Feb 8 2007

Service Manual

iR C5180/4580/3880 Series

ApplicationThis manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair

of products. This manual covers all localities where the products are sold. For this reason, there may be information in this

manual that does not apply to your locality.

CorrectionsThis manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When

changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need

arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition

of this manual.

The following paragraph does not apply to any countries where such provisions are inconsistent with local law.

TrademarksThe product names and company names used in this manual are the registered trademarks of the individual companies.

CopyrightThis manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or

translated into another language, in whole or in part, without the written consent of Canon Inc.

COPYRIGHT 2001 CANON INC.Printed in Japan

CautionUse of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction

Symbols UsedThis documentation uses the following symbols to indicate special information:

Symbol Description

Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.

Indicates an item requiring care to avoid electric shocks.

Indicates an item requiring care to avoid combustion (fire).

Indicates an item prohibiting disassembly to avoid electric shocks or problems.

Indicates an item requiring disconnection of the power plug from the electric outlet.

Indicates an item intended to provide notes assisting the understanding of the topic in question.

Indicates an item of reference assisting the understanding of the topic in question.

Provides a description of a service mode.

Provides a description of the nature of an error indication.

Memo

REF.

Introduction

The following rules apply throughout this Service Manual:1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with refer-

ence to the timing of operation.In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol , the arrow indicates thedirection of the electric signal.The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results insupplying the machine with power.

2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to indicate "Low".(The voltage value, how-ever, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'.In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessorsused in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of theDC controller PCB to the loads.

The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be com-municated in the form of Service Information bulletins.All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and beable to identify and isolate faults in the machine."

ContentsContents

Chapter 1 Introduction

1.1 System Construction ..................................................................................................................................1- 11.1.1 System Configuration with Pickup/Delivery Accessories [EUR] ..............................................................................1- 11.1.2 System Configuration with Pickup/Delivery Accessories [EUR] ..............................................................................1- 21.1.3 System Configuration with Printing/Transmission Accessories [EUR] ....................................................................1- 31.1.4 System Configuration with Printing/Transmission Accessories [EUR] ....................................................................1- 41.1.5 Functions of Printing/Transmission Accessories .....................................................................................................1- 51.1.6 Overview of Printing/Transmitting Accessories ....................................................................................................... 1- 5

1.2 Product Specifications ................................................................................................................................1- 61.2.1 Names of Parts........................................................................................................................................................1- 6

1.2.1.1 External View ........................................................................................................................................................................... 1- 61.2.1.2 Cross Section........................................................................................................................................................................... 1- 7

1.2.2 Using the Machine................................................................................................................................................... 1- 81.2.2.1 Turning On the Power Switch .................................................................................................................................................. 1- 81.2.2.2 Points to Note About Turing Off the Main Power Switch ......................................................................................................... 1- 91.2.2.3 Control Panel ......................................................................................................................................................................... 1- 10

1.2.3 User Mode Items ...................................................................................................................................................1- 111.2.3.1 Common Settings .................................................................................................................................................................. 1- 111.2.3.2 Timer Settings........................................................................................................................................................................ 1- 121.2.3.3 Adjustments and Cleaning ..................................................................................................................................................... 1- 121.2.3.4 Report Settings ...................................................................................................................................................................... 1- 131.2.3.5 System Settings ..................................................................................................................................................................... 1- 131.2.3.6 Copy Settings......................................................................................................................................................................... 1- 151.2.3.7 Communications Settings ...................................................................................................................................................... 1- 161.2.3.8 Mail Box Settings ................................................................................................................................................................... 1- 171.2.3.9 Printer Settings ...................................................................................................................................................................... 1- 171.2.3.10 Address Book Settings......................................................................................................................................................... 1- 19

1.2.4 User Maintenance ................................................................................................................................................. 1- 191.2.4.1 Cleaning................................................................................................................................................................................. 1- 191.2.4.2 Inspection............................................................................................................................................................................... 1- 20

1.2.5 Safety ....................................................................................................................................................................1- 221.2.5.1 CDRH Regulations................................................................................................................................................................. 1- 221.2.5.2 Laser safety ........................................................................................................................................................................... 1- 221.2.5.3 Handling the Laser Assembly ................................................................................................................................................ 1- 221.2.5.4 Safety of Toner ...................................................................................................................................................................... 1- 231.2.5.5 Notes when handling a lithium battery ................................................................................................................................... 1- 231.2.5.6 Notes at Replacing/Disposing the Fixing Unit........................................................................................................................ 1- 231.2.5.7 Notes before it works serving................................................................................................................................................. 1- 23

1.2.6 Product Specifications ...........................................................................................................................................1- 241.2.6.1 Type and Functions ............................................................................................................................................................... 1- 24

1.2.7 Function List ..........................................................................................................................................................1- 241.2.7.1 Print Speed ............................................................................................................................................................................ 1- 241.2.7.2 Print Size................................................................................................................................................................................ 1- 271.2.7.3 Others .................................................................................................................................................................................... 1- 271.2.7.4 Reader Unit Specifications..................................................................................................................................................... 1- 28

Chapter 2 Installation

2.1 Making Pre-Checks ....................................................................................................................................2- 12.1.1 Points to Note ..........................................................................................................................................................2- 12.1.2 Spatial Requirements ..............................................................................................................................................2- 22.1.3 Order of Installing Accessories................................................................................................................................2- 42.1.4 Checking the Contents ...........................................................................................................................................2- 4

Contents2.1.5 Checking the Contents ............................................................................................................................................2- 62.1.6 Checking the Contents (Color Image Reader-E1 / F1) ............................................................................................2- 8

2.2 Unpacking and Installation ......................................................................................................................... 2- 82.2.1 Installing the Printer Kit ............................................................................................................................................2- 82.2.2 Points to Note About Relocating the machine .........................................................................................................2- 92.2.3 Mounting the Reader Unit (Color Image Reader E1/F1)..........................................................................................2- 92.2.4 Mounting the Transfer Cleaning Unit .....................................................................................................................2- 132.2.5 Fitting the Toner Container in Place ......................................................................................................................2- 142.2.6 Fitting the Drum Unit in Place ................................................................................................................................2- 142.2.7 Fitting the Secondary Transfer Outside Roller Unit in Place..................................................................................2- 162.2.8 Cassette Setup .....................................................................................................................................................2- 172.2.9 Other Work ............................................................................................................................................................2- 172.2.10 Other Work ..........................................................................................................................................................2- 182.2.11 Dealing with power code mount ...........................................................................................................................2- 182.2.12 Connecting the Power Cord ................................................................................................................................2- 202.2.13 Adjustment of Fixing Assembly ............................................................................................................................2- 202.2.14 Checking the Image Margin ................................................................................................................................2- 202.2.15 Adjustment of Left Margin of Image ....................................................................................................................2- 202.2.16 Adjustment of the Margin along Leading Edge of Image .....................................................................................2- 212.2.17 Adjustment of the Image Area (non-image width)................................................................................................2- 222.2.18 Setting the Auto Gradation Adjustment ...............................................................................................................2- 22

2.3 Checking the Connection to the Network ................................................................................................. 2- 222.3.1 Summary................................................................................................................................................................2- 222.3.2 Checking the Network Connection ........................................................................................................................2- 222.3.3 Ping Operation ......................................................................................................................................................2- 22

2.4 Troubleshooting the Network ................................................................................................................... 2- 222.4.1 Summary................................................................................................................................................................2- 222.4.2 Checking the Connection of Network Cable .........................................................................................................2- 232.4.3 Making a Check Using a Loopback Address .........................................................................................................2- 232.4.4 Making a Check Using a Local Host Address .......................................................................................................2- 23

2.5 Installing the Copy Tray............................................................................................................................ 2- 232.5.1 Checking the Attachments (Copy Tray-N1) ...........................................................................................................2- 232.5.2 Turning Off the Host Machine ................................................................................................................................2- 232.5.3 Installation Procedure ............................................................................................................................................2- 23

2.6 Installing the Card Reader........................................................................................................................ 2- 252.6.1 Checking Contents (Card Reader-D1)...................................................................................................................2- 252.6.2 Turning off the Host Machine.................................................................................................................................2- 252.6.3 Installation Procedures ..........................................................................................................................................2- 262.6.4 Installation Procedure in the imageWARE Accounting Manager (henceforth: iWAM) environment ......................2- 27

2.7 Installing the Key Switch Unit ................................................................................................................... 2- 272.7.1 Checking Contents (Key Switch Unit-A2) ..............................................................................................................2- 272.7.2 Turning off the Host Machine.................................................................................................................................2- 282.7.3 Installation Procedures .........................................................................................................................................2- 282.7.4 Checking After the Installation ..............................................................................................................................2- 29

2.8 Installing the Reader Heater..................................................................................................................... 2- 302.8.1 Checking the Attachments (Reader Heater Unit-F1) .............................................................................................2- 302.8.2 Turning Off the Host Machine ................................................................................................................................2- 302.8.3 Installation Procedure ............................................................................................................................................2- 30

2.9 Installing the Cassette Heater .................................................................................................................. 2- 372.9.1 Checking the Attachments (Cassette Heater Kit-E1).............................................................................................2- 372.9.2 Checking the Attachments (Cassette Heater Unit-24) ...........................................................................................2- 382.9.3 Turning Off the Host Machine ................................................................................................................................2- 382.9.4 Installation Procedure (Cassette Heater Kit-E1) ....................................................................................................2- 382.9.5 Installation Procedure (Cassette Heater Unit-24) ..................................................................................................2- 39

2.10 Installing the Deck Heater ...................................................................................................................... 2- 41

Contents2.10.1 Checking the Contents ........................................................................................................................................2- 412.10.2 Installation Procedure ..........................................................................................................................................2- 41

2.11 Installing the Voice Guidance Kit ............................................................................................................2- 472.11.1 Checking Contents (Voice Guidance Kit-A2).......................................................................................................2- 472.11.2 Turning off the Host Machine...............................................................................................................................2- 482.11.3 Installation Procedures ........................................................................................................................................2- 48

Chapter 3 Basic Operation

3.1 Construction ...............................................................................................................................................3- 13.1.1 Functional Construction...........................................................................................................................................3- 1

3.2 Basic Sequence..........................................................................................................................................3- 13.2.1 Basic Sequence When the Power Is ON ................................................................................................................3- 13.2.2 Basic Sequence of Operations ................................................................................................................................3- 2

Chapter 4 Basic Operations (As a Printer)

4.1 Construction of the Electrical Circuitry........................................................................................................4- 14.1.1 Configuration of Main PCBs ....................................................................................................................................4- 14.1.2 DC Controller PCB 1 (IMG) .....................................................................................................................................4- 14.1.3 DC Controller PCB 2 (MAISY) ................................................................................................................................4- 2

4.2 Basic Sequence..........................................................................................................................................4- 34.2.1 Basic Sequence of Operations ................................................................................................................................4- 34.2.2 Basic Sequence of Operations ................................................................................................................................4- 4

Chapter 5 Main Controller

5.1 Construction ...............................................................................................................................................5- 15.1.1 Configuration/Functions...........................................................................................................................................5- 1

5.2 Construction of the Electrical Circuitry........................................................................................................5- 25.2.1 Main Controller Circuit Board (MAIN) ......................................................................................................................5- 25.2.2 SRAM Circuit Board ................................................................................................................................................ 5- 2

5.3 Start-Up Sequence .....................................................................................................................................5- 35.3.1 Overview..................................................................................................................................................................5- 35.3.2 Start-Up Sequence ..................................................................................................................................................5- 3

5.4 Actions when HDD Error.............................................................................................................................5- 55.4.1 E602 Details ............................................................................................................................................................5- 5

5.5 Image Processing.......................................................................................................................................5- 75.5.1 Overview of the Flow of Image Data .......................................................................................................................5- 75.5.2 Reader Input Image Processing ..............................................................................................................................5- 85.5.3 Printer Output Image Processing ............................................................................................................................5- 85.5.4 Compression, Decompression, and Edit Processing Blocks...................................................................................5- 9

5.6 Flow of Image Data ..................................................................................................................................5- 105.6.1 Flow of Image Data for Copier Functions ..............................................................................................................5- 105.6.2 Flow of Image Data for Box Functions ..................................................................................................................5- 105.6.3 Flow of Image Data for SEND Functions...............................................................................................................5- 115.6.4 Flow of Image Data for Fax Transmission Functions ............................................................................................5- 115.6.5 Flow of Image Data for Fax Reception Functions .................................................................................................5- 125.6.6 Flow of Image Data for PDL Functions..................................................................................................................5- 12

5.7 Parts Replacement Procedure .................................................................................................................5- 145.7.1 Main Controller Box ...............................................................................................................................................5- 14

5.7.1.1 Preparation for Removing the Main Controller Box ............................................................................................................... 5- 145.7.1.2 Removing the Main Controller Box ........................................................................................................................................ 5- 145.7.1.3 Removing the Main Controller Box ........................................................................................................................................ 5- 14

5.7.2 Main Controller PCB (main)...................................................................................................................................5- 145.7.2.1 Preparation for Removing the Main Controller PCB (main) ................................................................................................... 5- 14

Contents

5.7.2.2 Removing the Main Controller PCB (main)............................................................................................................................ 5- 14

5.7.3 Main Controller PCB (sub R-A)..............................................................................................................................5- 17

5.7.3.1 Preparation for Removing the Main Controller PCB (sub R-A).............................................................................................. 5- 175.7.3.2 Removing the Main Controller PCB (sub R-A)....................................................................................................................... 5- 175.7.3.3 Removing the Main Controller PCB (sub R-A)....................................................................................................................... 5- 18

5.7.4 Main Controller PCB (sub PDRM-A)......................................................................................................................5- 195.7.4.1 Preparation for Removing the Main Controller PCB (sub PDRM-EF-A) ................................................................................ 5- 195.7.4.2 Removing the Main Controller PCB (sub PDRM-EF-A)......................................................................................................... 5- 19

5.7.5 Main Controller PCB (sub SJ-A) ............................................................................................................................5- 195.7.5.1 Preparation for Removing the Main Controller PCB (sub SJ-A) ............................................................................................ 5- 195.7.5.2 Removing the Main Controller PCB (sub SJ-A) ..................................................................................................................... 5- 195.7.5.3 Preparation for Removing the Main Controller PCB (sub S-JJ)............................................................................................. 5- 205.7.5.4 Removing the Main Controller PCB (sub S-JJ)...................................................................................................................... 5- 20

5.7.6 Main Controller PCB (sub LAN-A) .........................................................................................................................5- 215.7.6.1 Preparation for Removing the Main Controller PCB (sub LAN-bar-C)................................................................................... 5- 215.7.6.2 Removing the Main Controller PCB (sub LAN-bar-C)............................................................................................................ 5- 21

5.7.7 Main Controller PCB (sub RB-A) ...........................................................................................................................5- 215.7.7.1 Preparation for Removing the Main Controller PCB (sub RB-A) ........................................................................................... 5- 215.7.7.2 Removing the Main Controller PCB (sub RB-A) .................................................................................................................... 5- 21

5.7.8 SRAM PCB ............................................................................................................................................................5- 225.7.8.1 Preparation for Removing the SRAM PCB ............................................................................................................................ 5- 225.7.8.2 Removing the SRAM PCB ..................................................................................................................................................... 5- 225.7.8.3 When Replacing the SRAM PCB........................................................................................................................................... 5- 23

5.7.9 Boot ROM PCB......................................................................................................................................................5- 235.7.9.1 Preparation for Removing the Boot ROM PCB...................................................................................................................... 5- 235.7.9.2 Removing the Boot ROM PCB............................................................................................................................................... 5- 23

5.7.10 Image Memory (SDRAM).....................................................................................................................................5- 245.7.10.1 Preparation for Removing the Image Memory (SDRAM)..................................................................................................... 5- 245.7.10.2 Removing the Image Memory (SDRAM) PCB ..................................................................................................................... 5- 24

5.7.11 HDD .....................................................................................................................................................................5- 255.7.11.1 Preparation for Removing the HDD ..................................................................................................................................... 5- 255.7.11.2 Removing the HDD .............................................................................................................................................................. 5- 255.7.11.3 When Replacing the HDD .................................................................................................................................................... 5- 25

5.7.12 Controller Fan ......................................................................................................................................................5- 265.7.12.1 Preparation for Removing the Controller Fan ...................................................................................................................... 5- 265.7.12.2 Removing the Controller Fan ............................................................................................................................................... 5- 26

Chapter 6 Original Exposure System

6.1 Construction ............................................................................................................................................... 6- 16.1.1 Specifications, Control Mechanisms, and Functions ...............................................................................................6- 16.1.2 Major Components...................................................................................................................................................6- 16.1.3 Construction of the Control System .........................................................................................................................6- 56.1.4 Reader Controller PCB ............................................................................................................................................6- 7

6.2 Basic Sequence ......................................................................................................................................... 6- 76.2.1 Basic Sequence of Operation at Power-On.............................................................................................................6- 76.2.2 Basic Sequence of Operation in Response to a Press on the Start Key .................................................................6- 8

6.3 Various Control Mechanisms ..................................................................................................................... 6- 96.3.1 Controlling the Scanner Drive System.....................................................................................................................6- 9

6.3.1.1 Overview .................................................................................................................................................................................. 6- 96.3.1.2 Controlling the Scanner Motor ............................................................................................................................................... 6- 10

6.3.2 Enlargement/Reduction .........................................................................................................................................6- 116.3.2.1 Changing the Magnification in Main Scanning Direction........................................................................................................ 6- 116.3.2.2 Changing the Magnification in Sub Scanning Direction ......................................................................................................... 6- 11

6.3.3 Controlling the Scanning Lamp..............................................................................................................................6- 116.3.3.1 Overview ................................................................................................................................................................................ 6- 116.3.3.2 Scanning Lamp ...................................................................................................................................................................... 6- 126.3.3.3 Turning On and Off the Scanning Lamp ................................................................................................................................ 6- 12

6.3.4 Detecting the Size of Originals...............................................................................................................................6- 12

Contents

6.3.4.1 Identifying the Size of Originals ............................................................................................................................................. 6- 12

6.3.4.2 Points of Measurement Used for Original Size Identification................................................................................................. 6- 126.3.4.3 Overview of Operation ........................................................................................................................................................... 6- 14

6.3.5 Dirt Sensor Control ................................................................................................................................................6- 156.3.5.1 Stream Reading Dust Detection Control ................................................................................................................................ 6- 156.3.5.2 White Plate Dust Detection Control ....................................................................................................................................... 6- 16

6.3.6 Image Processing..................................................................................................................................................6- 176.3.6.1 Overview ................................................................................................................................................................................ 6- 176.3.6.2 CCD Drive.............................................................................................................................................................................. 6- 186.3.6.3 CCD Gain Correction, Offset Correction................................................................................................................................ 6- 196.3.6.4 CCD Output A/D Conversion ................................................................................................................................................. 6- 196.3.6.5 Outline of Shading Correction................................................................................................................................................ 6- 196.3.6.6 Shading Adjustment............................................................................................................................................................... 6- 196.3.6.7 Shading Correction ................................................................................................................................................................ 6- 19

6.4 Parts Replacement Procedure .................................................................................................................6- 206.4.1 Copyboard Glass...................................................................................................................................................6- 20

6.4.1.1 Removing the Copyboard Glass ............................................................................................................................................ 6- 206.4.2 Exposure Lamp .....................................................................................................................................................6- 20

6.4.2.1 Preparation for Removing the Scanning Lamp ...................................................................................................................... 6- 206.4.2.2 Removing the Scanning Lamp............................................................................................................................................... 6- 206.4.2.3 After Replacing the Scanning Lanp ....................................................................................................................................... 6- 21

6.4.3 Reader Controller PCB..........................................................................................................................................6- 216.4.3.1 Preparation for Removing the Reader Controller PCB .......................................................................................................... 6- 216.4.3.2 Removing the Reader Controller PCB ................................................................................................................................... 6- 216.4.3.3 After Replacing the Reader Controller PCB........................................................................................................................... 6- 226.4.3.4 After Replacing the Reader Controller PCB........................................................................................................................... 6- 22

6.4.4 Interface PCB ........................................................................................................................................................6- 236.4.4.1 Preparation for Removing the Interface PCB......................................................................................................................... 6- 236.4.4.2 Removing the Interface PCB ................................................................................................................................................. 6- 236.4.4.3 Removing the Interface PCB ................................................................................................................................................. 6- 236.4.4.4 Points to Note When Attaching the Interface PCB................................................................................................................. 6- 24

6.4.5 Inverter PCB ..........................................................................................................................................................6- 246.4.5.1 Preparation for Removing the Inverter PCB .......................................................................................................................... 6- 246.4.5.2 Removing the Inverter PCB ................................................................................................................................................... 6- 246.4.5.3 After Replacing the Inverter PCB........................................................................................................................................... 6- 25

6.4.6 CCD Unit ............................................................................................................................................................... 6- 256.4.6.1 Preparation for Removing the CCD Unit................................................................................................................................ 6- 256.4.6.2 Removing the CCD Unit......................................................................................................................................................... 6- 256.4.6.3 After Replacing the CCD Unit ................................................................................................................................................ 6- 256.4.6.4 After Replacing the CCD Unit ................................................................................................................................................ 6- 26

6.4.7 Scanner Motor .......................................................................................................................................................6- 266.4.7.1 Preparation for Removing the Scanner Motor ....................................................................................................................... 6- 266.4.7.2 Removing the Scanner Motor ................................................................................................................................................ 6- 266.4.7.3 Attaching the Scanner Motor ................................................................................................................................................. 6- 26

6.4.8 ADF Open/Close Sensor .......................................................................................................................................6- 276.4.8.1 Preparation for Removing the ADF Open /Close Sensor ...................................................................................................... 6- 276.4.8.2 Removing the ADF Open/Closed Sensor .............................................................................................................................. 6- 27

6.4.9 Scanner HP Sensor...............................................................................................................................................6- 276.4.9.1 Preparation for Removing the Mirror Base Home Position Sensor........................................................................................ 6- 276.4.9.2 Removing the Mirror Base Home Position Sensor ................................................................................................................ 6- 27

6.4.10 Original Sensor ....................................................................................................................................................6- 286.4.10.1 Preparation for Removing the Original Size Sensor ............................................................................................................ 6- 286.4.10.2 Removing the Original Size Sensor ..................................................................................................................................... 6- 28

6.4.11 Cooling Fan .........................................................................................................................................................6- 286.4.11.1 Preparation for Removing the Cooling Fan.......................................................................................................................... 6- 286.4.11.2 Removing the Cooling Fan................................................................................................................................................... 6- 28

6.4.12 Scanner Drive Cable............................................................................................................................................6- 296.4.12.1 Preparation for Removing the Scanner Drive Cable ............................................................................................................ 6- 296.4.12.2 Removing the Scanner Drive Cable..................................................................................................................................... 6- 296.4.12.3 Attaching the Scanner Drive Cable ...................................................................................................................................... 6- 32

Contents

6.4.12.4 Adjusting the Position of the No. 1/No. 2 Mirror Base.......................................................................................................... 6- 33Chapter 7 Image Processing System

7.1 Digital Image Processing............................................................................................................................ 7- 17.1.1 Overview..................................................................................................................................................................7- 17.1.2 Shading Correction ..................................................................................................................................................7- 1

Chapter 8 Laser Exposure

8.1 Construction ............................................................................................................................................... 8- 18.1.1 Specifications, Control Mechanisms, and Functions ...............................................................................................8- 18.1.2 Major Components...................................................................................................................................................8- 18.1.3 Construction of the Control System .........................................................................................................................8- 2

8.2 Basic Sequence ......................................................................................................................................... 8- 38.2.1 Basic sequence of operation....................................................................................................................................8- 3

8.3 Various Control........................................................................................................................................... 8- 48.3.1 Controlling the Laser Activation Timing ...................................................................................................................8- 4

8.3.1.1 ON/OFF Control....................................................................................................................................................................... 8- 48.3.1.2 Controlling Synchronization in Main Scanning Direction ......................................................................................................... 8- 68.3.1.3 Controlling Synchronization in Sub Scanning Direction........................................................................................................... 8- 7

8.3.2 Controlling the Intensity of Laser Light.....................................................................................................................8- 88.3.2.1 APC Control ............................................................................................................................................................................. 8- 88.3.2.2 PWM Control............................................................................................................................................................................ 8- 8

8.3.3 Controlling the Laser Scanner Motor .......................................................................................................................8- 88.3.3.1 Laser scanner motor control .................................................................................................................................................... 8- 88.3.3.2 Laser Scanner Motor Speed Change Control.......................................................................................................................... 8- 9

8.3.4 Controlling the Laser Shutter .................................................................................................................................8- 108.3.4.1 Laser shutter control .............................................................................................................................................................. 8- 10

8.3.5 Correcting Image Displacement.............................................................................................................................8- 108.3.5.1 Outline.................................................................................................................................................................................... 8- 108.3.5.2 Timing of Color Displacement Detection/Correction .............................................................................................................. 8- 118.3.5.3 Detecting/Correcting Color Displacement in Sub Scanning Direction ................................................................................... 8- 118.3.5.4 Detecting/Correcting the Angle in Main Scanning Direction .................................................................................................. 8- 128.3.5.5 Detecting/Correcting Color Displacement in Main Scanning Direction .................................................................................. 8- 138.3.5.6 Detecting/Correcting Changes in the Reproduction Ratio in Main Scanning Direction ......................................................... 8- 14

8.4 Parts Replacement Procedure ................................................................................................................. 8- 168.4.1 Laser Unit...............................................................................................................................................................8- 16

8.4.1.1 Preparation for Removing the Laser Unit............................................................................................................................... 8- 168.4.1.2 Removing the Laser Unit ....................................................................................................................................................... 8- 168.4.1.3 After Replacing the Laser Unit ............................................................................................................................................... 8- 17

Chapter 9 Image Formation

9.1 Construction ............................................................................................................................................... 9- 19.1.1 Specifications, Control Mechanisms, and Functions ...............................................................................................9- 19.1.2 Major Components of the Image Formation System ...............................................................................................9- 29.1.3 Charging Specifications ...........................................................................................................................................9- 3

9.2 Image Formation Process .......................................................................................................................... 9- 49.2.1 Image Formation Process (general) ........................................................................................................................9- 49.2.2 Image Formation Process (image formation)...........................................................................................................9- 59.2.3 Image Formation Process (transfer) ........................................................................................................................9- 5

9.3 Basic Sequence ......................................................................................................................................... 9- 69.3.1 At Power-On (1) .......................................................................................................................................................9- 69.3.2 At Power-Oni2j ....................................................................................................................................................9- 79.3.3 During Copying/Printing Operations (normal speed) ...............................................................................................9- 79.3.4 Making Copies/Prints (half speed) ...........................................................................................................................9- 89.3.5 After Replacing the Drum Unit (D-UNIT)..................................................................................................................9- 8

Contents9.3.6 Printing Originals Containing a Color Page .............................................................................................................9- 99.4 Driving and Controlling the Image Formation System ................................................................................9- 9

9.4.1 Driving and Controlling the Image Formation System and the High-Voltage System .............................................9- 99.5 Image Stabilization Control.......................................................................................................................9- 10

9.5.1 Outline of Image Quality Control ...........................................................................................................................9- 109.5.2 Automated Image Stabilization Control .................................................................................................................9- 109.5.3 ATR Control...........................................................................................................................................................9- 139.5.4 Discharge Current Level Control ...........................................................................................................................9- 149.5.5 ATVC Control (transfer bias level correction) ........................................................................................................9- 149.5.6 PASCAL Control (image gradation).......................................................................................................................9- 149.5.7 SALT-Dmax Control (development characteristics correction)..............................................................................9- 159.5.8 SALT-Dhalf Control (development characteristics correction)...............................................................................9- 159.5.9 Auto Gradation Control..........................................................................................................................................9- 16

9.6 Drum Unit .................................................................................................................................................9- 179.6.1 Outline of the Drum Unit ........................................................................................................................................9- 17

9.6.1.1 Outline of the Drum Unit ........................................................................................................................................................ 9- 179.6.1.2 Drum Receptacle Presence / Absence Detection.................................................................................................................. 9- 179.6.1.3 Drum Unit (D-UNIT) Drive Control ......................................................................................................................................... 9- 18

9.6.2 Developing Assembly ............................................................................................................................................9- 189.6.2.1 Construction of the Developing Assembly ............................................................................................................................. 9- 189.6.2.2 Controlling the Developing Bias............................................................................................................................................. 9- 19

9.6.3 Auxiliary Brush.......................................................................................................................................................9- 209.6.3.1 Construction of the Auxiliary Brush........................................................................................................................................ 9- 209.6.3.2 Controlling the Auxiliary Bias ................................................................................................................................................. 9- 21

9.6.4 Charging Mechanism.............................................................................................................................................9- 249.6.4.1 Construction of the Charging Mechanism.............................................................................................................................. 9- 249.6.4.2 Controlling the Charging Bias ................................................................................................................................................ 9- 24

9.7 Toner Container........................................................................................................................................9- 269.7.1 Outline of the Toner Container ..............................................................................................................................9- 269.7.2 Toner Receptacle Presence / Absence Detection.................................................................................................9- 269.7.3 Controlling the Toner Container Drive ................................................................................................................... 9- 279.7.4 Checking the Level of Toner..................................................................................................................................9- 279.7.5 Controlling the Supply of Toner .............................................................................................................................9- 28

9.8 Transfer Unit .............................................................................................................................................9- 289.8.1 Outline of the Transfer Unit ...................................................................................................................................9- 28

9.8.1.1 Outline of the Transfer Unit.................................................................................................................................................... 9- 289.8.1.2 Transfer Unit Drive Control .................................................................................................................................................... 9- 29

9.8.2 Controlling the Transfer Bias .................................................................................................................................9- 299.8.2.1 Transfer Bias Control ............................................................................................................................................................. 9- 29

9.8.3 Cleaning ................................................................................................................................................................9- 319.8.3.1 Intermediate Transfer Belt (ITB) ............................................................................................................................................ 9- 319.8.3.2 Secondary External Roller ..................................................................................................................................................... 9- 319.8.3.3 Waste Toner Collection Mechanism ...................................................................................................................................... 9- 32

9.8.4 Separation Mechanism..........................................................................................................................................9- 329.8.4.1 Separation.............................................................................................................................................................................. 9- 32

9.9 Parts Replacement Procedure .................................................................................................................9- 349.9.1 Drum ITB Motor .....................................................................................................................................................9- 34

9.9.1.1 Preparation for Removing the Drum ITB Motor ..................................................................................................................... 9- 349.9.1.2 Removing the Drum ITB Motor .............................................................................................................................................. 9- 34

9.9.2 Drum Drive Unit .....................................................................................................................................................9- 349.9.2.1 Preparation for Removing the Drum Drive Unit ..................................................................................................................... 9- 349.9.2.2 Removing the Drum Drive Unit .............................................................................................................................................. 9- 35

9.9.3 Drive Roller............................................................................................................................................................9- 359.9.3.1 Preparation for Removing the Drive Roller ............................................................................................................................ 9- 359.9.3.2 Removing the Drive Roller ..................................................................................................................................................... 9- 36

9.9.4 Developing Motor (Bk/Y/M/C)................................................................................................................................9- 369.9.4.1 Preparation for Removing the Developing Motor .................................................................................................................. 9- 369.9.4.2 Removing the Developing Motor............................................................................................................................................ 9- 36

Contents9.9.5 Secondary Transfer Unit ........................................................................................................................................9- 379.9.5.1 Preparation for Removing the Secondary Transfer Unit ........................................................................................................ 9- 379.9.5.2 Removing the Secondary Transfer Unit................................................................................................................................. 9- 37

9.9.6 Intermediate Transfer Unit .....................................................................................................................................9- 389.9.6.1 Preparation for Removing the Intermediate Transfer Unit ..................................................................................................... 9- 389.9.6.2 Removing the Intermediate Transfer Unit .............................................................................................................................. 9- 38

9.9.7 Transfer Cleaning Unit ...........................................................................................................................................9- 389.9.7.1 Preparation for Removing the Transfer Cleaning Unit ........................................................................................................... 9- 389.9.7.2 Removing the Transfer Cleaning Unit.................................................................................................................................... 9- 39

9.9.8 Intermediate Transfer Belt .....................................................................................................................................9- 399.9.8.1 Preparation for Removing the Intermediate Transfer Belt ..................................................................................................... 9- 399.9.8.2 Removing the Intermediate Transfer Belt .............................................................................................................................. 9- 39

9.9.9 Intermediate Transfer Belt Tension Roller .............................................................................................................9- 419.9.9.1 Preparation for Removing the Intermediate Transfer Belt Tension Roller ............................................................................ 9- 419.9.9.2 Removing the Intermediate Transfer Belt Tension Roller ..................................................................................................... 9- 41

9.9.10 Primary Transfer Roller ........................................................................................................................................9- 419.9.10.1 Preparation for Removing the Primary Transfer Roller ........................................................................................................ 9- 419.9.10.2 Removing the Primary Transfer Roller................................................................................................................................. 9- 41

9.9.11 Secondary Transfer External Roller .....................................................................................................................9- 429.9.11.1 Preparation for Removing the Secondary Transfer External Roller ..................................................................................... 9- 429.9.11.2 Removing the Secondary Transfer External Roller.............................................................................................................. 9- 42

9.9.12 Secondary Transfer Internal Roller ......................................................................................................................9- 439.9.12.1 Preparation for Removing the Secondary Transfer Internal Roller ...................................................................................... 9- 439.9.12.2 Removing the Secondary Transfer Internal Roller ............................................................................................................... 9- 43

9.9.13 Toner Container Drive Unit ..................................................................................................................................9- 439.9.13.1 Preparation for Removing the Toner Container Drive Unit .................................................................................................. 9- 439.9.13.2 Removing the Toner Container Drive Unit ........................................................................................................................... 9- 44

9.9.14 Waste Toner Detection PCB................................................................................................................................9- 449.9.14.1 Preparation for Removing the Waste Toner Detection PCB ................................................................................................ 9- 449.9.14.2 Removing the Waste Toner Detection PCB......................................................................................................................... 9- 45

9.9.15 Feedscrew Rotation Sensor.................................................................................................................................9- 459.9.15.1 Preparation for Removing the Feedscrew Rotation Sensor................................................................................................. 9- 459.9.15.2 Removing the Feedscrew Rotation Sensor.......................................................................................................................... 9- 47

9.9.16 Tone Container Motor ..........................................................................................................................................9- 479.9.16.1 Preparation for Removing the Toner Container Motor ......................................................................................................... 9- 479.9.16.2 Removing the Toner Container Motor.................................................................................................................................. 9- 48

9.9.17 Waste Toner Feedscrew Case.............................................................................................................................9- 489.9.17.1 Preparation for Removing the Waste Toner Feedscrew Case............................................................................................. 9- 489.9.17.2 Removing the Waste Toner Feedscrew Case ..................................................................................................................... 9- 49

9.9.18 Pattern Reader Unit .............................................................................................................................................9- 499.9.18.1 Preparation for Removing the Pattern Reader Unit ............................................................................................................. 9- 499.9.18.2 Removing the Pattern Reader Unit ...................................................................................................................................... 9- 499.9.18.3 Procedure After Replacing the Pattern reader unit .............................................................................................................. 9- 50

9.9.19 Auto Registration Sensor PCB.............................................................................................................................9- 509.9.19.1 Preparation for Removing the Auto Registration Sensor PCB............................................................................................. 9- 509.9.19.2 Removing the Auto Registration Sensor PCB...................................................................................................................... 9- 50

9.9.20 SALT Sensor........................................................................................................................................................9- 519.9.20.1 Preparation for Removing the SALT Sensor........................................................................................................................ 9- 519.9.20.2 Removing the SALT Sensor................................................................................................................................................. 9- 51

Chapter 10 Pickup/Feeding System

10.1 Construction ........................................................................................................................................... 10- 110.1.1 Specifications, Control Mechanisms, and Functions............................................................................................10- 110.1.2 Arrangement of he Units ......................................................................................................................................10- 110.1.3 Arrangement of Rollers ........................................................................................................................................10- 110.1.4 Diagram of the Paper Paths.................................................................................................................................10- 210.1.5 Arrangement of Sensors ......................................................................................................................................10- 310.1.6 Arrangement of the Clutches and Solenoids........................................................................................................10- 4

Contents10.1.7 Route of Dive .......................................................................................................................................................10- 410.2 Basic Sequence......................................................................................................................................10- 5

10.2.1 Basic Sequence of Operations at Power-On .......................................................................................................10- 510.2.2 Basic Sequence of Operations in Response to a Press on the Start Key ........................................................... 10- 5

10.3 Detecting Jams .......................................................................................................................................10- 610.3.1 Delay Jams ..........................................................................................................................................................10- 6

10.3.1.1 Delay Jam in the Cassette Pickup Assembly....................................................................................................................... 10- 610.3.1.2 Delay Jam Outside the Cassette Pickup Assembly ............................................................................................................. 10- 6

10.3.2 Stationary Jams ...................................................................................................................................................10- 710.3.2.1 Stationary Jams ................................................................................................................................................................... 10- 710.3.2.2 Stationary Jams at Power-On .............................................................................................................................................. 10- 7

10.4 Cassette..................................................................................................................................................10- 710.4.1 Identifying the Paper Size....................................................................................................................................10- 710.4.2 Detecting the Level of Paper ...............................................................................................................................10- 8

10.5 Cassette Pick-Up Unit...........................................................................................................................10- 1010.5.1 Outline ...............................................................................................................................................................10- 1010.5.2 Basci Sequence of Operations ..........................................................................................................................10- 11

10.6 Manual Feed Pickup Unit......................................................................................................................10- 1110.6.1 Outline ...............................................................................................................................................................10- 1110.6.2 Basic Sequence of Operations ..........................................................................................................................10- 1210.6.3 Identifying the Size of Paper..............................................................................................................................10- 1210.6.4 Detecting the Presence/Absence of Paper........................................................................................................10- 1310.6.5 Detecting the Last paper....................................................................................................................................10- 14

10.7 Registration Unit ...................................................................................................................................10- 1510.7.1 Outline ...............................................................................................................................................................10- 15

10.8 Duplex Feeding Unit .............................................................................................................................10- 1610.8.1 Outline ...............................................................................................................................................................10- 1610.8.2 Controling Horizontal Registration .....................................................................................................................10- 1710.8.3 Face-Down Delivery, A4, 5 Sheets in Circulation ..............................................................................................10- 1810.8.4 Face-Down Delivery, A3, 3 Sheets in Cirucilation .............................................................................................10- 20

10.9 Delivery .................................................................................................................................................10- 2210.9.1 Delivery..............................................................................................................................................................10- 2210.9.2 Movement in the Direction of Face-Down Delivery............................................................................................10- 2310.9.3 Movement in the Direction of Face-Up Delivery ................................................................................................10- 2310.9.4 Movement for CenterTray delivery ....................................................................................................................10- 2410.9.5 Moement for Copy Tray Dievyer........................................................................................................................10- 24

10.10 Parts Replacement Procedure............................................................................................................10- 2510.10.1 Cassette Pickup Unit........................................................................................................................................10- 25

10.10.1.1 Preparatipon for Removing the Pickup Unit ..................................................................................................................... 10- 2510.10.1.2 Removing the Pickup Unit ................................................................................................................................................ 10- 25

10.10.2 Cassette Size Detection Unit ...........................................................................................................................10- 2510.10.2.1 Preparation for Removing the Cassette Size Detection Unit............................................................................................ 10- 2510.10.2.2 Removing the Cassette Size Detection Unit .................................................................................................................... 10- 25

10.10.3 Pre-registration Roller ......................................................................................................................................10- 2610.10.3.1 Preparation for Removing the Pre-registration Roller ...................................................................................................... 10- 2610.10.3.2 Removing the Pre-registration Roller ............................................................................................................................... 10- 26

10.10.4 Registration Upper Roller.................................................................................................................................10- 2610.10.4.1 Preparation for Removing the Registration Lower Roller ................................................................................................. 10- 2610.10.4.2 Remove the Registration Lower Roller............................................................................................................................. 10- 26

10.10.5 Re-pickup Roller ..............................................................................................................................................10- 2710.10.5.1 Preparation for Removing the Re-pickup Roller............................................................................................................... 10- 2710.10.5.2 Removing the Re-pickup Roller........................................................................................................................................ 10- 27

10.10.6 Pickup Roller....................................................................................................................................................10- 2810.10.6.1 Preparation for Removing the Pickup Roller .................................................................................................................... 10- 2810.10.6.2 Removing the Pickup Roller ............................................................................................................................................. 10- 28

10.10.7 Feed Roller ......................................................................................................................................................10- 2810.10.7.1 Preparation for Removing the Feeding Roller .................................................................................................................. 10- 28

Contents

10.10.7.2 Removing the Feeding Roller........................................................................................................................................... 10- 28

10.10.8 Separation Roller..............................................................................................................................................10- 28

10.10.8.1 Preparation for Removing the Separation Roller.............................................................................................................. 10- 2810.10.8.2 Removing the Separation Roller ...................................................................................................................................... 10- 28

10.10.9 Cassette Pickup Motor ..................................................................................................................................