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sep 30 2003 service manual LBP3200 series LBP3200 www..net

application this 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 ar e sold. for this reason, there may be information in this manual that does not apply to your locality. corrections this manual may contain technical inaccu racies or typographical errors due to improvements or ch anges 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 c ontents of this manual over a lo ng or short period, canon will issue a new edition of this manual. the following paragraph does not apply to any countries where such pr ovisions are inconsistent with local law. trademarks the product names and company names used in this manual are the registered trademarks of the individual companies. copyright this manual is copyrighted with all rights reserved. under the copyright la ws, this manual ma y not be copied, reproduced or translated into anothe r language, in whole or in part, without the writte n consent of canon inc. copyright ? 2001 canon inc. printed in japan caution use of this manual should be stri ctly supervised to avoid disclosu re of confidential information.
introduction symbols used this documentation uses the following symbols to indicate special information: symbol description indicates an item of a non-spec ific nature, possibly classified as note, caution, or warning. indicates an item re quiring care to avoi d electric shocks. indicates an item re quiring care to avoi d combustion (fire). indicates an item prohibiti ng disassembly to avoid elec tric shocks or problems. indicates an item requiring disconnection of the power plug from the electric outlet. indicates an item intended to provide notes as sisting the understanding of the topic in question. indicates an item of refere nce assisting the understandi ng of the topic in question. provides a descripti on 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 ex plaining the purpose of specific functions and the relationship between electrical and mechanical systems with refe rence to the timing of operation. in the diagrams, represents the path of mechanical drive; where a si gnal name accompanies the symbol , the arrow indicates the direc tion 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 in supplying the machine with power. 2. in the digital circuits, '1'is used to indicate that the vol tage level of a given signal is "high", while '0' is used to indicate "low".(the voltage value, howev er, differs from circuit to circuit.) in addition, the asterisk (*) as in "drmd*" indicates that the dr md signal goes on when '0'. in practically all cases, the intern al mechanisms of a micropro cessor cannot be checked in the field. therefore, the operations of the microprocessors used 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 the dc 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 communicated 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 be able to identify and isolate faults in the machine."

contents contents chapter 1 product description 1.1 product specifications.................................................................................................... ................... 1- 1 1.1.1product specifications .................................................................................................... ............................. 1- 1 1.2 detailed specifications.................................................................................................... .................................. 1- 3 1.2.1printing speed ............................................................................................................ ................................. 1- 3 1.2.2stack upon delivery ....................................................................................................... ............................ 1- 3 1.3 names of parts ............................................................................................................. ............................ 1- 5 1.3.1external view............................................................................................................. ................................. 1- 5 1.4 safety ..................................................................................................................... ....................................... 1- 7 1.4.1safety of laser light ..................................................................................................... .............................. 1- 7 1.4.2regulations under the center for devices and radiol ogical health (cdrh) ........................................... 1- 7 1.4.3handling the laser unit ................................................................................................... ........................... 1- 7 1.4.4safety of toner ........................................................................................................... ................................. 1- 8 chapter 2 technical reference 2.1 laser exposure system...................................................................................................... .................. 2- 1 2.1.1 overview/configuration ................................................................................................... .......................... 2- 1 2.2 image formation system ..................................................................................................... ............... 2- 3 2.2.1 overview/configuration ................................................................................................... .......................... 2- 3 2.3 pickup and feeding system .................................................................................................. .............. 2- 5 2.3.1 overview/configuration ................................................................................................... .......................... 2- 5 2.3.2 detecting jams ........................................................................................................... ................................. 2- 6 2.4 fixing system.............................................................................................................. ............................... 2- 9 2.4.1 overview/configuration ................................................................................................... .......................... 2- 9 2.4.2 various control mechanisms ............................................................................................... .................... 2- 10 chapter 3 disassembly and assembly 3.1 external and controls system ............................................................................................... ...... 3- 1 3.1.1 rear cover ............................................................................................................... ................................... 3- 1 3.1.2 right cover .............................................................................................................. ................................... 3- 1 3.1.3 left cover ............................................................................................................... .................................... 3- 2 3.1.4 top cover ................................................................................................................ ................................... 3- 3 3.1.5 front cover .............................................................................................................. ................................... 3- 4 3.1.6 engine controller board.................................................................................................. ............................. 3- 4 3.1.7 power supply board....................................................................................................... .............................. 3- 5 3.1.8 high-voltage board ....................................................................................................... .............................. 3- 7 3.1.9 capt board ............................................................................................................... ............................... 3- 10 3.1.10 top sensor .............................................................................................................. ................................. 3- 11 3.1.11 delivery sensor ......................................................................................................... .............................. 3- 13 3.2 image formation system ..................................................................................................... ............. 3- 16 3.2.1 transfer charging roller ................................................................................................. ......................... 3- 16
contents 3.3 laser exposure system ...................................................................................................... ................ 3- 17 3.3.1 laser scanner unit ....................................................................................................... ............................. 3- 17 3.4 pickup and feeding system.................................................................................................. ............. 3- 19 3.4.1 cassette pickup roller ................................................................................................... ........................... 3- 19 3.4.2 cassette separation pad .................................................................................................. .......................... 3- 21 3.4.3 cassette pickup solenoid ................................................................................................. .......................... 3- 22 3.4.4 gear unit ................................................................................................................ ................................... 3- 24 3.4.5 main motor ............................................................................................................... ................................ 3- 26 3.4.6 multi-purpose pickup roller .............................................................................................. ....................... 3- 29 3.4.7 multi-purpose pickup solenoid............................................................................................ ..................... 3- 32 3.5 fixing system .............................................................................................................. ............................. 3- 36 3.5.1 fixing pressure roller ................................................................................................... ............................ 3- 36 3.5.2 fixing film unit......................................................................................................... ............................... 3- 38 chapter 4 maintenance a nd inspection 4.1 periodically replaced parts .. .............. ............... .............. .............. .............. .............. ......... ............................... 4- 1 4.1.1parts requiring periodical re placement ............. .............. .............. .............. .............. ............... ................. 4- 1 4.2 consumables................................................................................................................ ...................................... 4- 2 4.2.1consumable ................................................................................................................ ................................. 4- 2 4.3 periodical service ......................................................................................................... ..................................... 4- 3 4.3.1items requiring scheduled serv icing ....................................................................................... .................. 4- 3 4.4 cleaning................................................................................................................... .......................................... 4- 4 4.4.1items requiring cleaning .................................................................................................. .......................... 4- 4 4.4.2cleaning method (external covers) .................. ....................................................................... .................... 4- 5 4.4.3cleaning method (printer uni t) ............................................................................................ ........................ 4- 5 4.5 lubrications ............................................................................................................... ........................................ 4- 7 4.5.1areas requiring application of grease..................................................................................... .................. 4- 7 4.5.2delivery idler gear ....................................................................................................... ............................... 4- 7 4.5.3fixing drive transmission g ear ............................................................................................ ..................... 4- 8 4.5.4large gear bushing r ...................................................................................................... ........................... 4- 8 4.5.5large gear ................................................................................................................ ................................... 4- 9 4.5.6feed gear................................................................................................................. .................................... 4- 9 4.5.7internal gear ............................................................................................................. ................................. 4- 10 4.5.8large gear decel eration gear/plate r ........ .............. .............. .............. .............. ........... ........... ................ 4- 10 4.5.9main motor ................................................................................................................ ................................ 4- 11 4.5.10drive releasing arm ...................................................................................................... ......................... 4- 12 4.5.11fu delivery roller ....................................................................................................... ........................... 4- 12 4.5.12pickup idler gear ........................................................................................................ ............................. 4- 13 4.5.13feed deceleration g ear .............. ............... .............. .............. .............. .............. .............. ........................ 4- 13 4.5.14fixing decel eration gear....... .............. .............. .............. .............. ............ ........... ........... ........................ 4- 14 4.5.15fd delivery roller ....................................................................................................... ........................... 4- 15 4.5.16large gear bushing f..................................................................................................... ......................... 4- 15 4.5.17pressure roller .......................................................................................................... ................................ 4- 16 chapter 5 troubleshooting 5.1 phenomenon table ........................................................................................................... ...................... 5- 1 5.1.1symptoms .................................................................................................................. .................................. 5- 1
contents 5.2 countermeasures ............................................................................................................ ................................... 5- 2 5.2.1 image faults............................................................................................................. ................................... 5- 2 5.2.2 malfunction.............................................................................................................. ................................... 5- 2 5.2.3 jam (main unit) .......................................................................................................... ................................ 5- 3 5.3 measurement and adjustment........ .............. .............. ............... .............. ........... ........... .......... ....... 5- 4 5.3.1 basic adjustment ......................................................................................................... ............................... 5- 4 5.4 service tools .............................................................................................................. .............................. 5- 5 5.4.1special tools ............................................................................................................. .................................. 5- 5 chapter 6 appendix 6.1 outline of electrical components ........................................................................................... ... 6- 1 6.1.1 sensor................................................................................................................... ....................................... 6- 1 6.1.2 pcbs ..................................................................................................................... ...................................... 6- 2

chapter 1 product description

contents contents 1.1 product specifications.................................................................................................... .................... 1-1 1.1.1 product specifications ................................................................................................... .............................. 1-1 1.2 detailed specifications.................................................................................................... ................................... 1-3 1.2.1 printing speed ........................................................................................................... .................................. 1-3 1.2.2 stack upon delivery ...................................................................................................... ............................. 1-3 1.3 names of parts ............................................................................................................. ............................. 1-5 1.3.1 external view............................................................................................................ .................................. 1-5 1.4 safety ..................................................................................................................... ........................................ 1-7 1.4.1 safety of laser light .................................................................................................... ............................... 1-7 1.4.2 regulations under the center for devices and radiol ogical health (cdrh) ........................................... 1-7 1.4.3 handling the laser unit .................................................................................................. ............................ 1-7 1.4.4 safety of toner .......................................................................................................... .................................. 1-8

chapter 1 1-1 1.1 product specifications 1.1.1 product specifications 0002-6360 body installation method desk-top page printer photosensitive medium opc drum exposure method semi-conductor laser development method toner projection transfer method roller transfer separation method curvature/bias on static eliminator cassette pickup method pad separation multifeeder pickup method single feed drum cleaning method blade fixing method on-demand fixing delivery method face-down/face-up toner supply type ep-26 toner cartridge; good for about 2500 prints warm-up time 0 second (less than 8 seconds when the printer on) print area within 5 mm of paper edge printing resolution 600 x 600 dpi first print time face-down mode: 10 sec or le ss (at 20 deg c; a4); face- up mode: 9 sec or less (at 20 deg c; a4) / the times are after the printer has received data. cassette paper size a4, b5, a5, letter, legal*, executive, envelope c5, envelope com10, envelope dl, envelope monarch / *if "lgl" is indicated in th e cassette, you can load the legal-size paper in the cassette. multi-purpose paper size a4, b5, a5, legal, letter, executive, envelope c5, envelope com10, envelope dl, envelope monarch, custom paper(76.2 to 215.9 mm in width, 127.0 to 355.6 mm in length) cassette paper type plain paper (64 to 90 g/m2), heavy paper (91 to 128 g/ m2), transparency, label, envelope
chapter 1 1-2 multi-purpose paper type plain paper (64 to 90 g/m2), heavy paper (91 to 163 g/ m2), transparency, label, envelope cassette capacity approx. 250 sheets (plain paper, 64 to 80 g/m2); approx. 100 sheets (heavy paper, 91 to 128 g/m2); approx. 100 sheets (transparency); approx. 100 sheets (label); approx. 20 sheets (envelope) multi-purpose capacity 1 sheet (plain paper, he avy paper, transparency, label, envelope) duplex method manual feed only (excluding transparency, envelope, label) memory 2 mb (built-in); no optional memory operating environment (temperature range) 7.5 to 32.5 deg c (45.5 to 90.5 deg f) operating environment (humidity range) 5 to 90 % rh noise during standby: background noi se level, during print: 55 db [a] or less power supply rating 120 v 50/60 hz (+/-2 hz), 220-240 v (+/-10 %) 50/60 hz (+/-2 hz) power consumption 120 v model: average dur ing operation; approx. 350 w, average during standby; approx. 7 w / 220-240 v model: average during operation; approx. 360 w, average during standby; approx. 7 w dimensions 367 (w) x 376.3 (d) x 245 (h) mm weight 120 v model: printer unit; approx.6.5 kg (excluding the toner cartridge), cass ette; approx.0.9 kg, toner cartridge; 0.7 kg / 220-240 v model: printer unit; approx.6.1 kg (excluding the toner cartridge), cassette; approx.0.8 kg, toner cartridge; 0.7 kg option none
chapter 1 1-3 1.2 detailed specifications 1.2.1 printing speed 0002-6870 t-1-1 (unit: sheets/min) *if "lgl" is indicated in the cassette, y ou can load the legal-size in the cassette. 1.2.2 stack upon delivery 0002-6888 t-1-2 fixing mode paper size p l a i n paper plain paper l heavy paper heavy paper h transpare ncy a4 (64 to 90 g/m2) 18 18 18 12 18 b5 (64 to 90 g/m2) 8 8 4 4 8 a5 (64 to 90 g/m2) 8 8 4 4 8 a4 (105 to 128 g/m2) - - 18 12 - b5 (105 to 128 g/m2) - - 4 4 - ltr (75 to 90 g/m2) 18 18 18 12 18 lgl (75 to 90 g/ m2)* 15---- ltr (bond 75 to 90 g/m2) - - 18 12 - ltr (105 g/m2) - - 18 12 - envelope monarch - - 4 - - envelope dl - - 4 - - envelope com10 - - 4 - - envelope c5 - - 4 - - paper type fa ce-down face-up plain paper (64 to 80 g/m2) approx. 100 sheets 1 sheet heavy paper (91 to 128 g/ m2) approx. 30 sheets 1 sheet
chapter 1 1-4 the values herein are estimate s only and are subject to change for product improvement. transparency approx. 5 sheets (for 120v model) approx. 10 sheets (for 230v model) 1 sheet label approx. 10 sheets 1 sheet envelope approx. 10 sheets 1 sheet paper type fa ce-down face-up
chapter 1 1-5 1.3 names of parts 1.3.1 external view 0002-9016 f-1-1 t-1-3 [1] face-down delivery tray [5] cassette [2] face-down delivery area [6] manual feed slot [3] delivery selection cover [7] paper guide [4] power switch [8] front cover a 5 a 4 l t r lg l o n b 5 e x e c o f f [1] [8] [7] [6] [2] [3] [4] [5]
chapter 1 1-6 f-1-2 t-1-4 [1] power socket [4] ventilation slot [2] face-up delivery slot [5] usb connector [3] power indicator [6] cassette protective cover [1] [2] [3] [4] [5] [6]
chapter 1 1-7 1.4 safety 1.4.1 safety of laser light 0002-4309 laser radiation could be hazardo us to the human body. for th is reason, laser radiation em itted inside this machine is hermetically sealed within th e protective housing and external cover. no radiation can l eaak from the machine in the normal operation of the product by the user. 1.4.2 regulations under the center fo r devices and radiological health (cdrh) 0002-4310 the cdrh of the us food and drug administration put into effect regulations governing the sale of laser products in the us on august 2, 1976. these regulations apply to a ll laser products produced on and after august 1, 1976, and a laser product cannot be sold unless it has been certified to comply with the regulations. the following is the label used to indicate that the product has been certified under the regulations, and all laser products sold in the us must bear the label. f-1-3 1.4.3 handling the laser unit 0002-4553 the laser scanner unit emits invisible laser light inside it. if exposed to laser light, the human eye can irreparably be damaged. never attempt to disassemble the laser scanner unit. (it is not designed for servicing in the field). the covers around the laser scanner unit ar e identified by the following label [1]. canon 30-2, shimomaruko, 3-chome, ohtaku, tokyo, 146, japan. manufactured: this product conforms with cqrh radiation performance standard 21cfr chapter 1 subchapter j.
chapter 1 1-8 f-1-4 1.4.4 safety of toner 0002-4556 the machine's toner is a non-toxic material composed of plastic, iron, and small amounts of dye. do not put the toner into fire. it may explode. toner on the skin or clothes 1. if your skin or clothes came into contact with toner, us e dry tissue to remove the toner, and then wash with water. 2. do not use warm or hot water, which will cause the toner to jell, permanently fusing it with the fibers of the clothes. 3. do not bring toner into contact with vinyl material. they are likely to react with each other. [1]
chapter 2 technical reference

contents contents 2.1 laser exposure system...................................................................................................... ................... 2-1 2.1.1 overview/configuration......... .......................................................................................... ........................... 2-1 2.1.1.1 overview ............................................................................................................... ............................... 2-1 2.2 image formation system ..................................................................................................... ................ 2-3 2.2.1 overview/configuration......... .......................................................................................... ........................... 2-3 2.2.1.1 overview ............................................................................................................... ............................... 2-3 2.3 pickup and feeding system .................................................................................................. ............... 2-5 2.3.1 overview/configuration......... .......................................................................................... ........................... 2-5 2.3.1.1 overview ............................................................................................................... ............................... 2-5 2.3.2 detecting jams ........................................................................................................... ................................. 2-6 2.3.2.1 jam detection outline .................................................................................................. ........................ 2-6 2.3.2.1.1 type so jams ......................................................................................................... ........................ 2-6 2.3.2.2 delay jams............................................................................................................. ............................... 2-7 2.3.2.2.1 pickup delay jam ..................................................................................................... ..................... 2-7 2.3.2.2.2 delivery delay jam ................................................................................................... .................... 2-7 2.3.2.3 stationary jams........................................................................................................ ............................. 2-7 2.3.2.3.1 pickup stationary jam ................................................................................................ ................... 2-7 2.3.2.3.2 delivery stationary jam .............................................................................................. .................. 2-7 2.3.2.4 other jams ............................................................................................................. ............................... 2-7 2.3.2.4.1 wrap jam............................................................................................................. .......................... 2-7 2.3.2.4.2 initial jam .......................................................................................................... ............................ 2-8 2.3.2.4.3 cover open jam ....................................................................................................... ..................... 2-8 2.4 fixing system.............................................................................................................. ................................ 2-9 2.4.1 overview/configuration......... .......................................................................................... ........................... 2-9 2.4.1.1 overview ............................................................................................................... ............................... 2-9 2.4.2 various control mechanisms ............................................................................................... ..................... 2-10 2.4.2.1 protective functions ................................................................................................... ........................ 2-10 2.4.2.1.1 protective mechanisms................................................................................................ ................ 2-10 2.4.2.1.2 detecting a fault in the fixing assembly .. ........................................................................... ...... 2-11

chapter 2 2-1 2.1 laser exposure system 2.1.1 overview/configuration 2.1.1.1 overview 0002-4749 f-2-1 t-2-1 the machine's laser scanner assembly cons ists of the laser driver and the scanner motor, which are driven by signals coming from the engine controller. the laser driver serves to turn on the laser diode according to the lase r control signal and vi deo signals from the engine controller. the laser beam moves thorough the collimator less and the cyli ndrical lens to reach the 4-facet mirror rotating at a specific speed. the leaser beam reflected by the 4-facet mirror moves through the imaging lens arranged in front of the 4-facet mirror [1] laser driver pcb [5] imaging lends [2] bd sensor [6] scanner motor [3] reflecting mirror [7] 4-facet mirror [4] photosensitive drum [8] cylindrical lens [2] [1] [3] [4] [5] [7] [6] [8]
chapter 2 2-2 and the reflecting mirror to reach an d focus on the phot osensitive drum. when the 4-facet mirror rotates at a sp ecific speed, the laser beam scans the phot osensitive drum in keeping with the mirror rotation, thus drawing static images on the photosensitive drum. memo: bd fault the machine identifies a bd fault if it does not detect th e /bdi signal within 0.1 s ec after the scanner motor is forced to accelerate. it also detects a bd fault if it does not detect a specifi c interval of /bdi signals for 2 sec continuously after the scanner motor has reached a specific revolution (n umber of rotations). scanner fault if the machine does not detect the /bdi signal 1.4 sc after it has stopped forcing the scanner motor to accelerate, it extends the period of detection by 120 sec; if it stil l does not detect a specific in terval of /bdi signals, it identifies a scanner fault. bd error the machine identifies a bd error if it does not detect the /bdi signal at a specific interval while the /bdi signal is being generated. it, however, does not identify a bd error under the following condition: -the door is identified as being open within 0.2 sec after detection of a bd error. -a bd fault or a scanner fault is detect ed after a bd error has been identified. the laser/scanner unit contains parts that cannot be adjusted in the field. do not attempt to disassemble the laser/ scanner unit.
chapter 2 2-3 2.2 image formation system 2.2.1 overview/configuration 2.2.1.1 overview 0002-8228 f-2-2 t-2-2 in response to a print command, the engine controller tu rns on the main motor to drive the photosensitive drum, developing cylinder, primary charging roller, and transfer charging roller. thereafter, the machine uses the primary charging roller to charge the surface of the photosensitive drum to an even, negative potential and, at the same t ime, directs the laser beam across the su rface of the photosensitive drum. (the laser beam is modulated to accord ing to the incoming video signals.) the image thus formed on the photosensitiv e drum is a static, latent image; it is turned into a visible image by means of the toner from the developing cylinder. the resulting toner image is then transferred to paper by the work of the transfer charging roller, an d the paper is sent to the fixing assembly . the surface of the photosensitive drum is cleaned by the cleaning bl ade so that it is free of residual toner; after cleaning, the primary char ging roller once again charges the surface to an even, negativ e potential to prepare for the format ion of a new static, latent image. [1] laser/scanner assembly [5] photosensitive drum [2] laser beam [6] transfer charging roller [3] blade [7] primary charging roller [4] developing cylinder [8] cleaning blade [1] [2] [6] [3] [4] [5] [8] [7]
chapter 2 2-4 drum cover shutter if the surface of the photosensitive drum is exposed to st rong light, it develops what is know as "photo memory," which can cause white spots or black lines in images. to protect the drum against ligh t, the machine is equipped with a drum cover shutter. the drum cover shutter must never be opened unless doing so proves to be absolutely necessary.
chapter 2 2-5 2.3 pickup and feeding system 2.3.1 overview/configuration 2.3.1.1 overview 0002-8681 f-2-3 t-2-3 [1] cassette feed [11] f ace-down delivery roller [2] cassette pickup rolle r [12] face-down delivery [3] separation pad [13] main motor [4] manual feed [14] ca ssette pickup solenoid [5] feed roller [15] manual feed pickup solenoid [6] transfer assembly (photosensitive drum, transfer charging roller) [16] cassette paper sensor [1] [13] [14] [16] [7] [8] [9] [10] [11] [19] [12] [2] [3] [5] [15] [4] [17] [18] [6]
chapter 2 2-6 pickup and feed operation (from the cassette) if the cassette paper sensor detects the presence of paper while the absence of paper is identified in the manual feed pickup assembly, the machine pi cks up paper from the cassette. when the main motor operates and the cassette pickup solenoid goes on, the cassette pickup roller makes a single rotation to pick up paper. the paper is then moved from the transfer assembly to th e fixing assembly by the feed roller; it is ultimately delivered outside the machine by the work of the delivery roller. when the face-up cover is open, the paper is delivered f ace-up at the rear of the m achine. if the face-up cover is closed, on the other hand, the paper is moved along the feed guide of the cover, and is de livered face-down at the top of the machine by the work of the face-down delivery roller. pickup and feed operation (f rom the manual feed section) when paper is inserted into the pickup assembly, the manual feed paper sensor detects the presence of paper, and the machine uses the feed roller to pick and hold the leading edge of the paper. when printing starts , the machine turns on the manual feed pickup solenoid to stop the rotation of the feed roller so that the paper will not move forward until the laser/scanner and the fixing unit become ready for oper ation. when the laser/scanne r and the fixing unit become ready for operation, the machine turns of f the manual feed pickup solenoid to rotate the feed roller, thus moving the paper forward; the operation thereafter is identical to the operation used for pickup from the cassette. 2.3.2 detecting jams 2.3.2.1 jam detection outline 2.3.2.1.1 type so jams 0002-8759 the machine identifies the following types of jams: pickup delay jam the top sensor does not go on within a specific period of time after pickup starts. pickup stationary jam the top sensor goes on, but does not go off within a specific period of time. delivery delay jam the top sensor goes on, but the delivery sensor does not go on within a specific period of time. wrap jam the delivery sensor goes on, but it goes off before a specific period of time passes. delivery stationary jam the delivery sensor goes on, but it does not go off within a specific period of time. [7] fixing assembly (fixing film, fixing pressure roller) [17] manual feed paper sensor [8] delivery roller [18] top sensor [9] face-up cover [19] delivery sensor [10] face-up delivery
chapter 2 2-7 initial jam the top sensor or the delivery sensor goes on while the main motor is starting to rotate. cover open jam the machine identifies a condition in which the front cover is opened while it is moving paper. 2.3.2.2 delay jams 2.3.2.2.1 pickup delay jam 0002-8760 if the top sensor does not detect the leading edge of pa per within 1.2 sec after the start of pickup operation, the machine initiates pickup operation once gain. the machine identifies a pickup delay jam if the top sensor does not detect the leading edge of paper within 1.2 sec after the 2nd pickup operation. 2.3.2.2.2 delivery delay jam 0002-8762 the machine identifies a delay jam if th e delivery sensor does not detect the leading edge of paper within 1.615 sec after the top sensor has detected the leading edge of paper. 2.3.2.3 stationary jams 2.3.2.3.1 pickup stationary jam 0002-8761 the machine identifies a pickup stationary jam if the top sensor does not detect the absence of paper within 3.575 sec after the top sensor has detected the leading edge of paper. 2.3.2.3.2 delivery stationary jam 0002-8763 the machine moves to a delivery stationary ja m sequence if it does not detect a wrap jam. the machine identifies a deliver y stationary jam if the delive ry sensor does not detect the trailing edge of paper for 1.715 sec after the top sensor has detected the trailing edge of paper. 2.3.2.4 other jams 2.3.2.4.1 wrap jam 0002-8764 the machine starts a wrap jam detection sequence in 0.1 sec if it does not detect a delivery delay jam. it identifies a wrap jam if the delivery sensor detects the trailing edge of paper within 1.06 sec after the top sensor has detected the trailing edge of paper. the term "wrap jam" refers to paper that wraps around the fixing pressure roller; its leading edge passes through the delivery sensor, but it jams thereafter. the machine is designed to identify such a jam so as to prevent wrapping paper from fully moving into the fixing assembly.
chapter 2 2-8 2.3.2.4.2 initial jam 0002-8765 the machine identifies an initial jam if the top sensor or the delivery sensor detects th e presence of paper when the main motor starts to rotate. 2.3.2.4.3 cover open jam 0002-8766 the machine identifies a cover open jam if it detects that the front cover is open with the top sensor or the delivery sensor detecting the presence of paper (while paper is being moved or the machine is not running a jam check).
chapter 2 2-9 2.4 fixing system 2.4.1 overview/configuration 2.4.1.1 overview 0002-8375 f-2-4 t-2-4 the machine's fixing system is an on-demand type, and its fixing assembly consists of the fixing film unit and the pressure roller: the fixing film has a built-in fixing heater, thermistor, and thermal fuse. the toner transferred to paper is heated by the fixing heater, which provides heat through the fixing film; the toner is forced under the pressure roller so that it is fused in to the fibers of the paper under both heat and pressure. [1] fixing film unit [2] fixing heater [3] pressure roller [1] [3] [2]
chapter 2 2-10 2.4.2 various control mechanisms 2.4.2.1 protective functions 2.4.2.1.1 protective mechanisms 0002-8543 the machine is equipped with the following 3 types of prot ective mechanisms used to pr event its fixing heater from going awry. 1. protective mechanism by the cpu 2. protective mechanism by the fixing heater safety circuit 3. protective mechanis m by the thermal fuse 1. protective mechanism by the cpu the machine's cpu monitors the voltage of the fixing heater temperature detect ion signal from the main thermistor and the sub thermist or at all times, and it cuts the power to th e fixing heater if it finds that the fixing temperature appreciably exceeds a specific level. when the fixing temperature abnorma lly increases and the voltage of the fixing heater temperature detection signal from the main thermistor drops to about 0.775 v (equivalent of 235 deg c) or less, the cpu causes the fixing heater drive signal to go low and turns off the photo triac coupler, thus cutting power to the fixing heater. if the temperature of the fixing heat er abnormally increases and the voltage of the fixing heater temperature detection signal from the sub thermist or reaches about 2.779 v (equivalent of 320 deg c) or more, the cpu causes the fixing heater drive signal to go low and turns off the photo triac couple, thus cutting off the power to the fixing heater. 2. protective mechanism by the fixing heater safety circuit the fixing heater safety circuit monito rs the voltage of the fixing heater temperature detection signal from the main thermistor and the sub thermistor at all times. if the fixing temperature a ppreciably exceeds a specific level, the machin e cuts off the power to the fixing heater regardless of the instructions from the cpu. when the temperature of the fixing heater increases ab normally and the voltage of the fixing heater temperature detection signal of the main thermist or reaches about 0.775 v (equivalent of 235 deg c) or less, the output of the comparator turns low to turn off the relay, thus cutting off the power to the fixing heater. likewise, if the temperature of the fixing heater increases abnormally and the voltage of the fixing heater temperature detection signal of the sub thermistor reaches about 2.779 v (equivalent of 320 deg c) or more, the output of the comparator turns low to turn off the transistor, thus turning off the relay and cutting off the power to the fixing heater regardless of the relay drive sign al from the cpu. 3. protective mechanism by the thermal fuse if the temperature of the fi xing heater increases abno rmally and the temperature of the thermal fuse exceeds about 228 deg c, the thermal fuse starts to me lt to cut off the power to the fixing heater.
chapter 2 2-11 2.4.2.1.2 detecting a fault in the fixing assembly 0002-8551 the cpu identifies a fault in the fixing assembly for the following conditions (a. thorough g.) and operates as described: 1. the cpu causes the fixing heater drive signal to go low to cut off the power to the fixing heater. 2. the cpu causes the relay drive sign al to go low to turn off the relay. 3. the cpu, if it detects a fault while printing is under wa y, discharges the paper being picked up or moved at the time, and immediately turns off the main motor, scanner mo tor, and high-voltage system and puts the printer unit in an error state. a) the reading of the main th ermistor does not exceed 50 de g c within 2.34 sec after the start-up temperature control mechanism is started. b) the cpu detects that the reading of the main thermistor remains 235 deg c or more for 1 sec continuously while fixing temperature control is under way. c) the cpu detects that the reading of the main thermistor remains 100 deg c or less for 1.2 sec continuously while paper passage temperature control is under way; or the cpu detects that the reading of the main thermistor remains 50 deg c or less for 0.3 sec continuously while between-sheets temperature control is under way. d) the cpu detects that the reading of the main thermistor remains less than 20 deg c for 0.3 sec continuously while fixing heater temperature control is under way. e) the temperature of the main ther mistor does not exceed 100 deg c within 20 sec after the start of start-up temperature control. f) the cpu detects that the reading of the sub thermistor remains less than 35 deg c for 0.15 sec continuously while fixing heater temperature control is under way. g) the cpu detects that the reading of the sub thermist or remains 320 deg c for 0.15 sec continuously while fixing heater temperature control is under way.

chapter 3 disassemb ly and assembly

contents contents 3.1 external and controls system ............................................................................................... ....... 3-1 3.1.1 rear cover............................................................................................................... .................................... 3-1 3.1.1.1 removing the cassette .................................................................................................. ....................... 3-1 3.1.1.2 removing the rear cover ................................................................................................ .................... 3-1 3.1.2 right cover .............................................................................................................. ................................... 3-1 3.1.2.1 removing the cassette .................................................................................................. ....................... 3-1 3.1.2.2 removing the rear cover ................................................................................................ .................... 3-1 3.1.2.3 removing the top cover ................................................................................................. .................... 3-1 3.1.2.4 removing the right cover............................................................................................... .................... 3-2 3.1.3 left cover............................................................................................................... ..................................... 3-2 3.1.3.1 removing the cassette .................................................................................................. ....................... 3-2 3.1.3.2 removing the rear cover ................................................................................................ .................... 3-2 3.1.3.3 removing the top cover ................................................................................................. .................... 3-2 3.1.3.4 removing the left cover ................................................................................................ ..................... 3-3 3.1.4 top cover................................................................................................................ .................................... 3-3 3.1.4.1 removing the cassette .................................................................................................. ....................... 3-3 3.1.4.2 removing the rear cover ................................................................................................ .................... 3-3 3.1.4.3 removing the top cover ................................................................................................. .................... 3-3 3.1.5 front cover.............................................................................................................. .................................... 3-4 3.1.5.1 removing the front cover ............................................................................................... .................... 3-4 3.1.6 engine controller board .................................................................................................. ............................. 3-4 3.1.6.1 removing the cassette .................................................................................................. ....................... 3-4 3.1.6.2 removing the rear cover ................................................................................................ .................... 3-4 3.1.6.3 removing the top cover ................................................................................................. .................... 3-4 3.1.6.4 removing the left cover ................................................................................................ ..................... 3-5 3.1.6.5 removing the engine controller board ......... .......................................................................... ............ 3-5 3.1.7 power supply board ....................................................................................................... .............................. 3-5 3.1.7.1 removing the cassette .................................................................................................. ....................... 3-5 3.1.7.2 removing the front cover ............................................................................................... .................... 3-5 3.1.7.3 removing the rear cover ................................................................................................ .................... 3-5 3.1.7.4 removing the top cover ................................................................................................. .................... 3-6 3.1.7.5 removing the right cover............................................................................................... .................... 3-6 3.1.7.6 removing the left cover ................................................................................................ ..................... 3-6 3.1.7.7 removing the power supply shield plate......... ........................................................................ ........... 3-7 3.1.7.8 removing the power supply assembly ..................................................................................... .......... 3-7 3.1.7.9 removing the power supply board ........................................................................................ ............. 3-7 3.1.8 high-voltage board....................................................................................................... ............................... 3-7 3.1.8.1 removing the cassette .................................................................................................. ....................... 3-7 3.1.8.2 removing the front cover ............................................................................................... .................... 3-7 3.1.8.3 removing the rear cover ................................................................................................ .................... 3-8 3.1.8.4 removing the top cover ................................................................................................. .................... 3-8 3.1.8.5 removing the right cover............................................................................................... .................... 3-8 3.1.8.6 removing the left cover ................................................................................................ ..................... 3-9 3.1.8.7 removing the power supply shield plate......... ........................................................................ ........... 3-9
3.1.8.8 removing the power supply assembly ..................................................................................... .......... 3-9 3.1.8.9 removing the high-voltage power supply boar d........................................................................... .. 3-10 3.1.9 capt board ............................................................................................................... ................................ 3-10 3.1.9.1 removing the cassette.................................................................................................. ...................... 3-10 3.1.9.2 removing the rear cover................................................................................................ ................... 3-10 3.1.9.3 removing the top cover................................................................................................. ................... 3-10 3.1.9.4 removing the left cover ................................................................................................ ................... 3-10 3.1.9.5 removing the capt board................................................................................................ ................ 3-11 3.1.10 top sensor.............................................................................................................. .................................. 3-11 3.1.10.1 removing the cassette................................................................................................. ..................... 3-11 3.1.10.2 removing the front cover .............................................................................................. ................. 3-11 3.1.10.3 removing the rear cover............................................................................................... .................. 3-11 3.1.10.4 removing the top cover................................................................................................ .................. 3-12 3.1.10.5 removing the right cover .............................................................................................. ................. 3-12 3.1.10.6 removing the left cover ............................................................................................... .................. 3-12 3.1.10.7 removing the power supply shield plate ....... ......................................................................... ........ 3-12 3.1.10.8 removing the power supply assembly .................................................................................... ....... 3-13 3.1.10.9 removing the top sensor............................................................................................... .................. 3-13 3.1.11 delivery sensor ......................................................................................................... ............................... 3-13 3.1.11.1 removing the cassette................................................................................................. ..................... 3-13 3.1.11.2 removing the rear cover............................................................................................... .................. 3-13 3.1.11.3 removing the top cover................................................................................................ .................. 3-14 3.1.11.4 removing the left cover ............................................................................................... .................. 3-14 3.1.11.5 removing the power supply shield plate ....... ......................................................................... ........ 3-14 3.1.11.6 removing the delivery sensor .......................................................................................... ............... 3-14 3.2 image formation system..................................................................................................... ............... 3-16 3.2.1 transfer charging roller ................................................................................................. .......................... 3-16 3.2.1.1 removing the transfer charging roller ........... ....................................................................... .......... 3-16 3.3 laser exposure system ...................................................................................................... ................. 3-17 3.3.1 laser scanner unit ....................................................................................................... ............................. 3-17 3.3.1.1 removing the cassette.................................................................................................. ...................... 3-17 3.3.1.2 removing the rear cover................................................................................................ ................... 3-17 3.3.1.3 removing the top cover................................................................................................. ................... 3-17 3.3.1.4 removing the left cover ................................................................................................ ................... 3-17 3.3.1.5 removing the laser/scanner unit........................................................................................ .............. 3-17 3.4 pickup and feeding system.................................................................................................. .............. 3-19 3.4.1 cassette pickup roller................................................................................................... ............................ 3-19 3.4.1.1 removing the cassette.................................................................................................. ...................... 3-19 3.4.1.2 removing the front cover ............................................................................................... .................. 3-19 3.4.1.3 removing the rear cover................................................................................................ ................... 3-19 3.4.1.4 removing the top cover................................................................................................. ................... 3-19 3.4.1.5 removing the right cover ............................................................................................... .................. 3-20 3.4.1.6 removing the left cover ................................................................................................ ................... 3-20 3.4.1.7 removing the gear unit ................................................................................................. .................... 3-20 3.4.1.8 removing the tooth-missing gear ................ ........................................................................ ............ 3-20 3.4.1.9 removing the cassette pickup roller .................................................................................... ............ 3-21 3.4.2 cassette separation pad .................................................................................................. ........................... 3-21 3.4.2.1 removing the cassette.................................................................................................. ...................... 3-21 3.4.2.2 removing the rear of the cassette...................................................................................... ............... 3-21
contents 3.4.2.3 removing the cassette separation pad ................................................................................... ........... 3-21 3.4.3 cassette pickup solenoid ................................................................................................. .......................... 3-22 3.4.3.1 removing the cassette .................................................................................................. ..................... 3-22 3.4.3.2 removing the front cover ............................................................................................... .................. 3-22 3.4.3.3 removing the rear cover ................................................................................................ .................. 3-22 3.4.3.4 removing the top cover ................................................................................................. .................. 3-23 3.4.3.5 removing the right cover............................................................................................... .................. 3-23 3.4.3.6 removing the left cover ................................................................................................ ................... 3-23 3.4.3.7 removing the power supply shield plate......... ........................................................................ ......... 3-23 3.4.3.8 removing the power supply assembly ..................................................................................... ........ 3-24 3.4.3.9 removing the cassette pickup solenoid.................................................................................. .......... 3-24 3.4.4 gear unit ................................................................................................................ ................................... 3-24 3.4.4.1 removing the cassette .................................................................................................. ..................... 3-24 3.4.4.2 removing the front cover ............................................................................................... .................. 3-24 3.4.4.3 removing the rear cover ................................................................................................ .................. 3-25 3.4.4.4 removing the top cover ................................................................................................. .................. 3-25 3.4.4.5 removing the right cover............................................................................................... .................. 3-25 3.4.4.6 removing the left cover ................................................................................................ ................... 3-26 3.4.4.7 removing the gear unit................................................................................................. .................... 3-26 3.4.5 main motor............................................................................................................... ................................. 3-26 3.4.5.1 removing the cassette .................................................................................................. ..................... 3-26 3.4.5.2 removing the front cover ............................................................................................... .................. 3-26 3.4.5.3 removing the rear cover ................................................................................................ .................. 3-27 3.4.5.4 removing the top cover ................................................................................................. .................. 3-27 3.4.5.5 removing the right cover............................................................................................... .................. 3-27 3.4.5.6 removing the left cover ................................................................................................ ................... 3-28 3.4.5.7 removing the power supply shield plate......... ........................................................................ ......... 3-28 3.4.5.8 removing the power supply assembly ..................................................................................... ........ 3-28 3.4.5.9 removing the main motor ................................................................................................ ................. 3-29 3.4.6 multi-purpose pickup roller .............................................................................................. ....................... 3-29 3.4.6.1 removing the cassette .................................................................................................. ..................... 3-29 3.4.6.2 removing the front cover ............................................................................................... .................. 3-29 3.4.6.3 removing the rear cover ................................................................................................ .................. 3-29 3.4.6.4 removing the top cover ................................................................................................. .................. 3-29 3.4.6.5 removing the right cover............................................................................................... .................. 3-30 3.4.6.6 removing the left cover ................................................................................................ ................... 3-30 3.4.6.7 removing the gear unit................................................................................................. .................... 3-30 3.4.6.8 removing the tooth-missing gear ................ ........................................................................ ............ 3-30 3.4.6.9 removing the engine controller board ......... .......................................................................... .......... 3-31 3.4.6.10 removing the manual feed stay ......................................................................................... ............ 3-31 3.4.6.11 removing the paper feed guide......................................................................................... ............. 3-31 3.4.6.12 removing the paper feed roller........................................................................................ .............. 3-31 3.4.7 multi-purpose pickup solenoid..................... ....................................................................... ..................... 3-32 3.4.7.1 removing the cassette .................................................................................................. ..................... 3-32 3.4.7.2 removing the front cover ............................................................................................... .................. 3-32 3.4.7.3 removing the rear cover ................................................................................................ .................. 3-32 3.4.7.4 removing the top cover ................................................................................................. .................. 3-32 3.4.7.5 removing the right cover............................................................................................... .................. 3-33 3.4.7.6 removing the left cover ................................................................................................ ................... 3-33
contents 3.4.7.7 removing the gear unit ................................................................................................. .................... 3-33 3.4.7.8 removing the tooth-missing gear ................ ........................................................................ ............ 3-33 3.4.7.9 removing the power supply shield plate ......... ........................................................................ ......... 3-34 3.4.7.10 removing the power supply assembly .................................................................................... ....... 3-34 3.4.7.11 removing the manual pickup solenoid ................................................................................... ........ 3-34 3.5 fixing system .............................................................................................................. .............................. 3-36 3.5.1 fixing pressure roller ................................................................................................... ............................ 3-36 3.5.1.1 removing the cassette.................................................................................................. ...................... 3-36 3.5.1.2 removing the front cover ............................................................................................... .................. 3-36 3.5.1.3 removing the rear cover................................................................................................ ................... 3-36 3.5.1.4 removing the top cover................................................................................................. ................... 3-36 3.5.1.5 removing the right cover ............................................................................................... .................. 3-37 3.5.1.6 removing the left cover ................................................................................................ ................... 3-37 3.5.1.7 removing the fixing film unit................ .......................................................................... ................ 3-37 3.5.1.8 removing the fixing pressure roller.......... .......................................................................... ............. 3-38 3.5.2 fixing film unit ......................................................................................................... ............................... 3-38 3.5.2.1 removing the cassette.................................................................................................. ...................... 3-38 3.5.2.2 removing the front cover ............................................................................................... .................. 3-38 3.5.2.3 removing the rear cover................................................................................................ ................... 3-39 3.5.2.4 removing the top cover................................................................................................. ................... 3-39 3.5.2.5 removing the right cover ............................................................................................... .................. 3-39 3.5.2.6 removing the left cover ................................................................................................ ................... 3-40 3.5.2.7 removing the fixing film unit................ .......................................................................... ................ 3-40
chapter 3 3-1 3.1 external and controls system 3.1.1 rear cover 3.1.1.1 removing the cassette 0002-3466 1) remove the cassette by holding the cassette handle. 3.1.1.2 removing the rear cover 0002-3475 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-1 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-2 3.1.2 right cover 3.1.2.1 removing the cassette 0002-3484 1) remove the cassette by holding the cassette handle. 3.1.2.2 removing the rear cover 0002-3487 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, de tach the face-up cover. f-3-3 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-4 3.1.2.3 removing the top cover 0002-3490 1) open the front cover. (this step may be skipped if [1] [2] [1] [2] [3] [4] [1] [2] [1] [2] [3] [4]
chapter 3 3-2 the front cover has already been removed.) 2) free the 2 claws [1], a nd detach the top cover [2]. f-3-5 3.1.2.4 removing the right cover 0002-3493 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-6 3.1.3 left cover 3.1.3.1 removing the cassette 0002-3485 1) remove the cassette by holding the cassette handle. 3.1.3.2 removing the rear cover 0002-3488 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, de tach the f ace-up cover. f-3-7 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to the rear to detach. f-3-8 3.1.3.3 removing the top cover 0002-3492 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. [1] [2] [3] [1] [2] [4] [1] [2] [1] [2] [3] [4]
chapter 3 3-3 f-3-9 3.1.3.4 removing the left cover 0002-3501 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-10 3.1.4 top cover 3.1.4.1 removing the cassette 0002-3468 1) remove the cassette by holding the cassette handle. 3.1.4.2 removing the rear cover 0002-3479 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-11 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-12 3.1.4.3 removing the top cover 0002-3481 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. [1] [2] [1] [4] [2] [3] [1] [2] [1] [2] [3] [4]
chapter 3 3-4 f-3-13 3.1.5 front cover 3.1.5.1 removing the front cover 0002-3448 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-14 3.1.6 engine controller board 3.1.6.1 removing the cassette 0002-3581 1) remove the cassette by holding the cassette handle. 3.1.6.2 removing the rear cover 0002-3584 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-15 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to the rear to detach. f-3-16 3.1.6.3 removing the top cover 0002-3585 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. [1] [2] [1] [3] [2] [1] [2] [1] [2] [3] [4]
chapter 3 3-5 f-3-17 3.1.6.4 removing the left cover 0002-3586 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-18 3.1.6.5 removing the engine controller board 0002-3587 1) disconnect the 5 connectors [1], and remove the 3 flat cables [2]. 2) remove the 3 screws [3], and detach the engine controller board [4] while paying attention to the sensor flag. f-3-19 3.1.7 power supply board 3.1.7.1 removing the cassette 0002-3735 1) remove the cassette by holding the cassette handle. 3.1.7.2 removing the front cover 0002-3736 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-20 3.1.7.3 removing the rear cover 0002-3738 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, de tach the face-up cover. [1] [2] [1] [4] [2] [3] [2] [2] [3] [3] [4] [1] [1] [3] [2]
chapter 3 3-6 f-3-21 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-22 3.1.7.4 removing the top cover 0002-3740 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], a nd detach the top cover [2]. f-3-23 3.1.7.5 removing the right cover 0002-3742 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-24 3.1.7.6 removing the left cover 0002-3744 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. [1] [2] [1] [2] [3] [4] [1] [2] [3] [1] [2] [4]
chapter 3 3-7 f-3-25 3.1.7.7 removing the power supply shield plate 0002-3746 1) remove the 5 screws [1], and detach the power supply shield plate [2]. f-3-26 3.1.7.8 removing the power supply assembly 0002-3747 1) remove the 3 screws [1]. 2) disconnect the 4 connect ors [2], and free the flat cable [3] of the engine controller board. f-3-27 3) push down the front of the power supply assembly [2] while feeding the left/right boss [2]; then, slide it out to detach. f-3-28 3.1.7.9 removing the power supply board 0002-3748 1) remove the flat cable [1]. 2) remove the 4 screws [2], and detach the power supply board [3]. f-3-29 3.1.8 high-voltage board 3.1.8.1 removing the cassette 0002-3734 1) remove the cassette by holding the cassette handle. 3.1.8.2 removing the front cover 0002-3737 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front [1] [4] [2] [3] [2] [1] [1] [1] [1] [2] [3] [1] [2] [1] [2] [2] [3]
chapter 3 3-8 cover. f-3-30 3.1.8.3 removing the rear cover 0002-3739 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-31 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-32 3.1.8.4 removing the top cover 0002-3741 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. f-3-33 3.1.8.5 removing the right cover 0002-3743 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. [1] [3] [2] [1] [2] [1] [2] [3] [4] [1] [2]
chapter 3 3-9 f-3-34 3.1.8.6 removing the left cover 0002-3745 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-35 3.1.8.7 removing the power supply shield plate 0002-3750 1) remove the 5 screws [1], and detach the power supply shield plate [2]. f-3-36 3.1.8.8 removing the power supply assembly 0002-3751 1) remove the 3 screws [1]. 2) disconnect the 4 connect ors [2], and free the flat cable [3] of the engine controller board. f-3-37 3) push down the front of the power supply assembly [2] while feeding the left/right boss [2]; then, slide it out to detach. f-3-38 [3] [1] [2] [4] [1] [4] [2] [3] [2] [1] [1] [1] [1] [2] [3] [1] [2]
chapter 3 3-10 3.1.8.9 removing the high- voltage power supply board 0002-3749 1) remove the flat cable [1]. 2) remove the 3 screws [2], and detach the high- voltage power supply board [3]. f-3-39 3.1.9 capt board 3.1.9.1 removing the cassette 0002-3591 1) remove the cassette by holding the cassette handle. 3.1.9.2 removing the rear cover 0002-3592 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-40 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to the rear to detach. f-3-41 3.1.9.3 removing the top cover 0002-3593 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. f-3-42 3.1.9.4 removing the left cover 0002-3594 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. [1] [2] [3] [1] [2] [1] [2] [3] [4] [1] [2]
chapter 3 3-11 f-3-43 3.1.9.5 removing the capt board 0002-3596 1) removing the flat cable [1]. 2) remove the 3 screws [2], and detach the capt board [3]. f-3-44 3.1.10 top sensor 3.1.10.1 removing the cassette 0002-3757 1) remove the cassette by holding the cassette handle. 3.1.10.2 removing the front cover 0002-3760 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-45 3.1.10.3 removing the rear cover 0002-3763 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, de tach the face-up cover. f-3-46 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. [1] [4] [2] [3] [1] [2] [3] [1] [3] [2] [1] [2]
chapter 3 3-12 f-3-47 3.1.10.4 removing the top cover 0002-3766 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], a nd detach the top cover [2]. f-3-48 3.1.10.5 removing the right cover 0002-3769 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-49 3.1.10.6 removing the left cover 0002-3772 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-50 3.1.10.7 removing the power supply shield plate 0002-3775 1) remove the 5 screws [1], and detach the power supply shield plate [2]. [1] [2] [3] [4] [1] [2] [3] [1] [2] [4] [1] [4] [2] [3]
chapter 3 3-13 f-3-51 3.1.10.8 removing the power supply assembly 0002-3778 1) remove the 3 screws [1]. 2) disconnect the 4 connect ors [2], and free the flat cable [3] of the engine controller board. f-3-52 3) push down the front of the power supply assembly [2] while feeding the left/right boss [2]; then, slide it out to detach. f-3-53 3.1.10.9 removing the top sensor 0002-3781 1) shift down the main unit so that its front faces down (i.e., the inside of the main unit is in view). 2) disconnect the connector [1] of the engine controller board, and free the cable from the cable guide. 3) removing the screw [2], and detach the top sensor. f-3-54 3.1.11 delivery sensor 3.1.11.1 removing the cassette 0002-3759 1) remove the cassette by holding the cassette handle. 3.1.11.2 removing the rear cover 0002-3764 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, de tach the face-up cover. f-3-55 [2] [1] [1] [1] [1] [2] [3] [1] [2] [1] [2] [3] [1] [2]
chapter 3 3-14 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-56 3.1.11.3 removing the top cover 0002-3765 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], a nd detach the top cover [2]. f-3-57 3.1.11.4 removing the left cover 0002-3773 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-58 3.1.11.5 removing the power supply shield plate 0002-3776 1) remove the 5 screws [1], and detach the power supply shield plate [2]. f-3-59 3.1.11.6 removing the delivery sensor 0002-3777 1) disconnect the connector [1] of the engine controller board, and free the cable from the cable guide. 2) remove the screw [2], and detach the delivery sensor [3]. [1] [2] [3] [4] [1] [2] [1] [4] [2] [3] [2] [1] [1]
chapter 3 3-15 f-3-60 [1] [2] [3]
chapter 3 3-16 3.2 image formation system 3.2.1 transfer charging roller 3.2.1.1 removing the transfer charging roller 0002-3718 1) open the front cover. 2) pick the 2 claws [1] on the right side of the roller, and lift it. 3) slide the transfer charging roller [2] to the right to detach. f-3-61 [1] [2]
chapter 3 3-17 3.3 laser exposure system 3.3.1 laser scanner unit 3.3.1.1 removing the cassette 0002-3683 1) remove the cassette by holding the cassette handle. 3.3.1.2 removing the rear cover 0002-3684 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-62 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-63 3.3.1.3 removing the top cover 0002-3685 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. f-3-64 3.3.1.4 removing the left cover 0002-3686 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-65 3.3.1.5 removing the laser/ scanner unit 0002-3687 1) disconnect the connector [1] of the engine [1] [2] [1] [2] [3] [4] [1] [2] [1] [4] [2] [3]
chapter 3 3-18 controller board, and free the cable from the cable guide. 2) remove the flat cable [2] from the laser/scanner unit board. 3) remove the 4 screws [3], and detach the laser/ scanner unit [4]. at this time, take care not to lose the grounding plate [5]. f-3-66 [1] [2] [3] [4] [3] [5] [3]
chapter 3 3-19 3.4 pickup and feeding system 3.4.1 cassette pickup roller 3.4.1.1 removing the cassette 0002-3510 1) remove the cassette by holding the cassette handle. 3.4.1.2 removing the front cover 0002-3513 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-67 3.4.1.3 removing the rear cover 0002-3515 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-68 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-69 3.4.1.4 removing the top cover 0002-3521 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. [1] [3] [2] [1] [2] [1] [2] [3] [4]
chapter 3 3-20 f-3-70 3.4.1.5 removing the right cover 0002-3524 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-71 3.4.1.6 removing the left cover 0002-3526 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-72 3.4.1.7 removing the gear unit 0002-3533 1) remove the 2 screws [1], and detach the drive plate (small) [2]. f-3-73 2) remove the 2 gears [1]. 3) while freeing the claw, detach the gear unit [2]. f-3-74 3.4.1.8 removing the tooth- missing gear 0002-3548 1) remove the 2 screws [1], and detach the gear support [2]. [1] [2] [3] [1] [2] [4] [1] [4] [2] [3] [2] [1] [2] [1]
chapter 3 3-21 f-3-75 2) remove the spring [1]. 3) while freeing the claw, detach the tooth-missing gear [2]. f-3-76 3.4.1.9 removing the cassette pickup roller 0002-3565 1) shift down the main unit so that its front faces down (i.e., the inside of the main unit is in view). 2) remove the boss of the bushing [1], and turn it to the front; then, slide it to detach the bushing. 3) slide the pickup roller [2] to remove it. f-3-77 3.4.2 cassette separation pad 3.4.2.1 removing the cassette 0002-2788 1) remove the cassette by holding the cassette handle. 3.4.2.2 removing the rear of the cassette 0002-2797 1) lift the rear of the cassette, and separate the rear from the front. 3.4.2.3 removing the cassette separation pad 0002-2799 1) remove the shafts [1] on both sides of the lifting plate. remove the liftin g plate [3] while watching the lifting plate spri ng [2] carefully. f-3-78 2) remove the 2 claws [1] on both sides of the cassette separation pad and lift it up while watching the lifting plate spring [2] carefully. ensure that the separation pad spring does not get lost. 3) remove both the plate and the cassette separation pad [3] by sliding them to the left. [2] [1] [2] [1] [1] [2] [2] [3] [1]
chapter 3 3-22 f-3-79 4) remove the 2 claws [1] and remove the cassette separation pad [2] by sliding it up. f-3-80 3.4.3 cassette pickup solenoid 3.4.3.1 removing the cassette 0002-3511 1) remove the cassette by holding the cassette handle. 3.4.3.2 removing the front cover 0002-3514 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-81 3.4.3.3 removing the rear cover 0002-3516 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, de tach the f ace-up cover. f-3-82 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to the rear to detach. [1] [3] [2] [1] [2] [1] [3] [2] [1] [2]
chapter 3 3-23 f-3-83 3.4.3.4 removing the top cover 0002-3522 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. f-3-84 3.4.3.5 removing the right cover 0002-3531 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-85 3.4.3.6 removing the left cover 0002-3528 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-86 3.4.3.7 removing the power supply shield plate 0002-3752 1) remove the 5 screws [1], and detach the power supply shield plate [2]. [1] [2] [3] [4] [1] [2] [3] [1] [2] [4] [1] [4] [2] [3]
chapter 3 3-24 f-3-87 3.4.3.8 removing the power supply assembly 0002-3753 1) remove the 3 screws [1]. 2) disconnect the 4 connect ors [2], and free the flat cable [3] of the engine controller board. f-3-88 3) push down the front of the power supply assembly [2] while feeding the left/right boss [2]; then, slide it out to detach. f-3-89 3.4.3.9 removing the cassette pickup solenoid 0002-3754 1) shift down the main unit so that its front faces down (i.e., the inside of the main unit is in view). 2) disconnect the connector [1] of the engine controller board and free the cable from the cable guide. 3) remove the screw [2], and detach the cassette pickup solenoid [3] (rear of the main motor). f-3-90 3.4.4 gear unit 3.4.4.1 removing the cassette 0002-3688 1) remove the cassette by holding the cassette handle. 3.4.4.2 removing the front cover 0002-3689 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. [2] [1] [1] [1] [1] [2] [3] [1] [2] [1] [2] [3]
chapter 3 3-25 f-3-91 3.4.4.3 removing the rear cover 0002-3691 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-92 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-93 3.4.4.4 removing the top cover 0002-3692 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. f-3-94 3.4.4.5 removing the right cover 0002-3693 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. [1] [3] [2] [1] [2] [1] [2] [3] [4] [1] [2]
chapter 3 3-26 f-3-95 3.4.4.6 removing the left cover 0002-3694 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-96 3.4.4.7 removing the gear unit 0002-3695 1) remove the 2 screws [1], and detach the drive plate (small) [2]. f-3-97 2) remove the 2 gears [1]. 3) while freeing the claw, detach the gear unit [2]. f-3-98 3.4.5 main motor 3.4.5.1 removing the cassette 0002-3755 1) remove the cassette by holding the cassette handle. 3.4.5.2 removing the front cover 0002-3761 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. [3] [1] [2] [4] [1] [4] [2] [3] [2] [1] [2] [1]
chapter 3 3-27 f-3-99 3.4.5.3 removing the rear cover 0002-3762 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-100 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-101 3.4.5.4 removing the top cover 0002-3770 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. f-3-102 3.4.5.5 removing the right cover 0002-3768 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. [1] [3] [2] [1] [2] [1] [2] [3] [4] [1] [2]
chapter 3 3-28 f-3-103 3.4.5.6 removing the left cover 0002-3771 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-104 3.4.5.7 removing the power supply shield plate 0002-3774 1) remove the 5 screws [1], and detach the power supply shield plate [2]. f-3-105 3.4.5.8 removing the power supply assembly 0002-3779 1) remove the 3 screws [1]. 2) disconnect the 4 connect ors [2], and free the flat cable [3] of the engine controller board. f-3-106 3) push down the front of the power supply assembly [2] while feeding the left/right boss [2]; then, slide it out to detach. f-3-107 [3] [1] [2] [4] [1] [4] [2] [3] [2] [1] [1] [1] [1] [2] [3] [1] [2]
chapter 3 3-29 3.4.5.9 removing the main motor 0002-3780 1) shift down the main unit so that its front faces down (i.e., the inside of the main unit is in view). 2) remove the 2 screws [1], and detach the main motor [2]. f-3-108 3.4.6 multi-purpose pickup roller 3.4.6.1 removing the cassette 0002-3696 1) remove the cassette by holding the cassette handle. 3.4.6.2 removing the front cover 0002-3698 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-109 3.4.6.3 removing the rear cover 0002-3700 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, de tach the face-up cover. f-3-110 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-111 3.4.6.4 removing the top cover 0002-3703 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. [1] [2] [1] [3] [2] [1] [2] [1] [2] [3] [4]
chapter 3 3-30 f-3-112 3.4.6.5 removing the right cover 0002-3705 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-113 3.4.6.6 removing the left cover 0002-3707 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-114 3.4.6.7 removing the gear unit 0002-3710 1) remove the 2 screws [1], and detach the drive plate (small) [2]. f-3-115 2) remove the 2 gears [1]. 3) while freeing the claw, detach the gear unit [2]. f-3-116 3.4.6.8 removing the tooth- missing gear 0002-3712 1) remove the 2 screws [1], and detach the gear support [2]. [1] [2] [3] [1] [2] [4] [1] [4] [2] [3] [2] [1] [2] [1]
chapter 3 3-31 f-3-117 2) remove the spring [1]. 3) while freeing the claw, detach the tooth-missing gear [2]. f-3-118 3.4.6.9 removing the engine controller board 0002-3714 1) disconnect the 5 connectors [1], and remove the 3 flat cables [2]. 2) remove the 3 screws [3], and detach the engine controller board [4] while paying attention to the sensor flag. f-3-119 3.4.6.10 removing the manual feed stay 0002-3715 1) remove the 3 screws [1], and detach the manual feed stay [2] while paying attention to the sensor flag. f-3-120 3.4.6.11 removing the paper feed guide 0002-3716 1) remove the screw [1], and detach the paper feed guide [2]. f-3-121 3.4.6.12 removing the paper feed roller 0002-3717 1) lift the left side of the paper feed roller [1], and slide it to detach. [2] [1] [2] [1] [2] [2] [3] [3] [4] [1] [2] [1] [1] [2]
chapter 3 3-32 f-3-122 3.4.7 multi-purpose pickup solenoid 3.4.7.1 removing the cassette 0002-3697 1) remove the cassette by holding the cassette handle. 3.4.7.2 removing the front cover 0002-3699 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-123 3.4.7.3 removing the rear cover 0002-3702 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-124 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to the rear to detach. f-3-125 3.4.7.4 removing the top cover 0002-3704 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. [1] [1] [3] [2] [1] [2] [1] [2] [3] [4]
chapter 3 3-33 f-3-126 3.4.7.5 removing the right cover 0002-3706 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-127 3.4.7.6 removing the left cover 0002-3709 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-128 3.4.7.7 removing the gear unit 0002-3711 1) remove the 2 screws [1], and detach the drive plate (small) [2]. f-3-129 2) remove the 2 gears [1]. 3) while freeing the claw, detach the gear unit [2]. f-3-130 3.4.7.8 removing the tooth- missing gear 0002-3713 1) remove the 2 screws [1], and detach the gear support [2]. [1] [2] [3] [1] [2] [4] [1] [4] [2] [3] [2] [1] [2] [1]
chapter 3 3-34 f-3-131 2) remove the spring [1]. 3) while freeing the claw, detach the tooth-missing gear [2]. f-3-132 3.4.7.9 removing the power supply shield plate 0002-6262 1) remove the 5 screws [1], and detach the power supply shield plate [2]. f-3-133 3.4.7.10 removing the power supply assembly 0002-6263 1) remove the 3 screws [1]. 2) disconnect the 4 connect ors [2], and free the flat cable [3] of the engine controller board. f-3-134 3) push down the front of the power supply assembly [2] while feeding the left/right boss [2]; then, slide it out to detach. f-3-135 3.4.7.11 removing the manual pickup solenoid 0002-6265 1) shift down the main unit so that its front faces down (i.e., the inside of the main unit is in view). 2) free the cable [1] front the cable guide. 3) remove the screw [2], and detach the manual pickup solenoid [3]. [2] [1] [2] [1] [2] [1] [1] [1] [1] [2] [3] [1] [2]
chapter 3 3-35 f-3-136 [1] [2] [3]
chapter 3 3-36 3.5 fixing system 3.5.1 fixing pressure roller 3.5.1.1 removing the cassette 0002-3720 1) remove the cassette by holding the cassette handle. 3.5.1.2 removing the front cover 0002-3722 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. f-3-137 3.5.1.3 removing the rear cover 0002-3724 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-138 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to the rear to detach. f-3-139 3.5.1.4 removing the top cover 0002-3726 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. [1] [3] [2] [1] [2] [1] [2] [3] [4]
chapter 3 3-37 f-3-140 3.5.1.5 removing the right cover 0002-3728 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. f-3-141 3.5.1.6 removing the left cover 0002-3730 1) remove the screw [1]. 2) free the claw [2 ] at the rear; then , free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-142 3.5.1.7 removing the fixing film unit 0002-3732 1) remove the 2 screws [1], and detach the fixing cover. f-3-143 2) remove the 2 screws [1], and detach the fixing entrance guide [2] by sliding it to the left and right. f-3-144 3) disconnect the connector [1] of the engine [1] [2] [3] [1] [2] [4] [1] [4] [2] [3] [1] [2] [1] [2]
chapter 3 3-38 controller board, and free the cable from the cable clamp. 4) disconnect the connector [2] of the power supply board. 5) remove the left/right pressure spring and grounding spring [3]. 6) remove the left/right pressure plate [4]. f-3-145 7) while holding the left/right frame [2] of the fixing film unit [1], life it at an angle to detach the fixing film unit. f-3-146 3.5.1.8 removing the fixing pressure roller 0002-3733 1) remove the gear [1] while freeing the claw. 2) remove the boss of the bushing [2], and turn it to detach the bushing. f-3-147 3) lift the shorter shaft [2] of the fixing pressure roller [1] at an angle to detach it from the bushing; then, slide it to detach the fixing pressure roller. f-3-148 3.5.2 fixing film unit 3.5.2.1 removing the cassette 0002-3719 1) remove the cassette by holding the cassette handle. 3.5.2.2 removing the front cover 0002-3721 1) open the front cover [1], and free the claw [2] of the arm to separate. 2) remove the left/right shaft [3], and detach the front cover. [1] [2] [3] [3] [4] [1] [2] [1] [2] [2] [1]
chapter 3 3-39 f-3-149 3.5.2.3 removing the rear cover 0002-3723 1) open the face-up cover [1], and remove the left/ right shaft [2]; then, detach the face-up cover. f-3-150 2) shift down the left/right fixing pressure release lever [1] to release the pressure. 3) remove the 2 screws [2]. 4) free the 2 claws [3] at the bottom; then, slide the rear cover [4] to th e rear to detach. f-3-151 3.5.2.4 removing the top cover 0002-3725 1) open the front cover. (this step may be skipped if the front cover has already been removed.) 2) free the 2 claws [1], and detach the top cover [2]. f-3-152 3.5.2.5 removing the right cover 0002-3727 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the right cover [3] to the front. 3) while opening the bottom of the right cover [3] slightly toward the outside, slide upward to detach the right cover. [1] [3] [2] [1] [2] [1] [2] [3] [4] [1] [2]
chapter 3 3-40 f-3-153 3.5.2.6 removing the left cover 0002-3729 1) remove the screw [1]. 2) free the claw [2] at the rear; then, free the claw [4] at the front bottom as by sliding the bottom of the left cover [3] to the front. 3) while opening the bottom of the left cover [3] slightly toward the outside, slide upward to detach the left cover. f-3-154 3.5.2.7 removing the fixing film unit 0002-3731 1) remove the 2 screws [1], and detach the fixing cover. f-3-155 2) remove the 2 screws [1], and detach the fixing entrance guide [2] by sliding it to the left and right. f-3-156 3) disconnect the connector [1] of the engine controller board, and free the cable from the cable clamp. 4) disconnect the connector [2] of the power supply board. 5) remove the left/right pressure spring and grounding spring [3]. 6) remove the left/right pressure plate [4]. f-3-157 [3] [1] [2] [4] [1] [4] [2] [3] [1] [2] [1] [2] [1] [2] [3] [3] [4]
chapter 3 3-41 7) while holding the left/right frame [2] of the fixing film unit [1], life it at an angle to detach the fixing film unit. f-3-158 [1] [2]

chapter 4 maintenan ce and inspection

contents contents 4.1 periodically replaced parts... .............. .............. .............. .............. ............... ........... ........... ................................ 4-1 4.1.1 parts requiring periodical replacement ............. .............. .............. .............. .............. .............. .................. 4-1 4.2 consumables ................................................................................................................ ...................................... 4-2 4.2.1 consumable ............................................................................................................... .................................. 4-2 4.3 periodical service......................................................................................................... ...................................... 4-3 4.3.1 items requiring scheduled servicing ...................................................................................... ................... 4-3 4.4 cleaning................................................................................................................... ........................................... 4-4 4.4.1 items requiring cleaning................................................................................................. ........................... 4-4 4.4.2 cleaning method (external covers) ........................................................................................ ..................... 4-5 4.4.3 cleaning method (printer unit)........................................................................................... ......................... 4-5 4.5 lubrications............................................................................................................... ......................................... 4-7 4.5.1 areas requiring application of grease .................................................................................... .................. 4-7 4.5.2 delivery idler gear...................................................................................................... ................................ 4-7 4.5.3 fixing drive transmission gear ...................... ..................................................................... ...................... 4-8 4.5.4 large gear bushing r ..................................................................................................... ............................ 4-8 4.5.5 large gear ............................................................................................................... .................................... 4-9 4.5.6 feed gear ................................................................................................................ .................................... 4-9 4.5.7 internal gear............................................................................................................ .................................. 4-10 4.5.8 large gear deceleratio n gear/plate r ............. .............. .............. ........... ............ ........... .......... ................. 4-10 4.5.9 main motor............................................................................................................... ................................. 4-11 4.5.10 drive releasing arm..................................................................................................... .......................... 4-12 4.5.11 fu delivery roller ...................................................................................................... ............................ 4-12 4.5.12 pickup idler gear....................................................................................................... .............................. 4-13 4.5.13 feed deceleration gear .............. .............. .............. .............. ............... .............. ............. ......................... 4-13 4.5.14 fixing decelerati on gear .............. .............. .............. .............. .............. .............. ............ ........................ 4-14 4.5.15 fd delivery roller ...................................................................................................... ............................ 4-15 4.5.16 large gear bushing f .................................................................................................... ......................... 4-15 4.5.17 pressure roller......................................................................................................... ................................. 4-16

chapter 4 4-1 4.1 periodically replaced parts 4.1.1 parts requiring periodical replacement 0002-4267 the machine does not have parts th at require periodical replacement.
chapter 4 4-2 4.2 consumables 4.2.1 consumable 0002-4308 t-4-1 work by item interval (guide) user ep-26 toner cartridge every 2500 prints (approx.) service technician none
chapter 4 4-3 4.3 periodical service 4.3.1 items requiring scheduled servicing 0002-4268 the machine does not have items that require scheduled servicing.
chapter 4 4-4 4.4 cleaning 4.4.1 items requiring cleaning 0002-4316 t-4-2 before starting cleaning work, be sure to turn off the power and disconnect the power plug to avoid fires and electric shocks. work by item intervals user external covers as needed (when soiled) service technician cassette pickup roller when paper pickup performance has lowered cassette separation pad w hen paper separation performance has lowered feed roller when paper feed performance has lowered transfer charging roller when the back of paper tends to become soiled; or, when a white spot appears in the images at intervals of about 46 mm static eliminator when dots appear in images paper feed guide when the back of paper tends to become soiled fixing entrance guide when paper tends to become soiled; when a black line appears vertically at irregular intervals; when paper jams; when paper wrinkles fixing film when images tend to become soiled at intervals of about 57 mm fixing pressure roller when the back of paper shows traces at interval s of about 64 mm; when fixing faults occur; when paper jams; when paper wrinkles
chapter 4 4-5 4.4.2 cleaning method (external covers) 0002-4545 moisten a soft cloth with water or solution of mild deterg ent, making sure it is well wrung; then, wipe the soiling. if you have used detergent, be sure to remove its residue using a soft, moist cloth. after removing all soiling, dry wipe the area with a soft, dry cloth. 4.4.3 cleaning method (printer unit) 0002-4507 f-4-1 [1] cassette pickup roller use lint-free paper to remove soling. [2] cassette separation pad use lint-free paper to remove soling. [3] feed roller use lint-free paper to remove soling. [4] transfer charging roller use lint-free paper to remove toner and paper lint. - do not touch the sponge area of the transfer charging ro ller to avoid soiling the back of paper or white spots in the images. - never use solvent. - if the soiling cannot be removed using lint-free paper or the rolle r is deformed, re place the roller. [1] [2] [3] [8] [9] [7] [4] [5] [6]
chapter 4 4-6 [5] static eliminator remove dust and paper lint using a brush. [6] paper feed guide use lint-free paper to remove soiling. [7] fixing inlet guide use lint-free paper moistened with isopropyl alcohol to remove the soiling. [8] fixing film use lint-free paper to remove soiling. [9] fixing pressure roller use lint-free paper to remove soiling.
chapter 4 4-7 4.5 lubrications 4.5.1 areas requiring application of grease 0002-4235 the machine has areas that require grease to permit smooth movement of parts or ensure good electrical conductivity. if you have replaced a part in these areas or if y ou have removed the grease, be sure to apply grease. f-4-2 t-4-3 4.5.2 delivery idler gear 0002-4236 area of application: [1] grease: molykote em-50l amount: 40 +/-10 mg location of application: - 2 locations on gear support shaft in opposition - spread in axial direction [1] delivery idler gear [9] drive releasing arm [2] fixing drive transmission gear [10] fu delivery roller [3] large gear bushing r [11] pickup idler gear [4] large gear [12] feed deceleration gear [5] feed gear [13] fixing deceleration gear [6] internal gear [14] fd delivery roller [7] large gear deceleration gear/p late r [15] large gear bushing f [8] main motor [16] pressure roller [9] [11] [10] [7] [8] [12] [13] [1] [5] [6] [4] [3] [2] [15] [14] [16]
chapter 4 4-8 f-4-3 4.5.3 fixing drive transmission gear 0002-4240 area of application: [1] grease: molykote em-50l amount: 10 +/-5 mg location of application: - 2 locations on gear butting ribs in opposition - spread in circumferential direction over a length of 1/4 or more f-4-4 4.5.4 large gear bushing r 0002-4248 area of application: [1] grease: molykote em-50l amount: 10 +/-5 mg location of application: - wall surface on inner circum ferential side of bushing - spread in circumferential direction over a length of 1/2 or more [1] [1]
chapter 4 4-9 f-4-5 4.5.5 large gear 0002-4249 area of application: [1] grease: molykote em-50l amount: 20 +/-10 mg location of application: - rib against which gear is butted - spread in circumferential direction over a length of 1/2 or more f-4-6 4.5.6 feed gear 0002-4250 area of application: [1] grease: molykote em-50l amount: 10 +/-5 mg location of application: - 1 location on boss engaging with internal gear - spread in axial direction [1] [1]
chapter 4 4-10 f-4-7 4.5.7 internal gear 0002-4251 area of application: [1] grease: molykote em-50l amount: 40 +/-10 mg location of application: - 5 teeth or more of internal gear in opposition - 2 locations in circumferential direction f-4-8 4.5.8 large gear decelera tion gear/plate r 0002-4252 area of application: [1] grease: molykote em-50l amount: 40 +/-10 mg location of application: - 5 teeth or more (covering entire small-dia tooth area) are of application: [2] grease: molykote em-50l amount: 10 +/-5 mg location of application - support shaft of plate r (sliding surface against larg e gear deceleration gear) [1] [1]
chapter 4 4-11 - spread in axial direction f-4-9 4.5.9 main motor 0002-4255 area of application: [1] grease: molykote em-50l amount: 40 +/-10 mg location of application: - 5 teeth or more (covering entire gear width) f-4-10 [1] [2] [1]
chapter 4 4-12 4.5.10 drive releasing arm 0002-4256 area of application: [1] grease: molykote em-50l amount: 10 +/-5 mg location of application: - 4 locations on sliding su rface against gear support sh aft of drive releasing arm f-4-11 4.5.11 fu delivery roller 0002-4260 area of application: [1] grease: molykote 41 amount: 10 +/-5 mg location of application: - edge of fu delivery roller shaft (slidi ng surface against fu grounding spring) area of application: [2] grease: molykote em-50l amount: 10 +/-5 mg location of application: - sliding surface between fu delivery roller shaft and fu delivery roller bushing area of application: [3] grease: molykote em-50l amount: 10 +/-5 mg location of application: - sliding surface between fu deliver y roller shaft and delivery guide (fu delivery roller shaft stop rib) [1]
chapter 4 4-13 f-4-12 4.5.12 pickup idler gear 0002-4258 are of application: [1] grease: molykote em-50l amount: 10 +/-5 mg location of application: - 2 locations on pickup idler gear support shaft - 5 teeth or more (covering entire large-diameter tooth surface of pickup idler gear) f-4-13 4.5.13 feed deceleration gear 0002-4259 area of application: [1] grease: molykote em-50l amount: 10 +/-5 mg location of application: - 2 locations on feed decel eration gear support shaft [1] [2] [3] [1]
chapter 4 4-14 - spread in axial direction f-4-14 4.5.14 fixing deceleration gear 0002-4261 area of application: [1] grease: molykote em-50l amount: 40 +/-10 mg location of application - 5 teeth or more (covering en tire surface of fixing decelerat ion gear; small- diameter teeth) area of application: [2] grease: molykote em-50l amount: 10 +/-5 mg location application: - tip of feed deceleration gear but ting rib in circumfere ntial direction over a length of 1/2 or more area of location: [3] grease: molykote em-50l amount: 10 +/-5 mg location of application: - sliding surface against plate r of fixing deceleration gear in circumstantial direction ov er a length of 1/2 or more f-4-15 [1] [1] [3] [2]
chapter 4 4-15 4.5.15 fd delivery roller 0002-4262 area of application: [1] grease: molykote em-50l amount: 30 +/-5 mg location of application - entire sliding surface agai nst fd delivery bushing f-4-16 4.5.16 large gear bushing f 0002-4263 area of application: [1] grease: molykote em-50l amount: 10 +/-5 mg location of application: - entire sliding surface agains t large gear support shaft f-4-17 [1] [1] [1]
chapter 4 4-16 4.5.17 pressure roller 0002-4264 area of application: [1] grease: molykote 41 amount: 10 +/-10 mg location of application: - edge of pressure roll er shaft (sliding surface against contact spring f) f-4-18 [1]
chapter 5 troublesh ooting

contents contents 5.1 phenomenon table ........................................................................................................... ....................... 5-1 5.1.1 symptoms ................................................................................................................. ................................... 5-1 5.2 countermeasures ............................................................................................................ .................................... 5-2 5.2.1 image faults ............................................................................................................. ................................... 5-2 5.2.1.1 smudged/streaked....................................................................................................... ......................... 5-2 5.2.1.1.1 there are vertical black lines or a vertical white line in a solid black image................................ 5-2 5.2.2 malfunction .............................................................................................................. ................................... 5-2 5.2.2.1 no power ............................................................................................................... ............................... 5-2 5.2.2.1.1 the machine at times fails to go on when its pow er is turned on after it ha s been turned off. ..... 5-2 5.2.2.2 malfunction/faulty detection ........................................................................................... ................... 5-2 5.2.2.2.1 the machine does not permit correct placement of pape r in its manual feed tray after it has delivered paper. ......................................................................................................................... ............................... 5-2 5.2.3 jam (main unit) .......................................................................................................... ................................ 5-3 5.2.3.1 the machine iden tifies a jam when it is turned off and then on with paper in its manual feed section. 5- 3 5.3 measurement and adjustment........ .............. .............. ............... .............. ........... ........... .......... ........ 5-4 5.3.1 basic adjustment ......................................................................................................... ............................... 5-4 5.3.1.1 items of adjustment .................................................................................................... ......................... 5-4 5.4 service tools .............................................................................................................. ............................... 5-5 5.4.1 special tools ............................................................................................................ ................................... 5-5

chapter 5 5-1 5.1 phenomenon table 5.1.1 symptoms 0002-9647 t-5-1 for details, see the instructions given as remedial action. level 1 classification description image faults there are vertical black lines or a vertical white line in a solid black image. malfunction the machine at times fails to go on when its power is turned on after it has been turned off. after the machine delivers paper, it does not pe rmit correct placement of paper in its manual feed section. jam (main unit) the machine identifies a jam when its power is turned off and then on with paper in its manual feed section.
chapter 5 5-2 5.2 countermeasures 5.2.1 image faults 5.2.1.1 smudged/streaked 5.2.1.1.1 there are vertical black lines or a ver tical white line in a solid black image. 0003-1622 the vertical black lines are likely to have been caused by the ribs of the heater holder. the ver tical white line is likely to have been caused by the thermal fuse (if it corresponds to the location of the fuse). select heavy paper mode. 5.2.2 malfunction 5.2.2.1 no power 5.2.2.1.1 the machine at times fails to go on when its po wer is turned on after it has been turned off. 0003-1624 if the machine is tuned on immediatel y after it has been turned off, resi dual power can momentarily start up the scanner motor, causing an overload (i.e., in excess of the rating indicated for power-on). if the machine fails to go on, turn off its power switc h; then, turn it back on after waiting for 30 sec. 5.2.2.2 malfunction/faulty detection 5.2.2.2.1 the machine does not permit corr ect placement of paper in its manual feed tray after it has delivered paper. 0003-1625 the machine cannot recognize insertion of paper from its manual feed tray while the main motor is on (rotating rollers) after delivery. insert paper from the manual feed tray only af ter the main motor (roller rotation) has stopped.
chapter 5 5-3 5.2.3 jam (main unit) 5.2.3.1 the machine identifies a jam when it is turned off and then on with paper in its manual feed section. 0003-1626 the machine is designed to identify a jam if the manual feed paper sensor is on when it is tuned on, as it is not sure whether the paper is set correctly or incorrectly. remove the paper, open and close the front cover, and place the paper back in the manual feed section.
chapter 5 5-4 5.3 measurement and adjustment 5.3.1 basic adjustment 5.3.1.1 items of adjustment 0002-4265 the machine does not have items that are cited for adjustment.
chapter 5 5-5 5.4 service tools 5.4.1 special tools 0002-4333 t-5-2 tool description parts no. grease(molykote em-50l) apply to specified areas. hy9-0007 grease (molykote 41) apply to specified areas. ck-8007

chapter 6 appendix

contents contents 6.1 outline of electrical components ........................................................................................... .... 6-1 6.1.1 sensor ................................................................................................................... ....................................... 6-1 6.1.1.1 arrangement of sensors and switches .................................................................................... ............. 6-1 6.1.2 pcbs ..................................................................................................................... ....................................... 6-2 6.1.2.1 arrangement of pcbs.................................................................................................... ....................... 6-2

chapter 6 6-1 6.1 outline of electrical components 6.1.1 sensor 6.1.1.1 arrangement of sensors and switches 0002-4576 f-6-1 [1] cassette paper sensor used to detect the presence/ab sence of paper in the cassette. [2] manual feed paper sensor used to detect the presence/absence of paper in the manual feed section. [3] paper leading edge sensor (top sensor) used to detect the leading/trailing edge of paper being moved. [4] paper delivery sensor used to monitor the delivery of paper. [5] front cover switch used to detect the state (ope n/closed) of the front cover. [6] power switch on and off of the power through the arm operating in conjunction with the switch on the power supply board. [1] [2] [3] [6] [4] [5]
chapter 6 6-2 6.1.2 pcbs 6.1.2.1 arrangement of pcbs 0002-4575 f-6-2 [1] engine controller board used to control the oper ation of the printer unit. [2] capt board used to serve as the interface between a pc and the printer unit. [3] power supply board used to control the supply of power to various components. [4] high-voltage power supply board used to supply high-voltage power to the printer unit. [1] [2] [3] [4]
sep 30 2003

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