Service Manual€¦1.2.1.12 High-Level Printer Functions to Support Networking Requirements(iR105).....1- 9 1.2.1.13 Support for MEAP (Multifunctional Embedded Application

Apr 5 2005

Service Manual

iR8500 Series

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Contents

Contents

Chapter 1 Introduction

1.1 System Construction ..................................................................................................................................1- 11.1.1 System Configuration ..............................................................................................................................................1- 11.1.2 System Configuration ..............................................................................................................................................1- 11.1.3 System Configuration ..............................................................................................................................................1- 21.1.4 Printing/Transmitting Accessories System Configuration........................................................................................1- 31.1.5 Printing/Transmitting Accessories System Configuration........................................................................................1- 41.1.6 Printing/Transmitting Accessories System Configuration........................................................................................1- 5

1.2 Product Specifications ................................................................................................................................1- 71.2.1 Features ..................................................................................................................................................................1- 7

1.2.1.1 High Speed, High Quality......................................................................................................................................................... 1- 71.2.1.2 High Speed, High Quality......................................................................................................................................................... 1- 71.2.1.3 High Speed, High Quality......................................................................................................................................................... 1- 71.2.1.4 High Durability, High Reliability................................................................................................................................................ 1- 71.2.1.5 High-Performance Controller, Large-Capacity Hard Disk ........................................................................................................ 1- 71.2.1.6 Ease of Operation .................................................................................................................................................................... 1- 71.2.1.7 Ease of Operation .................................................................................................................................................................... 1- 71.2.1.8 Large-Capacity Paper Source.................................................................................................................................................. 1- 71.2.1.9 Large-Capacity Paper Source.................................................................................................................................................. 1- 81.2.1.10 Various Delivery Processing (with options)............................................................................................................................ 1- 81.2.1.11 Various Delivery Processing (with options)............................................................................................................................ 1- 81.2.1.12 High-Level Printer Functions to Support Networking Requirements(iR105) .......................................................................... 1- 91.2.1.13 Support for MEAP (Multifunctional Embedded Application Platform) .................................................................................... 1- 9

1.2.2 Names of Parts........................................................................................................................................................1- 91.2.2.1 External View ........................................................................................................................................................................... 1- 91.2.2.2 External View ......................................................................................................................................................................... 1- 111.2.2.3 External View ......................................................................................................................................................................... 1- 111.2.2.4 Cross Section......................................................................................................................................................................... 1- 131.2.2.5 Cross Section......................................................................................................................................................................... 1- 141.2.2.6 Cross Section......................................................................................................................................................................... 1- 151.2.2.7 External Covers ..................................................................................................................................................................... 1- 171.2.2.8 External Covers ..................................................................................................................................................................... 1- 191.2.2.9 External Covers ..................................................................................................................................................................... 1- 21

1.2.3 Using the Machine................................................................................................................................................. 1- 231.2.3.1 Power Switch ......................................................................................................................................................................... 1- 231.2.3.2 Power Switch ......................................................................................................................................................................... 1- 241.2.3.3 Power Switch ......................................................................................................................................................................... 1- 251.2.3.4 Points to Note When Turning Off the Main Power Switch ..................................................................................................... 1- 261.2.3.5 Points to Note When Turning Off the Main Power Switch ..................................................................................................... 1- 271.2.3.6 Points to Note When Turning Off the Main Power Switch ..................................................................................................... 1- 281.2.3.7 Control Panel ......................................................................................................................................................................... 1- 291.2.3.8 Control Panel ......................................................................................................................................................................... 1- 301.2.3.9 Control Panel ......................................................................................................................................................................... 1- 301.2.3.10 Extension Mode Items.......................................................................................................................................................... 1- 31

1.2.4 User Mode Items ...................................................................................................................................................1- 321.2.4.1 Common Settings .................................................................................................................................................................. 1- 321.2.4.2 Common Settings .................................................................................................................................................................. 1- 331.2.4.3 Common Settings .................................................................................................................................................................. 1- 341.2.4.4 Timer Settings........................................................................................................................................................................ 1- 351.2.4.5 Adjustment/Cleaning.............................................................................................................................................................. 1- 351.2.4.6 Adjustment/Cleaning.............................................................................................................................................................. 1- 361.2.4.7 Report Settings ...................................................................................................................................................................... 1- 361.2.4.8 Report Settings ...................................................................................................................................................................... 1- 371.2.4.9 Copy Settings......................................................................................................................................................................... 1- 37

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Contents

1.2.4.10 System Settings ................................................................................................................................................................... 1- 371.2.4.11 System Settings ................................................................................................................................................................... 1- 381.2.4.12 Network Settings (in "System Settings") .............................................................................................................................. 1- 391.2.4.13 Copy Settings....................................................................................................................................................................... 1- 421.2.4.14 Copy Settings....................................................................................................................................................................... 1- 431.2.4.15 Communications Settings .................................................................................................................................................... 1- 431.2.4.16 Mail Box Settings ................................................................................................................................................................. 1- 441.2.4.17 Address Book Settings......................................................................................................................................................... 1- 44

1.2.5 Safety.....................................................................................................................................................................1- 441.2.5.1 Safety of Laser Light .............................................................................................................................................................. 1- 441.2.5.2 CDRH Ordinances ................................................................................................................................................................. 1- 451.2.5.3 CDRH Ordinances ................................................................................................................................................................. 1- 451.2.5.4 CDRH Ordinances ................................................................................................................................................................. 1- 461.2.5.5 Handling the Laser System.................................................................................................................................................... 1- 461.2.5.6 Handling the Laser System.................................................................................................................................................... 1- 471.2.5.7 Handling the Laser System.................................................................................................................................................... 1- 481.2.5.8 Safety of Toner ...................................................................................................................................................................... 1- 49

1.2.6 Product Specifications ...........................................................................................................................................1- 491.2.6.1 Sepecifications....................................................................................................................................................................... 1- 491.2.6.2 Sepecifications....................................................................................................................................................................... 1- 511.2.6.3 Sepecifications....................................................................................................................................................................... 1- 52

1.2.7 Function List...........................................................................................................................................................1- 541.2.7.1 Print speed............................................................................................................................................................................. 1- 541.2.7.2 Print speed............................................................................................................................................................................. 1- 551.2.7.3 Print speed............................................................................................................................................................................. 1- 551.2.7.4 Print speed............................................................................................................................................................................. 1- 571.2.7.5 Paper Type ............................................................................................................................................................................ 1- 58

Chapter 2 Installation

2.1 Making Pre-Checks .................................................................................................................................... 2- 12.1.1 Selecting the site......................................................................................................................................................2- 12.1.2 Selecting the site......................................................................................................................................................2- 22.1.3 Selecting the site......................................................................................................................................................2- 42.1.4 Selecting the site......................................................................................................................................................2- 62.1.5 Points to Note Before Starting the Work ..................................................................................................................2- 82.1.6 Points to Note Before Starting the Work ..................................................................................................................2- 82.1.7 Points to Note Before Starting the Installation Work................................................................................................2- 92.1.8 Points to Note Before Starting the Installation Work................................................................................................2- 92.1.9 Checking the Components.......................................................................................................................................2- 92.1.10 Checking the Components...................................................................................................................................2- 102.1.11 Checking the Components...................................................................................................................................2- 112.1.12 Checking the Components...................................................................................................................................2- 12

2.2 Unpacking and Installation ....................................................................................................................... 2- 132.2.1 Unpacking ..............................................................................................................................................................2- 132.2.2 Unpacking ..............................................................................................................................................................2- 152.2.3 Mounting the Scanner System...............................................................................................................................2- 172.2.4 Unpacking ..............................................................................................................................................................2- 172.2.5 Unpacking ..............................................................................................................................................................2- 202.2.6 Installing the Fixing Assembly................................................................................................................................2- 222.2.7 Mounting the Fixing Assembly ...............................................................................................................................2- 222.2.8 Mounting the Scanner System...............................................................................................................................2- 232.2.9 Mounting the Scanner System...............................................................................................................................2- 232.2.10 Mounting the Charging Assembly ........................................................................................................................2- 242.2.11 Mounting the Fixing Assembly .............................................................................................................................2- 252.2.12 Mounting the Fixing Assembly .............................................................................................................................2- 262.2.13 Checking the Developing Assembly.....................................................................................................................2- 272.2.14 Mounting the Charging Assembly ........................................................................................................................2- 27

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Contents

2.2.15 Mounting the Charging Assembly........................................................................................................................2- 292.2.16 Mounting the Pickup Assembly............................................................................................................................2- 312.2.17 Checking the Developing Assembly ....................................................................................................................2- 322.2.18 Checking the Developing Assembly ....................................................................................................................2- 322.2.19 Mounting the Control Panel .................................................................................................................................2- 332.2.20 Mounting the Pickup Assembly............................................................................................................................2- 352.2.21 Mounting the Pickup Assembly............................................................................................................................2- 362.2.22 Supplying the Toner.............................................................................................................................................2- 372.2.23 Supplying the Toner.............................................................................................................................................2- 372.2.24 Supplying the Toner.............................................................................................................................................2- 382.2.25 Supplying the Toner.............................................................................................................................................2- 392.2.26 Mounting the ADF................................................................................................................................................2- 392.2.27 Connectors ..........................................................................................................................................................2- 392.2.28 Installing the ADF ................................................................................................................................................2- 402.2.29 Cassette............................................................................................................................................................... 2- 402.2.30 Cassette............................................................................................................................................................... 2- 402.2.31 Cassette............................................................................................................................................................... 2- 412.2.32 Index Paper Attachment ......................................................................................................................................2- 412.2.33 Index Paper Attachment ......................................................................................................................................2- 412.2.34 Index Paper Attachment ......................................................................................................................................2- 412.2.35 Other attachment ................................................................................................................................................. 2- 422.2.36 Other attachment ................................................................................................................................................. 2- 422.2.37 Other attachment ................................................................................................................................................. 2- 422.2.38 Other attachment ................................................................................................................................................. 2- 422.2.39 Attaching the Labels, Setting Paper, Checking Images/Operations, and User Mode .........................................2- 432.2.40 Attaching the Labels, Setting Paper, Checking Images/Operations, and User Mode .........................................2- 442.2.41 Attaching the Labels, Setting Paper, Checking Images/Operations, and User Mode .........................................2- 452.2.42 Attaching the Labels, Setting Paper, Checking Images/Operations, and User Mode .........................................2- 462.2.43 Changing the Paper Size for the Front Deck (right, left) ......................................................................................2- 482.2.44 Changing the Paper Size for the Front Deck (right, left) ......................................................................................2- 482.2.45 Changing the Paper Size for the Front Deck (right, left) ......................................................................................2- 492.2.46 If Not Connected to a Network.............................................................................................................................2- 492.2.47 If Not Connected to a Network.............................................................................................................................2- 492.2.48 If Not Connected to a Network.............................................................................................................................2- 50

2.3 Checking the Connection to the Network .................................................................................................2- 512.3.1 Overview................................................................................................................................................................2- 512.3.2 Overview................................................................................................................................................................2- 512.3.3 Overview................................................................................................................................................................2- 512.3.4 Using the PING Function.......................................................................................................................................2- 512.3.5 Using the PING Function.......................................................................................................................................2- 512.3.6 Using the PING Function.......................................................................................................................................2- 522.3.7 Using the PING Function.......................................................................................................................................2- 522.3.8 Making a Check Using a Remote Host Address ...................................................................................................2- 532.3.9 Making a Check Using a Remote Host Address ...................................................................................................2- 532.3.10 Making a Check Using a Remote Host Address..................................................................................................2- 53

2.4 Troubleshooting the Network....................................................................................................................2- 542.4.1 Overview................................................................................................................................................................2- 542.4.2 Overview................................................................................................................................................................2- 542.4.3 Overview................................................................................................................................................................2- 542.4.4 Making a Check Using a Loopback Address.........................................................................................................2- 542.4.5 Making a Check Using a Loopback Address.........................................................................................................2- 542.4.6 Making a Check Using a Loopback Address.........................................................................................................2- 542.4.7 Making a Check Using a Local Host Address .......................................................................................................2- 542.4.8 Making a Check Using a Local Host Address .......................................................................................................2- 552.4.9 Making a Check Using a Local Host Address .......................................................................................................2- 55

2.5 Installing the Card Reader ........................................................................................................................2- 56

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Contents

2.5.1 Checking the Contents...........................................................................................................................................2- 562.5.2 Checking the Contents...........................................................................................................................................2- 562.5.3 Checking the Contents...........................................................................................................................................2- 572.5.4 Installing the Card Reader-D1 ...............................................................................................................................2- 572.5.5 Installing the Card Reader-D1 ...............................................................................................................................2- 612.5.6 Installing the Card Reader-D1 ...............................................................................................................................2- 642.5.7 Installing the Card Reader-D1 ...............................................................................................................................2- 67

2.6 Installing the NE Controller....................................................................................................................... 2- 722.6.1 Installing the NE Controller-A1/NE Controller-B1/Copy Data Controller-A1 ..........................................................2- 722.6.2 Installing the NE Controller-A1/NE Controller-B1/Copy Data Controller-A1 ..........................................................2- 742.6.3 Installing the NE Controller-A1/NE Controller-B1/Copy Data Controller-A1 ..........................................................2- 76

Chapter 3 Basic Operation

3.1 Construction ............................................................................................................................................... 3- 13.1.1 Functional Construction ...........................................................................................................................................3- 13.1.2 Connection Diagram of the Major PCBs(iR105) ......................................................................................................3- 13.1.3 Functional Construction ...........................................................................................................................................3- 23.1.4 Wiring Diagram of the Major PCBs ..........................................................................................................................3- 33.1.5 Wiring Diagram of the Major PCBs ..........................................................................................................................3- 43.1.6 Wiring Diagram of the Major PCBs ..........................................................................................................................3- 53.1.7 Inputs to the DC Controller PCB (1/6)......................................................................................................................3- 63.1.8 Inputs to the DC Controller PCB (2/6)......................................................................................................................3- 73.1.9 Inputs to the DC Controller PCB (3/6)......................................................................................................................3- 83.1.10 Inputs to the DC Controller PCB (4/6)....................................................................................................................3- 93.1.11 Inputs to the DC Controller PCB (5/6)..................................................................................................................3- 103.1.12 Inputs to the DC Controller PCB (6/6)..................................................................................................................3- 113.1.13 Outputs from the DC Controller PCB (1/7)...........................................................................................................3- 123.1.14 Outputs from the DC Controller PCB (2/7)...........................................................................................................3- 133.1.15 Outputs from the DC Controller PCB (3/7)...........................................................................................................3- 143.1.16 Outputs from the DC Controller PCB (4/7)...........................................................................................................3- 153.1.17 Outputs from the DC Controller PCB (5/7)...........................................................................................................3- 163.1.18 Outputs from the DC Controller PCB (6/7)...........................................................................................................3- 173.1.19 Outputs from the DC Controller PCB (7/7)...........................................................................................................3- 183.1.20 Controlling the Main Motor (M1)...........................................................................................................................3- 19

3.2 Basic Sequence ....................................................................................................................................... 3- 213.2.1 Basic Sequence of Operations (power-on) ............................................................................................................3- 213.2.2 Basic Sequence of Operations (power-on) ............................................................................................................3- 21

Chapter 4 Main Controller

4.1 Construction ............................................................................................................................................... 4- 14.1.1 Functional Construction(iR105) ...............................................................................................................................4- 14.1.2 Construction/Function ..............................................................................................................................................4- 14.1.3 Construction/Function ..............................................................................................................................................4- 2

4.2 Construction of the Electrical Circuitry........................................................................................................ 4- 44.2.1 Outline(iR105)..........................................................................................................................................................4- 44.2.2 Main Controller PCB ................................................................................................................................................4- 44.2.3 Main Controller PCB(iR105) ....................................................................................................................................4- 54.2.4 Hard Disk Drive(iR105) ............................................................................................................................................4- 5

4.3 Start-Up Sequence..................................................................................................................................... 4- 64.3.1 Outline(iR105)..........................................................................................................................................................4- 64.3.2 Overview..................................................................................................................................................................4- 64.3.3 Start-Up Sequence(iR105).......................................................................................................................................4- 74.3.4 Start-Up Sequence ..................................................................................................................................................4- 84.3.5 Start-Up Sequence ..................................................................................................................................................4- 9

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4.3.6 Construction of the System Software(iR105) ........................................................................................................4- 114.3.7 E602 in Detaill .......................................................................................................................................................4- 11

4.4 Shut-Down Sequence...............................................................................................................................4- 174.4.1 Overview................................................................................................................................................................4- 174.4.2 Flow of Operation ..................................................................................................................................................4- 17

4.5 Image Processing.....................................................................................................................................4- 184.5.1 Outline(iR105) .......................................................................................................................................................4- 184.5.2 Overview of the Image Flow ..................................................................................................................................4- 184.5.3 Input Image Processing(iR105) .............................................................................................................................4- 194.5.4 Construction of the Image Processing Module......................................................................................................4- 194.5.5 Construction of the Image Processing Module......................................................................................................4- 204.5.6 Controlling the Image Memory(iR105)................................................................................................................... 4- 214.5.7 Reader Unit Input Image Processing.....................................................................................................................4- 214.5.8 Output Image Processing(iR105) ..........................................................................................................................4- 214.5.9 Compression/Extension/Editing Block................................................................................................................... 4- 224.5.10 Compression/Extension/Editing Block .................................................................................................................4- 224.5.11 Printer unit Output Image Processing..................................................................................................................4- 22

4.6 Flow of Image Data ..................................................................................................................................4- 244.6.1 Flow of Image Data for the Copy Function ............................................................................................................4- 244.6.2 Flow of Image Data for the Box Function ..............................................................................................................4- 244.6.3 Flow of Image Data for the SEND Function ..........................................................................................................4- 254.6.4 Flow of Image Data for the PDL Function .............................................................................................................4- 25

4.7 Parts Replacement Procedure .................................................................................................................4- 264.7.1 Main Controller Box ...............................................................................................................................................4- 26

4.7.1.1 Removing the Rear Cover ..................................................................................................................................................... 4- 264.7.1.2 Removing the Rear Cover ..................................................................................................................................................... 4- 264.7.1.3 Removing the Rear Cover ..................................................................................................................................................... 4- 264.7.1.4 Removing the System Connector Cover................................................................................................................................ 4- 264.7.1.5 Removing the Main Controller Box ........................................................................................................................................ 4- 26

4.7.2 Main Controller PCB.............................................................................................................................................. 4- 274.7.2.1 Removing the Rear Cover ..................................................................................................................................................... 4- 274.7.2.2 Removing the Rear Cover ..................................................................................................................................................... 4- 274.7.2.3 Removing the Rear Cover ..................................................................................................................................................... 4- 274.7.2.4 Removing the Main Controller Box Cover.............................................................................................................................. 4- 284.7.2.5 Removing the Differential PCB/Differential PCB Relay Board............................................................................................... 4- 284.7.2.6 Removing the Pixel/Line Conversion PCB............................................................................................................................. 4- 284.7.2.7 Removing the Main Controller PCB ....................................................................................................................................... 4- 284.7.2.8 When Replacing the Main Controller PCB............................................................................................................................. 4- 29

4.7.3 Boot ROM..............................................................................................................................................................4- 294.7.3.1 Removing the Rear Cover ..................................................................................................................................................... 4- 294.7.3.2 Removing the Rear Cover ..................................................................................................................................................... 4- 294.7.3.3 Removing the Rear Cover ..................................................................................................................................................... 4- 304.7.3.4 Removing the Main Controller Box Cover.............................................................................................................................. 4- 304.7.3.5 Removing the Boot ROM ....................................................................................................................................................... 4- 30

4.7.4 Differential PCB .....................................................................................................................................................4- 304.7.4.1 Removing the Rear Cover ..................................................................................................................................................... 4- 304.7.4.2 Removing the Rear Cover ..................................................................................................................................................... 4- 314.7.4.3 Removing the Main Controller Box Cover.............................................................................................................................. 4- 314.7.4.4 Removing the Differential PCB/Differential PCB Relay Board............................................................................................... 4- 31

4.7.5 HDD.......................................................................................................................................................................4- 314.7.5.1 Points to Note on Handling the Hard Disk ............................................................................................................................. 4- 314.7.5.2 Removing the Rear Cover ..................................................................................................................................................... 4- 324.7.5.3 Removing the Rear Cover ..................................................................................................................................................... 4- 324.7.5.4 Removing the Rear Cover ..................................................................................................................................................... 4- 324.7.5.5 Removing the Main Controller Box Cover.............................................................................................................................. 4- 324.7.5.6 Removing the Differential PCB/Differential PCB Relay Board............................................................................................... 4- 324.7.5.7 Removing the Hard Disk ........................................................................................................................................................ 4- 334.7.5.8 Points to Note on Attaching the Hard Disk............................................................................................................................. 4- 33

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4.7.5.9 When Replacing the HDD...................................................................................................................................................... 4- 334.7.6 Controller Fan ........................................................................................................................................................4- 33

4.7.6.1 Removing the Rear Cover ..................................................................................................................................................... 4- 334.7.6.2 Removing the Rear Cover ..................................................................................................................................................... 4- 344.7.6.3 Removing the Rear Cover ..................................................................................................................................................... 4- 344.7.6.4 Removing the System Connector Cover................................................................................................................................ 4- 344.7.6.5 Removing the Main Controller Box Cover.............................................................................................................................. 4- 344.7.6.6 Removing the Controller Fan ................................................................................................................................................. 4- 34

Chapter 5 Original Exposure System

5.1 Construction ............................................................................................................................................... 5- 15.1.1 Outline of the Original Exposure System(iR105) .....................................................................................................5- 15.1.2 Outline......................................................................................................................................................................5- 15.1.3 Major Components...................................................................................................................................................5- 25.1.4 Arrangement of PCBs..............................................................................................................................................5- 35.1.5 Outline......................................................................................................................................................................5- 35.1.6 Major Components...................................................................................................................................................5- 45.1.7 Arrangement of PCBs..............................................................................................................................................5- 5

5.2 Basic Sequence ......................................................................................................................................... 5- 75.2.1 Basic Sequence of Operations ................................................................................................................................5- 75.2.2 Book Mode, 1 Original, Copyboard Closed..............................................................................................................5- 75.2.3 Book Mode, 1 Original, Copyboard Cover Open .....................................................................................................5- 8

5.3 Various Control......................................................................................................................................... 5- 105.3.1 Controlling the Scanner Drive System...................................................................................................................5- 10

5.3.1.1 Outline.................................................................................................................................................................................... 5- 105.3.1.2 Controlling the Scanner Motor ............................................................................................................................................... 5- 105.3.1.3 Preventing Overheating of the Scanner Motor....................................................................................................................... 5- 125.3.1.4 Outline.................................................................................................................................................................................... 5- 135.3.1.5 Controlling the Scanner Motor ............................................................................................................................................... 5- 13

5.3.2 Enlargement/Reduction .........................................................................................................................................5- 145.3.2.1 Changing the Reproduction Ratio in Main Scanning Direction .............................................................................................. 5- 145.3.2.2 Enlargement/Reduction(iR105).............................................................................................................................................. 5- 145.3.2.3 Changing the Reproduction Ratio in Sub Scanning Direction ............................................................................................... 5- 155.3.2.4 Changing the Reproduction Ratio in Main Scanning Direction .............................................................................................. 5- 155.3.2.5 Changing the Reproduction Ratio in Sub Scanning Direction ............................................................................................... 5- 15

5.3.3 Controlling the Scanning Lamp..............................................................................................................................5- 155.3.3.1 Outline.................................................................................................................................................................................... 5- 155.3.3.2 Stabilizing the Scanning Lamp(iR105)................................................................................................................................... 5- 165.3.3.3 Controlling the Temperature by a Fluorescent Lamp Heater................................................................................................. 5- 165.3.3.4 Controlling Pre-Heat Voltage ................................................................................................................................................. 5- 175.3.3.5 Initial Activation ...................................................................................................................................................................... 5- 175.3.3.6 Detecting an Error.................................................................................................................................................................. 5- 185.3.3.7 Outline.................................................................................................................................................................................... 5- 195.3.3.8 Scanning Lamp ...................................................................................................................................................................... 5- 195.3.3.9 Turning On/Off the Lamp ....................................................................................................................................................... 5- 195.3.3.10 Detecting an Error ................................................................................................................................................................ 5- 19

5.3.4 Detecting the Size of Originals...............................................................................................................................5- 205.3.4.1 Outline.................................................................................................................................................................................... 5- 205.3.4.2 Detecting the State (open/closed) of the ADF ....................................................................................................................... 5- 205.3.4.3 Outline.................................................................................................................................................................................... 5- 215.3.4.4 Points of Detection................................................................................................................................................................. 5- 215.3.4.5 Outline of Detection ............................................................................................................................................................... 5- 225.3.4.6 Book Mode, 1 Original, Copyboard Cover Open ................................................................................................................... 5- 225.3.4.7 Book Mode, 1 Original, Copyboard Cover Close ................................................................................................................... 5- 23

5.3.5 Dirt Sensor Control ................................................................................................................................................5- 255.3.5.1 Detecting Dust in Stream Reading......................................................................................................................................... 5- 25

5.4 Parts Replacement Procedure ................................................................................................................. 5- 275.4.1 Reader Unit............................................................................................................................................................5- 27

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5.4.1.1 Removing the Reader Unit..................................................................................................................................................... 5- 275.4.1.2 Sliding the Reader Unit .......................................................................................................................................................... 5- 27

5.4.2 CCD Unit ............................................................................................................................................................... 5- 275.4.2.1 Removing the CCD Unit......................................................................................................................................................... 5- 275.4.2.2 Removing the CCD Unit......................................................................................................................................................... 5- 285.4.2.3 Removing the CCD Unit......................................................................................................................................................... 5- 285.4.2.4 When Replacing the CCD Unit .............................................................................................................................................. 5- 295.4.2.5 When Replacing the CCD Unit .............................................................................................................................................. 5- 295.4.2.6 When Replacing the CCD/AP Unit......................................................................................................................................... 5- 295.4.2.7 Points to Note when Replacing the CCD Unit........................................................................................................................ 5- 30

5.4.3 Standard White Plate.............................................................................................................................................5- 305.4.3.1 Removing the Standard White Plate...................................................................................................................................... 5- 305.4.3.2 Removing the Standard White Plate...................................................................................................................................... 5- 305.4.3.3 When Replacing the Standard White Plate............................................................................................................................ 5- 315.4.3.4 When Replacing the Standard White Plate............................................................................................................................ 5- 31

5.4.4 Scanning Lamp......................................................................................................................................................5- 315.4.4.1 Remove the Scanning Lamp/Scanning Lamp Heater............................................................................................................ 5- 315.4.4.2 Remove the Scanning Lamp/Scanning Lamp Heater............................................................................................................ 5- 325.4.4.3 Removing the Scanning Lamp............................................................................................................................................... 5- 345.4.4.4 Points to Note When Replacing the Scanning Lamp ............................................................................................................. 5- 355.4.4.5 Points to Note When Replacing the Scanning Lamp ............................................................................................................. 5- 355.4.4.6 Points to Note When Replacing the Scanning Lamp ............................................................................................................. 5- 355.4.4.7 When Replacing the Scanning Lamp..................................................................................................................................... 5- 355.4.4.8 When Replacing the Scanning Lamp..................................................................................................................................... 5- 365.4.4.9 After Replacing the Scanning Lamp ...................................................................................................................................... 5- 36

5.4.5 Reader Controller PCB..........................................................................................................................................5- 365.4.5.1 Removing the Reader Controller PCB ................................................................................................................................... 5- 365.4.5.2 Removing the Reader Controller PCB Unit............................................................................................................................ 5- 365.4.5.3 Removing the Reader Controller PCB ................................................................................................................................... 5- 365.4.5.4 Removing the Reader Controller PCB ................................................................................................................................... 5- 365.4.5.5 When Replacing the Reader Controller PCB......................................................................................................................... 5- 375.4.5.6 Removing the Reader Controller PCB Unit............................................................................................................................ 5- 375.4.5.7 Points to Note When Replacing the reader controller PCB ................................................................................................... 5- 375.4.5.8 Points to Note When Replacing the reader controller PCB ................................................................................................... 5- 37

5.4.6 Inverter PCB ..........................................................................................................................................................5- 375.4.6.1 Removing the Inverter PCB ................................................................................................................................................... 5- 375.4.6.2 Removing the Inverter PCB ................................................................................................................................................... 5- 385.4.6.3 Removing the Inverter PCB ................................................................................................................................................... 5- 38

5.4.7 Light Intensity Control PCB ...................................................................................................................................5- 395.4.7.1 Removing the Light Adjustment PCB..................................................................................................................................... 5- 395.4.7.2 Removing the Light Adjustment PCB..................................................................................................................................... 5- 40

5.4.8 Transformer PCB...................................................................................................................................................5- 405.4.8.1 Removing the Transformer Unit............................................................................................................................................. 5- 405.4.8.2 Removing the Transformer Unit............................................................................................................................................. 5- 405.4.8.3 Removing the Transformer PCB............................................................................................................................................ 5- 405.4.8.4 Removing the Transformer PCB(iR105) ................................................................................................................................ 5- 41

5.4.9 Original Orientation Detection PCB .......................................................................................................................5- 415.4.9.1 Removing the Original Orientation Detection PCB ................................................................................................................ 5- 415.4.9.2 Removing the Original Orientation Detection PCB ................................................................................................................ 5- 41

5.4.10 Fuse PCB ............................................................................................................................................................5- 415.4.10.1 Removing the Fuse PCB...................................................................................................................................................... 5- 41

5.4.11 Scanner Motor .....................................................................................................................................................5- 425.4.11.1 Removing the Scanner Motor .............................................................................................................................................. 5- 425.4.11.2 Removing the Scanner Motor .............................................................................................................................................. 5- 425.4.11.3 Removing the Scanner Motor .............................................................................................................................................. 5- 425.4.11.4 Mounting the Scanner Motor................................................................................................................................................ 5- 43

5.4.12 Copyboard Cover Open/Close Sensor ................................................................................................................5- 435.4.12.1 Removing the Copyboard Cover Sensor ............................................................................................................................. 5- 43

5.4.13 Original Size Sensor ............................................................................................................................................5- 435.4.13.1 Removing the Original Size Sensor 1/2 ............................................................................................................................... 5- 43

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Contents

5.4.13.2 Removing the Original Size Sensor 1/2 ............................................................................................................................... 5- 445.4.13.3 Removing the Original Size Sensor ..................................................................................................................................... 5- 445.4.13.4 Removing the Original Size Sensor 3/4 ............................................................................................................................... 5- 445.4.13.5 Removing the Original Size Sensor 3/4 ............................................................................................................................... 5- 45

5.4.14 Scanner Home Position Sensor ...........................................................................................................................5- 455.4.14.1 Removing the HP Sensor..................................................................................................................................................... 5- 455.4.14.2 Removing the Scanner Home Position Sensor.................................................................................................................... 5- 455.4.14.3 Removing the Scanner Home Position Sensor.................................................................................................................... 5- 46

5.4.15 Copyboard Glass Sensor .....................................................................................................................................5- 465.4.15.1 Removing the Copyboard Glass Sensor.............................................................................................................................. 5- 465.4.15.2 Removing the Copyboard Glass Sensor.............................................................................................................................. 5- 46

5.4.16 Image Leading Edge Sensor................................................................................................................................5- 475.4.16.1 Removing the Image Leading Edge Sensor ........................................................................................................................ 5- 475.4.16.2 Removing the Image Leading Edge Sensor ........................................................................................................................ 5- 47

5.4.17 Scanner Drive Cable ............................................................................................................................................5- 475.4.17.1 Adjusting the Tension of the Scanner Drive Cable .............................................................................................................. 5- 475.4.17.2 Adjusting the Tension of the Scanner Drive Cable .............................................................................................................. 5- 495.4.17.3 Removing the Scanner System Drive Cable........................................................................................................................ 5- 505.4.17.4 Removing the No. 1 Mirror Case Flexible Cable.................................................................................................................. 5- 505.4.17.5 Removing the No. 1 Mirror Case Flexible Cable.................................................................................................................. 5- 515.4.17.6 Routing the Scanner Drive Cable......................................................................................................................................... 5- 525.4.17.7 Positioning the No. 1/2 Mirror Base ..................................................................................................................................... 5- 53

Chapter 6 Image Processing System

6.1 Outline ........................................................................................................................................................ 6- 16.1.1 Outline of the Image Processing System.................................................................................................................6- 16.1.2 Outline......................................................................................................................................................................6- 1

6.2 Analog Image Processing .......................................................................................................................... 6- 26.2.1 Analog Image Processing ........................................................................................................................................6- 26.2.2 Outline......................................................................................................................................................................6- 26.2.3 Driving the CCD.......................................................................................................................................................6- 36.2.4 Gain Correction and Offset Correction of the CCD Output ......................................................................................6- 36.2.5 A/D Conversion of the CCD Output .........................................................................................................................6- 36.2.6 4-Channel High-Speed Reading CCD .....................................................................................................................6- 36.2.7 CCD Adjustment ......................................................................................................................................................6- 4

6.3 Digital Image Processing............................................................................................................................ 6- 56.3.1 Digital Image Processing .........................................................................................................................................6- 56.3.2 Outline......................................................................................................................................................................6- 56.3.3 Detecting the Orientation of Originals ......................................................................................................................6- 56.3.4 Shading Correction ..................................................................................................................................................6- 66.3.5 Auto Density Adjustment (AE) .................................................................................................................................6- 7

Chapter 7 Laser Exposure

7.1 Construction ............................................................................................................................................... 7- 17.1.1 Outline of the Laser Exposure System ....................................................................................................................7- 17.1.2 Outline of the Laser Exposure System ....................................................................................................................7- 1

7.2 Basic Sequence ......................................................................................................................................... 7- 37.2.1 Basic Sequence of Operations (laser exposure system) .........................................................................................7- 37.2.2 Basic Sequence .......................................................................................................................................................7- 3

7.3 Various Controls ......................................................................................................................................... 7- 47.3.1 Controlling the Laser Activation Timing ...................................................................................................................7- 4

7.3.1.1 Flow of the BD Signal .............................................................................................................................................................. 7- 47.3.2 Controlling the Intensity of Laser Light.....................................................................................................................7- 4

7.3.2.1 Outline...................................................................................................................................................................................... 7- 47.3.2.2 Controlling Laser Activation ..................................................................................................................................................... 7- 57.3.2.3 Controlling the Laser Intensity ................................................................................................................................................. 7- 6

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Contents

7.3.3 Controlling the Laser Scanner Motor.......................................................................................................................7- 77.3.3.1 Outline...................................................................................................................................................................................... 7- 7

7.4 Parts Replacement Procedure ...................................................................................................................7- 97.4.1 Laser Scanner Unit..................................................................................................................................................7- 9

7.4.1.1 Removing the Laser Unit ......................................................................................................................................................... 7- 97.4.1.2 Removing the Laser Unit ......................................................................................................................................................... 7- 97.4.1.3 Removing the Laser Unit ......................................................................................................................................................... 7- 97.4.1.4 Removing the Laser Unit ....................................................................................................................................................... 7- 107.4.1.5 Points to Note When Replacing the Laser Unit...................................................................................................................... 7- 117.4.1.6 Points to Note When Replacing the Laser Unit...................................................................................................................... 7- 11

7.4.2 BD Unit ..................................................................................................................................................................7- 117.4.2.1 Removing the BD Unit ........................................................................................................................................................... 7- 117.4.2.2 Removing the BD Unit ........................................................................................................................................................... 7- 11

Chapter 8 Image Formation

8.1 Construction ...............................................................................................................................................8- 18.1.1 Outline .....................................................................................................................................................................8- 18.1.2 Outline of the Image Formation System(iR105) ......................................................................................................8- 18.1.3 Major Components ..................................................................................................................................................8- 38.1.4 Pre-Transfer Exposure LED ....................................................................................................................................8- 48.1.5 Pre-Transfer Exposure LED ....................................................................................................................................8- 48.1.6 Pre-Transfer Exposure LED ....................................................................................................................................8- 48.1.7 Pre-Transfer Exposure LED ....................................................................................................................................8- 58.1.8 Addition of the Developing Fan(iR105)....................................................................................................................8- 5

8.2 Basic Sequence..........................................................................................................................................8- 68.2.1 Basic Sequence.......................................................................................................................................................8- 68.2.2 Basic Sequence.......................................................................................................................................................8- 6

8.3 Potential Control .........................................................................................................................................8- 78.3.1 Outline .....................................................................................................................................................................8- 78.3.2 Basic Sequence.......................................................................................................................................................8- 78.3.3 Basic Sequence.......................................................................................................................................................8- 88.3.4 Determining the Optimum Grid Bias........................................................................................................................8- 98.3.5 Grid Bias Corrective Control....................................................................................................................................8- 98.3.6 Determining the Optimum Laser Output................................................................................................................8- 108.3.7 Laser Output Corrective Control............................................................................................................................8- 108.3.8 Determining the Optimum Developing Bias...........................................................................................................8- 118.3.9 Potential Control for Transparency Mode..............................................................................................................8- 118.3.10 Target Potential Correction in Each Mode...........................................................................................................8- 128.3.11 Target Potential Correction in Each Mode...........................................................................................................8- 14

8.4 Charging Mechanism................................................................................................................................8- 168.4.1 Primary Charging Mechanism ...............................................................................................................................8- 16

8.4.1.1 Outline.................................................................................................................................................................................... 8- 168.4.1.2 Primary Charging Assembly Cleaning Mechanism................................................................................................................ 8- 168.4.1.3 Others .................................................................................................................................................................................... 8- 17

8.4.2 Dust-Collecting Roller Bias....................................................................................................................................8- 178.4.2.1 Outline.................................................................................................................................................................................... 8- 17

8.4.3 Pre-Transfer Charging Mechanism .......................................................................................................................8- 188.4.3.1 Outline.................................................................................................................................................................................... 8- 188.4.3.2 Controlling the Output to Suit the Environment (fuzzy control) .............................................................................................. 8- 198.4.3.3 Pre-Transfer Charging Assembly Cleaning Mechanism ........................................................................................................ 8- 208.4.3.4 Others .................................................................................................................................................................................... 8- 20

8.5 Drum Cleaner Unit ....................................................................................................................................8- 228.5.1 Outline ...................................................................................................................................................................8- 228.5.2 Outline ...................................................................................................................................................................8- 228.5.3 Detecting the Waste Toner (case full condition)....................................................................................................8- 23

8.6 Developing Assembly ...............................................................................................................................8- 25

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Contents

8.6.1 Outline....................................................................................................................................................................8- 258.6.2 Controlling the Developing Assembly ....................................................................................................................8- 258.6.3 Controlling the Toner Cartridge Drive Mechanism.................................................................................................8- 268.6.4 Controlling the Developing Bias.............................................................................................................................8- 278.6.5 Detecting the Toner Level and Controlling the Toner Supply Mechanism.............................................................8- 28

8.7 Transfer Mechanism................................................................................................................................. 8- 318.7.1 Transfer Guide Bias ...............................................................................................................................................8- 31

8.7.1.1 Outline.................................................................................................................................................................................... 8- 318.7.1.2 Controlling the Output to Suit the Environment...................................................................................................................... 8- 31

8.7.2 Transfer Charging Mechanism...............................................................................................................................8- 328.7.2.1 Outline.................................................................................................................................................................................... 8- 328.7.2.2 Controlling the Output to Suit the Environment (fuzzy control) .............................................................................................. 8- 328.7.2.3 Correcting the Output at the Trailing Edge of Paper.............................................................................................................. 8- 338.7.2.4 Transfer Charging Assembly Cleaning Mechanism............................................................................................................... 8- 348.7.2.5 Others .................................................................................................................................................................................... 8- 35

8.8 Separation Mechanism............................................................................................................................. 8- 368.8.1 Separation Charging Mechanism...........................................................................................................................8- 36

8.8.1.1 Outline.................................................................................................................................................................................... 8- 368.8.1.2 Correcting the Output to Suit the Environment and the Toner Deposit.................................................................................. 8- 368.8.1.3 Correcting the Output upon Detection of Leakage................................................................................................................. 8- 378.8.1.4 Others .................................................................................................................................................................................... 8- 38

8.9 Parts Replacement Procedure ................................................................................................................. 8- 398.9.1 Process Unit...........................................................................................................................................................8- 39

8.9.1.1 Removing the Process Unit ................................................................................................................................................... 8- 398.9.1.2 Removing the Process Unit ................................................................................................................................................... 8- 398.9.1.3 Mounting the Process Unit..................................................................................................................................................... 8- 408.9.1.4 Mounting the Process Unit..................................................................................................................................................... 8- 41

8.9.2 Pre-Exposure Lamp...............................................................................................................................................8- 418.9.2.1 Removing the Pre-Exposure Lamp Unit ................................................................................................................................ 8- 41

8.9.3 Primary Charging Assembly ..................................................................................................................................8- 418.9.3.1 Removing the Primary Charging Assembly ........................................................................................................................... 8- 41

8.9.4 Pre-Transfer Charging Assembly...........................................................................................................................8- 428.9.4.1 Removing the Pre-Transfer Charging Assembly ................................................................................................................... 8- 42

8.9.5 Photosensitive Drum..............................................................................................................................................8- 428.9.5.1 Points to Note When Handling the Photosensitive Drum....................................................................................................... 8- 428.9.5.2 Points to Note When Handling the Photosensitive Drum....................................................................................................... 8- 428.9.5.3 Removing the Photosensitive Drum....................................................................................................................................... 8- 428.9.5.4 Removing the Photosensitive Drum....................................................................................................................................... 8- 43

8.9.6 Drum Cleaner Unit .................................................................................................................................................8- 448.9.6.1 Construction........................................................................................................................................................................... 8- 448.9.6.2 Construction........................................................................................................................................................................... 8- 448.9.6.3 Removing the Cleaning Blade ............................................................................................................................................... 8- 448.9.6.4 Removing the Cleaning Blade ............................................................................................................................................... 8- 458.9.6.5 Mounting the Cleaning Blade................................................................................................................................................. 8- 458.9.6.6 Mounting the Cleaning Blade................................................................................................................................................. 8- 468.9.6.7 Removing the Blade Vibrating Unit ........................................................................................................................................ 8- 46

8.9.7 Photosensitive Drum Heater ..................................................................................................................................8- 468.9.7.1 Replacing the Photosensitive Drum Heater ........................................................................................................................... 8- 46

8.9.8 Developing Assembly ............................................................................................................................................8- 478.9.8.1 Removing the Developing Assembly ..................................................................................................................................... 8- 478.9.8.2 Removing the Hopper ............................................................................................................................................................ 8- 47

8.9.9 Developing Cylinder...............................................................................................................................................8- 478.9.9.1 Removing the Developing Cylinder........................................................................................................................................ 8- 47

8.9.10 Developing Blade .................................................................................................................................................8- 498.9.10.1 Removing the Blade Unit ..................................................................................................................................................... 8- 498.9.10.2 Mounting the Blade .............................................................................................................................................................. 8- 49

8.9.11 Developing Cylinder Deceleration Clutch.............................................................................................................8- 498.9.11.1 Remove the Developing Cylinder Deceleration Clutch ........................................................................................................ 8- 498.9.11.2 Remove the Developing Cylinder Deceleration Clutch ........................................................................................................ 8- 50

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Contents

8.9.12 Developing Cylinder Clutch .................................................................................................................................8- 508.9.12.1 Remove the Developing Cylinder Clutch ............................................................................................................................. 8- 508.9.12.2 Remove the Developing Cylinder Clutch ............................................................................................................................. 8- 51

8.9.13 Transfer/Separation Charging Assembly.............................................................................................................8- 518.9.13.1 Removing the Transfer/Separation Charging Assembly ...................................................................................................... 8- 51

8.9.14 Pre-Transfer Exposure LED ................................................................................................................................8- 528.9.14.1 Removing the Pre-Transfer Exposure LED.......................................................................................................................... 8- 528.9.14.2 Removing the Pre-Transfer Exposure LED.......................................................................................................................... 8- 52

8.9.15 Separation Claw/Separation Claw Drive Assembly .............................................................................................8- 538.9.15.1 Separation Claw/Separation Claw Drive Assembly ............................................................................................................. 8- 53

8.9.16 Potential Sensor ..................................................................................................................................................8- 538.9.16.1 Removing the Potential Sensor Unit .................................................................................................................................... 8- 53

8.9.17 Dust-Collecting Roller ..........................................................................................................................................8- 548.9.17.1 Removing the Dust-Collecting Roller ................................................................................................................................... 8- 54

8.9.18 Charging Wire......................................................................................................................................................8- 548.9.18.1 Outline.................................................................................................................................................................................. 8- 548.9.18.2 Outline.................................................................................................................................................................................. 8- 548.9.18.3 Removing the Wire Cleaner for the Primary Charging Assembly ........................................................................................ 8- 548.9.18.4 Removing the Wire Cleaner for the Primary Charging Assembly ........................................................................................ 8- 548.9.18.5 Stringing the Charging Wire ................................................................................................................................................. 8- 558.9.18.6 Stringing the Charging Wire ................................................................................................................................................. 8- 568.9.18.7 Stringing the Grid of the Primary Charging Assembly.......................................................................................................... 8- 568.9.18.8 Stringing the Grid of the Primary Charging Assembly.......................................................................................................... 8- 578.9.18.9 Adjusting the Height of the Charging Wire ........................................................................................................................... 8- 578.9.18.10 Adjusting the Height of the Charging Wire ......................................................................................................................... 8- 58

Chapter 9 Pickup/Feeding System

9.1 Construction ...............................................................................................................................................9- 19.1.1 Outline of the Pickup/Feeding System(iR105).........................................................................................................9- 19.1.2 Specifications and Construction ..............................................................................................................................9- 39.1.3 Optical Sensors(iR105) ...........................................................................................................................................9- 49.1.4 Arrangement of Rollers and Sensors ......................................................................................................................9- 49.1.5 Arrangement of Rollers and Sensors ......................................................................................................................9- 59.1.6 Control System ........................................................................................................................................................9- 69.1.7 Index Paper Attachment ..........................................................................................................................................9- 79.1.8 Controlling the Pickup Motor (M2) ...........................................................................................................................9- 8

9.2 Basic Sequence..........................................................................................................................................9- 99.2.1 Right Deck ...............................................................................................................................................................9- 99.2.2 Pickup from the front deck.......................................................................................................................................9- 99.2.3 Pickup from the cassette 4 ....................................................................................................................................9- 109.2.4 Pickup from the cassette 4 ....................................................................................................................................9- 11

9.3 Detecting Jams.........................................................................................................................................9- 129.3.1 Jam Detection Outline ...........................................................................................................................................9- 12

9.3.1.1 Outline.................................................................................................................................................................................... 9- 129.3.1.2 Outline.................................................................................................................................................................................... 9- 13

9.3.2 Delay Jams............................................................................................................................................................9- 149.3.2.1 Cassette Pickup (Right deck, Left deck, cassette 3, 4).......................................................................................................... 9- 149.3.2.2 Cassette Pickup (Right deck, Left deck, cassette 3, 4).......................................................................................................... 9- 149.3.2.3 Other Delay Jams .................................................................................................................................................................. 9- 159.3.2.4 Other Delay Jams .................................................................................................................................................................. 9- 169.3.2.5 Other Delay Jams .................................................................................................................................................................. 9- 17

9.3.3 Stationary Jams.....................................................................................................................................................9- 189.3.3.1 Common Stationary Jams...................................................................................................................................................... 9- 189.3.3.2 Common Stationary Jams...................................................................................................................................................... 9- 199.3.3.3 Stationary Jam at Power-On.................................................................................................................................................. 9- 19

9.4 Cassette Pick-Up Unit ..............................................................................................................................9- 209.4.1 Outline ...................................................................................................................................................................9- 20

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Contents

9.4.2 Detecting the Presence/Absence of Paper ............................................................................................................9- 219.4.3 Detecting the Level of Paper..................................................................................................................................9- 229.4.4 Cassette 3/4...........................................................................................................................................................9- 239.4.5 Markings on the Width Guide Rail .........................................................................................................................9- 249.4.6 Paper Size .............................................................................................................................................................9- 24

9.5 Manual Feed Pickup Unit ......................................................................................................................... 9- 279.5.1 Pickup Operation ...................................................................................................................................................9- 279.5.2 Detecting the Paper Size .......................................................................................................................................9- 27

9.6 Deck ......................................................................................................................................................... 9- 299.6.1 Outline....................................................................................................................................................................9- 299.6.2 Lifter Limiter (deck right/left) ..................................................................................................................................9- 309.6.3 Detecting the Presence/Absence of Paper ............................................................................................................9- 319.6.4 Detecting the Level of Paper..................................................................................................................................9- 329.6.5 Cassette Deck Right/Left .......................................................................................................................................9- 34

9.7 Registration Unit ....................................................................................................................................... 9- 359.7.1 Outline....................................................................................................................................................................9- 359.7.2 Control System ......................................................................................................................................................9- 359.7.3 Sequence of Operations (registration brake) .........................................................................................................9- 35

9.8 Duplex Feeding Unit ................................................................................................................................. 9- 379.8.1 Copying on the First Side.......................................................................................................................................9- 379.8.2 Printing on the First Side........................................................................................................................................9- 379.8.3 Copying on the Second Side .................................................................................................................................9- 389.8.4 Printing on the Second Side ..................................................................................................................................9- 399.8.5 Sequence of Operations ........................................................................................................................................9- 409.8.6 Sequence of Operations ........................................................................................................................................9- 409.8.7 Controlling the reversal motor (M11) .....................................................................................................................9- 409.8.8 Controlling the duplexing feeder motor (M12)........................................................................................................9- 419.8.9 No-Stacking Operation...........................................................................................................................................9- 429.8.10 No-Stacking Operation.........................................................................................................................................9- 479.8.11 Detecting the Horizontal Registration Position.....................................................................................................9- 529.8.12 Controlling the Horizontal Registration Motor (M15) ............................................................................................9- 53

9.9 Delivery .................................................................................................................................................... 9- 559.9.1 Reversal Delivery...................................................................................................................................................9- 559.9.2 Reversal Delivery...................................................................................................................................................9- 55

9.10 Parts Replacement Procedure ............................................................................................................... 9- 579.10.1 Cassette Pickup Assembly...................................................................................................................................9- 57

9.10.1.1 Removing the Cassette 3 Pickup Assembly ........................................................................................................................ 9- 579.10.1.2 Removing the Cassette 4 Pickup Assembly ........................................................................................................................ 9- 579.10.1.3 Removing the Vertical Path 3/4 Sensor and the Cassette 3/4 Pickup Sensor..................................................................... 9- 57

9.10.2 Cassette Lifter Motor............................................................................................................................................9- 579.10.2.1 Removing the Lifter Motor (M16/M17) of the Cassette (3/4)................................................................................................ 9- 57

9.10.3 Front Deck Pickup Assembly ...............................................................................................................................9- 589.10.3.1 Removing the Front Deck (right) .......................................................................................................................................... 9- 589.10.3.2 Removing the Pickup Assembly of the Front Deck (left) ...................................................................................................... 9- 58

9.10.4 Left Deck Pickup Sensor......................................................................................................................................9- 599.10.4.1 Removing the Left Deck Pickup Sensor............................................................................................................................... 9- 59

9.10.5 Right Deck Pickup Sensor ...................................................................................................................................9- 599.10.5.1 Removing the Right Deck Feed Sensor/Right Deck Pickup Sensor .................................................................................... 9- 59

9.10.6 Manual Tray Assembly.........................................................................................................................................9- 599.10.6.1 Removing the Manual Feed Tray Unit ................................................................................................................................. 9- 599.10.6.2 Removing the Manual Feed Tray Unit ................................................................................................................................. 9- 609.10.6.3 Fitting the Side Guide Timing Belt for the Manual Feed Tray Assembly(iR105).................................................................. 9- 609.10.6.4 Fitting the Side Guide Timing Belt for the Manual Feed Tray Assembly.............................................................................. 9- 60

9.10.7 Manual Pickup Roller ...........................................................................................................................................9- 609.10.7.1 Removing the Pickup Roller................................................................................................................................................. 9- 609.10.7.2 Mounting the Pickup Roller .................................................................................................................................................. 9- 60

9.10.8 Manual Feed Roller..............................................................................................................................................9- 61

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Contents

9.10.8.1 Removing the Feeding Roller............................................................................................................................................... 9- 619.10.8.2 Orientation of the Feeding Roller ......................................................................................................................................... 9- 619.10.8.3 Removing the Manual Feed Roller....................................................................................................................................... 9- 619.10.8.4 Mounting the Manual Feed Roller ........................................................................................................................................ 9- 62

9.10.9 Manual Separation Roller ....................................................................................................................................9- 629.10.9.1 Removing the Separation Roller .......................................................................................................................................... 9- 62

9.10.10 Manual Feed Tray sensor ..................................................................................................................................9- 639.10.10.1 Removing the Manual Feed Tray Paper Sensor ................................................................................................................ 9- 639.10.10.2 Removing the Manual Feed Tray Paper Sensor ................................................................................................................ 9- 64

9.10.11 Registration Roller .............................................................................................................................................9- 659.10.11.1 Removing the Registration Roller....................................................................................................................................... 9- 65

9.10.12 Pre-Registration Roller.......................................................................................................................................9- 669.10.12.1 Removing the Pre-Registration Roller................................................................................................................................ 9- 66

9.10.13 Registration Clutch.............................................................................................................................................9- 679.10.13.1 Removing the Registration Clutch...................................................................................................................................... 9- 679.10.13.2 Removing the Registration Clutch...................................................................................................................................... 9- 67

9.10.14 Registration Brake Clutch ..................................................................................................................................9- 689.10.14.1 Removing the Registration Brake Clutch ........................................................................................................................... 9- 689.10.14.2 Removing the Registration Brake Clutch ........................................................................................................................... 9- 68

9.10.15 Fixing/Feed Unit................................................................................................................................................. 9- 689.10.15.1 Removing the Fixing/Feed Unit .......................................................................................................................................... 9- 689.10.15.2 Removing the Fixing/Feed Unit .......................................................................................................................................... 9- 69

9.10.16 Feeding Roller....................................................................................................................................................9- 699.10.16.1 Removing the Feeding Roller............................................................................................................................................. 9- 699.10.16.2 Orientation of the Feeding Roller of the Deck/Cassette Pickup Assembly......................................................................... 9- 69

9.10.17 Vertical Path Roller ............................................................................................................................................9- 699.10.17.1 Removing the Vertical Path Roller 1/3/4 ............................................................................................................................ 9- 699.10.17.2 Removing the Vertical Path Roller 1/3/4 ............................................................................................................................ 9- 709.10.17.3 Removing the Vertical Path Roller 2 .................................................................................................................................. 9- 709.10.17.4 Removing the Vertical Path Roller 2 .................................................................................................................................. 9- 71

9.10.18 Fixing Feeding Unit Releasing Lever Sensor..................................................................................................... 9- 719.10.18.1 Removing the Fixing Feeding Unit Releasing lever Sensor ............................................................................................... 9- 71

9.10.19 Feeding Belt.......................................................................................................................................................9- 719.10.19.1 Removing the Feeding Belt ................................................................................................................................................ 9- 71

9.10.20 Duplexing Unit....................................................................................................................................................9- 729.10.20.1 Removing the Duplexing Unit............................................................................................................................................. 9- 729.10.20.2 Removing the Reversal Motor............................................................................................................................................ 9- 739.10.20.3 Removing the Reversal Motor............................................................................................................................................ 9- 739.10.20.4 Removing the Duplex Left Feed Motor............................................................................................................................... 9- 739.10.20.5 Removing the Lower Feed Motor ....................................................................................................................................... 9- 739.10.20.6 Removing the Reversing Flapper Solenoid........................................................................................................................ 9- 749.10.20.7 Removing the Duplex Right Feed Motor ............................................................................................................................ 9- 749.10.20.8 Removing the Left Deck Feed Sensor ............................................................................................................................... 9- 749.10.20.9 Removing the Horizontal Registration Motor...................................................................................................................... 9- 749.10.20.10 Removing the Deck (left) Draw- Out Clutch/Lower Feeder Middle Clutch ....................................................................... 9- 759.10.20.11 Removing the Lower Feeding Right Clutch ...................................................................................................................... 9- 759.10.20.12 Removing the Pre-Confluence Sensor ............................................................................................................................. 9- 759.10.20.13 Removing the Post-Confluence Sensor ........................................................................................................................... 9- 759.10.20.14 Removing the Front Deck (lifter) Draw-Out Sensor.......................................................................................................... 9- 769.10.20.15 Removing the Horizontal Registration Sensor.................................................................................................................. 9- 76

9.10.21 Separation Roller ...............................................................................................................................................9- 779.10.21.1 Removing the Separation Roller ........................................................................................................................................ 9- 779.10.21.2 Orientation of the Separation Roller ................................................................................................................................... 9- 77

Chapter 10 Fixing System

10.1 Construction............................................................................................................................................10- 110.1.1 Outline .................................................................................................................................................................10- 110.1.2 Outline .................................................................................................................................................................10- 110.1.3 Outline .................................................................................................................................................................10- 1

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Contents

10.1.4 Outline..................................................................................................................................................................10- 210.1.5 Major Components...............................................................................................................................................10- 210.1.6 Fixing Drive System Outline.................................................................................................................................10- 310.1.7 Controlling the Fixing Roller Drive Mechanism ....................................................................................................10- 410.1.8 Controlling the Cleaning Belt Drive Mechanism...................................................................................................10- 510.1.9 Controlling the Thermistor Reciprocating Mechanism .........................................................................................10- 510.1.10 Controlling the Upper Separation Claw Reciprocating Mechanism....................................................................10- 6

10.2 Basic Sequence...................................................................................................................................... 10- 710.2.1 Basic Sequence ...................................................................................................................................................10- 710.2.2 Basic Sequence ...................................................................................................................................................10- 710.2.3 Basic Sequence ...................................................................................................................................................10- 7

10.3 Various Control Mechanisms.................................................................................................................. 10- 910.3.1 Controlling the Fixing Roller Temperature ...........................................................................................................10- 9

10.3.1.1 Down Sequence Control ...................................................................................................................................................... 10- 910.3.1.2 Down Sequence Control ...................................................................................................................................................... 10- 910.3.1.3 Down Sequence Control .................................................................................................................................................... 10- 1010.3.1.4 Down Sequence Control .................................................................................................................................................... 10- 1110.3.1.5 Fixing Temperature Control(iR105).................................................................................................................................... 10- 1210.3.1.6 Transparency Mode ........................................................................................................................................................... 10- 1310.3.1.7 Transparency Mode ........................................................................................................................................................... 10- 1310.3.1.8 Transparency Mode ........................................................................................................................................................... 10- 1410.3.1.9 Thick Paper Mode .............................................................................................................................................................. 10- 1510.3.1.10 Thick Paper Mode ............................................................................................................................................................ 10- 1510.3.1.11 Thick Paper Mode ............................................................................................................................................................ 10- 1510.3.1.12 Thick Paper Mode ............................................................................................................................................................ 10- 1610.3.1.13 Thick Paper Mode ............................................................................................................................................................ 10- 1610.3.1.14 Power Save Mode ............................................................................................................................................................ 10- 1610.3.1.15 Power Save Mode ............................................................................................................................................................ 10- 17

10.4 Protective Functions ............................................................................................................................. 10- 1810.4.1 Detecting an Error ..............................................................................................................................................10- 1810.4.2 Detecting an Error ..............................................................................................................................................10- 18

10.5 Parts Replacement Procedure ............................................................................................................. 10- 2010.5.1 Fixing Unit ..........................................................................................................................................................10- 20

10.5.1.1 Removing the Fixing Assembly.......................................................................................................................................... 10- 2010.5.2 Upper Fixing Roller ............................................................................................................................................10- 21

10.5.2.1 Removing the Fixing Upper Roller ..................................................................................................................................... 10- 2110.5.2.2 Removing the Fixing Upper Roller ..................................................................................................................................... 10- 2210.5.2.3 Mounting the Fixing Upper Roller....................................................................................................................................... 10- 2310.5.2.4 Mounting the Fixing Upper Roller....................................................................................................................................... 10- 23

10.5.3 Lower Fixing Roller ............................................................................................................................................10- 2310.5.3.1 Removing the Lower Fixing Roller ..................................................................................................................................... 10- 2310.5.3.2 Adjusting the Lower Roller Pressure (nip width) ................................................................................................................ 10- 2410.5.3.3 Adjusting the Lower Roller Pressure (nip).......................................................................................................................... 10- 24

10.5.4 External Delivery Roller......................................................................................................................................10- 2410.5.4.1 Removing the External Delivery Roller .............................................................................................................................. 10- 2410.5.4.2 Removing the External Delivery Roller .............................................................................................................................. 10- 25

10.5.5 Internal Delivery Roller.......................................................................................................................................10- 2610.5.5.1 Removing the Internal Delivery Roller................................................................................................................................ 10- 2610.5.5.2 Removing the Internal Delivery Roller................................................................................................................................ 10- 26

10.5.6 Main Thermistor .................................................................................................................................................10- 2610.5.6.1 Removing the Main Thermistor .......................................................................................................................................... 10- 2610.5.6.2 Removing the Main Thermistor .......................................................................................................................................... 10- 2710.5.6.3 Mounting the Main Thermistor ........................................................................................................................................... 10- 2710.5.6.4 Mounting the Main Thermistor ........................................................................................................................................... 10- 27

10.5.7 Sub Thermistor...................................................................................................................................................10- 2710.5.7.1 Removing the Sub Thermistor ........................................................................................................................................... 10- 2710.5.7.2 Removing the Sub Thermistor ........................................................................................................................................... 10- 28

10.5.8 Thermal Switch ..................................................................................................................................................10- 2810.5.8.1 Removing the Thermal Switch Unit.................................................................................................................................... 10- 28

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Contents

10.5.8.2 Removing the Thermal Switch Unit .................................................................................................................................... 10- 2910.5.8.3 Mounting the Thermal Switch Unit ..................................................................................................................................... 10- 2910.5.8.4 Mounting the Thermal Switch Unit ..................................................................................................................................... 10- 29

10.5.9 Fixing Heater .....................................................................................................................................................10- 3010.5.9.1 Removing the Main/Sub Heater ......................................................................................................................................... 10- 3010.5.9.2 Removing the Main/Sub Heater ......................................................................................................................................... 10- 3010.5.9.3 Mounting the Main/Sub Heater .......................................................................................................................................... 10- 3010.5.9.4 Mounting the Main/Sub Heater .......................................................................................................................................... 10- 3110.5.9.5 Points to Note When Mounting the Fixing Heater .............................................................................................................. 10- 3110.5.9.6 Points to Note When Mounting the Fixing Heater .............................................................................................................. 10- 31

10.5.10 Fixing Cleaning Belt .........................................................................................................................................10- 3110.5.10.1 Removing the Fixing Cleaning Belt .................................................................................................................................. 10- 3110.5.10.2 Mounting the Fixing Cleaning Belt.................................................................................................................................... 10- 32

10.5.11 Claw Jam Sensor.............................................................................................................................................10- 3310.5.11.1 Removing the Claw Jam Sensor ...................................................................................................................................... 10- 3310.5.11.2 Removing the Delivery Speed Switching Clutch .............................................................................................................. 10- 33

10.5.12 External Delivery Sensor .................................................................................................................................10- 3310.5.12.1 Remove the External Delivery Sensor ............................................................................................................................. 10- 3310.5.12.2 Remove the External Delivery Sensor ............................................................................................................................. 10- 33

10.5.13 Internal Delivery Sensor...................................................................................................................................10- 3410.5.13.1 Removing the Internal Delivery Sensor............................................................................................................................ 10- 3410.5.13.2 Removing the Internal Delivery Sensor............................................................................................................................ 10- 34

10.5.14 Reversal Sensor ..............................................................................................................................................10- 3410.5.14.1 Removing the Reversal Sensor........................................................................................................................................ 10- 34

10.5.15 Fixing/Feeding Outlet Sensor ..........................................................................................................................10- 3510.5.15.1 Remove the Fixing/Feeder Unit Outlet Sensor................................................................................................................. 10- 3510.5.15.2 Remove the Fixing/Feeder Unit Outlet Sensor................................................................................................................. 10- 35

10.5.16 Delivery Speed Switch Clutch..........................................................................................................................10- 3510.5.16.1 Removing the Delivery Speed Switching Clutch .............................................................................................................. 10- 3510.5.16.2 Removing the Delivery Speed Switching Clutch .............................................................................................................. 10- 36

10.5.17 Upper Separation Claw....................................................................................................................................10- 3610.5.17.1 Removing the Upper Separation Claw ............................................................................................................................. 10- 36

10.5.18 Lower Separation Claw....................................................................................................................................10- 3710.5.18.1 Removing the Lower Separation Claw ............................................................................................................................. 10- 37

Chapter 11 External and Controls

11.1 Control Panel ..........................................................................................................................................11- 111.1.1 Outline .................................................................................................................................................................11- 111.1.2 Outline .................................................................................................................................................................11- 1

11.2 Counters .................................................................................................................................................11- 311.2.1 Soft Counters.......................................................................................................................................................11- 311.2.2 Soft Counters.......................................................................................................................................................11- 4

11.3 Fans........................................................................................................................................................11- 611.3.1 Changes Made to Externals/Auxiliary Controls(iR105)........................................................................................11- 611.3.2 Fans.....................................................................................................................................................................11- 711.3.3 Fans.....................................................................................................................................................................11- 911.3.4 Fans...................................................................................................................................................................11- 1011.3.5 Fans...................................................................................................................................................................11- 1111.3.6 Sequence of Fan Operation............................................................................................................................... 11- 1211.3.7 Sequence of Fan Operation............................................................................................................................... 11- 1311.3.8 Sequence of Fan Operation............................................................................................................................... 11- 14

11.4 Power Supply System...........................................................................................................................11- 1511.4.1 Power Supply.....................................................................................................................................................11- 15

11.4.1.1 Outline of the Power Supply............................................................................................................................................... 11- 1511.4.2 Protection Function............................................................................................................................................ 11- 15

11.4.2.1 Protective Functions........................................................................................................................................................... 11- 1511.4.3 Backup Battery ..................................................................................................................................................11- 16

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11.4.3.1 Backup Battery................................................................................................................................................................... 11- 1611.4.4 Energy-Saving Function.....................................................................................................................................11- 16

11.4.4.1 Outline................................................................................................................................................................................ 11- 1611.4.4.2 Outline................................................................................................................................................................................ 11- 1711.4.4.3 Outline................................................................................................................................................................................ 11- 1711.4.4.4 Outline................................................................................................................................................................................ 11- 1811.4.4.5 Power Supply Mode ........................................................................................................................................................... 11- 1811.4.4.6 Standby Mode (normal operation)...................................................................................................................................... 11- 1911.4.4.7 Power Save Mode.............................................................................................................................................................. 11- 1911.4.4.8 Low Power Mode ............................................................................................................................................................... 11- 1911.4.4.9 Sleep Mode ........................................................................................................................................................................ 11- 1911.4.4.10 OFF Mode(iR105) ............................................................................................................................................................ 11- 1911.4.4.11 Power Supply OFF Mode ................................................................................................................................................. 11- 20

11.5 Parts Replacement Procedure ............................................................................................................. 11- 2111.5.1 Left Pickup Drive Assembly ...............................................................................................................................11- 21

11.5.1.1 Removing the Left Pickup Drive Assembly ........................................................................................................................ 11- 2111.5.2 Pickup Drive Assembly ......................................................................................................................................11- 21

11.5.2.1 Removing the Pickup Drive Assembly ............................................................................................................................... 11- 2111.5.3 Developing Drive Assembly ...............................................................................................................................11- 21

11.5.3.1 Removing the Developing Drive Assembly ........................................................................................................................ 11- 2111.5.4 Vertical Path Drive Assembly.............................................................................................................................11- 22

11.5.4.1 Removing the Vertical Path Drive Assembly...................................................................................................................... 11- 2211.5.5 Waste Toner Drive Assembly.............................................................................................................................11- 23

11.5.5.1 Removing the Waste Toner Drive Assembly ..................................................................................................................... 11- 2311.5.6 Multifeeder Pickup Drive Assembly....................................................................................................................11- 23

11.5.6.1 Removing the Multifeeder Pickup Drive Assembly ............................................................................................................ 11- 2311.5.7 Lifter Drive Assembly .........................................................................................................................................11- 23

11.5.7.1 Removing the Lifter Drive Assembly (right deck) ............................................................................................................... 11- 2311.5.7.2 Removing the Lifter Drive Assembly (left deck) ................................................................................................................. 11- 24

11.5.8 Main Drive Assembly .........................................................................................................................................11- 2411.5.8.1 Removing the Main Drive Assembly .................................................................................................................................. 11- 24

11.5.9 Drum Drive Assembly ........................................................................................................................................11- 2511.5.9.1 Removing the Drum Drive Assembly ................................................................................................................................. 11- 2511.5.9.2 Removing the Drive Assembly ........................................................................................................................................... 11- 26

11.5.10 Cassette Pickup Drive Assembly .....................................................................................................................11- 2711.5.10.1 Removing the Cassette Pickup Drive Assembly .............................................................................................................. 11- 2711.5.10.2 Removing the Cassette Pickup Drive Assembly .............................................................................................................. 11- 27

11.5.11 Toner Cartridge Drive Assembly ......................................................................................................................11- 2711.5.11.1 Removing the Toner Cartridge Drive Assembly ............................................................................................................... 11- 27

11.5.12 Power Supply Unit............................................................................................................................................11- 2811.5.12.1 Removing the Power Supply Unit..................................................................................................................................... 11- 2811.5.12.2 Removing the Power Supply Unit..................................................................................................................................... 11- 28

11.5.13 Control Panel....................................................................................................................................................11- 2911.5.13.1 Removing the Control Panel Unit ..................................................................................................................................... 11- 2911.5.13.2 Removing the Control Panel Unit ..................................................................................................................................... 11- 3011.5.13.3 Removing the Control Panel Unit ..................................................................................................................................... 11- 3111.5.13.4 Removing the Control Panel Unit ..................................................................................................................................... 11- 31

11.5.14 Control Panel Support Unit...............................................................................................................................11- 3311.5.14.1 Removing the Control Panel Support Unit ....................................................................................................................... 11- 33

11.5.15 Cover Switch Assembly....................................................................................................................................11- 3311.5.15.1 Removing the Front Cover Switch Assembly ................................................................................................................... 11- 3311.5.15.2 Removing the Front Cover Switch Assembly ................................................................................................................... 11- 34

11.5.16 Manual Feed Tray Switch Assembly ................................................................................................................11- 3411.5.16.1 Removing the Manual Feed Tray Switch Assembly......................................................................................................... 11- 3411.5.16.2 Removing the Manual Feed Tray Switch Assembly......................................................................................................... 11- 34

11.5.17 Drum Heater Switch Assembly.........................................................................................................................11- 3511.5.17.1 Removing the Drum Heater Switch Assembly ................................................................................................................. 11- 3511.5.17.2 Removing the Drum Heater Switch Assembly ................................................................................................................. 11- 35

11.5.18 DC Controller PCB ...........................................................................................................................................11- 3511.5.18.1 Removing the DC Controller PCB .................................................................................................................................... 11- 35

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11.5.18.2 Removing the DC Controller PCB .................................................................................................................................... 11- 3611.5.18.3 When Replacing the DC Controller PCB.......................................................................................................................... 11- 3611.5.18.4 When Replacing the DC Controller PCB.......................................................................................................................... 11- 36

11.5.19 Control Panel Controller PCB ..........................................................................................................................11- 3611.5.19.1 Removing the Control Panel Controller (CPU) PCB ........................................................................................................ 11- 3611.5.19.2 Removing the Control Panel Controller (CPU) PCB ........................................................................................................ 11- 37

11.5.20 Control Panel Inverter PCB..............................................................................................................................11- 3711.5.20.1 Removing the Control Panel Inverter PCB....................................................................................................................... 11- 3711.5.20.2 Removing the Control Panel Inverter ............................................................................................................................... 11- 37

11.5.21 Control Panel PCB...........................................................................................................................................11- 3711.5.21.1 Removing the Control Panel PCB .................................................................................................................................... 11- 3711.5.21.2 Removing the Control Panel PCB .................................................................................................................................... 11- 3811.5.21.3 Removing the Control Panel PCB .................................................................................................................................... 11- 38

11.5.22 AC Driver PCB .................................................................................................................................................11- 3811.5.22.1 Removing the AC Driver PCB .......................................................................................................................................... 11- 3811.5.22.2 Removing the AC Driver PCB .......................................................................................................................................... 11- 39

11.5.23 All Night Power Supply PCB ............................................................................................................................11- 3911.5.23.1 Removing the All Night Power Supply PCB ..................................................................................................................... 11- 3911.5.23.2 Removing the All Night Power Supply PCB ..................................................................................................................... 11- 39

11.5.24 Relay PCB .......................................................................................................................................................11- 4011.5.24.1 Removing the Relay PCB................................................................................................................................................. 11- 4011.5.24.2 Removing the Relay PCB................................................................................................................................................. 11- 40

11.5.25 High-Voltage Transformer (AC) .......................................................................................................................11- 4011.5.25.1 Removing the High-Voltage Transformer Assembly (AC)................................................................................................ 11- 4011.5.25.2 Removing the High-Voltage Transformer Assembly (AC)................................................................................................ 11- 40

11.5.26 HV-AC PCB .....................................................................................................................................................11- 4111.5.26.1 Removing the HV-AC PCB............................................................................................................................................... 11- 4111.5.26.2 Removing the HV-AC PCB............................................................................................................................................... 11- 41

11.5.27 HV-DC PCB .....................................................................................................................................................11- 4111.5.27.1 Removing the HV-DC PCB .............................................................................................................................................. 11- 4111.5.27.2 Removing the HV-DC PCB .............................................................................................................................................. 11- 4111.5.27.3 When Replacing the HV-DC PCB .................................................................................................................................... 11- 4211.5.27.4 When Replacing the HV-DC PCB .................................................................................................................................... 11- 42

11.5.28 Fixing Heat Discharge Fan ..............................................................................................................................11- 4211.5.28.1 Removing the Fixing Heat Discharge Fan (FM2) ............................................................................................................. 11- 42

11.5.29 Scanner Cooling Fan .......................................................................................................................................11- 4211.5.29.1 Removing the Scanner Motor Cooling Fan (FM18).......................................................................................................... 11- 42

11.5.30 Stream Reading Fan........................................................................................................................................11- 4311.5.30.1 Removing the Stream Reading Fan (FM4) ...................................................................................................................... 11- 43

11.5.31 Laser Cooling Fan............................................................................................................................................ 11- 4311.5.31.1 Removing the Laser Motor Cooling Fan (FM1) ................................................................................................................ 11- 4311.5.31.2 Removing the Laser Cooling Fan 2 (FM5) ....................................................................................................................... 11- 4311.5.31.3 Removing the Laser Cooling Fan 1 (FM3) ....................................................................................................................... 11- 4411.5.31.4 Removing the Laser Cooling Fan 2 (FM5) ....................................................................................................................... 11- 44

11.5.32 De-Curling Fan.................................................................................................................................................11- 4411.5.32.1 Removing the Curl-Reducing Fan (FM6) ......................................................................................................................... 11- 4411.5.32.2 Removing the Curl-Reducing Fan (FM6) ......................................................................................................................... 11- 45

11.5.33 Drum Fan .........................................................................................................................................................11- 4511.5.33.1 Removing the Drum Fan (FM8)........................................................................................................................................ 11- 45

11.5.34 Inverter Cooling Fan ........................................................................................................................................11- 4611.5.34.1 Removing the Inverter Cooling Fan (FM9) ....................................................................................................................... 11- 46

11.5.35 Pre-Transfer Charging Assembly Fan .............................................................................................................11- 4611.5.35.1 Removing the Pre-Transfer Charging Assembly Fan (FM10) .......................................................................................... 11- 46

11.5.36 Power Supply Cooling Fan 1 ...........................................................................................................................11- 4711.5.36.1 Removing the Power Supply Cooling Fan 1 (FM11) ........................................................................................................ 11- 4711.5.36.2 Removing the Power Supply Cooling Fan 1 (FM11) ........................................................................................................ 11- 47

11.5.37 Power Supply Cooling Fan 2 ...........................................................................................................................11- 4811.5.37.1 Removing the Power Supply Cooling Fan 2 (FM12) ........................................................................................................ 11- 4811.5.37.2 Removing the Power Supply Cooling Fan 2 (FM12) ........................................................................................................ 11- 48

11.5.38 Separation Fan ................................................................................................................................................11- 48

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11.5.38.1 Removing the Separation Fan (FM13) ............................................................................................................................. 11- 4811.5.38.2 Removing the Separation Fan (FM13) ............................................................................................................................. 11- 49

11.5.39 Developing Fan ................................................................................................................................................11- 4911.5.39.1 Removing the Developing Fan (FM15) ............................................................................................................................ 11- 4911.5.39.2 Removing the Developing Fan (FM15) ............................................................................................................................ 11- 50

11.5.40 Delivery Anti-Adhesion Fan..............................................................................................................................11- 5011.5.40.1 Removing the Delivery Anti-Adhesion Fan (FM17) .......................................................................................................... 11- 5011.5.40.2 Removing the Delivery Anti-Adhesion Fan (FM17) .......................................................................................................... 11- 50

11.5.41 Duplex Feed Fan..............................................................................................................................................11- 5111.5.41.1 Removing the Duplex Feed Fan (FM19) .......................................................................................................................... 11- 51

11.5.42 Separation Heat Discharge Fan .......................................................................................................................11- 5111.5.42.1 Removing the Separation Heat Discharge Fan (FM20) ................................................................................................... 11- 51

11.5.43 LCD Panel ........................................................................................................................................................11- 5111.5.43.1 Removing the LCD Panel................................................................................................................................................. 11- 5111.5.43.2 Removing the LCD Panel................................................................................................................................................. 11- 5111.5.43.3 Removing the LCD Panel................................................................................................................................................. 11- 52

Chapter 12 MEAP

12.1 MEAP ..................................................................................................................................................... 12- 112.1.1 Overview ..............................................................................................................................................................12- 112.1.2 MEAP Counter .....................................................................................................................................................12- 112.1.3 Construction of the MEAP Platform .....................................................................................................................12- 1

Chapter 13 Maintenance and Inspection

13.1 Periodically Replaced Parts.................................................................................................................... 13- 113.1.1 Overview ..............................................................................................................................................................13- 113.1.2 Overview ..............................................................................................................................................................13- 113.1.3 Main Body ............................................................................................................................................................13- 113.1.4 Main body.............................................................................................................................................................13- 213.1.5 Main body.............................................................................................................................................................13- 3

13.2 Durables and Consumables ................................................................................................................... 13- 613.2.1 Overview ..............................................................................................................................................................13- 613.2.2 Overview ..............................................................................................................................................................13- 613.2.3 Main Body ............................................................................................................................................................13- 613.2.4 Main body.............................................................................................................................................................13- 813.2.5 Main body...........................................................................................................................................................13- 1113.2.6 Main body...........................................................................................................................................................13- 1313.2.7 Side Paper Deck ................................................................................................................................................13- 1613.2.8 Side Paper Deck ................................................................................................................................................13- 17

13.3 Scheduled Servicing Basic Procedure ................................................................................................. 13- 1913.3.1 Scheduled Service Chart ...................................................................................................................................13- 1913.3.2 Scheduled Service Chart ...................................................................................................................................13- 2013.3.3 Scheduled Service Chart ...................................................................................................................................13- 2313.3.4 Scheduled Service Chart ...................................................................................................................................13- 2513.3.5 Scheduled Service Items ...................................................................................................................................13- 2813.3.6 Scheduled Service Items ...................................................................................................................................13- 3013.3.7 Scheduled Service Items ...................................................................................................................................13- 3213.3.8 Scheduled Service Items ...................................................................................................................................13- 3413.3.9 Scheduled Service Work....................................................................................................................................13- 3613.3.10 Scheduled Maintenance Work Procedure........................................................................................................13- 4113.3.11 Scheduled Maintenance Work Procedure........................................................................................................13- 4513.3.12 Points to Note for Scheduled Servicing Work ..................................................................................................13- 4913.3.13 Point to Note on Scheduled Servicing..............................................................................................................13- 5113.3.14 Point to Note on Scheduled Servicing..............................................................................................................13- 53

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Chapter 14 Standards and Adjustments

14.1 Image Adjustment Basic Procedure........................................................................................................14- 114.1.1 Making Pre-Checks .............................................................................................................................................14- 114.1.2 Making Pre-Checks .............................................................................................................................................14- 114.1.3 Making Checks on the Printer Side (Checking the Images) ................................................................................14- 214.1.4 Making Checks on the Printer Side (Checking the Density Slope)......................................................................14- 214.1.5 Making Checks on the Printer Side (Checking the Solid Black Density) .............................................................14- 314.1.6 Making Checks on the Printer Side (Checking for fogging) .................................................................................14- 414.1.7 Making Checks on the Printer Side (Checking Halftone Density)........................................................................14- 514.1.8 Making Checks on the Scanner Side (Initial Checks)..........................................................................................14- 614.1.9 Making Checks on the Scanner Side (Checking the Density Slope) ...................................................................14- 614.1.10 Making Checks on the Scanner Side (Checking the Density Slope) .................................................................14- 714.1.11 Making Checks on the Scanner Side (Checking for fogging) ............................................................................14- 714.1.12 Making Checks on the Scanner Side(Checking Halftone Density) ....................................................................14- 814.1.13 Making Checks on the Scanner Side(Initial Checks) .........................................................................................14- 914.1.14 Making Checks on the Scanner Side(Checking the Density Slope) ..................................................................14- 914.1.15 Making Checks on the Scanner Side(Checking the Solid Black).......................................................................14- 914.1.16 Making Checks on the Scanner Side(Checking for fogging) ...........................................................................14- 1014.1.17 Making Checks on the Scanner Side(Checking Halftone Density) ..................................................................14- 1114.1.18 Potential Control System Conversion Table ....................................................................................................14- 12

14.2 Image Adjustments ...............................................................................................................................14- 1514.2.1 Overview............................................................................................................................................................14- 1514.2.2 Outline ...............................................................................................................................................................14- 1514.2.3 Conversion Table for the Potential Control System...........................................................................................14- 1514.2.4 Adjusting the Image Position for Printer Output.................................................................................................14- 1814.2.5 Adjusting the Image Position for Printer Output.................................................................................................14- 1914.2.6 Adjusting the Image Position of Copier Output (book mode).............................................................................14- 2114.2.7 Adjusting the Image Position for Copier Output (book mode) ...........................................................................14- 2214.2.8 Adjusting the Image Position of Copier Output (ADF mode) .............................................................................14- 2314.2.9 Adjusting the Image Position for Copier Output (ADF mode) ............................................................................14- 23

14.3 Scanning System..................................................................................................................................14- 2514.3.1 When Replacing the CCD Unit ..........................................................................................................................14- 2514.3.2 Points to Note when Replacing the CCD Unit ................................................................................................... 14- 2514.3.3 Points to Note when Replacing the CCD Unit ................................................................................................... 14- 2514.3.4 When Replacing the Standard White Plate .......................................................................................................14- 2614.3.5 When Replacing the Standard White Plate .......................................................................................................14- 2614.3.6 When Replacing the Scanning Lamp ................................................................................................................14- 2614.3.7 When Replacing the Scanning Lamp ................................................................................................................14- 2614.3.8 After Replacing the Scanning Lamp ..................................................................................................................14- 2614.3.9 Points to Note When Replacing the reader controller PCB ...............................................................................14- 2714.3.10 When Replacing the Reader Controller PCB................................................................................................... 14- 2714.3.11 When Replacing the Reder controller PCB......................................................................................................14- 27

14.4 Laser Exposure System........................................................................................................................14- 2814.4.1 Points to Note When Replacing the Laser Unit .................................................................................................14- 2814.4.2 When Replacing the Laser Unit .........................................................................................................................14- 2814.4.3 Checking the Laser Power.................................................................................................................................14- 2814.4.4 Checking the Laser Power.................................................................................................................................14- 2914.4.5 Checking the Laser Power.................................................................................................................................14- 29

14.5 Image Formation System......................................................................................................................14- 3114.5.1 Adjusting the Height of the Charging Wire.........................................................................................................14- 31

14.6 Fixing System .......................................................................................................................................14- 3214.6.1 Adjusting the Lower Roller Pressure (nip) .........................................................................................................14- 3214.6.2 Adjusting the Lower Roller Pressure (nip) .........................................................................................................14- 32

14.7 Electrical Components ..........................................................................................................................14- 3314.7.1 Electrical Parts Requiring Work After Replacement ..........................................................................................14- 33

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Contents

14.7.2 Electrical Components Requiring Work After Replacement...............................................................................14- 3314.7.3 Electrical Parts Requiring Work After Replacement...........................................................................................14- 3314.7.4 When Replacing the HDD..................................................................................................................................14- 3314.7.5 When Replacing the Main Controller PCB.........................................................................................................14- 3314.7.6 Replacing the Main Controller PCB ...................................................................................................................14- 3414.7.7 When Replacing the Main Controller PCB.........................................................................................................14- 3414.7.8 When Replacing the HV-DC PCB......................................................................................................................14- 3414.7.9 When Replacing the DC Controller PCB............................................................................................................14- 3514.7.10 When Replacing the DC Controller PCB..........................................................................................................14- 3514.7.11 Replacing the Potential Sensor/Potential Control PCB....................................................................................14- 3514.7.12 When Replacing the HV-DC PCB ....................................................................................................................14- 3614.7.13 Checking the Surface Potential Control System ..............................................................................................14- 3714.7.14 When Replacing the Potential Sensor/Potential Control PCB..........................................................................14- 3814.7.15 Replacing the Potential Sensor/Potential Control PCB....................................................................................14- 3914.7.16 Checking the Surface Potential Control System ..............................................................................................14- 4014.7.17 Checking the Surface Potential Control System ..............................................................................................14- 4214.7.18 Checking the Environment Sensor...................................................................................................................14- 4314.7.19 Checking the Environment Sensor...................................................................................................................14- 4314.7.20 Checking the Photointerrupters........................................................................................................................14- 4314.7.21 Checking the Photointerrupters........................................................................................................................14- 4614.7.22 Checking the Photointerrupters........................................................................................................................14- 5014.7.23 Checking the Optical Sensors ..........................................................................................................................14- 5314.7.24 Checking the Photointerrupters........................................................................................................................14- 54

14.8 Pickup/Feeding System........................................................................................................................ 14- 5814.8.1 Orientation of the Deck/Cassette Pickup Roller .................................................................................................14- 5814.8.2 Orientation of the Deck/Cassette Pickup Roller .................................................................................................14- 5814.8.3 Orientation of the Deck/Cassette Separation Roller ..........................................................................................14- 5814.8.4 Orientation of the Deck/Cassette Separation Roller ..........................................................................................14- 5814.8.5 Orientation of the Feeding Roller of the Deck/Cassette Pickup Assembly ........................................................14- 5814.8.6 Orientation of the Feeding Roller of the Deck/Cassette Pickup Assembly ........................................................14- 5914.8.7 Orientation of the Pickup Roller of the Manual Feed Tray/Side Paper ..............................................................14- 5914.8.8 Orientation of the Pickup Roller of the Manual Feed Tray/Side Paper Deck .....................................................14- 5914.8.9 Orientation of the Feeding Roller of the Manual Feed Tray ...............................................................................14- 5914.8.10 Orientation for the Feeding Roller of the Manual Feed Tray ............................................................................14- 6014.8.11 Orientation of the Feeding Roller of the Side Paper Deck ...............................................................................14- 6014.8.12 Orientation of the Feeding Roller of the Side Paper Deck ...............................................................................14- 6014.8.13 Adjusting the Pressure of the Deck/Cassette Separation Roller ......................................................................14- 6014.8.14 Adjusting the Pressure of the Separation Roller of the Deck/Cassette ............................................................14- 6114.8.15 Adjusting the Pressure of the Pickup/Feeding Roller of the Manual ................................................................14- 6114.8.16 Adjusting the Pressure of the Pickup/Feeding Roller of the Manual Feed Tray...............................................14- 6114.8.17 Locations of the Solenoid .................................................................................................................................14- 6114.8.18 Position of the Solenoids..................................................................................................................................14- 6214.8.19 Location of the Fixing Web Solenoid (SL2) ......................................................................................................14- 6414.8.20 Position of the Fixing Web Solenoid (SL2).......................................................................................................14- 6414.8.21 Position of the Delivery Flapper Solenoid (SL3)...............................................................................................14- 6414.8.22 Position of the Delivery Flapper Solenoid (SL3)...............................................................................................14- 6414.8.23 Position the Fixing/Feeder Unit Locking Solenoid (SL4) ..................................................................................14- 6514.8.24 Position of the Fixing Feeding Unit Locking Solenoid (SL4) ............................................................................14- 6514.8.25 Position of the Multifeeder Latch Solenoid (SL6) .............................................................................................14- 6514.8.26 Adjusting the Position for the Multifeeder Pickup Latch Solenoid (SL6) ..........................................................14- 6514.8.27 Position of the Deck (right) Pickup Solenoid (SL7) ..........................................................................................14- 6514.8.28 Position of the Deck (right) Pickup Solenoid (SL7) ..........................................................................................14- 6614.8.29 Position of the Deck (Left) Pickup Solenoid (SL8) ...........................................................................................14- 6614.8.30 Position of the Deck (left) Pickup Solenoid (SL8).............................................................................................14- 6614.8.31 Position of the Cassette 3/4 Pickup Solenoid (SL9/10)....................................................................................14- 6614.8.32 Position for the Cassette 3/4 Pickup Solenoid (SL9/10)...................................................................................14- 67

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Contents

14.8.33 Position of the Side Paper Deck Pickup Roller Releasing Solenoid ................................................................14- 6714.8.34 Position of the Side Paper Deck Pickup Roller Releasing Solenoid ................................................................14- 6714.8.35 Fitting the Side Guide Timing Belt of the Manual Feed Tray Assembly...........................................................14- 6714.8.36 Attaching the Timing Belt for the Manual Feed Tray Assembly Side Guide ....................................................14- 6714.8.37 Fitting the Drive Belt.........................................................................................................................................14- 6814.8.38 Attaching the Drive Belts..................................................................................................................................14- 68

Chapter 15 Correcting Faulty Images

15.1 Making lnitial Checks ..............................................................................................................................15- 115.1.1 Checking the Side of Installation .........................................................................................................................15- 115.1.2 Checking the Originals.........................................................................................................................................15- 115.1.3 Checking the Copyboard Cover, Copyboard Glass, and Standard White Plate..................................................15- 115.1.4 Checking the Charging Assemblies.....................................................................................................................15- 115.1.5 Checking the Developing Assembly ....................................................................................................................15- 115.1.6 Checking the Developing Assembly ....................................................................................................................15- 115.1.7 Checking the Paper .............................................................................................................................................15- 215.1.8 Checking the Periodically Replaced Parts...........................................................................................................15- 215.1.9 Others ..................................................................................................................................................................15- 215.1.10 Others ................................................................................................................................................................15- 2

15.2 Troubleshooting ......................................................................................................................................15- 315.2.1 Countermeasures ................................................................................................................................................15- 3

15.2.1.1 Lead edge voids of paper due to retransferring iR105....................................................................................................... 15- 315.2.1.2 Black lines: when using ADF................................................................................................................................................ 15- 315.2.1.3 E220-0001: the inverter PCB is not properly grounded Error Code..................................................................................... 15- 315.2.1.4 E712-0001/E712-0002 Error Code ...................................................................................................................................... 15- 315.2.1.5 E743-0000 Error Code ......................................................................................................................................................... 15- 4

15.2.2 Image Faults ........................................................................................................................................................15- 415.2.2.1 Foggy Image ........................................................................................................................................................................ 15- 415.2.2.2 Out of Focus......................................................................................................................................................................... 15- 415.2.2.3 Smudged/Streaked .............................................................................................................................................................. 15- 4

15.2.3 Malfunction ..........................................................................................................................................................15- 615.2.3.1 No Power ............................................................................................................................................................................. 15- 615.2.3.2 Malfunction/Faulty Detection................................................................................................................................................ 15- 615.2.3.3 User Warning Message........................................................................................................................................................ 15- 815.2.3.4 Other Defect......................................................................................................................................................................... 15- 9

15.2.4 Printing/scanning ................................................................................................................................................. 15- 915.2.4.1 No Output............................................................................................................................................................................. 15- 9

15.2.5 Jam (Main Unit) .................................................................................................................................................15- 1015.2.5.1 JAM CODE 010C, 020A: External delivery sensor arm being shaved............................................................................... 15- 1015.2.5.2 JAM CODE 010C: Malfunction of solenoid arm actuating delivery reversal flapper .......................................................... 15- 10

15.2.6 Jam (FIN)...........................................................................................................................................................15- 1215.2.6.1 JAM CODE 1123 Paper Folding Unit-C1 ........................................................................................................................... 15- 1215.2.6.2 JAM CODE 1129/E577 Error Code: FIN-K1/K2/K3/K4/K1N/K2/K3N................................................................................. 15- 13

15.2.7 Error Code .........................................................................................................................................................15- 1315.2.7.1 E065: due to faulty HV-DC transformer PCB Error Code ................................................................................................. 15- 1315.2.7.2 E240 Error Code, Control panel locking up, power suddenly being shut down ................................................................. 15- 1415.2.7.3 E245/E246/E247 Error Code ............................................................................................................................................. 15- 1415.2.7.4 E350 Error Code ................................................................................................................................................................ 15- 1415.2.7.5 E354 Error Code ................................................................................................................................................................ 15- 1415.2.7.6 E355 Error Code ................................................................................................................................................................ 15- 1515.2.7.7 E402 DADF-J1: ADF belt motor does not rotate Error Code ............................................................................................ 15- 1515.2.7.8 E532 Finisher-K1/K2/K3/K4N Error Code ......................................................................................................................... 15- 15

15.2.8 Specifications-related FAQ ................................................................................................................................15- 1515.2.8.1 FAQ on Main Unit Specifications ....................................................................................................................................... 15- 1515.2.8.2 FAQ on Send Specifications .............................................................................................................................................. 15- 18

15.3 Outline of Electrical Components..........................................................................................................15- 1915.3.1 Clutch/Solenoid..................................................................................................................................................15- 19

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Contents

15.3.1.1 Clutches ............................................................................................................................................................................. 15- 1915.3.1.2 Clutches ............................................................................................................................................................................. 15- 2015.3.1.3 Clutches ............................................................................................................................................................................. 15- 2015.3.1.4 Solenoids ........................................................................................................................................................................... 15- 2115.3.1.5 Solenoids ........................................................................................................................................................................... 15- 2215.3.1.6 Solenoids ........................................................................................................................................................................... 15- 23

15.3.2 Motor ..................................................................................................................................................................15- 2415.3.2.1 Motors ................................................................................................................................................................................ 15- 2415.3.2.2 Motors ................................................................................................................................................................................ 15- 2515.3.2.3 Motors ................................................................................................................................................................................ 15- 2615.3.2.4 Motors ................................................................................................................................................................................ 15- 27

15.3.3 Fan.....................................................................................................................................................................15- 2815.3.3.1 Fans ................................................................................................................................................................................... 15- 2815.3.3.2 Fans ................................................................................................................................................................................... 15- 2915.3.3.3 Fans ................................................................................................................................................................................... 15- 3015.3.3.4 Fans ................................................................................................................................................................................... 15- 31

15.3.4 Sensor................................................................................................................................................................15- 3215.3.4.1 Sensor 1............................................................................................................................................................................. 15- 3215.3.4.2 Sensor 1............................................................................................................................................................................. 15- 3415.3.4.3 Sensor 1............................................................................................................................................................................. 15- 3615.3.4.4 Sensor 1............................................................................................................................................................................. 15- 3815.3.4.5 Sensor 2............................................................................................................................................................................. 15- 4015.3.4.6 Sensor 2............................................................................................................................................................................. 15- 4115.3.4.7 Sensor 2............................................................................................................................................................................. 15- 4215.3.4.8 Sensor 2............................................................................................................................................................................. 15- 43

15.3.5 Switch.................................................................................................................................................................15- 4415.3.5.1 Switches............................................................................................................................................................................. 15- 4415.3.5.2 Switches............................................................................................................................................................................. 15- 4515.3.5.3 Switches............................................................................................................................................................................. 15- 46

15.3.6 Lamps, Heaters, and Others ..............................................................................................................................15- 4715.3.6.1 Lamp, Heater, and Others.................................................................................................................................................. 15- 4715.3.6.2 Lamp, Heater, and Others.................................................................................................................................................. 15- 4815.3.6.3 Lamp, Heater, and Others.................................................................................................................................................. 15- 4915.3.6.4 Lamp, Heater, and Others.................................................................................................................................................. 15- 50

15.3.7 PCBs..................................................................................................................................................................15- 5115.3.7.1 PCBs .................................................................................................................................................................................. 15- 5115.3.7.2 PCBs .................................................................................................................................................................................. 15- 5315.3.7.3 PCBs .................................................................................................................................................................................. 15- 5415.3.7.4 PCBs .................................................................................................................................................................................. 15- 56

15.3.8 Plane Pedistal ....................................................................................................................................................15- 5715.3.8.1 Side Paper Deck-N1 .......................................................................................................................................................... 15- 57

15.3.9 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB...............................................15- 5815.3.9.1 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB............................................................... 15- 5815.3.9.2 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB............................................................... 15- 5915.3.9.3 Main Controller PCB .......................................................................................................................................................... 15- 5915.3.9.4 Main Controller PCB .......................................................................................................................................................... 15- 5915.3.9.5 Reader Controller PCB ...................................................................................................................................................... 15- 6015.3.9.6 Reader Controller PCB ...................................................................................................................................................... 15- 6015.3.9.7 Reader Controller PCB ...................................................................................................................................................... 15- 6115.3.9.8 DC controller PCB.............................................................................................................................................................. 15- 6115.3.9.9 DC controller PCB.............................................................................................................................................................. 15- 6215.3.9.10 HV-DC PCB...................................................................................................................................................................... 15- 6215.3.9.11 HV-DC PCB...................................................................................................................................................................... 15- 62

Chapter 16 Self Diagnosis

16.1 Error Code Table .................................................................................................................................... 16- 116.1.1 Outline..................................................................................................................................................................16- 116.1.2 Outline..................................................................................................................................................................16- 116.1.3 Error Code List .....................................................................................................................................................16- 1

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Contents

16.1.4 Error Code List.....................................................................................................................................................16- 316.1.5 Error Code List.....................................................................................................................................................16- 4

16.2 Error Code Details ..................................................................................................................................16- 616.2.1 Error Code Detail ................................................................................................................................................. 16- 616.2.2 Error Code Detail ............................................................................................................................................... 16- 1516.2.3 Error Code Detail ............................................................................................................................................... 16- 2416.2.4 E602 in Detaill....................................................................................................................................................16- 31

16.3 Jam Code .............................................................................................................................................16- 3716.3.1 Jam Code (Main Body-related)..........................................................................................................................16- 3716.3.2 Jam Code (Main Body-related)..........................................................................................................................16- 3716.3.3 Jam Code (Finisher-related) ..............................................................................................................................16- 3816.3.4 Jam Code (ADF-related)....................................................................................................................................16- 3916.3.5 Jam Code (ADF-related)....................................................................................................................................16- 41

16.4 Alarm Code...........................................................................................................................................16- 4216.4.1 Alarm Code........................................................................................................................................................16- 4216.4.2 Alarm Code........................................................................................................................................................16- 4316.4.3 Alarm Code........................................................................................................................................................16- 43

Chapter 17 Service Mode

17.1 Outline ....................................................................................................................................................17- 117.1.1 Construction of Service Mode(iR105)..................................................................................................................17- 117.1.2 Service mode screen configuration .....................................................................................................................17- 117.1.3 Service mode screen configuration .....................................................................................................................17- 217.1.4 Starting Service Mode and Making Selections(iR105) ........................................................................................17- 317.1.5 Entering or selecting service modes....................................................................................................................17- 417.1.6 Entering or selecting service modes....................................................................................................................17- 417.1.7 Ending Service Mode(iR105)...............................................................................................................................17- 517.1.8 Exiting service modes..........................................................................................................................................17- 517.1.9 Backing Up Service Mode ...................................................................................................................................17- 517.1.10 Backing Up Service Mode..................................................................................................................................17- 617.1.11 Initial Screen(iR105) ..........................................................................................................................................17- 617.1.12 Initial screen.......................................................................................................................................................17- 717.1.13 Initial screen.......................................................................................................................................................17- 717.1.14 Level 1/2 Screen(iR105) ....................................................................................................................................17- 817.1.15 Main/intermediate item screen...........................................................................................................................17- 817.1.16 Level 3 Screen(iR105) .......................................................................................................................................17- 917.1.17 Sub-item screen............................................................................................................................................... 17- 10

17.2 DISPLAY (Status Display Mode) ..........................................................................................................17- 1217.2.1 COPIER ............................................................................................................................................................. 17- 12

17.2.1.1 Copier List .......................................................................................................................................................................... 17- 1217.2.1.2 Copier List .......................................................................................................................................................................... 17- 1617.2.1.3 Copier List .......................................................................................................................................................................... 17- 2117.2.1.4 Copier List .......................................................................................................................................................................... 17- 24

17.2.2 FEEDER ............................................................................................................................................................17- 2917.2.2.1 Feeder List ......................................................................................................................................................................... 17- 2917.2.2.2 Feeder List ......................................................................................................................................................................... 17- 2917.2.2.3 Feeder List ......................................................................................................................................................................... 17- 29

17.3 I/O (I/O Display Mode) ..........................................................................................................................17- 3017.3.1 Overview............................................................................................................................................................17- 3017.3.2 Overview............................................................................................................................................................17- 3017.3.3 DC-CON ............................................................................................................................................................17- 3117.3.4 DC-CON ............................................................................................................................................................17- 3717.3.5 R-CON ...............................................................................................................................................................17- 4317.3.6 R-CON ...............................................................................................................................................................17- 4417.3.7 FEEDER ............................................................................................................................................................17- 46

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Contents

17.3.8 FEEDER.............................................................................................................................................................17- 4917.3.9 SORTER ............................................................................................................................................................17- 5117.3.10 MN-CON(iR105)...............................................................................................................................................17- 58

17.4 ADJUST (Adjustment Mode) ................................................................................................................ 17- 6017.4.1 COPIER .............................................................................................................................................................17- 60

17.4.1.1 Copier List .......................................................................................................................................................................... 17- 6017.4.1.2 Copier List .......................................................................................................................................................................... 17- 6817.4.1.3 Copier List .......................................................................................................................................................................... 17- 7517.4.1.4 Copier List .......................................................................................................................................................................... 17- 80

17.4.2 FEEDER.............................................................................................................................................................17- 8917.4.2.1 Feeder List ......................................................................................................................................................................... 17- 8917.4.2.2 Feeder List ......................................................................................................................................................................... 17- 9017.4.2.3 Feeder List ......................................................................................................................................................................... 17- 91

17.4.3 SORTER ............................................................................................................................................................17- 9217.4.3.1 Sorter List........................................................................................................................................................................... 17- 9217.4.3.2 Sorter List........................................................................................................................................................................... 17- 9217.4.3.3 Sorter List........................................................................................................................................................................... 17- 9317.4.3.4 Sorter List........................................................................................................................................................................... 17- 93

17.5 FUNCTION (Operation/Inspection Mode)............................................................................................. 17- 9517.5.1 COPIER .............................................................................................................................................................17- 95

17.5.1.1 Copier List .......................................................................................................................................................................... 17- 9517.5.1.2 Copier List ........................................................................................................................................................................ 17- 10317.5.1.3 Copier List ........................................................................................................................................................................ 17- 11217.5.1.4 Copier List ........................................................................................................................................................................ 17- 118

17.5.2 FEEDER...........................................................................................................................................................17- 12617.5.2.1 Feeder List ....................................................................................................................................................................... 17- 12617.5.2.2 Feeder List ....................................................................................................................................................................... 17- 12717.5.2.3 Feeder List ....................................................................................................................................................................... 17- 127

17.6 OPTION (Machine Settings Mode) ..................................................................................................... 17- 12817.6.1 COPIER ...........................................................................................................................................................17- 128

17.6.1.1 Copier List ........................................................................................................................................................................ 17- 12817.6.1.2 Copier List ........................................................................................................................................................................ 17- 14717.6.1.3 Copier List ........................................................................................................................................................................ 17- 16717.6.1.4 Copier List ........................................................................................................................................................................ 17- 184

17.6.2 FEEDER...........................................................................................................................................................17- 20417.6.2.1 Feeder List ....................................................................................................................................................................... 17- 20417.6.2.2 Feeder List ....................................................................................................................................................................... 17- 20417.6.2.3 Feeder List ....................................................................................................................................................................... 17- 204

17.6.3 SORTER ..........................................................................................................................................................17- 20517.6.3.1 Sorter List......................................................................................................................................................................... 17- 20517.6.3.2 Sorter List......................................................................................................................................................................... 17- 20517.6.3.3 Sorter List......................................................................................................................................................................... 17- 20617.6.3.4 Sorter List......................................................................................................................................................................... 17- 207

17.6.4 BOARD ............................................................................................................................................................17- 20717.6.4.1 Board List ......................................................................................................................................................................... 17- 20717.6.4.2 Board List ......................................................................................................................................................................... 17- 20817.6.4.3 Board List ......................................................................................................................................................................... 17- 20817.6.4.4 Board List ......................................................................................................................................................................... 17- 208

17.7 TEST (Test Print Mode)...................................................................................................................... 17- 20917.7.1 COPIER ...........................................................................................................................................................17- 209

17.7.1.1 Copier List ........................................................................................................................................................................ 17- 20917.7.1.2 Copier List ........................................................................................................................................................................ 17- 21017.7.1.3 Copier List ........................................................................................................................................................................ 17- 21117.7.1.4 Copier List ........................................................................................................................................................................ 17- 213

17.8 COUNTER (Counter Mode)................................................................................................................ 17- 21517.8.1 COPIER ...........................................................................................................................................................17- 215

17.8.1.1 Copier List ........................................................................................................................................................................ 17- 21517.8.1.2 Copier List ........................................................................................................................................................................ 17- 21917.8.1.3 Copier List ........................................................................................................................................................................ 17- 223

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Contents

17.8.1.4 Copier List ........................................................................................................................................................................ 17- 227

Chapter 18 Upgrading

18.1 Outline ....................................................................................................................................................18- 118.1.1 Outline of Version upgrade ..................................................................................................................................18- 118.1.2 Outline of Version upgrade ..................................................................................................................................18- 118.1.3 Outline of the Service Support Tool.....................................................................................................................18- 1

18.2 Making Preparations...............................................................................................................................18- 518.2.1 Registering the Firmware.....................................................................................................................................18- 518.2.2 Registering the Firmware.....................................................................................................................................18- 618.2.3 Making Connections ............................................................................................................................................18- 8

18.3 Formatting the HDD..............................................................................................................................18- 1018.3.1 Formatting All Partitions.....................................................................................................................................18- 1018.3.2 Formatting Selected Partitions...........................................................................................................................18- 1018.3.3 Formatting the Partitions....................................................................................................................................18- 11

18.4 Downloading System Software.............................................................................................................18- 1318.4.1 Downloading System .........................................................................................................................................18- 13

18.4.1.1 Downloading Procedure..................................................................................................................................................... 18- 1318.4.2 Downloading RUI, and Language......................................................................................................................18- 14

18.4.2.1 Outline................................................................................................................................................................................ 18- 1418.4.2.2 Downloading Procedure..................................................................................................................................................... 18- 15

18.4.3 Downloading SDICT ..........................................................................................................................................18- 1618.4.3.1 Downloading Procedure..................................................................................................................................................... 18- 16

18.4.4 Downloading MEAPCONT.................................................................................................................................18- 1718.4.4.1 Downloading Procedure..................................................................................................................................................... 18- 17

18.4.5 Downloading KEY..............................................................................................................................................18- 1818.4.5.1 Outline................................................................................................................................................................................ 18- 1818.4.5.2 Downloading Procedure..................................................................................................................................................... 18- 18

18.4.6 Downloading BOOT...........................................................................................................................................18- 1918.4.6.1 Outline................................................................................................................................................................................ 18- 1918.4.6.2 Downloading Procedure..................................................................................................................................................... 18- 20

18.4.7 Downloading Dcon and Rcon ............................................................................................................................18- 2118.4.7.1 Outline................................................................................................................................................................................ 18- 2118.4.7.2 Outline................................................................................................................................................................................ 18- 2218.4.7.3 Outline................................................................................................................................................................................ 18- 22

18.4.8 Other Upgrade Methods ....................................................................................................................................18- 2318.4.8.1 Upgrading by Replacing the DIMM/ROM........................................................................................................................... 18- 2318.4.8.2 Upgrading by Replacing the DIMM/ROM........................................................................................................................... 18- 2418.4.8.3 Upgrading by Replacing the DIMM/ROM........................................................................................................................... 18- 25

18.4.9 Uploading and Downloading Backup Data ........................................................................................................18- 2618.4.9.1 Outline................................................................................................................................................................................ 18- 2618.4.9.2 Uploading Procedure ......................................................................................................................................................... 18- 2718.4.9.3 Procedure for Downloading................................................................................................................................................ 18- 29

Chapter 19 Service Tools

19.1 Service Tools ..........................................................................................................................................19- 119.1.1 Special Tools Table .............................................................................................................................................19- 119.1.2 Special Tools Table .............................................................................................................................................19- 219.1.3 Solvents/Oils........................................................................................................................................................19- 419.1.4 Solvents/Oils........................................................................................................................................................19- 5

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FY8-13H3-010

iR8500/7200

REVISION 1

AUG. 2001

COPYRIGHT© 2001 C PRIME AU JAPON)


INTRODUCTION

ON iR8500/7200 REV.1 AUG. 2001

Outline of the Manual

This Service Manual provides basic facts and figures about the iR8500 series and the sideper deck designed as an option to the copier; use the information for servicing the ma-ine in the field, thus ensuring the initial product quality.For the DADF and other options, separate service manuals are made available for infor-ation, refer to their respective manuals.

This Service Manual consists of the following chapters:

apter 1 Introduction: features, specifications, names of parts, operation of the ma-chine

apter 2 New Functions: differences from the GP605 in terms of various mechanisms,disassembly/assembly of mechanical systems.

apter 3 Main Controller: outline of the main controllerapter 4 Installation: requirements for the site of installation, installation procedure,

relocation procedures, and installation of optionsChapter 5 Maintenance and Inspection:

periodically replaced parts, consumables and durables tables,scheduled servicing chart

Chapter 6 Troubleshooting: standards, adjustments, arrangement of electrical components,troubleshooting image faults, troubleshooting malfunctions,upgrading

Appendix: general timing chart, general circuit diagramService ModesError Codes

The contents of this Service Manual are subject to change for product improvement, andmajor changes will be communicated in the form of Service Information bulletins.

All service persons are expected to be familar with the contents of this Service Manualand the Service Information bulletins, equipping themselves with the ability to isolate andcorrect possible faults in the machine.


COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001xii

CONTENTS

ContentsCHAPTER 1 INTRODUCTION1 Features ............................................... 1-1

1.1 High-Speed,High-Quality Images .................. 1-1

1.2 High Durability,High Reliability ......................... 1-1

1.3 High-Performance Controller,Large-Capacity Hard Disk forHigh-Level Processing ............... 1-1

1.4 Ease of Use ................................ 1-11.5 Large Source of Paper ................ 1-11.6 Various Delivery Handling

(w/ options) ................................ 1-21.7 High-Level Printing

Functions SupportingUses on a Network ..................... 1-2

2 Specifications ...................................... 1-32.1 Copier ......................................... 1-3

2.1.1 Type ..................................... 1-32.1.2 Methods ............................... 1-32.1.3 Functions ............................. 1-42.1.4 Others ................................ 1-10

2.2 Side Paper Deck-M1 ................ 1-133 Names of Parts .................................. 1-14

3.1 External View (iR8500) ........... 1-143.2 External View (iR7200) ........... 1-163.3 Cross Section (iR8500) ............ 1-183.4 Cross Section (iR7200) ............ 1-20

4 Using the Machine ............................ 1-224.1 Power Switch ........................... 1-22

4.1.1 iR8500 ............................... 1-224.1.2 iR7200 ............................... 1-23

4.2 Control Panel ........................... 1-244.3 Special Features ....................... 1-254.4 User Mode ................................ 1-26

CHAPTER 2 NEW FUNCTION1 Basic Construction .............................. 2-1

1.1 Basic Construction Outline(iR8500) ..................................... 2-1

1.2 Basic Construction Outline(iR7200) ..................................... 2-2

1.3 Inputs to and Outputs fromthe Major PCBs (iR8500) .......... 2-3

1.4 Inputs to and Outputs fromthe Major PCBs (iR7200) .......... 2-4

2 Original Exposure System(iR8500) .............................................. 2-52.1 Outline ....................................... 2-52.2 Changes in the Original

Exposure System ....................... 2-62.3 Enlargement/

Reduction Method ..................... 2-72.4 Preventing Overheating of

the Scanner Motor ...................... 2-82.5 Arrangement of the PCBs .......... 2-9

2.6 Stabilizing the ScanningLamp ........................................ 2-10

2.7 Detecting the State(open/closed) of the ADF ......... 2-10

2.8 Detecting Dust in StreamReading Mode .......................... 2-12

2.9 Disassembly/Assembly(iR8500) ................................... 2-14

2.9.1 No. 1 Mirror BaseAssembly ........................... 2-15

2.9.2 Scanner Drive Assembly .... 2-192.9.3 PCBs .................................. 2-272.9.4 Others ................................ 2-33

3 Original Exposure System(iR7200) ............................................ 2-413.1 Outline ..................................... 2-413.2 Change in the Original

Exposure System ..................... 2-433.3 Arrangement of the PCBs ........ 2-44

COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001 xiii

CONTENTS

3.4 Sequence of Operations(original exposure) ................... 2-45

3.4.1 Book Mode, 1 Original,Copyboard Closed ............. 2-45

3.4.2 Book Mode, 1 Original,Copyboard Cover Open ..... 2-46

3.5 Enlargement/Reduction(zoom) ...................................... 2-47

3.5.1 Changing the ReproductionRatio in Main ScanningDirection ............................ 2-47

3.5.2 Changing the ReproductionRatio in Sub ScanningDirection ............................ 2-47

3.6 Scanner Drive System .............. 2-483.6.1 Outline ............................... 2-483.6.2 Controlling the Scanner

Motor ................................. 2-493.7 Controlling the Scanning

Lamp (LA101) ......................... 2-513.7.1 Outline ............................... 2-513.7.2 Scanning Lamp .................. 2-513.7.3 Turning On/Off

the Lamp ............................ 2-513.7.4 Detecting an Error ............. 2-52

3.8 Detecting the Size ofOriginals ................................... 2-53

3.8.1 Outline ............................... 2-533.8.2 Points of Detection ............ 2-533.8.3 Outline of Detection .......... 2-53

3.9 Disassembly/Assembly(iR7200) ................................... 2-57

3.9.1 Removing the ReaderUnit .................................... 2-58

3.9.2 Removing the ScanningLamp .................................. 2-59

3.9.3 Points to NoteWhen Replacingthe Scanning Lamp ............ 2-60

3.9.4 After Replacingthe Scanning Lamp ............ 2-61

3.9.5 Removing the ScannerMotor ................................. 2-61

3.9.6 Mounting the ScannerMotor ................................. 2-62

3.9.7 Removing the ScannerSystem Drive Cable ........... 2-62

3.9.8 Routing the Scanner DriveCable .................................. 2-65

3.9.9 Positioning the No. 1/2Mirror Base ........................ 2-66

3.9.10 Removing the OriginalSize Sensor ........................ 2-68

3.9.11 Removingthe HP Sensor .................... 2-68

3.9.12 Removing the CopyboardCover Sensor ...................... 2-69

3.9.13 Removing the Fuse PCB ... 2-703.9.14 Removing the Inverter

PCB .................................... 2-714 Outline of the Image Processing

System (iR8500) ............................... 2-734.1 Outline ..................................... 2-734.2 Changes to the Image

Processing System ................... 2-744.3 4-Channels High-speed

CCD ......................................... 2-754.4 CCD Adjustment ...................... 2-764.5 Analog Image Processing ........ 2-774.6 Digital Image Processing ......... 2-784.7 Detecting the Orientation of

Originals ................................... 2-794.8 Disassembly/Assembly

(iR8500) ................................... 2-804.8.1 CCD Unit ........................... 2-814.8.2 Hard Disk ........................... 2-83

5 Image Processing System(iR7200) ............................................ 2-865.1 Outline ..................................... 2-865.2 Analog Image Processing ........ 2-87

5.2.1 Outline ............................... 2-875.2.2 Driving the CCD ................ 2-875.2.3 Gain Correction and Offset

Correction of the CCDOutput ................................ 2-88

5.2.4 A/D Conversion ofthe CCD Output ................. 2-88

COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001xiv

CONTENTS

5.3 Digital Image Processing ......... 2-895.3.1 Outline ............................... 2-895.3.2 Shading Correction ............ 2-895.3.3 Auto Density Adjustment

(AE) ................................... 2-915.4 Disassembly/Assembly

(iR7200) ................................... 2-945.4.1 CCD/AP PCB .................... 2-955.4.2 Reader Controller PCB ...... 2-965.4.3 Hard Disk ........................... 2-97

6 Laser Exposure System .................. 2-1006.1 Outline ................................... 2-1006.2 Changes in the Laser

Exposure System ................... 2-1026.3 Disassembly/Assembly .......... 2-103

6.3.1 Reader Unit ...................... 2-1046.3.2 Laser Unit ........................ 2-1056.3.3 BD Unit ........................... 2-106

Image Formation System ................ 2-1087.1 Outline ................................... 2-1087.2 Changes in the Image

formation System ................... 2-1107.3 Photosensitive Drum .............. 2-1117.4 Pre-Transfer Exposure LED

(addition) ................................ 2-1117.5 Preventing Overheating of

the Developing Unit ............... 2-1127.6 Development Fan ................... 2-1127.7 Revising the Developing

Cylinder Cover ....................... 2-1127.8 2-Speed Drive of

the Developing Cylinder ........ 2-1147.9 Disassembly/Assembly .......... 2-116

7.9.1 Process Unit ..................... 2-1177.9.2 Charging Wires ................ 2-1227.9.3 Area Around the Process

Unit .................................. 2-1288 Pickup/Feeding System .................. 2-131

8.1 Outline ................................... 2-1318.2 Changes to the Pickup/Feed

System (iR8500) .................... 2-1328.3 List of Changes Made to

the Pickup/Feeding System(iR7200) ................................. 2-133

8.4 Index Sheet Attachment ......... 2-1338.5 Disassembly/Assembly .......... 2-134

8.5.1 Manual Feed TrayAssembly ......................... 2-135

8.5.2 Vertical Path RollerAssembly ......................... 2-139

8.5.3 Registration FeedAssembly ......................... 2-142

8.5.4 Duplexing Unit ................ 2-1438.5.5 Others .............................. 2-145

9 Fixing System ................................. 2-1469.1 Outline ................................... 2-1469.2 Changes to the Fixing

System .................................... 2-1489.3 Controlling the Fixing

Temperature ........................... 2-1499.4 Transparency Mode ............... 2-1509.5 Thick Paper Mode .................. 2-1519.6 Power Save Mode .................. 2-1529.7 Error Detection ...................... 2-1539.8 Down Sequence Control

(100V) .................................... 2-1549.9 Disassembly/Assembly .......... 2-156

9.9.1 Fixing Heater andthe Control Parts .............. 2-157

9.9.2 Fixing Roller Assembly ... 2-1639.9.3 Delivery Assembly ........... 2-1669.9.4 Paper Sensors ................... 2-169

10 Externals/Auxiliary Controls ......... 2-17310.1 Changes Made to

the Externals/AuxiliaryControls .................................. 2-173

10.2 Fans ........................................ 2-17410.3 Sequence of Operations

(fans) ...................................... 2-17610.4 Disassembly/Assembly .......... 2-178

10.4.1 External Covers ............... 2-17910.4.2 Control Panel ................... 2-19110.4.4 Drive Assembly ............... 2-20510.4.5 Switches ........................... 2-20910.4.6 PCBs ................................ 2-21110.4.7 Others .............................. 2-223

11 Side Paper Deck ............................ 2-22711.1 Outline ............................. 2-227

COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001 xv

CONTENTS

CHAPTER 3 MAIN CONTROLLER1 Basic Operation .................................. 3-1

1.1 Functional Construction ............ 3-11.2 Outline of the Electrical

Circuit ........................................ 3-21.2.1 Outline ................................. 3-21.2.2 Main Controller PCB ........... 3-21.2.3 Hard Disk Drive ................... 3-2

1.3 Start-Up Sequence ..................... 3-41.3.1 Outline ................................. 3-41.3.2 Start-Up Sequence ............... 3-51.3.3 Composition of the System

Software ............................... 3-61.4 Inputs to and Outputs from

the Major PCBs .......................... 3-71.4.1 Wiring Diagram of

the Major PCBs ................... 3-72 Digital image Processing .................... 3-8

2.1 Outline ....................................... 3-82.2 Input Image Processing .............. 3-9

2.2.1 Image Data from the ReaderUnit ...................................... 3-9

2.2.2 Enlargement/Reduction(main scanning direction) .... 3-9

2.2.3 Edge Emphasis .................... 3-92.2.4 Editing ................................. 3-92.2.5 Density Conversion

(LUT) ................................... 3-92.2.6 Binary Processing (error

diffusion method; T-BIC) .... 3-92.2.7 Binary Processing

(dither screen method) ....... 3-102.3 Controlling the Image

Memory .................................... 3-102.3.1 Compression/Expansion,

Rotation, and Enlargement/Reduction ........................... 3-10

2.3.2 SDRAM ............................. 3-102.3.3 HDD .................................. 3-10

2.4 Processing Output Image ......... 3-2.4.1 Smoothing ......................... 3-2.4.2 Thickening

(PDL output only) ............. 3-2.4.3 Binary-Binary Density

Conversion (read imageoutput only) ....................... 3-

3 Soft Counter ...................................... 3-4 Controlling the Power Supply .......... 3-

4.1 Outline ..................................... 3-4.2 Power Supply Mode ................ 3-4.3 Standby Mode

(normal operation) ................... 3-4.4 Power Save Mode .................... 3-4.5 Low-Power Mode .................... 3-

4.5.1 Shift from Standby Mode(standby → low-power) ..... 3-

4.5.2 Shift to standby Mode(low-power mode→ standby) ........................ 3-15

4.6 Sleep Mode .............................. 3-154.6.1 Shift from Standby Mode

(standby → sleep) .............. 3-154.6.2 Shift from Low Power

Mode (low-power mode→ sleep) ............................. 3-15

4.6.3 Return to Standby Mode(sleep → standby) .............. 3-15

4.7 Off Mode .................................. 3-164.7.1 Shift from Standby Mode

(standby → off mode) ....... 3-164.7.2 Shift from Low-Power

Mode (low-power→ off mode) ...................... 3-16

4.7.3 Return to Standby Mode(off mode → standby) ....... 3-16

4.8 Power Supply Off Mode .......... 3-16

V.1 AUG. 2001xvi

CONTENTS

CHAPTER 4 INSTALLATION1 Selecting the Site ................................ 4-12 Unpacking and Installation

(iR8500 Series) ................................... 4-42.1 Points to Note Before Starting

the Installation Work .................. 4-42.1.1 Attachments ......................... 4-5

2.2 Unpacking .................................. 4-62.3 Mounting the Scanner System

(iR8500/iR8500P) .................... 4-112.4 Mounting the Fixing

Assembly ................................. 4-122.5 Mounting the Charging

Assembly ................................. 4-142.6 Checking the Developing

Assembly ................................. 4-192.7 Mounting the Pickup

Assembly ................................. 4-212.8 Supplying the Toner ................. 4-232.9 Installing the ADF

(iR8500/iR8500P) .................... 4-252.10 Cassette .................................... 4-262.11 Index Paper Attachment ........... 4-272.12 Attaching the Labels,

Setting Paper, CheckingImages/Operations,and User Mode ......................... 4-28

2.13 Connecting to the Network ...... 4-322.14 Checking the Connection to

the Network .............................. 4-322.15 Troubleshooting Network

Faults ........................................ 4-332.16 Changing the Paper Size for the

Front Deck (right, left) ............. 4-343 Unpacking and Installation

(iR7200 Series) ................................. 4-373.1 Points to Note Before Starting

the Work ................................... 4-373.1.1 Attachments ....................... 4-37

3.2 Unpacking ................................ 4-39

3.3 Mounting the Scanner System(iR8500/iR8500P) .................... 4-43

3.4 Mounting the FixingAssembly ................................. 4-45

3.5 Mounting the ChargingAssembly ................................. 4-46

3.6 Checking the DevelopingAssembly ................................. 4-51

3.7 Mounting the PickupAssembly ................................. 4-53

3.8 Supplying the Toner ................. 4-553.9 Connectors ............................... 4-573.10 Cassette .................................... 4-583.11 Index Paper Attachment ........... 4-583.12 Setting Label Sheet/Paper,

Checking Images andOperation, and UsingUser Mode ................................ 4-58

3.13 Connecting to the Network ...... 4-583.14 Checking the Connection to

the Network .............................. 4-583.15 Troubleshooting Network

Faults ........................................ 4-583.16 Switching the Paper Size for

the Front Deck (right, left) ....... 4-584 Relocating the Machine .................... 4-595 Installing the Card Reader-D1 .......... 4-60

5.1 Installingthe Card Reader-D1 ................. 4-60

6 Installing the NE Controller-A1/NE Controller-B1/Copy Data Controller-A1 ................. 4-656.1 Installing the NE Controller-A1/

NE Controller-B1/Copy DataController-A1 ........................... 4-65

7 Installing the Network LIPS PrinterKit -B1 .............................................. 4-697.1 Installing the Network LIPS

Printer Kit-B1 .......................... 4-69


COPYRIGHT© xvii

CONTENTS

CHAPTER 6 TROUBLESHOOTING1 Guide to the Troubleshooting

Tables .................................................. 6-11.1 Image Adjustment Basic

Procedure ................................... 6-31.1.1 Making Pre-Checks ............. 6-31.1.2 Making Checks on

the Printer Side (1/2) ........... 6-41.1.3 Making Checks on


the Scanner Side (iR8500) ... 6-61.1.5 Making Checks on

the Reader Unit (iR7200) .... 6-72 Standards and Adjustments ................. 6-9

2.1 Making Image Adjustments ....... 6-92.1.1 Adjusting the Image Position

for Printer Output ................ 6-92.1.2 Adjusting the Image Position

for Copier Output(book mode) ...................... 6-14

2.1.3 Adjusting the Image Positionfor Copier Output(ADF mode) ....................... 6-17

2.2 Scanner System ........................ 6-182.2.1 Replacing the Scanner Drive

Cable .................................. 6-182.2.2 Adjusting the Position of

the Scanner Mirror Base .... 6-182.2.3 When Replacing the Scanning

Lamp/When Replacingthe Standard White Plate ... 6-18

2.3 Image Formation System ......... 6-19

2.3.1 Stringing the Grid Wire ofthe Primary ChargingAssembly ........................... 6-19

2.3.2 Stringing the ChargingWire of ChargingAssemblies ......................... 6-19

2.4 Pickup/Feeding System ........... 6-202.4.1 Orientation of the Deck/

Cassette Pickup Roller ....... 6-202.4.2 Orientation of the Deck/

Cassette SeparationRoller ................................. 6-21

2.4.3 Orientation of the FeedingRoller of the Deck/CassettePickup Assembly ............... 6-21

2.4.4 Orientation of the PickupRoller of the Manual FeedTray/Side Paper Deck ........ 6-22

2.4.5 Orientation for the FeedingRoller of the Manual FeedTray .................................... 6-23

2.4.6 Orientation of the FeedingRoller of the Side PaperDeck ................................... 6-23

2.4.7 Adjusting the Pressure ofthe Separation Roller ofthe Deck/Cassette .............. 6-24

2.4.8 Adjusting the Pressure ofthe Pickup/Feeding Roller ofthe Manual Feed Tray ........ 6-25

2.4.9 Position of the Solenoids ... 6-262.4.10 Position of the Fixing Web

Solenoid (SL2) .................. 6-27

CHAPTER 5 MAINTENANCE AND INSPECTION1 Periodically Replaced Parts ................ 5-12 Guide to Durables ............................... 5-4

2.1 Copier ......................................... 5-42.2 Side Paper Deck ......................... 5-8

3 Scheduled Servicing Work ................. 5-94 Scheduled Service Chart ................... 5-13

4.1 Copier ....................................... 5-134.2 Point to Note on Scheduled

Servicing .................................. 5-174.3 Work Procedure ....................... 5-19

4.3.1 Work Procedure 1 .............. 5-194.3.2 Work Procedure 2 .............. 5-22



COPY xviii

CONTENTS

2.4.11 Position of the DeliveryFlapper Solenoid (SL3) ..... 6-29

2.4.12 Position of the Fixing FeedingUnit Locking Solenoid(SL4) .................................. 6-30

2.4.13 Adjusting the Position forthe Multifeeder Pickup LatchSolenoid (SL6) .................. 6-31

2.4.14 Position of the Deck (right)Pickup Solenoid (SL7) ...... 6-32

2.4.15 Position of the Deck (left)Pickup Solenoid (SL8) ...... 6-33

2.4.16 Position for the Cassette 3/4Pickup Solenoid(SL9/10) ............................. 6-34

2.4.17 Position of the Side PaperDeck Pickup RollerReleasing Solenoid ............ 6-35

2.4.18 Attaching the Timing Belt forthe Manual Feed Tray Assembly Side Guide ....... 6-35

2.4.19 Attachingthe Drive Belts ................... 6-36

2.5 Fixing System .......................... 6-372.5.1 Points to Note

When Mounting the FixingHeater ................................. 6-37

2.5.2 Adjusting the Lower RollerPressure (nip width) ........... 6-38

2.6 Laser Exposure System ............ 6-392.6.1 Replacing the Laser Unit ......... 6-392.6.2 Checking the Laser Power ....... 6-402.7 Items Related to Electrical

Components ............................. 6-432.7.1 Electrical Components

Requiring Work AfterReplacement ...................... 6-43

2.7.2 Points to Note whenReplacing the CCD Unit .... 6-43

2.7.3 When Replacing the ReaderController PCB(iR8500) ............................. 6-45

2.7.4 When Replacing the Redercontroller PCB(iR7200) ............................. 6-46

2.7.5 Replacing the MainController PCB .................. 6-47

2.7.6 Replacing the HDD Unit ... 6-472.7.7 Replacing the DC Controller

PCB .................................... 6-482.7.8 After Replacing the

High-Voltage DC PCB....... 6-492.7.9 When Replacing the Laser

Unit .................................... 6-502.7.10 Replacing the Potential

Sensor/Potential ControlPCB .................................... 6-50

2.7.11 Checking the SurfacePotential Control System ... 6-54

2.8 Conversion Table forthe Potential Control System ... 6-60

2.9 Checking the EnvironmentSensor ....................................... 6-65

2.10 Checking the Photointerrupters 6-663 Troubleshooting Image Faults .......... 6-72

3.1 Making Initial Checks .............. 6-723.1.1 Site of Installation .............. 6-723.1.2 Checking the Originals

Against Symptoms ............. 6-723.1.3 Checking the Copyboard

Cover, Copyboard Glass,and Standard White Platefor Dirt and Scratches ........ 6-73

3.1.4 Checking the ChargingWires .................................. 6-73

3.1.5 Checking the DevelopingAssembly ........................... 6-73

3.1.6 Checking the Paper ............ 6-733.1.7 Checking the Periodically

Replaced Parts ................... 6-733.1.8 Others ................................ 6-73

3.2 Sample Faulty Images .............. 6-763.3 Troubleshooting Faulty

Images ...................................... 6-773.3.1 The copy is too light

(halftone area) .................... 6-77


COPYRIGHT© 2001 CANON INC.

CONTENTS

3.3.2 The copy is too light (solidblack area) .......................... 6-78

3.3.3 The copy is too light (entireface, considerable) ............. 6-78

3.3.4 The copy has uneven density(darker front) ..................... 6-80

3.3.5 The copy has uneven density(lighter front) ..................... 6-80

3.3.6 The copy is foggy(entire face) ........................ 6-81

3.3.7 The copy is foggy invertical direction ................ 6-82

3.3.8 The copy has a vertical line(vertical, thick, fuzzy) ........ 6-82

3.3.9 The copy has a black line(vertical, fine) .................... 6-83

3.3.10 The copy has white spots(vertical) ............................. 6-84

3.3.11 The copy has white lines(vertical) ............................. 6-84

3.3.12 The copy has white spots(horizontal) ........................ 6-86

3.3.13 The back of the copy issoiled .................................. 6-87

3.3.14 The copy has faultyfixing .................................. 6-87

3.3.15 The copy has a displacedleading edge (considerablylarge margin) ...................... 6-88

3.3.16 The copy has a displacedleading edge(large margin) .................... 6-88

3.3.17 The copy has a displacedleading edge (no margin) ... 6-88

3.3.18 The copy is wobbly ........... 6-893.3.19 The copy is foggy

horizontally ........................ 6-903.3.20 The copy has poor

sharpness ............................ 6-903.3.21 The copy is blank .............. 6-913.3.22 The copy is solid black ...... 6-92

4 Troubleshooting Malfunctions ......... 6-934.1 Troubleshooting

Malfunctions ............................ 6-93

4.1.1 E000 ................................... 6-934.1.2 E001 ................................... 6-944.1.3 E002 ................................... 6-954.1.4 E003 ................................... 6-954.1.5 E004 ................................... 6-964.1.6 E005 ................................... 6-964.1.7 E010 ................................... 6-964.1.8 E012 ................................... 6-974.1.9 E013 ................................... 6-4.1.10 E014 ................................... 6-4.1.11 E015 ................................... 6-4.1.12 E019 ................................... 6-4.1.13 E020 ................................. 6-14.1.14 E025 ................................. 6-14.1.15 E032 ................................. 6-14.1.16 E043 ................................. 6-14.1.17 E051 ................................. 6-14.1.18 E065 ................................. 6-14.1.19 E067 ................................. 6-14.1.20 E068 ................................. 6-14.1.21 E069 ................................. 6-14.1.22 E100 ................................. 6-14.1.23 E110 ................................. 6-14.1.24 E111 ................................. 6-14.1.25 E121-0001 ....................... 6-14.1.26 E121-0002 ....................... 6-14.1.27 E202 (The keys in

the control panel becomelocked) ............................. 6-1

4.1.28 E204 (The keys inthe control panel becomelocked) ............................. 6-109

4.1.29 E211 ................................. 6-1104.1.30 E215 ................................. 6-1104.1.31 E218

(Indicated if iR8500) ....... 6-1104.1.32 E219

(Indicated if iR8500) ....... 6-1114.1.33 E220 (iR8500) ................. 6-1114.1.34 E222

(Indicated if iR8500) ....... 6-1114.1.35 E220 (iR7200) ................. 6-1114.1.36 E225 (iR7200) ................. 6-1114.1.37 E226 (iR8500) ................. 6-112


COPYRIGHT© 2001 CANON INC. CANON iR8500/7200 REV.1 AUG. 2001xx

CONTENTS

4.1.38 E240 ................................. 6-1124.1.39 E241 (iR8500) ................. 6-1124.1.40 E243 ................................. 6-1134.1.41 E248 (iR7200) ................. 6-1134.1.42 E251

(Indicated if iR8500) ....... 6-1134.1.43 E302 ................................. 6-1144.1.44 E315 ................................. 6-1144.1.45 E320 ................................. 6-1144.1.46 E400

(Indicated if iR8500) ....... 6-1144.1.47 E402

(Indicated if iR8500) ....... 6-1154.1.48 E404

(Indicated if iR8500) ....... 6-1164.1.49 E405

(Indicated if iR8500) ....... 6-1184.1.50 E410

(Indicated if iR8500) ....... 6-1194.1.51 E412

(Indicated if iR7200) ....... 6-1204.1.52 E420

(Indicated if iR7200) ....... 6-1204.1.53 E421

(Indicated if iR7200) ....... 6-1214.1.54 E422 (iR8500) ................. 6-1214.1.55 E422 (iR7200) ................. 6-1214.1.56 E601 ................................. 6-1224.1.57 E602 ................................. 6-1224.1.58 E676 ................................. 6-1234.1.59 E677 ................................. 6-1234.1.60 E710-0001 (Reader

controller PCB), E710-0002(DC controller PCB) ........ 6-123E710-0003 (Main controllerPCB) ................................ 6-123

4.1.61 E711-0001 (Readercontroller PCB), E711-0002(DC controller PCB) ........ 6-123E711-0003 (Main controllerPCB) ................................ 6-123

4.1.62 E712 ................................. 6-1244.1.63 E713 ................................. 6-1244.1.64 E717 ................................. 6-125

4.1.65 E732 ................................. 6-1254.1.66 E733 ................................. 6-1264.1.67 E737 ................................. 6-1264.1.68 E740 ................................. 6-1264.1.69 E741 ................................. 6-1274.1.70 E744 ................................. 6-1274.1.71 E800 ................................. 6-1274.1.72 E804 ................................. 6-1284.1.73 E805 ................................. 6-1284.1.74 E820 ................................. 6-1294.1.75 E823 ................................. 6-1294.1.76 E824 ................................. 6-1304.1.77 E830 ................................. 6-1304.1.78 AC power is absent .......... 6-1314.1.79 DC power is absent .......... 6-1324.1.80 Pickup fails ...................... 6-1334.1.81 The lifter fails to

move up ........................... 6-1354.1.82 The lifter fails to move up

(pickup from cassette) ..... 6-1364.1.83 Pickup fails

(multifeeder) .................... 6-1374.1.84 The vertical path roller

fails to rotate .................... 6-1394.1.85 The registration roller

fails to rotate .................... 6-1414.1.86 The No. 1 mirror base

fails to operate ................. 6-1424.1.87 The pre-exposure lamp

fails to go ON .................. 6-1434.1.88 The scanning lamp fails

to go ON .......................... 6-1434.1.89 The toner feed motor

(M6) inside the cartridgefails to operate ................. 6-144

4.1.90 The toner feed motor(M18) inside the hopperfails to rotate .................... 6-144

4.1.91 The drum heater fails tooperate ............................. 6-145

4.1.92 The “Add Toner” messagefails to turn ON ................ 6-145

4.1.93 The “Add Toner” messagefails to go OFF ................. 6-146

COPYRIGHT© 2001 CANON INC.

CONTENTS

4.1.94 The “Card Reader Set”message fails to turnON ................................... 6-146

4.1.95 The “Card Reader Set”message fails to go OFF .. 6-146

4.1.96 The “Add Paper” messagefails to go OFF(deck right/left) ................ 6-147

4.1.97 The “Add Paper Message”fails to go OFF(cassette 3/4) .................... 6-147

4.1.98 The fixing heater fails tooperate ............................. 6-148

4.1.99 Pickup fails(side paper deck) .............. 6-149

4.1.100The deck lifter fails to moveup (side paper deck) ........ 6-150

5 Troubleshooting Feeding Faults ..... 6-1515.1 Paper Jams ............................. 6-151

5.1.1 Pickup Assembly ............. 6-1525.1.2 Separation/Feeding

Assembly ......................... 6-1535.1.3 Fixing/Delivery

Assembly ......................... 6-1545.1.4 Fixing, Delivery Assembly

(reversal deliveryassembly) ......................... 6-155

5.1.5 Cleaning Assembly .......... 6-1555.1.6 Lower Feeding

Assembly ......................... 6-1565.2 Faulty Feeding ....................... 6-157

5.2.1 Double Feeding ............... 6-1575.2.2 Wrinkles .......................... 6-157

6 Arrangement and Function ofElectrical Parts ................................ 6-1586.1 Clutches ................................. 6-1586.2 Solenoids ................................ 6-1606.3 Motors .................................... 6-1626.4 Fans ........................................ 6-1646.5 Sensor 1 ................................. 6-1666.6 Sensor 2 ................................. 6-1706.7 Switches ................................. 6-1726.8 Counters, Heaters, Fuses,

and Others .............................. 6-174

6.9 PCBs ...................................... 6-1766.10 Variable Registers (VR),

Light-Emitting Diodes,and Check Pins by PCB ......... 6-180

6.10.1 Main Controller PCB ....... 6-1806.10.2 Reader Controller PCB

(iR8500) ........................... 6-1816.10.3 Reader Controller PCB

(iR7200) ........................... 6-1816.10.4 DC Controller PCB ......... 6-1826.10.5 HV-DC PCB .................... 6-183

7 Upgrading ....................................... 6-1847.1 Outline ................................... 6-184

7.1.1 Download Mode .............. 6-1847.1.2 Making Pre-Checks ......... 6-185

7.2 Data Control ........................... 6-1887.3 Downloading the System

Software, RUI, and LanguageModule ................................... 6-191

7.3.1 Making Connections ........ 6-1917.3.2 Downloading ................... 6-1917.3.3 After Downloading .......... 6-197

7.4 Upgrading the BOOT ROM ... 6-1977.4.1 Making Preparations ........ 6-1977.4.2 Connection ....................... 6-1987.4.3 Preparing BOOT ROM .... 6-1987.4.4 After Downloading .......... 6-202

7.5 Formatting the HDD .............. 6-2037.5.1 Making Connections ........ 6-2037.5.2 Starting Formatting .......... 6-2037.5.3 Points to Note

When Formattingthe Hard Disk ................... 6-209

7.6 Upgrading by Replacingthe DIMM/ROM .................... 6-210

8 Backing Up Data ............................ 6-2128.1 Outline ................................... 6-2128.2 Backing Up Data .................... 6-213

8.2.1 Making Preparations ........ 6-2138.2.2 Making Connections ........ 6-2138.2.3 Backing Up Data ............. 6-2148.2.4 Downloading Backup

Data .................................. 6-2198.2.5 Managing Backup Data ... 6-223


1 AUG. 2001xxii

CONTENTS

ERROR CODE1 Error Codes ........................................ E-1

1.1 Introduction ............................... E-1

APPENDIX1 GENERAL TIMING CHART ........... A-12 LIST OF SIGNALS/

ABBREVIATIONS............................ A-3

3 GENERAL CIRCUIT DIAGRAM .... A-74 Special Tools Table .......................... A-135 Solvents/Oils .................................... A-16

SERVICE MODE1 Construction of Service Mode ............ S-1

1.1 Outline ....................................... S-11.2 Starting Service Mode and

Making Selections ..................... S-21.3 Ending Service Mode ................ S-31.4 Backing Up Service Mode ......... S-31.5 Basic Operation .......................... S-4

1.5.1 Initial Screen ........................ S-41.5.2 Level 1/Level 2

Items Screen ........................ S-41.5.3 Level 3 Items Screen ........... S-5

2 COPIER .............................................. S-62.1 DISPLAY ................................... S-62.2 I/O ............................................ S-232.3 ADJUST................................... S-54

2.4 FUNCTION ............................. S-712.5 OPTION ................................... S-912.6 TEST ...................................... S-1102.7 COUNTER ............................. S-118

3 FEEDER ......................................... S-1253.1 DISPLAY ............................... S-1253.2 ADJUST................................. S-1253.3 FUNCTION ........................... S-1273.4 OPTION ................................. S-128

4 SORTER ......................................... S-1294.1 ADJUST................................. S-1294.2 OPTION ................................. S-130

5 BOARD .......................................... S-1315.1 OPTION ................................. S-131



FY8-13H3-000

iR8500

REVISION 0

MAR. 2001

COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001 PRINTED IN JAPAN (IMPRIME AU JAPON)

COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001x

CONTENTS

ContentsCHAPTER 1 INTRODUCTION1 Features ............................................... 1-1

1.1 High-Speed,High-Quality Images .................. 1-1

1.2 High Durability,High Reliability ......................... 1-1

1.3 High-Performance Controller,Large-Capacity Hard Disk forHigh-Level Processing ............... 1-1

1.4 Ease of Use ................................ 1-11.5 Large Source of Paper ................ 1-11.6 Various Delivery Handling

(w/ accessories) .......................... 1-21.7 High-Level Printing

Functions Supporting Useson a Network .............................. 1-2

2 Specifications ........ .......... 1-32.1 Copier ........... .......... 1-3

2.1.1 Type ....... .......... 1-32.1.2 Methods . .......... 1-32.1.3 Functions .......... 1-42.1.4 Others .... ........ 1-10

2.2 Side Paper De ........ 1-133 Names of Parts ...... ........ 1-14

3.1 External View ........ 1-143.2 Cross Section ........ 1-16

4 Using the Machine ............................ 1-184.1 Power Switch ........................... 1-184.2 Control Panel ........................... 1-194.3 Special Features ....................... 1-204.4 User Mode ................................ 1-21

CHAPTER 2 NEW FUNCTION1 Basic Construction .............................. 2-1

1.1 Functional Construction ............ 2-11.2 Inputs to the Major PCBs .......... 2-2

1.2.1 Wiring of the major PCBs ... 2-22 New Functions .................................... 2-3

2.1 Original Exposure System ......... 2-52.1.1 Changes in the Original

Exposure System ................. 2-52.1.2 Outline of the Original

Exposure System ................. 2-72.1 3 Enlargement/

2.

2.1.5 Arrangement of he PCBs .... 2 92.1.6 Stabilizing the Scanning

Lamp .................................. 2-102.1.7 Detecting the State (open/

closed) of the DADF .......... 2-102.1.8 Detecting Dust in Stream

Reading Mode ................... 2-12

2.2 Image Processing System ........ 2-152.2.1 Changes to the Image

Processing System ............. 2-152.2.2 Outline of the Image

Processing System ............. 2-172.2.3 4-Channels High-speed

CCD ................................... 2-182.2.4 CCD Adjustment ............... 2-192.2.5 Analog Image

Processing .......................... 2-202 2 6 Digital Image Processing ... 2-21

Orientation of.................... 2-22

stem ............ 2-232.3.1 Changes in he Laser

Exposure System ............... 2-232.3.2 Outline of the Laser

Exposure System ............... 2-252.4 Image Formation System ......... 2-27

2.4.1 Changes in the Imageformation System ............... 2-27


COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001 xi

CONTENTS

2.4.2 Outline of the ImageFormation System .............. 2-29

2.4.3 Photosensitive drum .......... 2-302.4.4 Pre-Transfer Exposure

LED ................................... 2-302.4.5 Preventing Overheating of

the Developing Unit ........... 2-322.4.6 Development Fan ............... 2-322.4.7 Revising the Developing

Cylinder Cover .................. 2-322.4.8 2-Speed Drive of the

Developing Cylinder .......... 2-342.5 Pickup/Feed System ................. 2-37

2.5.1 Changes to the Pickup/Feed System ....................... 2-37

2.5.2 Outline of the Pickup/Feed System ....................... 2-39

2.5.3 Index Sheet Attachment ..... 2-392.6 Fixing System .......................... 2-41

2.6.1 Changes to the FixingSystem ............................... 2-41

2.6.2 Outline for the FixingAssembly ........................... 2-43

2.6.3 Controlling the FixingTemperature ....................... 2-45

2.6.4 Transparency Mode ........... 2-462.6.5 Thick Paper Mode ............. 2-472.6.6 Power Save Mode .............. 2-482.6.7 Error Detection .................. 2-492.6.8 Down Sequence Control .... 2-50

2.7 Externals/Auxiliary Controls ... 2-512.7.1 Changes Made to

the Externals/AuxiliaryControls ............................. 2-51

2.7.2 Fans .................................... 2-532.7.3 Sequence of Operations

(fans) .................................. 2-552.8 Side Paper Deck ....................... 2-57

2.8.1 Outline of the Side PaperDeck ................................... 2-57

CHAPTER 3 MAIN CONTROLLER1 Basic Operation .................................. 3-1

1.1 Functional Construction ............ 3-11.2 Outline of the Electrical

Circuit ........................................ 3-21.2.1 Outline ................................. 3-21.2.2 Main Controller PCB ........... 3-21.2.3 Hard Disk Drive ................... 3-2

1.3 Start-Up Sequence ..................... 3-41.3.1 Outline ................................. 3-41.3.2 Start-Up Sequence ............... 3-51.3.3 Composition of the System

Software ............................... 3-61.4 Inputs to and Outputs from

the Major PCBs .......................... 3-71.4.1 Wiring Diagram of the

Major PCBs ......................... 3-72 Digital image Processing .................... 3-8

2.1 Outline ....................................... 3-82.2 Input Image Processing .............. 3-9

2.2.1 Image Data from the ReaderUnit ...................................... 3-9

2.2.2 Enlargement/Reduction(main scanning direction) .... 3-9

2.2.3 Edge Emphasis .................... 3-92.2.4 Editing ................................. 3-92.2.5 Density Conversion

(LUT) ................................... 3-92.2.6 Binary Processing

(error diffusion method;T-BASIC) ............................. 3-9

2.2.7 Binary Processing(dither screen method) ....... 3-10

2.3 Controlling the ImageMemory .................................... 3-10

2.3.1 Compression/Expansion,Rotation, and Enlargement/Reduction ........................... 3-10

2.3.2 SDRAM ............................. 3-102.3.3 HDD .................................. 3-10

2.4 Processing Output Image ......... 3-102.4.1 Smoothing ......................... 3-10

COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001xii

CONTENTS

2.4.2 Thickening(PDL output only) ............. 3-10

2.4.3 Binary-Binary DensityConversion (read imageoutput only) ....................... 3-11

3 Soft Counter ...................................... 3-124 Controlling the Power Supply .......... 3-14

4.1 Outline ..................................... 3-144.2 Power Supply Mode ................ 3-144.3 Standby Mode

(normal operation) ................... 3-144.4 Power Save Mode .................... 3-144.5 Low-Power Mode .................... 3-15

4.5.1 Shift from Standby Mode(standby � low-power) ..... 3-15

4.5.2 Shift to standby Mode(low-power mode� standby) ......................... 3-15

4.6 Sleep Mode .. ........ 3-154.6.1 Shift from ode

(standby � ........ 3-154.6.2 Shift from r

Mode (low de� sleep) . ........ 3-15

4.6.3 Return to de(sleep � s ) ........ 3-15

4.7 Off Mode .................................. 3-164.7.1 Shift from Standby Mode

(standby � off mode) ........ 3-164.7.2 Shift from Low-Power

Mode (low-power� off mode) ....................... 3-16

4.7.3 Return to Standby Mode(off mode � standby) ........ 3-16

4.8 Power Supply Off Mode .......... 3-16

CHAPTER 4 INSTALLATION1 Selecting the Site ................................ 4-12 Unpacking and Installation ................. 4-4

2.1 Points to Note Before Startingthe Installation Work .................. 4-4

2.2 Unpacking .................................. 4-52.3 Mounting the Scanner .............. 4-102.4 Mounting the Fixing

Assembly ................................. 4-112.5 Mounting the Charging

Assemblies ............................... 4-142.6 Checking the Developing

Assembly ................................. 4-182.7 Mounting the Pickup

Assembly ................................. 4-20

2.8 Supplying Toner ....................... 4-222.9 Installing the ADF .................... 4-242.10 Setting the Cassette .................. 4-252.11 Checking the Images and

Operations ................................ 4-262.12 Switching the Paper Size for

the Front Deck (right/left) ........ 4-293 Relocating the Machine .................... 4-304 Installing the Card Reader-D1 .......... 4-31

4.1 Installingthe Card Reader-D1 ................. 4-31

CHAPTER 5 MAINTENANCE AND INSPECTION1 Periodically Replaced Parts ................ 5-12 Guide to Durables ............................... 5-4

2.1 Copier ......................................... 5-42.2 Side Paper Deck ......................... 5-8

3 Scheduled Servicing Work ................. 5-94 Scheduled Service Chart ................... 5-13

4.1 Copier ....................................... 5-134.2 Work Procedure ....................... 5-16

4.2.1 Work Procedure 1 .............. 5-164.2.2 Work Procedure 2 .............. 5-19

5 Mechanical System ........................... 5-235.1 No. 1 Mirror Base .................... 5-23

COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001 xiii

CONTENTS

5.1.1 Removing the ScanningLamp/Scanning LampHeater ................................. 5-23

5.1.2 Points to Note WhenReplacing the ScanningLamp .................................. 5-26

5.1.3 After Replacing theScanning Lamp .................. 5-26

5.2 Scanner Drive Assembly .......... 5-275.2.1 Removing the Scanner

Motor ................................. 5-275.2.2 Scanner Drive Cable .......... 5-28

5.3 PCBs ........................................ 5-355.3.1 Removing the Light

Control PCB ...................... 5-355.3.2 Removing the Inverter

PCB .................................... 5-365.4 Others ....................................... 5-38

5.4.1 Removing the OriginalSize Sensor (1/2) ............... 5-38

5.4.2 Removing the OriginalSize Sensor ........................ 5-39

5.4.3 Removing the ScannerHome Position Sensor ....... 5-40

5.4.4 Removing the CopyboardGlass Sensor ...................... 5-41

5.4.5 Removing the ImageLeading Edge Sensor ......... 5-42

5.4.6 Removing the StandardWhite Plate ........................ 5-43

5.4.7 After Replacingthe Standard White Plate ... 5-44

5.5 Removing the CCD PCB ......... 5-455.5.1 Removing the CCD PCB ... 5-45

g

5.6.2 After Replacing the LaserUnit .................................... 5-49

5.7 BD Unit .................................... 5-505.7.1 Removing the BD Unit ...... 5-50

5.8 Components Aroundthe Process Unit ....................... 5-51

5.8.1 Removing the Pre-TransferExposure LED ................... 5-51

5.8.2 Removing the DevelopingCylinder DeceleratingClutch ................................ 5-52

5.8.3 Removing the DevelopingCylinder Clutch ................. 5-53

5.9 Charging Wires ........................ 5-545.9.1 Outline ............................... 5-545.9.2 Removing the Wire

Cleaner of the PrimaryCharging Assembly ............ 5-54

5.9.3 Stringing the ChargingWires .................................. 5-55

5.9.4 Strutting the Grid Wire ofthe Primary ChargingAssembly ........................... 5-58

5.9.5 Adjusting the Height ofthe Charging Wire .............. 5-59

5.10 Process Unit ............................. 5-605.10.1 Removing the Process

Unit .................................... 5-605.10.2 Mounting the Process

Unit .................................... 5-625.11 Manual Feed Tray Assembly ... 5-64

5.11.1 Removing the ManualFeed Tray Unit ................... 5-64

5.11.2 Removing the ManualFeed Tray Pickup Sensor ... 5-65

5.11.3 Attaching the Side GuideTiming Belt in the ManualFeed Tray Assembly .......... 5-67

5.12 Vertical Path RollerAssembly ................................. 5-68

5.12.1 Removing the Vertical PathRoller 1/3/4 ........................ 5-68

5.12.2 Removing the Vertical PathRoller 2 .............................. 5-69

5.13 Registration FeedingAssembly ................................. 5-70

5.13.1 Removing the RegistrationClutch ................................ 5-70

5.13.2 Removing the RegistrationBrake Clutch ...................... 5-71


COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001xiv

CONTENTS

5.14 Duplexing Unit ........................ 5-725.14.1 Removing the Reversal

Motor ................................. 5-725.14.2 Removing the Lower Feed

Motor ................................. 5-735.15 Fixing Assembly ...................... 5-74

5.15.1 Removing the Main/Sub Heater ......................... 5-74

5.15.2 Mounting the Main/Sub Heater ......................... 5-75

5.15.3 Removing the ThermalSwitch ................................ 5-75

5.15.4 Removing the MainThermistor ......................... 5-77

5.15.5 Removing the SubThermistor ......................... 5-79

5.15.6 Fixing Roller Assembly ..... 5-805.16 Delivery Assembly ................... 5-81

5.16.1 Removing the ExternalDelivery Roller .................. 5-81

5.16.2 Removing the InternalDelivery Roller .................. 5-82

5.16.3 Removing the DeliverySpeed Switching Clutch .... 5-83

5.17 Paper Sensor ............................ 5-845.17.1 Removing the Claw Jam

Sensor ................................ 5-845.17.2 Removing the External

Delivery Sensor ................. 5-845.17.3 Removing the Internal

Delivery Sensor ................. 5-855.17.4 Removing the Reversal

Sensor ................................ 5-865.17.5 Removing the Fixing/

Feeding Unit OutputSensor ................................ 5-87

5.18 External Covers ........................ 5-885.18.1 Removing the Front

Cover ................................. 5-895.18.2 Removing the Inside Upper

Cover ................................. 5-905.18.3 Removing the Fixing/

Feeding Unit Cover ........... 5-915.18.4 Removing the Rear

Cover ................................. 5-91

5.19 Control panel ........................... 5-935.19.1 Removing the Control

Panel ...... ........ 5-935.19.2 Removing

Panel Con U)PCB and t Panel In-verter PCB ........ 5-95

5.19.3 Removing Panel PCB CDPanel ...... ........ 5-96

5.20 Fans .............. ........ 5-985.20.1 Removing river

Cooling F ........ 5-985.20.2 Removing educing

Fan ......... ....... 5-1005.20.3 Removing

Supply Co ...... 5-1015.20.4 Removing

Supply Co ....... 5-1025.20.5 Removing ion

Fan ......... ....... 5-1025.20.6 Developin

Fan ......... ....... 5-1045.20.7 System Fa ...... 5-1055.20.8 Delivery A on

Fan ................................... 5-1065.20.9 Removing the Drum Drive

Assembly ......................... 5-1065.20.10Removing the Cassette

Pickup Drive Assembly ... 5-1095.21 Switches ................................. 5-110

5.21.1 Removing the CoverSwitch (door switch)Assembly ......................... 5-110

5.21.2 Removing the ManualTray Switch Assembly ..... 5-111

5.21.3 Removing the DrumHeater SwitchAssembly ......................... 5-112

5.22 PCBs ...................................... 5-1135.22.1 DC Controller PCB ......... 5-1135.22.2 After Replacing the DC

Controller PCB ................ 5-1135.22.3 Removing the Differential

PCB .................................. 5-113

COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001 xv

CONTENTS

5.22.4 Pixel/Line ConversionPCB .................................. 5-115

5.22.5 Main Controller PCB ....... 5-1165.22.6 After Replacing the Main

Controller PCB ................ 5-1175.22.7 Reader Controller PCB .... 5-1185.22.8 After Replacing the

Reader Controller PCB .... 5-1185.22.9 Original Orientation

Detection PCB ................. 5-1185.22.10AC Driver PCB ................ 5-1195.22.11Voltage Converter PCB .... 5-1195.22.12High-Voltage Transformer

(AC) PCB......................... 5-1205.22.13All-Day Power Supply

PCB .................................. 5-120

5.22.14Bi-Centronics PCB .......... 5-1215.23 Power Supply Unit ................. 5-1235.24 High-Voltage Transformer

(AC) ....................................... 5-1245.25 High-Voltage Transformer

(DC) ....................................... 5-1255.25.1 After Replacing

the High-VoltageTransformer (DC) ............ 5-125

5.26 Relay PCB.............................. 5-1255.27 Removing the Voltage

Converter Unit ........................ 5-1265.28 Removing the Hard Disk ....... 5-127

5.28.1 After Replacing the HardDisk .................................. 5-128

CHAPTER 6 TROUBLESHOOTING1 Guide to the Troubleshooting

Tables .................................................. 6-11.1 Image Adjustment Basic

Procedure ................................... 6-31.1.1 Making Pre-Checks ............. 6-31.1.2 Making Checks on



the Scanner Side .................. 6-62 Standards and Adjustments ................. 6-9

2.1 Making Image Adjustments ....... 6-92.1.1 Adjusting the Image

Position for Printer

(book mode) ...................... 6 12.1.3 Adjusting the Image

Position for Copier Output(ADF mode) ....................... 6-17

2.2 Scanner System ........................ 6-182.2.1 Replacing the Scanner

Drive Cable ........................ 6-18

2.2.2 Adjusting the Position ofthe Scanner Mirror Base .... 6-18

2.2.3 When Replacingthe Scanning LampWhen Replacingthe Standard White Plate ... 6-18

2.3 Image Formation System ......... 6-192.3.1 Stringing the Grid Wire of

the Primary ChargingAssembly ........................... 6-19

2.3.2 Stringing the ChargingWire of ChargingAssemblies ......................... 6-19

2.3.3 Mounting the DrumCleaning Blade .................. 6-19

Pickup/Feeding System ........... 6-20.1 Orientation of the Deck/

Cassette Pickup Roller ....... 6-202. .2 Orientation of the Deck/

Cassette SeparationRoller ................................. 6-21

2.4.3 Orientation of the FeedingRoller of the Deck/CassettePickup Assembly ............... 6-21


COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001xvi

CONTENTS

2.4.4 Orientation of the PickupRoller of the Manual FeedTray/Side Paper Deck ........ 6-22

2.4.5 Orientation for the FeedingRoller of the Manual FeedTray .................................... 6-23

2.4.6 Orientation of the FeedingRoller of the Side PaperDeck ................................... 6-23

2.4.7 Adjusting the Pressure ofthe Separation Roller ofthe Deck/Cassette .............. 6-24

2.4.8 Adjusting the Pressure ofthe Pickup/Feeding Rollerof the Manual Feed Tray ... 6-25

2.4.9 Position of the Solenoids ... 6-262.4.10 Position of the Fixing Web

Solenoid (SL2) .................. 6-272.4.11 Position of the Delivery

Flapper Solenoid (SL3) ..... 6-292.4.12 Position of the Fixing

Feeding Unit LockingSolenoid (SL4) .................. 6-30

2.4.13 Adjusting the Position forthe Multifeeder PickupLatch Solenoid (SL6) ........ 6-31

2.4.14 Position of the Deck (right)Pickup Solenoid (SL7) ...... 6-32

2.4.15 Position of the Deck (left)Pickup Solenoid (SL8) ...... 6-33

2.4.16 Position for the Cassette 3/4Pickup Solenoid(SL9/10) ............................. 6-34

2.4.17 Position of the Side Paper

. 6-35

Assembly Side Guide ........ 6-35

2.4.19 Attaching the Drive Belts .. 6-362.5 Fixing System .......................... 6-37

2.5.1 Points to Note WhenMounting the FixingHeater ................................. 6-37

2.5.2 Adjusting the Lower RollerPressure (nip width) ........... 6-38

2.6 Laser Exposure System ............ 6-392.6.1 Replacing the Laser Unit ... 6-392.6.2 Checking the Laser

Power ................................. 6-402.7 Items Related to Electrical

Components ............................. 6-432.7.1 Electrical Components

Requiring Work AfterReplacement ...................... 6-43

2.7.2 Points to Note whenReplacing the StandardWhite Plate ........................ 6-43

2.7.3 Points to Note whenReplacing the Scanninglamp ................................... 6-44

2.7.4 Points to Note whenReplacing the CCD Unit .... 6-44

2.7.5 When Replacing theReader Controller PCB ...... 6-46

2.7.6 Replacing the MainController PCB .................. 6-47

2.7.7 Replacing the HDDUnit .................................... 6-47

2.7.8 Replacing the DCController PCB .................. 6-48

2.7.9 After Replacingthe High-Voltage DCPCB .................................... 6-49

2.7.10 When Replacing the LaserUnit .................................... 6-50

2.7.11 Replacing the PotentialSensor/Potential ControlPCB .................................... 6-50

2.7.12 Checking the SurfacePotential Control System ... 6-54

2.8 Conversion Table forthe Potential Control System ... 6-62

2.9 Checking the EnvironmentSensor ....................................... 6-67

2.10 Checkingthe Photointerrupters ................ 6-68

3 Troubleshooting Image Faults .......... 6-74


COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001 xvii

CONTENTS

3.1 Making Initial Checks .............. 6-743.1.1 Site of Installation .............. 6-743.1.2 Checking the Originals

Against Symptoms ............. 6-743.1.3 Checking the Copyboard

Cover, Copyboard Glass,and Standard White Platefor Dirt and Scratches ........ 6-75

3.1.4 Checking the ChargingWires .................................. 6-75

3.1.5 Checking the DevelopingAssembly ........................... 6-75

3.1.6 Checking the Paper ............ 6-753.1.7 Checking the Periodically

Replaced Parts ................... 6-753.1.8 Others ................................ 6-75

3.2 Sample Faulty Images .............. 6-783.3 Troubleshooting Faulty

Images ...................................... 6-793.3.1 The copy is too light

(halftone area) .................... 6-793.3.2 The copy is too light

(solid black area) ............... 6-803.3.3 The copy is too light

(entire face,considerable) ...................... 6-80

3.3.4 The copy has unevendensity (darker front) ......... 6-82

3.3.5 The copy has unevendensity (lighter front) ......... 6-82

3.3.6 The copy is foggy(entire face) ........................ 6-83

3.3.7 The copy is foggy invertical direction ................ 6-84

p (vertical, fine) .................... 6-85

3.3.10 The copy has white spots(vertical). ............................ 6-86

3.3.11 The copy has white lines(vertical) ............................. 6-86

3.3.12 The copy has white spots(horizontal) ........................ 6-88

3.3.13 The b opy issoiled .................................. 6-89

3.3.14 The copy has faultyfixing .................................. 6-89

3.3.15 The copy has a displacedleading edge (considerablylarge margin) ...................... 6-90

3.3.16 The copy has a displacedleading edge(large margin) .................... 6-90

3.3.17 The copy has a displacedleading edge(no margin) ........................ 6-90

3.3.18 The copy is wobbly ........... 6-913.3.19 The copy is foggy

horizontally ........................ 6-923.3.20 The copy has poor

sharpness ............................ 6-923.3.21 The copy is blank .............. 6-933.3.22 The copy is solid black ...... 6-94

4 Troubleshooting Malfunctions ......... 6-954.1 Troubleshooting

Malfunctions ............................ 6-954.1.1 E000 ................................... 6-954.1.2 E001 ................................... 6-964.1.3 E002 ................................... 6-974.1.4 E003 ................................... 6-974.1.5 E004 ................................... 6-984.1.6 E005 ................................... 6-984.1.7 E010 ................................... 6-984.1.8 E012 ................................... 6-994.1.9 E013 ................................... 6-994.1.10 E014 ................................. 6-1004.1.11 E015 ................................. 6-100

.......................... 6-101

.......................... 6-102

.......................... 6-102

.......................... 6-1034.1.16 E043 ................................. 6-1034.1.17 E051 ................................. 6-1044.1.18 E065 ................................. 6-1054.1.19 E067 ................................. 6-1064.1.20 E068 ................................. 6-1074.1.21 E069 ................................. 6-1084.1.22 E100 ................................. 6-109


COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001xviii

CONTENTS

4.1.23 E110 ................................. 6-1094.1.24 E111 ................................. 6-1104.1.25 E121-0001 ....................... 6-1104.1.26 E121-0002 ....................... 6-1114.1.27 E202 (The keys in

the control panel becomelocked) ............................. 6-111

4.1.28 E204 (The keys inthe control panel becomelocked) ............................. 6-111

4.1.29 E211 ................................. 6-1124.1.30 E215 ................................. 6-1124.1.31 E218 ................................. 6-1124.1.32 E219 ................................. 6-1134.1.33 E220 ................................. 6-1134.1.34 E222 ................................. 6-1134.1.35 E226 ................................. 6-1134.1.36 E240 ................................. 6-1144.1.37 E241 ................................. 6-1144.1.38 E243 ................................. 6-1144.1.39 E251 ................................. 6-1154.1.40 E302 ................................. 6-1154.1.41 E320 ................................. 6-1154.1.42 E315 ................................. 6-1164.1.43 E320 ................................. 6-1164.1.44 E400 ................................. 6-1164.1.45 E402 ................................. 6-1174.1.46 E404 ................................. 6-1184.1.47 E405 ................................. 6-1204.1.48 E410 ................................. 6-1214.1.49 E422 ................................. 6-1224.1.50 E601 ................................. 6-1234.1.51 E602 ................................. 6-1234.1.52 E676 ................................. 6-1244.1.53 E677 ................................. 6-1244.1.54 E710-0001 (Reader

controller PCB), E710-0002(DC controller PCB), E710-0003 (Main controllerPCB) ................................ 6-124

4.1.55 E711-0001 (Readercontroller PCB), E711-0002(DC controller PCB), E711-0003 (Main controllerPCB) ................................ 6-124

4.1.56 E712 ................................. 6-1254.1.57 E713 ................................. 6-1254.1.58 E717 ................................. 6-1264.1.59 E732 ................................. 6-1264.1.60 E733 ................................. 6-1274.1.61 E737 ................................. 6-1274.1.62 E740 ................................. 6-1274.1.63 E741 ................................. 6-1284.1.64 E744 ................................. 6-1284.1.65 E800 ................................. 6-1284.1.66 E804 ................................. 6-1294.1.67 E805 ................................. 6-1294.1.68 E820 ................................. 6-1304.1.69 E823 ................................. 6-1304.1.70 E824 ................................. 6-1314.1.71 E830 ................................. 6-1314.1.72 AC power is absent .......... 6-1324.1.73 DC power is absent 1 ....... 6-1334.1.74 Pickup fails ...................... 6-1344.1.75 The lifter fails to

move up ........................... 6-1364.1.76 The lifter fails to move up

(pickup from cassette) ..... 6-1374.1.77 Pickup fails

(multifeeder) .................... 6-1384.1.78 The vertical path roller

fails to rotate .................... 6-1404.1.79 The registration roller

fails to rotate .................... 6-1424.1.80 The No. 1 mirror base

fails to operate ................. 6-1434.1.81 The pre-exposure lamp

fails to go ON .................. 6-1444.1.82 The scanning lamp fails

to go ON .......................... 6-1444.1.83 The toner feed motor

(M6) inside the cartridgefails to operate ................. 6-145

4.1.84 The toner feed motor(M18) inside the hopperfails to rotate .................... 6-145

4.1.85 The drum heater fails tooperate ............................. 6-146


COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.1 MAR. 2001 xix

CONTENTS


4.1.88 The “Card Reader Set”message fails to turnON ................................... 6-147

4.1.89 The “Control Card Set”message fails to goOFF .................................. 6-147

4.1.90 The “Add Paper” messagefails to go OFF(deck right/left) ................ 6-148

4.1.91 The “Add Paper Message”fails to go OFF(cassette 3/4) .................... 6-148

4.1.92 The fixing heater fails tooperate ............................. 6-149

4.1.93 Pickup fails(side paper deck) .............. 6-150

4.1.94 The deck lifter fails tomove up (side paperdeck) ................................ 6-151

5 Troubleshooting Feeding Faults ..... 6-1525.1 Copy Paper Jams .................... 6-152

5.1.1 Pickup Assembly ............. 6-1535.1.2 Separation/Feeding

Assembly ......................... 6-1545.1.3 Fixing/Delivery

Assembly ......................... 6-1555.1.4 Fixing, Delivery

Assembly (reversaldelivery assembly) ........... 6-156

5.1.5 Cleaning Assembly .......... 6-1565.1.6 Lower Feeding

Assembly ......................... 6-157 ........ 6-158

........ 6-158........ 6-158

g Electrical Parts ................................ 6-1596.1 Clutches ................................. 6-1606.2 Solenoids ................................ 6-1626.3 Motors .................................... 6-1646.4 Fans ........................................ 6-1666.5 Sensor 1 ................................. 6-1686.6 Sensor 2 ................................. 6-170

6.7 Switches ................................. 6-1726.8 Counters, Heaters, Fuses, and

Others ..................................... 6-1746.9 PCBs ...................................... 6-1766.10 Variable Registers (VR),

Light-Emitting Diodes, andCheck Pins by PCB ................ 6-178

6.10.1 Main Controller PCB ....... 6-1786.10.2 Reader Controller PCB .... 6-1796.10.3 DC Controller PCB ......... 6-1796.10.4 HV-DC PCB .................... 6-180

7 Upgrading ....................................... 6-1817.1 Outline ................................... 6-181

7.1.1 Download Mode .............. 6-1817.1.2 Making Pre-Checks ......... 6-182

7.2 Data Control ........................... 6-1857.3 Downloading the System

Software, RUI, and LanguageModule ................................... 6-188

7.3.1 Making Connections ........ 6-1887.3.2 Downloading ................... 6-1887.3.3 After Downloading .......... 6-194

7.4 Upgrading the BOOTROM ...................................... 6-194

7.4.1 Making Preparations ........ 6-1947.4.2 Connection ....................... 6-1957.4.3 Preparing BOOT ROM .... 6-1957.4.4 After Downloading .......... 6-199

7.5 Formatting the HDD .............. 6-2007.5.1 Making Connections ........ 6-2007.5.2 Starting Formatting .......... 6-2007.5.3 Points to Note When

Formatting the HardDisk .................................. 6-206

7.6 Upgrading by Repackingthe DIMM/ROM .................... 6-207

8 Backing Up Data ............................ 6-2098.1 Outline ................................... 6-2098.2 Backing Up Data .................... 6-210

8.2.1 Making Preparations ........ 6-2108.2.2 Making Connections ........ 6-2108.2.3 Backing Up Data ............. 6-2118.2.4 Downloading Backup

Data .................................. 6-2168.2.5 Managing Backup Data ... 6-220


COPYRIGHT© 2001 CANON INC. CANON iR8500 REV.0 MAR. 2001xx

CONTENTS

ERROR CODE1 Error Codes ........................................ E-1

1.1 Introduction ............................... E-1

APPENDIX1 GENERAL TIMING CHART ........... A-12 GENERAL CIRCUIT DIAGRAM .... A-3

4 Special Tools Table ......... A-75 Solvents/Oils ......... ....... A-10

SERVICE MODE1 Construction of Service Mode ............ S-1

1.1 Outline ....................................... S-11.2 Starting Service Mode and

Making Selections ..................... S-21.3 Ending Service Mode ................ S-31.4 Backing Up Service Mode ......... S-31.5 Basic Operation .......................... S-4

1.5.1 Initial Screen ........................ S-41.5.2 Level 1/Level 2 Items

Screen .................................. S-41.5.3 Level 3 Items Screen ........... S-5

2 COPIER .............................................. S-62.1 DISPLAY ................................... S-62.2 I/O ............................................ S-232.3 ADJUST................................... S-49

2.4 FUNCTION . ........ S-662.5 OPTION ....... ........ S-832.6 TEST ............ ...... S-1012.7 COUNTER ... ...... S-109

3 FEEDER ............... ...... S-1163.1 DISPLAY ..... ...... S-1163.2 ADJUST....... ...... S-1163.3 FUNCTION . ...... S-1183.4 OPTION ....... ...... S-119

4 SORTER ............... ...... S-1204.1 ADJUST....... ...... S-1204.2 OPTION ....... ...... S-121

5 BOARD ................ ...... S-1225.1 OPTION ................................. S-122

PARTS CATALOG

iR8500/85/85+/7200/8070

Jan 18 200
5

Contents

Parts List Index

iR8500/85/85+/7200/8070 ......................................................................1-1

iR8500/85/85+/7200/8070

A ASSEMBLY LOCATION DIAGRAM ......................................2-1020 SPECIAL TOOLS ....................................................................2-7100 EXTERNAL COVERS, PANELS, ETC. (IR8500/7200/8570/8070 TYPE)

2-8100A EXTERNAL COVERS, PANELS, ETC. (IR8500B/85/85+ TYPE) 2-14101 MACHINE FRONT PLATE ...................................................2-18102 INTERNAL COMPONENTS 1 ...............................................2-22103 INTERNAL COMPONENTS 2 ...............................................2-26104 INTERNAL COMPONENTS 3 ...............................................2-29105 INTERNAL COMPONENTS 4 ...............................................2-32106 MACHINE REAR PLATE 1 ...................................................2-36107 MACHINE REAR PLATE 2 ...................................................2-38108 MACHINE BOTTOM PLATE ................................................2-41110 POWER CORD TERMINAL ASSEMBLY (100V) ................2-42111 POWER CORD TERMINAL ASSEMBLY (208/220/240V) ...2-44120 DOOR SWITCH MOUNT ASSEMBLY ..................................2-46130 CONTROL PANEL ASSEMBLY ...........................................2-48190 FIXING EXHAUST FAN ASSEMBLY ...................................2-52194 SCANNER COOLING FAN ASSEMBLY ...............................2-53195 DRUM INTAKE FAN ASSEMBLY ........................................2-54210 LENS MOUNT ASSEMBLY (IR8500/8500P/8570N TYPE) .....2-55210A LENS MOUNT ASSEMBLY (IR8500B/85/85+ TYPE) ............2-61211 READER ASSEMBLY (IR7200/7200P/8070/7270N TYPE) .....2-63215 SCANNER MOUNT ASSEMBLY ..........................................2-69230 VERTICAL PATH DRIVE ASSEMBLY .................................2-72231 LIFTER DRIVE ASSEMBLY .................................................2-73250 MAIN DRIVE ASSEMBLY ...................................................2-74251 DRUM DRIVE ASSEMBLY ..................................................2-77260 PAPER PICK-UP DRIVE ASSEMBLY ...................................2-78261 CASSETTE PICK-UP DRIVE ASSEMBLY ............................2-80263 LEFT PICK-UP DRIVE ASSEMBLY ......................................2-81264 MULTI FEED DRIVE ASSEMBLY ........................................2-82270 DEVELOPING DRIVE ASSEMBLY ......................................2-84275 TONER CARTRIDGE DRIVE ASSEMBLY ............................2-86280 WASTE TONER DRIVE ASSEMBLY ....................................2-91300 CASSETTE ...........................................................................2-93302 1.5K RIGHT PAPER STOCK ASSEMBLY .............................2-97


Contents

303 1.5K LEFT PAPER STOCK ASSEMBLY ..............................2-100305 CASSETTE HEATER ASSEMBLY ......................................2-104311 CASSETTE PICK-UP ASSEMBLY ......................................2-105312 FRONT DECK RIGHT PICK-UP ASSEMBLY ......................2-110313 FRONT DECK LEFT PICK-UP ASSEMBLY ........................2-114315 MULTI FEED ASSEMBLY ..................................................2-118316 MULTI FEED TRAY ASSEMBLY .......................................2-122320 FIXING/FEEDER FRAME ASSEMBLY ...............................2-124325 REGISTRATION/TRANSFER ASSEMBLY .........................2-134330 FEEDER ASSEMBLY .........................................................2-137350 INTERNAL DELIVERY UPPER ASSEMBLY ......................2-139351 EXTERNAL DELIVERY UPPER ASSEMBLY .....................2-142360 DUPLEXING FEEDER ASSEMBLY ....................................2-145420 MIRROR ASSEMBLY 1 (IR8500/8500P/8570N TYPE) .........2-153421 MIRROR ASSEMBLY 1 (IR7200/8070/7270N TYPE) ...........2-156430 MIRROR ASSEMBLY 2 (IR8500/8500P/8570N TYPE) .........2-158431 MIRROR ASSEMBLY 2 (IR7200/8070/7270N TYPE) ...........2-159460 SCANNER ASSEMBLY ......................................................2-161510 PHOTO-SENSITIVE DRUM ASSEMBLY ............................2-163550 PRIMARY CORONA ASSEMBLY ......................................2-165570 PRE-TRANSFER CORONA ASSEMBLY .............................2-168580 TRANSFER/SEPARATE CORONA ASSEMBLY .................2-170600 AP KIT ASSEMBLY ...........................................................2-173640 DEVELOPING ASSEMBLY ................................................2-179645 BUFFER ASSEMBLY .........................................................2-182720 SEPARATION CLAW DRIVE ASSEMBLY .........................2-185770 WASTE TONER ASSEMBLY ..............................................2-187775 WASTE TONER PIPE ASSEMBLY .....................................2-189810 FIXING ASSEMBLY ...........................................................2-190900 CONTROLLER BOX ASSEMBLY (IR8500/85/7200 TYPE) ..2-197900A CONTROLLER BOX ASSEMBLY (IR8570N/8070/85+ TYPE) 2-200910 DC POWER SUPPLY PCB ASSEMBLY ..............................2-203920 CONTROL PANEL CPU PCB ASSEMBLY ..........................2-205925 CONTROL PANEL INVERTER PCB ASSEMBLY ...............2-206930 DC CONTROLLER PCB ASSEMBLY ..................................2-207935 READER CONTROLLER PCB ASSEMBLY (IR8500/8570N TYPE) 2-

208936 READER CONTROLLER PCB ASSEMBLY (IR7200/8070 TYPE) 2-

209940 POTENTIAL MEASURING PCB ASSEMBLY .....................2-210945 INVERTER PCB ASSEMBLY .............................................2-212960 AC DRIVER PCB ASSEMBLY ............................................2-213970 DOCUMENT DETECT PCB ASSEMBLY (iR8500/8500P TYPE) 2-

214980 H.V. AC TRANSFORMER PCB ASSEMBLY .......................2-215

Contents

985 H.V. DC TRANSFORMER PCB ASSEMBLY .......................2-216B LIST OF CONNECTORS .....................................................2-218

COPYRIGHT C 2001 CANON INC. CANON iR8500/8500P/7200/7200P REV.1 OCT. 2001 PRINTED IN U.S.A. [IMPRIME AU U.S.A.

PARTSCATALOGREVISION 1

OCT. 2001 FY8-31F7-010 I - 1

CONTENTS

－ iR8500/8500P/7200/7200P －

A. ASSEMBLY LOCATION DIAGRAM

020. SPECIAL TOOLS

100. EXTERNAL COVERS, PANELS, ETC.

101. MACHINE FRONT PLATE

102. INTERNAL COMPONENTS 1




106. MACHINE REAR PLATE 1

107. MACHINE REAR PLATE 2

108. MACHINE BOTTOM PLATE

110. POWER CORD TERMINAL ASSEMBLY

(100V)

111. POWER CORD TERMINAL ASSEMBLY

(208/220/240V)

120. DOOR SWITCH MOUNT ASSEMBLY

130. CONTROL PANEL ASSEMBLY

190. FIXING EXHAUST FAN ASSEMBLY

194. SCANNER COOLING FAN ASSEMBLY

195. DRUM INTAKE FAN ASSEMBLY

210. LENS MOUNT ASSEMBLY

(iR8500/8500P TYPE)

211. READER ASSEMBLY (iR7200/7200P TYPE)

215. SCANNER MOUNT ASSEMBLY

230. VERTICAL PATH DRIVE ASSEMBLY

231. LIFTER DRIVE ASSEMBLY

250. MAIN DRIVE ASSEMBLY

251. DRUM DRIVE ASSEMBLY

260. PAPER PICK-UP DRIVE ASSEMBLY

261. CASSETTE PICK-UP DRIVE ASSEMBLY

263. LEFT PICK-UP DRIVE ASSEMBLY

264. MULTI FEED DRIVE ASSEMBLY

270. DEVELOPING DRIVE ASSEMBLY

275. TONER CARTRIDGE DRIVE ASSEMBLY

280. WASTE TONER DRIVE ASSEMBLY

300. CASSETTE

302. 1.5K RIGHT PAPER STOCK ASSEMBLY

303. 1.5K LEFT PAPER STOCK ASSEMBLY

305. CASSETTE HEATER ASSEMBLY

311. CASSETTE PICK-UP ASSEMBLY

312. FRONT DECK RIGHT PICK-UP ASSEMBLY

313. FRONT DECK LEFT PICK-UP ASSEMBLY

315. MULTI FEED ASSEMBLY

316. MULTI FEED TRAY ASSEMBLY

320. FIXING/FEEDER FRAME ASSEMBLY

325. REGISTRATION/TRANSFER ASSEMBLY

330. FEEDER ASSEMBLY

350. INTERNAL DELIVERY UPPER ASSEMBLY

351. EXTERNAL DELIVERY UPPER ASSEMBLY

360. DUPLEXING FEEDER ASSEMBLY

420. MIRROR ASSEMBLY 1 (iR8500/8500P TYPE)




460. SCANNER ASSEMBLY

510. PHOTO-SENSITIVE DRUM ASSEMBLY

550. PRIMARY CORONA ASSEMBLY

570. PRE-TRANSFER CORONA ASSEMBLY

580. TRANSFER/SEPARATE CORONA ASSEMBLY

600. AP KIT ASSEMBLY

640. DEVELOPING ASSEMBLY

645. BUFFER ASSEMBLY

720. SEPARATION CLAW DRIVE ASSEMBLY

770. WASTE TONER ASSEMBLY

775. WASTE TONER PIPE ASSEMBLY

810. FIXING ASSEMBLY

900. CONTROLLER BOX ASSEMBLY

910. DC POWER SUPPLY PCB ASSEMBLY

920. CONTROL PANEL CPU PCB ASSEMBLY

925. CONTROL PANEL INVERTER PCB ASSEMBLY

930. DC CONTROLLER PCB ASSEMBLY

935. READER CONTROLLER PCB ASSEMBLY

(iR8500/8500P TYPE)

936. READER CONTROLLER PCB ASSEMBLY

(iR7200/7200P TYPE)

940. POTENTIAL MEASURING PCB ASSEMBLY

945. INVERTER PCB ASSEMBLY

960. AC DRIVER PCB ASSEMBLY

970. DOCUMENT DETECT PCB ASSEMBLY

(iR8500/8500P TYPE)

980. H.V. AC TRANSFORMER PCB ASSEMBLY

985. H.V. DC TRANSFORMER PCB ASSEMBLY

B. LIST OF CONNECTORS

COPYRIGHT © 2001 CANO Ⅰ-5


CONTENTS

－－

UA. ASSEMBLY LOCATION DIAGRAM

U10. LIPS PRINTER KIT ASSEMBLY

U90. LIPS BOARD PCB ASSEMBLY

－ Ethernet Network Interface Adapter

iN-E3 －

GA. ASSEMBLY LOCATION DIAGRAM

G10. NETWORK MULTI PDL PRINTER KIT ASSEMBLY

C. LIST OF STANDARD FASTENERS

D1. NUMERICAL INDEX

(iR8500/8500P/7200/7200P)

D2. NUMERICAL INDEX

D3. NUMERICAL INDEX

(Ethernet Network Interface Adapter

iN-E3)

COPYRIGHT © 2001 CANON INC. CANON iR8500/8500P/7200/7200P REV.1 OCT. 2001Ⅰ-6

CANON imageRUNNER iR-8500 iR-85+ iR-105 iR-7200 iR-8070 iR-9070 service manual


















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