imageCLASS D800 Series, imageCLASS D860 Service Manual

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Chapter 1 Introduction
1.1 Product Specifications
1.1.1 Names of Parts
1.1.2 Using the Machine
1.1.3 User Mode Items
1.1.4 Maintenance by the User
1.1.5 Safety
1.1.6 Product Specifications
1.1.7 Function List

Chapter 2 Installation
2.1 Making Pre-Checks
2.1.1Selecting the Site
2.2 Unpacking and Installation
2.2.1Before Starting
2.2.2Installation Procedure
2.2.4Fitting the Cartridge
2.2.5Putting Paper in the Cassette
2.2.6Putting Paper in the Manual Feed Tray
2.2.7Connecting the Interface Cable
2.2.8Connecting the Power Cord
2.2.9Fitting the Delivery Tray
2.2.10Setting the Printer Functions (if equipped with printer functions)
2.3 Connection to Telephone Line
2.3.1Connecting the Modular Cable (if equipped with fax functions)
2.3.2Setting the Date/Time (user mode)
2.3.3Setting According to Line Type
2.3.4Executing Fax Communications Testing
2.4 Checking the Images/Operations
2.4.1Checking the Copy Images

Chapter 3 Basic Operation
3.1 Construction
3.1.1Functional Construction
3.1.2Functional Block Diagram
3.1.3Image Processor PCB
3.1.4DC Controller PCB
3.1.5Control Panel PCB
3.1.6Power Supply PCB
3.1.7Analog Processor PCB
3.1.8Sensor PCB
3.1.9Laser Driver/BD PCB
3.1.10Main Motor/Scanner Motor Driver
3.1.11Printer Controller PCB (if equipped with printer functions)
3.1.12NCU PCB (if equipped with fax functions)
3.1.13Modular Jack PCB (if equipped with fax functions)
3.1.14Controlling the Main Motor
3.1.15Reproduction Processes
3.2 Basic Sequence
3.2.1Power-On Sequence

Chapter 4 Original Exposure System
4.1 Construction
4.1.1Major Components
4.2 Parts Replacement Procedure
4.2.1 Reader Unit
4.2.2 Copyboard glass
4.2.3 Sensor PCB
4.2.4 Scanner Motor
4.2.5 Contact sensor

Chapter 5 Laser Exposure
5.1 Construction
5.2 Parts Replacement Procedure
5.2.1 Laser Scanner Unit

Chapter 6 Image Formation
6.1 Construction
6.2 Parts Replacement Procedure
6.2.1 Transfer Charging Roller

Chapter 7 Pickup/Feeding System
7.1 Construction
7.2 Detecting Jams
7.2.1 Jam Detection Outline
7.2.2 Delivery Jams
7.2.3 Stationary Jams
7.2.4 Other Jams
7.3 Cassette Pick-Up Unit
7.3.2Retry Pickup
7.3.3Detecting the Size of Paper
7.4 Manual Feed Pickup Unit
7.4.2Retry Pickup
7.4.3Detecting the Size of Paper
7.5 Delivery
7.5.2Auto Delivery Control
7.5.3Reducing the Copying Speed
7.6 Parts Replacement Procedure
7.6.1 Pickup Roller
7.6.2 Separation Pad
7.6.3 Cassette Pickup Solenoid
7.6.4 Manual Feed (Upper)
7.6.5 Manual Feed (Lower)
7.6.6 Manual Pickup Roller
7.6.7 Manual Feed Tray sensor
7.6.8 Manual Feed Pickup Solenoid
7.6.9 Registration Roller Unit
7.6.10 Vertical Path Roller

Chapter 8 Fixing System
8.1 Construction
8.2 Various Control Mechanisms
8.2.1 Controlling the Speed of the Fixing Roller
8.2.2 Controlling the Fixing File Bias Temperature
8.3 Protective Functions
8.3.2Detecting a Fault in the Fixing Assembly
8.4 Parts Replacement Procedure
8.4.1 Fixing Unit
8.4.2 Pressure Roller
8.4.3 Fixing Film
8.4.4 Fixing Delivery Sensor

Chapter 9 External and Controls
9.1 Fans
9.2 Power Supply System
9.2.1 Power Supply
9.2.2 Protection Function
9.2.3 Backup Battery
9.2.4 Energy-Saving Function
9.3 Parts Replacement Procedure
9.3.1 Control Panel
9.3.2 Analog Processor PCB
9.3.3 Removing the DC Controller PCB
9.3.4 Image Processor PCB
9.3.5 Printer Controller PCB
9.3.6 NCU PCB
9.3.7 Modular Jack PCB
9.3.8 Removing the Printer Power Supply PCB
9.3.9 Reader Unit Slide Detecting Switch
9.3.10 Fans
9.3.11 Motor of Main Drive Assembly
9.3.12 Right Door

Chapter 10 Original Feeding System
10.1 Basic Construction
10.2 Basic Operation
10.2.1Picking Up and Moving Originals
10.2.2Moving Down the Original Pickup Roller and Moving Up the Original
10.3 Detection Jams
10.3.2Types of Jams
10.4 Parts Replacement Procedure
10.4.1 ADF
10.4.2 ADF Drive Unit
10.4.3 ADF Motor Unit
10.4.4 Feeding Outside Guide
10.4.5 Separation Roller Unit
10.4.6 Separation Roller
10.4.7 Pickup Roller
10.4.8 Original Separation Pad
10.4.9 Registration Roller
10.4.10 White Roller
10.4.11 Feed Roller
10.4.12 Original Feed Roller
10.4.13 Original Delivery Roller
10.4.14 Original Sensor
10.4.15 Registration Sensor
10.4.16 Original Delivery Sensor
10.4.17 Slide Guide
10.4.18 Delivery Stacking Tray

Chapter 11 Maintenance and Inspection
11.1 Periodically Replaced Parts
11.1.1Periodically Replaced Parts
11.2 Durables and Consumables
11.3 Scheduled Servicing Basic Procedure
11.3.1Scheduled Servicing Chart
11.4 Cleaning
11.4.2Selfoc Lens Array of the Contact Sensor
11.4.3Cassette Pickup Roller
11.4.4Manual Feed Pickup Roller
11.4.5Separation Pad
11.4.6Registration Roller
11.4.7Transfer Guide
11.4.8Transfer Charging Roller
11.4.9Separation Static Eliminator
11.4.10Paper Path
11.4.11Fixing Inlet Guide
11.4.12Fixing Pressure Roller
11.4.13Delivery Roller
11.4.14Back of Copyboard Glass (Back of Shading Plate)
11.4.15Original Pickup Roller (ADF)
11.4.16Original Feed/Separation Roller (ADF)
11.4.17Original Separation Pad (ADF)
11.4.18Registration Roller (ADF)
11.4.19Original Feed Roller (ADF)
11.4.20Original Delivery Roller (ADF)
11.4.21Copyboard Glass (Original Reading Area) (ADF)

Chapter 12 Standards and Adjustments
12.1 Image Adjustments
12.1.1Leading Edge Read Start Position Adjustment
12.1.2Left/Right Edge Read Start Position Adjustment
12.2 Scanning System
12.2.1Preparing a Test Sheet for Adjustment
12.2.2Contact Sensor LED Intensity Auto Adjustment
12.3 Fixing System
12.3.1Nip Adjustment
12.4 Electrical Components
12.4.2When Replacing the Image Processor PCB
12.5 ADF
12.5.1 Outline
12.5.2 Adjusting the Mechanical System
12.5.3 Adjusting the Ellectrical System

Chapter 13 Correcting Faulty Images
13.1 Making lnitial Checks
13.1.2Making Initial Checks
13.1.3Site Environment
13.1.4Checking the Cartridge
13.1.5Checking the Paper
13.1.7Troubleshooting Flow Chart
13.1.8Making Checks in Response to an Image Fault
13.1.9Checking the Photointerrupters
13.2 Troubleshooting
13.2.1 Image Faults
13.2.2 Faulty Feeding
13.2.3 Malfunction
13.2.4 Printing/Scanning
13.2.5 Transmission/Fax-Related
13.2.6 Jam (Main Unit)
13.2.7 Jam (Document Feeder)
13.3 Outline of Electrical Components
13.3.1 Clutch/Solenoid
13.3.2 Sensor
13.3.3 Lamps, Heaters, and Others
13.3.4 PCBs
13.3.5 Variable Resistors(VR), Light-Emitting Diodes(LED),and Check Pins by PCB

Chapter 14 Self Diagnosis
14.1 Error Code Table
14.1.1Error Code Table
14.2 FAX Error Codes
14.2.1 Outline
14.2.2 User Error Code
14.2.3 Service Error Code

Chapter 15 Service Mode
15.1 Outline
15.1.2Using Service Mode
15.1.3List of Menus
15.2 Service Mode Table
15.2.1Bit Switch Settings
15.2.2Menu Switch Settings
15.2.3Numeric Parameter Setting
15.2.4SPECIAL Setting
15.2.5NCU Setting
15.2.6ISDN Setting
15.2.7Country/Region of Installation
15.2.8Setting the Original Reading Functions
15.2.9Setting the Printer Parameters
15.2.12Generating a Report
15.2.15ROM Indication
15.2.16Resetting the Contact Sensor Position
15.2.17Test Mode
15.2.18Test Mode
15.2.19Service Report

Chapter 16 Service Tools
16.1 List of Special Tools
16.2 List of Solvents and Oils

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