover unit: New inside delivery cover unit has a grip ring [1] at hinge. In this case, de- tach the cover following the procedure below. F-7-80 When mounting the fixing film cover unit, be sure to check that it has not rid- den over the emboss [1] indicated by the arrow in the figure before tightening...
  • Page 227 Chapter 7 F-7-88 2) Remove the 2 screws [1]. F-7-84 3) Slide the left side plate [1] in the direction of the arrow to detach. F-7-85 F-7-89 Do not touch the screw [1] used to keep the fixing assembly in place. Turning the screw will change the pressure of the fixing assembly, which cannot be adjusted in the field, necessitating the replacement of the fixing assembly.
  • Page 228 Chapter 7 F-7-92 F-7-97 2) While pushing down the release lever (rear) [1], pull out the heater contact 7) Remove the fixing film unit [1]. [2]. F-7-98 F-7-93 7.5.5 Internal Delivery Sensor 3) Remove the screw [1], and free the AC harness [2]. 7.5.5.1 Removing the inside delivery cover unit (old) 0007-7923 The difference between new and old inside delivery cover unit:...
  • Page 229 Chapter 7 erwise, the guide may come off the inside delivery cover unit. [d] [2] F-7-101 Note 2 Procedure for attaching the guide Perform the following steps if the guide has come off the inside delivery cov- er unit. 1) Attach the torsion spring [2] to the duplexing support feeder mount [1]. At this time, hook the edge of the torsion spring on the area A of the duplex- ing support feeder mount.
  • Page 230 Chapter 7 F-7-108 7.5.5.3 Removing the Grounding Plate 0007-7924 1) Remove the 2 screws [1], and detach the grounding plate [2]. F-7-105 2) Attach the screw [1] and the stepped screw [2], and fix the inside delivery cover unit [3]. F-7-109 7.5.5.4 Removing the Fixing Film Cover 0007-7925...
  • Page 231 Chapter 7 F-7-116 F-7-112 F-7-117 When mounting the left side plate, be sure that it is correctly positioned so that the locking lever and the teeth are correctly engaged. (See the figure.) F-7-113 7.5.5.5 Removing the Left Side Plate 0007-7926 1) Remove the screw [1], and detach the left side plate cover [2].
  • Page 232 Chapter 7 F-7-124 3) Remove the screw [1], and free the AC harness [2]. F-7-120 Do not touch the screw [1] used to keep the fixing assembly in place. Turning the screw will change the pressure of the fixing assembly, which cannot be adjusted in the field, necessitating the replacement of the fixing assembly.
  • Page 233 Chapter 7 livery cover unit [3]. F-7-129 F-7-133 7.5.5.8 Removing the Inside Delivery Sensor Note 1 0007-7932 1) Disconnect the connector [2] of the harness [1]. Point to note when removing the inside delivery cover unit Remove the inside delivery cover unit while supporting the guide [1] in the arrow direction A and opening it in the arrow direction B in the figure.
  • Page 234 Chapter 7 [d] [2] F-7-138 2) Attach the screw [1] and the stepped screw [2], and fix the inside delivery cover unit [3]. F-7-139 F-7-136 3) Hook the edge [1] of the torsion spring on the spring-hook area [2] of the 7.5.6.2 Removing the inside delivery cover unit (new) inside delivery cover.
  • Page 235 Chapter 7 F-7-141 F-7-145 7.5.6.3 Removing the Grounding Plate 0007-7896 1) Remove the 2 screws [1], and detach the grounding plate [2]. F-7-142 7.5.6.4 Removing the Fixing Film Sensor 0007-7897 1) Remove the screw [1]. F-7-143 2) Detach the harness [1] from the guide [2]. F-7-144 3) Disconnect the connector [1], and detach the fixing film sensor [2].
  • Page 237 Chapter 8 External and Controls...
  • Page 239 Contents Contents 8.1 Parts Replacement Procedure............................8-1 8.1.1 Main Drive Assembly .................................. 8-1 8.1.1.1 Removing the Rear Cover ....................................8-1 8.1.1.2 Removing the Main Drive Assembly................................8-1 8.1.2 Power Supply Unit ..................................8-1 8.1.2.1 Removing the Rear Cover ....................................8-1 8.1.2.2 Removing the Left Cover (lower) ...................................8-2 8.1.2.3 Removing the Accessories Power Supply PCB ..............................8-2 8.1.2.4 Removing the Main Power Supply .................................8-2 8.1.3 Control Panel ....................................
  • Page 240 Contents 8.1.12.8 Removing the Pre-Exposure Lamp................................8-15 8.1.12.9 Removing the Left Cover ................................... 8-15 8.1.12.10 Removing the Laser Unit ..................................8-15 8.1.12.11 Removing the Hopper Assembly ................................8-16 8.1.12.12 Removing the Right Cover (rear) ................................8-16 8.1.12.13 Removing the Right Door..................................8-16 8.1.12.14 Removing the Right Door..................................
  • Page 241 Chapter 8 8.1 Parts Replacement Procedure 8.1.1 Main Drive Assembly 8.1.1.1 Removing the Rear Cover 0007-6423 1) Remove the 13 screws [1] and then the other screw [2]; then, detach the rear cover [3]. If the left cover (lower) has already been detached, the screw [3] should also have been removed.
  • Page 242 Chapter 8 F-8-6 2) Remove the 6 connectors [1], and free the harness from the cable clamp [2]. F-8-4 8.1.2.2 Removing the Left Cover (lower) F-8-7 0007-6376 1) Take out the cassettes 1 and 2 [1]. 3) Remove the 5 binding screws [1], and detach the accessories power supply 2) Remove the 4 screws [2] and the other screw [3];...
  • Page 243 Chapter 8 F-8-10 3) Free the harness [1] of the pedestal connector from the lamp [2]. F-8-14 8.1.3 Control Panel 8.1.3.1 Removing the Control Panel 0007-6426 1) Remove the rubber cap [1], and remove the screw [2]. F-8-11 4) Disconnect the 7 connectors [1], and free the harness from the 4 clamps [2].
  • Page 244 Chapter 8 F-8-18 5) Free the harness [2] from the clamp [1]. F-8-22 3) Remove the 2 screws [1]. F-8-19 6) Disconnect the connector [1], and detach the control panel. F-8-23 4) Slide the control panel [1] in the direction of the arrow. F-8-20 F-8-24 8.1.4 Control Panel LCD Unit...
  • Page 245 Chapter 8 F-8-30 F-8-27 8.1.5 DC Controller PCB 8.1.4.3 Removing the Control Panel Inside Frame 8.1.5.1 Removing the Rear Cover 0007-7573 1) Disconnect the 2 connectors between the control panel PCB and the con- trol panel key switch PCB; then, free the harness from the 2 clamps [2]. 0007-7370 1) Remove the 13 screws [1] and then the other screw [2];...
  • Page 246 Chapter 8 How to Remove the Flexible Cable [1] F-8-37 3) Remove the 2 screws [1]. F-8-33 2) Remove the screw [1], and detach the DC controller PCB. F-8-38 4) Slide the control panel [1] in the direction of the arrow. F-8-34 Points to Note When Replacing the DC Controller PCB Be sure to remove the boot ROM [1] from the exiting DC controller PCB,...
  • Page 247 Chapter 8 F-8-42 F-8-46 4) Slide the control panel [1] in the direction of the arrow. 8.1.6.3 Removing the Control Panel Inverter PCB 0007-6466 1) Remove the control panel inverter PCB [1]. - 3 connectors [2] - 4 screws [3] F-8-47 5) Free the harness [2] from the clamp [1].
  • Page 248 Chapter 8 8.1.7.3 Removing the Control Panel Frame 8.1.8 Control Panel CPU PCB 0007-6456 1) Disconnect the 2 connectors [1] between the control panel PCB and the 8.1.8.1 Removing the Control Panel control panel key switch PCB; then, free the harness front the 3 clamps [2].
  • Page 249 Chapter 8 8.1.9 All Night Power Supply PCB 8.1.9.1 Removing the Rear Cover 0007-6385 1) Remove the 13 screws [1] and then the other screw [2]; then, detach the rear cover [3]. If the left cover (lower) has already been detached, the screw [3] should also have been removed.
  • Page 250 Chapter 8 8.1.10 Controller Power Supply PCB 8.1.10.1 Removing the Rear Cover 0007-6380 1) Remove the 13 screws [1] and then the other screw [2]; then, detach the rear cover [3]. If the left cover (lower) has already been detached, the screw [3] should also have been removed.
  • Page 251 Chapter 8 If the rear cover has already been detached, the screw [3] should also have been removed. F-8-71 2) Remove the 6 screws [1], and detach the controller power supply PCB [2]. F-8-74 8.1.11.3 Removing the Left Cover (Rear) 0007-6372 F-8-72 1) Remove the 2 screws [1];...
  • Page 252 Chapter 8 F-8-77 3) Remove the 5 binding screws [1], and detach the accessories power supply F-8-81 PCB [2]. Point to note after attaching the waste toner receptacle After attaching the waste toner receptacle, move the waste toner full detec- tion lever [1] up and down to make sure that the lever is moved smoothly.
  • Page 253 Chapter 8 5) Remove the drum unit [1]. F-8-85 F-8-90 8.1.12.4 Removing the Drum Unit Be sure to hold the drum unit as shown. 0007-8401 1) Open the right door [1]. F-8-86 2) Remove the screw [1]. F-8-91 8.1.12.5 Removing the Developing Assembly F-8-87 0007-8402 1) Remove the screw [1].
  • Page 254 Chapter 8 F-8-97 8.1.12.6 Removing the Upper Tray 0007-8403 1) Remove the 2 screws [1], and detach the upper tray [2]. F-8-94 4) Remove the developing assembly [1]. F-8-98 Reference: Lift the front of the upper tray [1], and detach it as if to slide it toward the front.
  • Page 255 Chapter 8 8.1.12.8 Removing the Pre-Exposure Lamp 0007-8405 1) Open the 2 wire saddles [1], and disconnect the 2 relay connectors [2]. F-8-105 F-8-101 2) While freeing the lock [1] toward the right, detach the pre-exposure lamp [2]. When you have disconnected the connector [1], be sure to take care so that it will not come into contact with the PCB that is mounted to the laser scanner unit.
  • Page 256 Chapter 8 When sliding out the laser scanner unit, be sure to take care not to touch the PCB mounted to the laser scanner unit. (The PCB is equipped with a laser When fitting the hopper assembly to the machine, be sure that the connectors scanner intensity adjustment variable resistor, and contact with the PCB can [1] are securely connected.
  • Page 257 Chapter 8 F-8-116 3) Remove the joint shaft [1], and free the extension delivery unit [2] from the right door. F-8-120 F-8-117 4) Disconnect the connector [1], and remove the reuse band [2]; then, remove When tightening the 2 screws used to fix the hinge in place, be sure to close the 2 screws (M4x8;...
  • Page 258 Chapter 8 When tightening the 2 screws used to fix the hinge in place, be sure to close the right door first. 8.1.12.15 Removing the Fixing Unit 0007-8419 1) Remove the screw [1], and detach the harness cover [2]. F-8-123 4) Disconnect the connector [1], and remove the reuse band [2];...
  • Page 259 Chapter 8 F-8-134 8.1.12.17 Removing the High-Voltage PCB 0007-8422 1) Remove the screw [1], and detach the fixing member [2]. F-8-131 Do not touch the screw [1]. Turning it will change the pressure of the fixing assembly, which cannot be adjusted in the field, necessitating the replace- ment of the fixing assembly.
  • Page 260 Chapter 8 F-8-142 F-8-138 5) Disconnect the connector [1], and detach the heat discharge fan [2]. 8.1.13 Exhaust Fan 8.1.13.1 Removing the Heat Discharge Fan 0007-6433 1) Open the right door. F-8-143 8.1.14 Motor of Main Drive Assembly 8.1.14.1 Removing the Rear Cover 0007-7368 1) Remove the 13 screws [1] and then the other screw [2];...
  • Page 261 Chapter 8 Be sure that the 2 timing belts [2] are fitted to the shaft [1] of the main drive motor as shown. F-8-145 2) Remove the 4 screws [1], and detach the main drive assembly [2]. F-8-148 Adjusting the Tension of the Main Drive Motor 1) Temporarily fix the main drive motor in place to the main motor base.
  • Page 262 Chapter 8 F-8-154 Points to Note When Replacing the DC Controller PCB Be sure to remove the boot ROM [1] from the exiting DC controller PCB, and mount it to the new DC controller PCB. F-8-151 8.1.15.2 Removing the DC Controller PCB 0007-6404 1) Disconnect the connector [1].
  • Page 263 Chapter 8 F-8-162 5) While freeing the hinge assembly [2], detach the right door. F-8-158 8.1.16.2 Removing the Right Door 0007-6444 1) Open the right door. F-8-163 Attaching the Right Door 1) Match the hinge [1] found at the bottom of the right door against the lug. 2) Engage the hinge [2] found on the top of the right door with the hook found on the side plate.
  • Page 264 Chapter 8 F-8-168 F-8-165 8.1.17.2 Removing the Circuit Breaker 0007-6389 1) Remove the 2 screws [1]. F-8-166 2) Remove the 4 fastons [1], and detach the circuit breaker [2]. F-8-167 Points to Note When Mounting When mounting the circuit breaker, be sure that the AC harness is identified correctly by color as shown.
  • Page 265 Chapter 9 Correcting Faulty Images...
  • Page 267 Contents Contents 9.1 Troubleshooting ................................9-1 9.1.1 Image Faults....................................9-1 9.1.1.1 Light Image/Weak Density .....................................9-1 9.1.1.1.1 Light image occurs when copying blue original (iR3025/3030/3035/3045) ..................9-1 9.1.2 Faulty Feeding ..................................... 9-1 9.1.2.1 Skew Feed ........................................9-1 9.1.2.1.1 Paper skewing/jam: Tab in rear side of vertical path guide is broken ....................9-1 9.1.3 Malfunction....................................
  • Page 269 9.1.1.1.1 Light image occurs when copying blue original (iR3025/3030/3035/3045) 0016-4309 [ Verified by Canon Inc. ] Description Since characters and lines were copied pale in color when copying an original including blue characters such as pressure-sensitive paper and transmittal form, sharpness was adjusted for solution.
  • Page 270 Chapter 9 Cause When the front door is opened and closed with a toner bottle being empty, or when this machine recovers from sleep mode (including power-on), the toner bottle motor rotates for about 100 sec. This is a normal operation of this machine, but the following 2 modifications were made in order to avoid users' complaint about this operating noise.
  • Page 271 9.1.6.1 0105/0101/0102/0103/0201/0202/0203/0204 Jam Code: Paper lint adheres to surface of vertical path roller 0015-2583 [ Inspected by Canon Inc. ] Description Since a type of paper that can easily generate lint was used, the paper lint adhered to the surface of the vertical path roller and decreased the paper feed performance of the roller, causing the jam code "0105."...
  • Page 272 0015-1338 [ Inspected by Canon Inc. ] Description Since paper loaded on a cassette was moistened, 2nd page failed to separate and crashed into the cleaner, causing the jam code "0107." As the remedy, a cassette heater was mounted.
  • Page 273 Chapter 9 - 0A08: No.1 delivery full sensor residual jam Field Remedy 1. When a jam code "0208" or "0A08" occurs, interchange the No.1 delivery sensor (PS14) with the No. 1 delivery full sensor (PS15). 2. After Step 1, if the other code than displayed before Step 1 appears, the No. 1 delivery sensor is faulty. Replace the sensor with a new one. F-9-6 FK2-0149 Photointerrupter 9.1.7 Error Code...
  • Page 274 Chapter 9 F-9-7 9.1.9.1.2 Instead of Copy tab, black bar appears on LCD: Main power switch is not turned OFF/ON after changing service mode setting 0015-0819 [ Manual-related ] Description Instead of the Copy tab, a black bar was displayed on the LCD. This was because the main power switch was not turned OFF and then ON after the service mode setting for the Copy tab was changed to hide the tab from the LCD.
  • Page 275 Chapter 9 Description In case A4-size standard original (image ratio: 5%) is used, the NGP-26 toner bottle can make approx. 24,000 copies. This toner bottle includes 1,220g of toner. Note: In case an original with image ratio of higher than 5% is used, the printable number will be less than 24,000 copies. 9.1.9.1.6 Description on service mode used to deactivate sleep function 0016-4201 [ Manual-related ]...
  • Page 277 Sep 4 2007...

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