Return to Main Form Return to Service Form Exit Program Di450/Di550 SERVICE MANUAL [FIELD SERVICE]
Safety Precautions for Inspection and Service When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. ✽ Depending on the model, some of the precautions given in the following do not apply. Different markings are used to denote specific meanings as detailed below. WARNING CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
4. Handle the power cord with care and never use a multiple outlet. • Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock. • Do not use a multiple outlet to which any other appliance or machine is connected. • Be sure the power outlet meets or exceeds the specified capacity. 5. Be careful with the high-voltage parts.
CAUTION 1. Precautions for Service Jobs • A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire. • When reassembling parts, make sure that the correct screws (size, type) are used in the correct places. Using the wrong screw could lead to stripped threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury.
. Precautions for the Laser Beam (Only for Products Employing a Laser) • Removing the cover marked with the following caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover. • If removing this cover while the power is ON is unavoidable, be sure to wear protective laser goggles that meet specifications. • Make sure that no one enters the room when the machine is in this condition.
Other Precautions • To reassemble the product, reverse the order of disassembly unless otherwise specified. • While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses. • The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube. • An air gun and vacuum cleaner generates a strong electrostatic charge that can destroy the ATDC sensor and other sensors.
Used Batteries Precautions ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ. Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
PRECAUTIONS FOR SERVICE When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. ✽ Depending on the model, some of the precautions given in the following do not apply. Precautions Before Service • When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads.
Precautions for Dis/Reassembly • Be sure to unplug the copier from the outlet before attempting to service the copier. • The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears.
Handling of PWBs 1. During Transportation/Storage: • During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature. • When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity.
Handling of the PC Drum ✽ Only for Products Not Employing an Imaging Cartridge. 1. During Transportation/Storage: • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. • In summer, avoid leaving the PC Drum in a car for a long time. 2. Handling: • Ensure that the correct PC Drum is used. • Whenever the PC Drum has been removed from the copier, store it in its carton or protect it with a Drum Cloth.
3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times. ✽ Never move the Pad back and forth. 1076D003 4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped.
DIS/REASSEMBLY, ADJUSTMENT
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1. SERVICE INSTRUCTIONS 1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS Inverter Board INV 250 V 2 A (F1) DC Power Supply Main PU1 <100 V Areas> 125 V 15 A (F1) 125 V 4 A (F2) 125 V 15 A (F3) 125 V 6.3 A (F4) <200 V Areas> 250 V 8 A (F1) 250 V 3.15 A (F2) 250 V 8 A (F3) 250 V 3.15 A (F4) DC Power Supply Sub PU2 <100 V Areas> 125 V 4 A (F1) 250 V 3.15 A (F2) <200 V Areas> 250 V 3.15 A (F1) 250 V 1.60 A (F2) 1-2. Power Supply Board PWB-C 250 V 4 A (6 pcs.
NOTES • The Organic Photoconductor Drum is softer than CdS and Selenium Drums and is therefore susceptible to scratches. • Even when the PC Drum is only locally dirtied, wipe the entire surface. • Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. • If dirt remains after cleaning, repeat the entire procedure from the beginning one more time. 1-3.
2. DISASSEMBLY/REASSEMBLY 2-1.
No. Part Name Removal Procedure 1 Original Glass Remove No.3. 2 EDH Glass Remove No.3. 3 EDH Glass Holder Raise No.13. → Remove four EDH Glass Holder mounting screws. 4 Control Panel Raise No.13. → Swing down No.5. → Remove No.18. → Remove No.11. → Remove five Control Panel mounting screws. → Unplug two connectors. 5 Front Door Swing down the Front Door. → Remove two Front Door hinge shafts. → Remove two belt mounting screws inside the Front Door. Slide out the drawer.
2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS • When removing a circuit board or other electrical component, refer to “Handling of PWBs” and follow the corresponding removal procedures. • The removal procedures given in the following omit the removal of connectors and screws securing the circuit board support or circuit board. • Where it is absolutely necessary to touch the ICs and other electrical components on the board, be sure to ground your body.
Symbol Part Name Removal Procedure INV Inverter Board Remove the Scanner. → Unplug two connectors and remove two screws and the Inverter Board Mounting Bracket Assy. → INV PWB-A Master Board Remove the Right Cover. → Remove the Rear Cover. → Remove three screws and the Cover. → Remove four screws and the Cover. → PWB-A PWB-B Image Processing ☞ D-7 Board PWB-C Power Supply Board Remove the Right Cover. → Remove the Rear Cover. → Remove six screws and the Board Cover.
Removal of the Image Processing Board 1. Remove the Rear Cover and Right Cover. 2. Remove the Original Glass and EDH Glass. 3. Remove eight screws and the CCD Unit Cover. 4002D043AB 4. Remove four screws and the cover on the left. 5. Remove three screws and the cover on the right. 4002D044AC 6. Remove three screws and the PH Cooling Fan Motor mounting bracket Assy. 7. Remove six screws and the mounting bracket. 4002D046AB 8. Remove five screws and the Cover. Cover 4002D238AC 9.
10. Unplug two connectors, one flat cable. 4002D034AC 11. Unplug five connectors, two flat cables. 12. Remove the harness from the edge cover. 4002D258AB 13. Unplug four connectors. 14. Remove five screws and the Imaging Processing Board Mounting Bracket Assy. 4002D515AA 15. Remove ten screws and the Imaging Processing Board.
2-3. (1) Removal of the Unit Removal of the Multi Bypass Unit 1. Open the Upper Right Door. 2. Remove two connectors and the cover. 3. Unplug two connectors. 4002D027AD 4. Remove two screws and the Upper Right Cover. NOTE When reinstalling the Upper Right Cover, Adjustment of the Upper Right Door (Multi Bypass Unit). ☞ D-106 4002D028AB (2) 1. 2. 3. 4. Removal of the Suction Unit Swing down the Front Door and slide out the Developer Unit. Remove the Paper Dust Remover Assy. Slide out the Fusing Unit.
8. Swing down the Transport Section Release Lever. 9. Holding up the Suction Unit, remove the compression coil. 4002D031AD 10. Remove the Suction Unit by sliding it to the right. 1136D101AA NOTE When reinstalling the Suction Unit, make sure that two positioning pins on the copier fit into the positioning holes in the Suction Unit. 1134D028AA (3) Removal of the Main Hopper Unit 1. Swing down the Front Door and slide out the Developer Unit. 2. Remove the Right Cover. 3.
(4) Removal of the IR Unit 1. Swing down the Front Door and slide out the Developer Unit. 2. Remove the Right Door, Left Door, Rear Upper Cover, Rear Cover and Control Panel. 3. Slide out the Fusing Unit. 4. Remove four screws and the Cover. NOTE Do not remove the belt mounting screw on the cover. 4002D196AC 5. Unplug two connectors, remove four screws and remove the Main Hopper Unit. 4002D032AD 6. Remove three screws and the PH Cooling Fan Motor mounting bracket Assy. 7.
11. Unplug two connectors, one flat cable from the Imaging Processing Board. 4002D034AC 12. Unplug four connectors at the front. 4002D035AD 13. Remove five screws and the Cover. Cover 4002D238AC 14. Remove five screws and the Master Board Mounting Bracket Assy. 4002D069AC 15. Unplug ten connectors in the rear. 16. Remove one screw and the ground wire.
17. Remove two screws and the relay connector. 4002D037AB 18. Remove four screws and the right mounting bracket. 4002D038AC 19. Remove four screws and the left mounting bracket. 4002D039AC 20. Remove five screws that secure the IR Unit on the front side. 4002D040AD 21. Remove four screws that secure the IR Unit in the rear.
22. Remove the IR Unit. 4002D042AB (5) Removal of the PH Unit NOTES • Do not place the PH Unit upside down, tilt it excessively, or subject it to excessive shock. • Replace the PH Unit as one unit. • NEVER attempt to disassemble or adjust the PH Unit. • Whenever the PH Unit has been removed, make the following adjustments: Lead/Trail Edge Erase and Registration (CD/FD). 1. Remove the Right Cover. 2. Remove the Original Glass and EDH Glass. 3. Remove eight screws and the CCD Unit Cover. 4002D043AB 4.
7. Remove three screws and the PH Cooling Fan Motor mounting bracket Assy. 8. Remove six screws and the mounting bracket. 4002D046AB 9. Remove the harness from two cord clamps and one edge cover. 4002D047AC 10. Unplug two relay connectors and remove the harness from the cord clamp. 4002D048AB 11. Swing down the Front Door and slide out the Developer Unit. 12. Remove two thumbscrews and one bolt. 4002D049AB 13. Remove the PH Unit.
(6) Removal of the Developing Unit 1. Swing down the Front Door. 2. Swing down the Transport Section Release Lever. 4002D051AB 3. Loosen two screws and remove the Developing Unit. 4002U072AB (7) Removal of the Sub Hopper Unit 1. Swing down the Front Door and slide out the Developing Unit. 2. Unplug one connector and remove three screws and the Sub Hopper Unit. 4002D053AA (8) Removal of the Fusing Unit 1. Open the Left Door. 2. Swing Down the Front Door. 3.
(9) Removal of the Upper Left Door (Exit/Duplex Switching Unit) 1. Swing down the Front Cover and slide out the Fusing Unit. 2. Remove the cable from the spring. 4002D261AA 3. 4. 5. 6. Remove the Rear Cover. Open the Upper Left Door. Remove the Left Cover. Unplug one connector and remove the harness from the edge cover. 7. Remove one screw, holding bracket, and the band. 4002D055AC 8. Remove one screw and the holding bracket. 9. Remove the Upper Left Door.
2-4. (1) PAPER TAKE-UP/TRANSPORT SECTION Removal of the Paper Take-Up Roll, Paper Feed Roll and Paper Separator Roll Assy. 1. Remove the Right Door. 2. Remove one screw and the Paper Guide Plate from each drawer. 4002D057AB 3. Remove the Paper Separator Roll/Paper Guide Plate Assy. by turning it about 90 in the direction of the arrow. 4002D058AC 4. Loosen one screw and remove the Paper Separator Roll Mounting Bracket Assy. 4002D059AE 5. Disassemble the Paper Separator Roll Assy.
6. Unbending one tab of the holder, remove the holder. 4002D061AB 7. Remove the Paper Take-Up Roll and Paper Feed Roll. 4002D062AB (2) Cleaning of the Paper Take-Up Roll and Paper Feed Roll 1. Remove the Paper Separator Roll Mounting Bracket Assy. 2. Using a soft cloth dampened with alcohol, wipe each roll clean of dirt. 4002D063AA (3) Cleaning of the Paper Separator Roll 1. Remove the Paper Separator Roll Mounting Bracket Assy. 2.
(4) Removal of the Drawer Lift-Up Motor 1. Remove the Right Door. 2. Slide out the drawer and remove one screw and the right stopper. 4002D065AB 3. Pushing the tab on the left rail, pull out the drawer. 4002D066AC 4. Remove three screws and the Drawer Set Sensor Mounting Bracket Assy. 5. Unplug one connector. NOTE Reinstall the Drawer Set Sensor Mounting Bracket as you hold the lever. 4002D067AB 6. Unplug two connectors. 7. Remove one screw and the Drawer Lift-Up Unit.
8. Disassemble the Drawer Lift-Up Unit. 1156D022AA (5) Removal of the Upper and Lower Transport Rollers 1. Swing down the Front Door and slide out the Developing Unit. 2. Slide out the 1st Drawer. 3. Remove the Rear Cover. 4. Remove the Right Cover. 5. Remove five screws and the Cover. Cover 4002D238AC 6. Remove five screws and the Master Board Mounting Bracket Assy. 4002D069AC 7. Remove six screws and the board cover.
8. Remove three screws and the Power Supply Board Mounting Bracket Assy. 4002D070AB 9. Remove three screws and the Flywheel. 4002D071AB 10. Remove three screws and the Transport/Synchronizing Rollers Drive Assy. 4002D073AB 11. Snap off the E-ring and remove the gear. 12. Unhook one spring and snap off one E-ring. Then remove the bushing from the rear end of the Upper Transport Roller. 13. Snap off one E-ring and remove the bearing from the rear end of the Lower Transport Roller. 4002D239AC 14.
15. Unhook one spring and snap off two E-rings. Then remove the bushings from the front end of the Upper and Lower Transport Roller. 4002D240AB 16. Remove the Upper Transport Roller. 17. Remove the Lower Transport Roller. 4002D241AA (6) Cleaning of the Upper Transport Roller 1. Swing down the Front Door and slide out the Developing Unit. 2. Using a soft cloth dampened with alcohol, clean the Upper Transport Roller. 4002D242AA (7) Cleaning of the Lower Transport Roller 1.
(8) Cleaning of the Vertical Transport Rollers 1. Open the Upper Right Door. 2. Using a soft cloth dampened with alcohol, wipe each roller clean of dirt. 4002D244AA (9) Removal of the Synchronizing Roller 1. Swing down the Front Door and slide out the Developing Unit. 2. Remove the Rear Cover. 3. Remove the Right Cover. 4. Remove five screws and the Cover. Cover 4002D238AC 5. Remove five screws and the Master Board Mounting Bracket Assy. 4002D069AC 6. Remove six screws and the board cover.
8. Remove three screws and the Flywheel. 4002D071AB 9. Unplug two connectors and remove five screws and the Developing Unit Drive Assy. 4002D072AB 10. Unplug two connectors and remove three screws and the Transport/Synchronizing Rollers Drive Assy. 4002D073AB 11. Snap off the E-ring and remove the gear. 12. Snap off one E-ring and remove the bushing from the rear end of the Upper Synchronizing Roller. 4002D074AA 13. Remove three screws and the Cover.
14. Snap off the E-ring and remove the bushing from the front end of the Upper Synchronizing Roller. 15. Remove the Upper Synchronizing Roller. 4002D076AB (10) Cleaning of the Upper Synchronizing Roller 1. Swing down the Front Door and slide out the Developing Unit. 2. Using a brush or a vacuum cleaner, clean the Upper Synchronizing Roller. 4002D080AB (11) Removal of the Lower Synchronizing Roller 1. Remove the Suction Unit. 2.
(12) Cleaning of the Lower Synchronizing Roller 1. Swing down the Transport Section Release Lever. 2. Using a brush or a vacuum cleaner, clean the Lower Synchronizing Roller. 4002D081AB (13) Removal of the Synchronizing Paper Dust Remover 1. Swing down the Front Door and slide out the Developing Unit. 2. Remove one screw and the Synchronizing Paper Dust Remover Assy. 4002D082AB NOTE When only the Paper Dust Remover is to be replaced, affix the new one along the reference line as shown on the left.
NOTE When only the Paper Dust Remover is to be replaced, affix the new one along the reference line as shown on the left. 1 mm 4002D517AA (15) Cleaning of the Paper Dust Remover 1. Remove the Synchronizing Paper Dust Remover Assy. 2. Using a brush, whisk dust off the Synchronizing Paper Dust Remover. 1136D095AA 1. Remove the Transport Paper Dust Remover Assy. 2. Using a brush, whisk dust off the Transport Paper Dust Remover. 4002D541AA (16) Disassembly of the Suction Unit 1. Remove the Suction Unit.
5. Remove four Suction Belts. 4002D085AB 6. Remove the Suction Roller as shown on the left. 4002D086AB (17) Disassembly of the Multi Bypass Unit 1. Remove the Right Door. 2. Remove four screws and the Separator Guide Plate Assy. 4002D087AB 3. Remove the Spring. NOTE When reinstalling the Spring, place it so that its closecoiled end faces the Separator Unit. 4002D088AB 4. Snap off the C-clip and remove the Separator Assy.
5. Snap off the C-clip and remove the Separator Roll Assy. 1136D109AA 6. Remove five screws and the Solenoid Mounting Bracket Assy. NOTE Whenever a solenoid has been replaced or a solenoid mounting screw removed, be sure to adjust the position of the solenoid. ☞ D-72 4002D090AB 7. Snap off the E-ring and remove the gear. 8. Unhook the spring and remove the gear assy. 4002D091AB 9. Snap off the E-ring and remove the Paper Take-Up Roll Assy. 4002D092AB 10.
11. Snap off the E-ring and remove the Paper Take-Up Roll. 4002D094AB (18) Cleaning of the Multi Bypass Paper Take-Up Roll/Paper Feed Roll 1. Using a soft cloth dampened with alcohol, clean the Paper Take-Up Roll/Paper Feed Roll. 4002D095AB (19) Cleaning of the Multi Bypass Paper Separator Roll Assy. 1. Using a soft cloth dampened with alcohol, clean the Paper Separator Roll Assy.
2-5. (1) OPTICAL SECTION Cleaning of the Original Glass and EDH Glass 1. Wipe clean the Original Glass and EDH Glass with a soft cloth. 4002O262AB (2) Cleaning of the Mirrors 1. Remove the Original Glass. 2. Wipe the surface of each mirror clean of dirt using a soft cloth. 4002D107AA (3) Cleaning of the Lens 1. Remove the Original Glass and EDH Glass. 2. Remove eight screws and the CCD Unit Cover. 3. Remove four screws and the Lens Cover. 4002D108AB 4. Wipe clean the Lens with a soft cloth.
(4) Cleaning of the Scanner Rails/bushings 1. Remove the Original Glass. 2. Wipe clean the Scanner Rails/bushings with a soft cloth. NOTE Apply lubricant to the Scanner Rails/Bushings after they have been cleaned. 4002D100AA (5) Cleaning of the PH Glass 1. Swing down the Front Door and slide out the Developing Unit. 2. Open the cover. 4002D265AA 3. Wipe clean the PH Glass with a soft cloth. 4002D099AB (6) Removal of the Scanner 1. Remove the Original Glass. 2.
Scanner mounting screws NOTE Do not remove the Scanner positioning screws. Scanner positioning screws 4002D264AB 4. Swing the Scanner counterclockwise and take it out of the copier. NOTE At this point, the Scanner is kept connected to a flat cable and cannot be taken off. 4002D102AB 5. Unplug one connector. 6. Remove two screws and the flat cable board. 7. Remove the Scanner. 4002D103AB (7) Removal of the Exposure Lamp 1. Remove the Scanner. 2. Unplug one connector from the Inverter Board. 3.
(8) Removal of the EDH Glass 1. Remove four screws and the EDH Glass Holder. 2. Remove the EDH Glass. 4002D245AB (9) 1. 2. 3. 4. Removal of the Scanner Drive Cable Remove the Original Glass and EDH Glass. Remove the Left Cover, Right Cover, Rear Upper Cover and Control Panel. Remove the CCD Unit Cover. Remove the Scanner. 5. Unhook the springs of the Scanner Drive Cables on the hook side, one each at the front and in the rear. 6. Remove the front and rear Scanner Drive Cables. 4002D110AB 7.
9. Remove one screw and the slide the rear pulley and bushing toward the front. 4002D113AA 10. Remove the Scanner Drive Gear, pulleys and bushings at the front and rear, and the shaft. 4002D114AD (10) Winding of the Scanner Drive Cable Pulley F Pulley E Pulley D Pulley C Pulley B 4002D001AA Pulley A Front Bead 1. Position the round bead of the Scanner Drive Cable in the pulley as shown. NOTE Make sure that the bead snugly rests in the slit in the pulley.
2. Wind the fixed bead end of the cable around the pulley five turns clockwise, from the rear toward the front side. 4002D003AA 3. Wind the hook end of the cable around the pulley five turns counterclockwise, from the front toward the rear side. NOTE Make sure that no part of the cable rides on the other. 4002D004AA 4. Slip the Cable Holding Jig onto the pulley to secure the cable in position. 4002D501AA Rear Bead 5. Position the round bead of the Scanner Drive Cable in the pulley as shown.
7. Wind the hook end of the cable around the pulley five turns counterclockwise, from the rear toward the front side. NOTE Make sure that no part of the cable rides on the other. 4002D007AA 8. Slip the Cable Holding Jig onto the pulley to secure the cable in position. 4002D502AA 9. Mount the front and rear pulleys and bushings on the shaft and install the shaft to the IR Unit. 10. Mount the Scanner Drive Gear on the shaft and secure it in position with one screw. 4002D115AD 11.
13. Slide the rear pulley and bushing to the rear and secure install one mounting screw. 4002D118AD Front Pulley C 14. Wind the bead end of the cable around pulley C and pulley B, then hook the bead onto the Adjustable Anchor. Pulley B 4002D008AA 15. Wind the hook end of the cable around pulley A and pulley B. Pulley B Pulley A 4002D009AA 16. Fit the hook end of the cable into the groove in the Cable Guide and hook the spring. Cable Guide 4002D119AB Pulley F Rear 17.
18. Wind the hook end of the cable around pulley D and pulley E. Pulley E Pulley D 4002D011AA 19. Fit the hook end of the cable into the groove in the Cable Guide and hook the spring. Cable Guide 4002D120AB 20. Mount the Scanner Motor Mounting Bracket Assy. 21. Remove the Cable Holding Jigs from the front and rear pulleys. 22. Remove the Allen wrench. 23. Mount the Scanner. 24. Reinstall the Left Cover, Right Cover, Rear Upper Cover and Control Panel. 25. Reinstall the Original Glass and EDH Glass.
2-6. (1) DEVELOPING UNIT Remove of the Developing Unit 1. Swing down the Front Door and slide out the Developing Unit. 2. Move the PC Drum Charge Corona to the rear, raise it, and take it off. 4002U015AA 3. Loosen the two screws of the PC Drum stopper and remove the PC Drum stopper. 4. Remove the PC Drum. 4002D122AB 4002D123AB NOTES • When reinstalling the PC Drum, refer to the illustration on the left and make sure of the correct direction of installation.
6. Remove two screws and the Stopper and Developer Scattering Prevention Plate. 4002D125AB 7. Remove two screws and the Cleaning Blade. 4002D127AB NOTE When reinstalling the Cleaning Blade, press the blade tightly up against the mounting bracket. 1136D173AA 8. Remove two screws, unplug one connector, and remove the ATDC Sensor. 4002D246AA 9. Unplug one connector. 10. Remove three screws and the PC Drum Paper Finger Holder Assy.
Coupling Holder NOTE When reinstalling the PC Drum Paper Separator Finger Holder Assy., fit the collar of the assy onto the coupling holder in the rear. Collar 1134D047AA 11. Remove the PC Drum Paper Fingers and AIDC Sensor Board as shown below. Assy AIDC Sensor Board 4002D128AB NOTES • At removal and reinstallation, use care not to damage the tip of the fingers. Also, use care not to get hurt by the tip of the fingers.
(2) Cleaning of the Developer Scattering Prevention Plate 1. Using a brush, whisk dust off the Developer Scattering Prevention Plate. 4002D129AA (3) Cleaning of the DS Positioning Collars 1. Using a brush or a soft cloth dampened with alcohol, clean the DS Positioning Collars. 1136D177AA (4) Cleaning of the Toner Antispill Trap 1. Using a brush or a soft cloth, clean the Toner Antispill Trap. 4002D130AA (5) Replacement of the Cleaning Blade 1.
2. Remove the Toner Bottle from Main Hopper. Insert a brush through the toner port and into the toner. 4002U022AA 3. Apply toner to the entire surface of the new Cleaning Blade. 4002D132AA 4. Using the brush, apply lubricant shipped with the Cleaning Blade to the two side seals shown. 4002D133AB 5. Install the PC Drum. 4002D123AB 6. Fit the PC Drum stopper and tighten the screws.
7. Apply a thin coat of toner to the surface of the PC Drum. 4002U023AB 8. Holding onto the both sides of the PC Drum with hands, turn the PC Drum a half turn in the direction of the arrow. 4002U024AC 9. Holding onto the both sides of the PC Drum with hands, turn the PC Drum a half turn in the direction of the arrow. 4002U025AC (6) Replacement of the Developer 1. Remove the Sub Hopper Unit. 2. Dump the developer out the Developing Unit.
3. Turning the Bucket Roller, pour fresh developer evenly into the chamber. 1134D051AA (7) NOTES • Shake the packet of developer well before opening it. • When the developer has been replaced, clear the counts of “Developer 1” and “Developer 2” of “PM” of “Counter” available from the Tech. Rep. mode and run the F8 ATDC Sensor operation. ☞ D-81 Cleaning of the AIDC Sensor Board 1. Remove the PC Drum. 2. Using a brush or a soft cloth dampened with alcohol, clean the AIDC Sensor Board.
NOTE When reinstalling the Toner Antispill Plate and Toner Antispill Seal, press them in the direction of the arrows. 4002D139AB (10) Cleaning of the Toner Antispill Seal 1. Remove the Toner Antispill Seal. 2. Using a brush, clean the Toner Antispill Seal. 4002D140AA (11) Removal of the Main Erase Lamp 1. Swing down the Front Door. 2. Unplug one connector. 3. Remove one screw and the Main Erase Lamp. 4002D141AB (12) Cleaning of the Main Erase Lamp Filter 1. Swing down the Front Door. 2.
3. Using a soft cloth dampened with alcohol, wipe clean the Main Erase Lamp Filter. 1136D187AA (13) Removal of the Ozone Filter (PC Drum Charge Corona) 1. Swing down the Front Door. 2. Swing out the Main Hopper. 3. Slide out the Ozone Filter. 4002D143AB (14) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas) 1. Unhook one tab and remove the Filter Cover. 2. Pull out the Ozone Filter. 4002D144AB (15) Removal of the Toner Collecting Bottle 1.
2-7. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/ PAPER SEPARATOR CORONAS (1) Removal of the PC Drum Charge Corona 1. Swing down the Front Door and slide out the Developing Unit. 2. Move the PC Drum Charge Corona to the rear, raise it, and take it off. 4002U015AA (2) Cleaning of the PC Drum Charge Corona Housing 1. Remove the PC Drum Charge Corona. 2. Press the Mesh Holder on the front of the Corona Unit in the direction of arrow A to remove the Grid Mesh. 1156D070AA 3. Remove the Cleaning Pad Holder.
NOTE When handling the Comb Electrode, be sure to hold it onto its both ends. 10 mm 17 mm 4002D147AB 6. Wipe clean the Housing with a soft cloth. 1139D177AA (3) Cleaning of the PC Drum Charge Corona Grid Mesh 1. Blow all foreign matter off the Grid Mesh with a blower brush. 1136D195AA 1136D196AA NOTES • If the blower brush is not effective in cleaning serious contamination of the Grid Mesh, use a soft cloth dampened with alcohol.
(4) Cleaning of the Comb Electrode 1. Clean Comb Electrode using the PC Drum Charge Corona Cleaning Lever. 1156D072AA (5) Removal of the Image Transfer/Paper Separator Coronas 1. Swing down the Front Door. 2. Pull out the Transfer/Paper Separator Coronas. 1134D062AA (6) Cleaning of the Image Transfer Corona Wire 1. Swing down the Front Door. 2. Clean Image Transfer Corona Wire using the Image Transfer Corona Wire Cleaning Lever.
(7) Removal of the Image Transfer Corona Wire 1. Remove the End Caps from the front and rear ends of the Unit. 4002D149AA 2. Remove the corona wire, first at the spring end. 4002D150AA (8) Cleaning of the Paper Separator Corona Wire 1. Remove the four Paper Guides. 4002D151AA 2. Dampen a soft cloth with alcohol, hold it with a pair of tweezers, and wipe the Paper Separator Corona Wire gently in one direction. NOTE Wipe the wire from the hook to spring end.
(9) Removal of the Paper Separator Corona Wire 1. Remove the End Caps from the front and rear ends of the Unit. 4002D149AA 2. Remove the four Paper Guides. 4002D151AA 3. Remove the corona wire, first at the spring end. 4002D150AA (10) Cleaning of the Image Transfer/Paper Separator Coronas Housing 1. Remove the four Paper Guides. 2. Remove the End Caps from the front and rear ends of the Unit. 3. Remove the corona wire, first at the spring end. 4. Wipe clean the Housing with a soft cloth.
(11) Cleaning of the Pre-Image Transfer Guide Plate 1. Using a soft cloth dampened with alcohol, wipe clean the Pre-Image Transfer Guide Plate.
2-8. (1) FUSING UNIT Disassembly of the Fusing Unit 1. Slide out the Fusing Unit. 2. Remove two screws and the Fusing Unit Front Cover. 4002D153AB NOTE When reinstalling the Front Cover, hook the tab into position. 4002D266AA 3. Remove four harness holders. 4. Unplug the connector of the Heater Lamp on the front. 5. Remove the Heater Lamp cord from the one edge cover. 4002D154AC 6. Remove five harness holders. 7. Remove one screw and the Heater Lamp cord. 4002D155AB 8.
9. Remove four harness holders. 10. Remove the Upper Fusing Roller Heater Lamp harness from one wiring saddle. 11. Unplug two connectors of the Heater Lamp on the rear. 12. Remove the Upper and Lower Fusing Roller Heater Lamp harnesses from three edge covers. 4002D157AB 13. From the front side, slide out the Upper and Lower Fusing Roller Heater Lamps. 4002D158AB 14. Unplug one Thermistor connector. 15. Remove the Thermistor harness from the harness guide. 16. Remove one screw and the cord.
19. Remove two screws and the Web Roller Assy. 4002D162AD 20. Remove two springs. 21. Remove one shoulder screw and the Lower Exit Guide Assy. 4002D165AA NOTE When reinstalling the Upper Fusing Guide Plate Assy, press both ends of the guide plate up against the frame. 4002D164AB 22. Remove two screws and the Upper Fusing Guide Plate Assy. 4002D163AA 23. Loosen the front roller pressure screw and unhook the upper end of the spring. NOTE Repeat the same step for the spring in the rear.
NOTE When tightening the roller pressure screws with the springs installed, tighten the front and rear ones alternately until there is no clearance in the mounting bracket. 4002D167AB 24. Remove two screws and the rear holder. 4002D168AA 25. Remove two screws and the front holder. 4002D169AA 26. Remove two screws and the bracket. 4002D170AB NOTE When installing the mounting bracket, press its both ends up against the frame.
27. Remove one shoulder screw and the Pre-Fusing Guide Plate. 28. Remove two springs. 4002D172AA NOTE When reinstalling the Pre-Fusing Guide Plate, make sure that the rear harness is on the inside of the shoulder screw. 4002D173AA 29. Remove one E-ring, two shoulder screws, and two gears. 4002D174AC 30. Remove two bearings. 31. Remove the bushing and Upper Fusing Roller. 4002D175AB 32. Remove the bearing and Lower Fusing Roller.
(2) Removal of the Upper Fusing Paper Separator Fingers 1. Remove the Upper Fusing Guide Plate Assy. 2. Remove five springs. 3. Slide out the shaft to remove five Upper Fusing Paper Separator Fingers. 4002D177AA (3) Cleaning of the Upper Fusing Paper Separator Fingers 1. Remove the Upper Fusing Guide Plate Assy. 2. Using a soft cloth dampened with oil, wipe the five Upper Fusing Paper Separator Fingers clean of dirt. 4002D178AA (4) Cleaning of the Lower Fusing Paper Separator Fingers 1.
(6) Removal of the Upper Fusing Roller Thermistor 1. Slide out the Fusing Unit. 2. Unplug one connector. 3. Remove one screw and the Upper Fusing Roller Thermistor Assy. 4002D159AD 4. Remove one screw and the Upper Fusing Roller Thermistor. 4002D182AB (7) Cleaning of the Upper Fusing Roller Thermistor 1. Remove the Upper Fusing Roller Thermistor Assy. 2. Using a soft cloth dampened with oil, wipe the Upper Fusing Roller Thermistor clean of dirt.
5. Remove the rubber stopper, and slide out the shaft. 6. Remove the Lower Fusing Roller Thermistor. 4002D185AB (9) Cleaning of the Lower Fusing Roller Thermistor 1. Remove the Lower Fusing Roller Thermistor Assy. 2. Using a soft cloth dampened with oil, wipe the Lower Fusing Roller Thermistor clean of dirt. 4002D186AA (10) Removal of the Upper Fusing Roller Thermostat 1. Remove the Harness Guide. 2. Remove two screws and the Upper Fusing Roller Thermostat Assy. 3.
(12) Removal of the Web Roller 1. Remove the Web Roller Assy. 2. Remove two screws and the Web Roller bushing and Web Take-Up Roller bushing. NOTE When reinstalling the Web Roller bushing and Web Take-Up Roller bushing, ensure that they are in correct position without being tilted or out of position. 4002D189AA 3. Remove the Web Roller and Web Take-Up Roller. 4002D190AB NOTES • When reinstalling the Web Roller and Web Take-Up Roller, wind the web around the Web Take-Up Roller at least one complete turn.
(14) Removal of the Misfeed Removal Knob Bushing 1. Slide out the Fusing Unit. 2. Remove one E-ring and the gear and bearing. 4002D193AC 3. Remove the Misfeed Removal Knob Assy. and bushing. 4002D194AB (15) Removal of the Fusing Unit Drive Coupling Gear 1. Slide out the Fusing Unit. 2. Remove one E-ring and the Fusing Unit Drive Coupling Gear. 4002D248AC 2-9. (1) TURNOVER UNIT Cleaning of the Turnover Roller, Transport Rollers 1. Open the Lower Left Door. 2.
3. 3-1. ADJUSTMENT ADJUSTMENT JIGS AND TOOLS USED 1. Front Door Interlock Switch Actuating Jig 2. Predrive Inhibit Switch Actuating Jig 1136D001AA 1136D005AA 3. Scanner Positioning Jig (Front) 4. Scanner Positioning Jig (Rear) 4002D505AA 4002D504AA 5. Sleeve/Magnet Roller Positioning Jig 6. D.B. Adjusting Jigs 1136D003AA 1074D129AA 7. PC Drum Paper Separator Finger Positioning Jig 8.
3-2. ADJUSTMENT REQUIREMENTS LIST Adjustment Item Requirements Ref. Page Automatically adjusted ☞ D-79 F5 AIDC Sensor → → → ☞ D-80 Registration (CD) 5.0 ± 0.5 mm ☞ D-83 Registration (FD) Lead Edge Erase Touch Panel Adj. Orig. Size Adjust F8 ATDC Sensor ☞ D-81 ☞ D-82 → ☞ D-85 3.0 ± 1.0 mm ☞ D-87 Trail Edge Erase → ☞ D-89 Loop Adjustment Approx. 4.0 mm ☞ D-91 3.0 mm ☞ D-93 Erasure Width Zoom (CD) 200 ± 1.0 mm ☞ D-95 Zoom (FD) 300 ± 1.
3-3. (1) ADJUSTMENT OF SWITCHES Microswitches The following microswitches are used in various parts of this copier. Blue (NC) Yellow (NO) Red (COM) Red (COM) 1136D007AA 1136D008AA Wiring for the NO Type Wiring for the NC Type NC (Normally-Closed) : Current flows between NC and COM when the actuator is open. NO (Normally-Open) : Current flows between NC and COM when the actuator is closed. COM (Common) : Common contact for NC and NO. Requirement Actuator COM 0.1 mm to 0.
(2) Adjustment of Front Door Interlock Switch 1. 2. 3. 4. Swing down the Front Door. Remove the Left Cover. Slide out the Fusing Unit. Remove four screws and the Cover. NOTE Do not remove the belt mounting screw on the cover. 4002D196AC 5. Loosen two screws that secure Front Door Interlock Switch. 4002D197AB 6. If the interlock switch is OFF when the Front Door is closed in position, move the interlock switch toward the front. 7.
3-4. ADJUSTMENT OF BELT TENSION Checks after Adjustment • Turn the Timing Belt and check that all the Pulleys and grooves of the Belt fit securely. • Each Belt should flex a little when the Belt is lightly pressed with a finger. Reference Since a given tension is applied by a tension spring to the Tension Lever that maintains the tension of each timing belt, adjustment is completed by re-tightening the mounting screw after it has been loosened. (1) Adjustment of the Suction Drive Timing Belt 1.
Tension Lever 2 7. Loosen two screws by which the Tension Lever 2 is mounted as shown on the left and then re-tighten it. 4002D202AC (3) Adjustment of the Scanner Motor Timing Belt 1. Remove the Rear Upper Cover. 2. Loosen three screws on the Scanner Motor mounting bracket and then re-tighten them.
3-5. (1) SOLENOID POSITION ADJUSTMENT Adjustment of Manual Feed Paper Pick-Up Solenoid Requirement The Paper Stoppers should be fixed perpendicularly when the Pick-Up Solenoid is ON. Adjustment Procedure 1. Remove the Right Cover. 2. Remove five screws and the Manual Feed Paper Pick-Up Solenoid mounting bracket Assy. 4002D090AB 3. Remove two screws and the bracket. 4002D206AB 4. Set the Pick-Up Solenoid to ON.
5. Move the Pick-Up Solenoid in the direction of arrow ➀, then slowly move it in the direction of arrow ➁. 6. Move the Pick-Up Solenoid up to the position where the Lock Lever of the Paper Stopper becomes perpendicular (the position where the Paper Stopper is locked). NOTES • Be careful that the Pick-Up Solenoid is canceled from its set condition if moved excessively. • If the set condition is canceled, set the solenoid to the energized (ON) position again and repeat steps starting with step 6.
(2) Adjustment of Turnover Roller Retraction Solenoid Requirement The gap between the E-ring of the plunger and the Retraction Solenoid should be 3 ± 0.2 mm when the Retraction Solenoid OFF. Adjustment Procedure 1. Slide out the Fusing Unit. 2. Loosen two screws by which the Retraction Solenoid is mounted. 4002D210AC 3. Move the Retraction Solenoid so that the gap between the E-ring of the plunger and the Solenoid is 3 ± 0.2 mm when the Retraction Solenoid OFF. 3 ± 0.2 mm 4002D012AA 4.
(3) Adjustment of Exit/Duplex Switching Solenoid Requirement The gap between the E-ring of the plunger and the Switching Solenoid should be 3 ± 0.2 mm when the Switching Solenoid OFF. Adjustment Procedure 1. 2. 3. 4. Remove the Left Cover. Slide out the Fusing Unit. Remove the Left Inner Cover. Loosen two screws by which the Switching Solenoid is mounted. 4002D211AB 5. Move the Switching Solenoid so that the gap between the E-ring of the plunger and the Solenoid is 3 ± 0.
(4) Positioning of the PC Drum Paper Separator Fingers (Separator Finger Solenoid) Requirement The gap between the three PC Drum Paper Separator Fingers and the PC Drum should be 0.3 to 1.0 mm when the Separator Finger Solenoid OFF. NOTE Use care not to deform the Separator Fingers during the adjustment procedure. Adjustment Procedure 1. Attach the PC Drum Paper Separator Finger Positioning Jig to the Developer Unit. 1136D053AA 2.
(5) Adjustment of Turnover Route Switching Solenoid Requirement The gap between the E-ring of the plunger and the Switching Solenoid should be 3 ± 0.2 mm when the Switching Solenoid OFF. Adjustment Procedure 1. Remove the Left Cover. 2. Loosen two screws by which the Switching Solenoid is mounted. 4002D214AC 3. Move the Switching Solenoid so that the gap between the E-ring of the plunger and the Solenoid is 3 ± 0.2 mm when the Switching Solenoid OFF. 3 ± 0.2 mm 4002D014AA 4.
3-6. (1) ACCESSING THE TECH. REP. MODE AND ADJUST MODE Accessing the Tech. Rep. Mode 1. Press the Utility key. 2. Touch [Meter Count]. 3. Press the following keys in this order: Stop → 0 → 0 → Stop → 0 → 1 (2) Accessing the Adjust Mode 1. Enter the Tech. Rep. mode. 2.
3-7. (1) ELECTRICAL/IMAGE ADJUSTMENT Touch Panel Adj. Make this adjustment after either of the following procedures have been performed: • Memory Clear • Control Panel replacement Adjustment Procedure 1. Call the Tech. Rep. mode to the screen. 2. Touch [Tech. Rep. Choice] and [System Set], in that order. 3. Touch [Touch Panel Adj.]. 4. With the tip of a pen or similar object, touch the four crosses (+) on the screen in sequence.
(2) Orig. Size Adjust Make this adjustment after any of the following procedures have been performed: • Memory Clear • The original size is incorrectly detected • Replacement of the CCD Unit and Scanner parts • An Original Size Detecting Sensor has been replaced or added Adjustment Procedure 1. Place a blank sheet of A3 or 11 × 17 paper on the Original Glass and lower the Original Cover. 4002D215AB 2. 3. 4. 5. 6. Call the Tech. Rep. mode to the screen. Touch [I.R. & EDH Check]. Touch [Function (I.R.
(3) F8 ATDC Sensor Make this adjustment after any of the following procedures have been performed: • Developer replacement • ATDC replacement • Memory Clear NOTE Make this adjustment before running an F5 AIDC Sensor operation. Adjustment Procedure 1. Load the Developing Unit with fresh developer. 2. Install the Developing Unit in the copier. 3. Close the Front Door. NOTE Do not open and close the Front Door until the F8 ATDC Sensor operation is completed after the Power Switch has been turned ON.
(4) F5 AIDC Sensor Make this adjustment after any of the following procedures have been performed: • Developer replacement • ATDC replacement • Memory Clear NOTE This adjustment must be made after F8 ATDC Sensor. Adjustment Procedure 1. Turn the Power Switch ON. 2. Call the Tech. Rep. mode to the screen. 3. Touch [Function]. 4. Touch [Printer]. 5. Touch [F5 AIDC Sensor]. 6. Press the Start Key to let the copier make the F5 AIDC Sensor. (It will run for about 30 seconds.
(5) Registration (CD) Requirement Width A on the test pattern output should fall within the following range. lead edge 1155D154AB Specification Adjust Mode Setting Range 5.0 ± 0.5 mm Registration (CD) -8.2 to +8.2 This adjustment must be made after the PH Unit has been replaced. Adjustment Procedure 1. Call the Adjust mode to the screen. 2. Touch [Printer]. 3. Touch [Registration (CD)]. 4. Select the paper source to be checked and adjusted. 5.
7. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 3 4 5 6 7 8 9 0 C Use to change the + or - sign. 4002D510CB 8. Use the 10-key pad to change the setting value. NOTE Use the Access key to select the sign of + or -. Setting Value 4002D509CB Setting Instructions If width A is longer than the specifications, make the setting value smaller than the current one.
(6) Registration (FD) Requirement lead edge Width A on the test pattern output should fall within the following range. 1155D155AB Specification Adjust Mode Setting Range 5.0 ± 0.5 mm Registration (FD) -8.2 to +8.2 This adjustment must be made after the PH Unit has been replaced. Adjustment Procedure 1. Call the Adjust mode to the screen. 2. Touch [Printer]. 3. Touch [Registration (FD)]. 4. Press the Start Key to let the copier produce a test pattern. 5.
6. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 3 4 5 6 7 8 9 0 C Use to change the + or - sign. 4002D510CB 7. Use the 10-key pad to change the setting value. NOTE Use the Access key to select the sign of + or -. Setting Value 4002D511CB Setting Instructions If width A is longer than the specifications, make the setting value smaller than the current one.
(7) Lead Edge Erase Requirement Width A on the test pattern output should fall within the following range. NOTE The measurement shall be taken at the center on the leading edge of the paper. 1155D156AB Specification Adjust Mode Setting Range 3.0 ± 1.0 mm Lead Edge Erase 0 to 5 This adjustment must be made after the PH Unit has been replaced and following Registration (CD/FD). Adjustment Procedure 1. Call the Adjust mode to the screen. 2. Touch [Printer]. 3. Touch [Lead Edge Erase]. 4.
6. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 3 4 5 6 7 8 9 0 C 4002D519AA 7. Use the 10-key pad to change the setting value. Setting Value 4002D512CB Setting Instructions If width A is longer than the specifications, make the setting value smaller than the current one. If width A is shorter than the specifications, make the setting value greater than the current one. 8.
(8) Trail Edge Erase Requirement Width A on the test pattern output should fall within the following range. NOTE The measurement shall be taken at the center on the trailing edge of the paper. 1155D157AB Specification Adjust Mode Setting Range 3.0 ± 1.0 mm Trail Edge Erase 0 to 5 This adjustment must be made after the PH Unit has been replaced and following Registration (CD/FD). Adjustment Procedure 1. Call the Adjust mode to the screen. 2. Touch [Printer]. 3. Touch [Trail Edge Erase]. 4.
6. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 3 4 5 6 7 8 9 0 C 4002D519AA 7. Use the 10-key pad to change the setting value. Setting Value 4002D513CB Setting Instructions If width A is longer than the specifications, make the setting value smaller than the current one. If width A is shorter than the specifications, make the setting value greater than the current one. 8.
(9) Loop Adjustment Requirement Adjust so that a correct loop is formed at part A when paper is fed through. Specification Adjust Mode Setting Range Approx. 4.0 mm (visual) Loop Adjustment -3 to +3 This adjustment is to be made when any of the following symptoms occurs: variation in the amount of print leading edge void, paper skew, folded edge, and misfeed. Adjustment Procedure 1. Swing down the Front Door and fit the Front Door Interlock Switch Actuating Jig. 4002D249AA 2.
If the loop length falls outside the specified range, perform the following adjustment steps. 4. Call the Adjust mode to the screen. 5. Touch [Printer]. 6. Touch [Loop Adjustment]. 7. Touch [Drawer]. 8. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 3 4 5 6 7 8 9 0 C Use to change the + or - sign. 4002D510CB 9. Use the 10-key pad to change the setting value. NOTE Use the Access key to select the sign of + or -.
(10) Erasure Width Requirement Adjust so that no shade of the Original Scale is produced on the sample copy. Adjust Mode Setting Range Erasure Width 0 to 5 This adjustment must be made when a shadow is produced from the Original Scale. Adjustment Procedure 1. Call the Tech. Rep. mode to the screen. 2. Touch [I.R. (EDH) Check]. 3. Touch [Tech. Rep. Choice]. 4. Touch [Erasure Width]. 5. Press the Clear key to clear the current setting value. Use to clear the setting value.
4002D215AB 11. Place a sheet of A3 or 11 × 17 paper on the Original Glass and lower the Original Cover. 12. Make a copy in the full size (× 1.000) mode. 13. Check to see if a shadow of the Original Scale is produced on the sample copy. If no shadow is produced, return Lead Edge Erase to the value which has been recorded. If a shadow is produced, perform the following adjustment steps. 14. Call the Tech. Rep. mode to the screen. 15. Touch [I.R. (EDH) Check]. 16. Touch [Tech. Rep. Choice]. 17.
(11) Zoom (CD) Requirement Adjust to eliminate any difference in width between the original test pattern and a test pattern copy. Adjust Mode Setting Range Zoom (CD) 0.990 to 1.010 This adjustment must be made when the CCD Unit has been replaced. Adjustment Procedure 1. Call the Tech. Rep. mode to the screen. 2. Touch [Function]. 3. Touch [Printer]. 4. Touch [F12 Test Pattern]. 5. Touch [F12-3 (64-dot checkered)]. 6. Select the paper source loaded with A4 crosswise or Letter crosswise paper. 7.
12. Call the Adjust mode to the screen. 13. Touch [IR]. 14. Touch [Zoom (CD)]. 15. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 1 2 3 4 5 6 7 8 9 0 C 4002D519AA 16. Use the 10-key pad to change the setting value. Setting Value 4002D534CA Setting Instructions If width A on the test pattern copy is greater than that on the original test pattern, decrease the setting value.
(12) Zoom (FD) Requirement Adjust to eliminate any difference in width between the original test pattern and a test pattern copy. Adjust Mode Setting Range Zoom (FD) 0.990 to 1.010 This adjustment must be made when the Scanner Drive Cable has been replaced. Adjustment Procedure 1. Call the Tech. Rep. mode to the screen. 2. Touch [Function]. 3. Touch [Printer]. 4. Touch [F12 Test Pattern]. 5. Touch [F12-3 (64-dot checkered)]. 6.
12. Call the Adjust mode to the screen. 13. Touch [IR]. 14. Touch [Zoom (FD)]. 15. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 1 2 3 4 5 6 7 8 9 0 C 4002D519AA 16. Use the 10-key pad to change the setting value. Setting Value 4002D535CA Setting Instructions If width A on the test pattern copy is greater than that on the original test pattern, decrease the setting value.
(13) Scale (CD) Requirement Adjust so that the leading edge of the image of the scale on the copy sample meets the requirements. Adjust Mode Setting Range Scale (CD) -10.0 to +10.0 This adjustment must be made when the CCD Unit or Original Glass has been replaced. Adjustment Procedure 1. Place a scale on the Original Glass so that it runs parallel with the Original Width Scale and its leading edge is aligned with the Original Length Scale. 4002D270AA 2. Set Registration (CD) to +8.2. ☞ D-83 3.
10. Call the Adjust mode to the screen. 11. Touch [IR]. 12. Touch [Scale (CD)]. 13. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 3 4 5 6 7 8 9 0 C Use to change the + or - sign. 4002D510CB 14. Use the 10-key pad to change the setting value. NOTE Use the Access key to select the sign of + or -.
(14) Scale (FD) Requirement Adjust so that the leading edge of the image of the scale on the copy sample meets the requirements. Adjust Mode Setting Range Scale (FD) -7.0 to +7.0 This adjustment must be made when the Scanner has been removed the Scanner Drive Cable or Original Glass has been replaced. Adjustment Procedure 1. Place a scale on the Original Glass so that it runs parallel with the Original Length Scale and its leading edge is aligned with the Original Width Scale. 4002D218AC 2.
10. Call the Adjust mode to the screen. 11. Touch [IR]. 12. Touch [Scale (FD)]. 13. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 3 4 5 6 7 8 9 0 C Use to change the + or - sign. 4002D510CB 14. Use the 10-key pad to change the setting value. NOTE Use the Access key to select the sign of + or -.
3-8. (1) OTHER ADJUSTMENTS Adjustment of the Reference Position of Each Drawer Requirement lead edge Width A on the test pattern output should fall within the following range. Specification 5 ± 0.5 mm 1155D154AB The adjustment should be made after Registration (CD/FD). Adjustment Procedure 1. Call the Adjust mode to the screen. 2. Touch [Printer]. 3. Touch [Registration (CD)]. 4. Select the paper source to be checked and adjusted. 5. Press the Start Key to let the copier produce a test pattern. 6.
7. Slide out the drawer used as the paper source for the test pattern and then loosen the seven screws shown on the left. 4002D250AA 8. Watching the scale on the adjustment plate in the drawer, move the Edge Guide. 4002D251AA Setting Instructions If width A on the test pattern is greater than the specifications, move the Edge Guide to the rear. If width A on the test pattern is smaller than the specifications, move the Edge Guide to the front. 9.
(2) Adjustment of the Reference Position of the Multi Bypass Tray Requirement lead edge Width A on the test pattern output should fall within the following range. Specification 5 ± 0.5 mm 1155D154AB The adjustment should be made after Registration (CD/FD). Adjustment Procedure 1. Place a sheet of paper on the Multi Bypass Tray. 2. Call the Adjust mode to the screen. 3. Touch [Printer]. 4. Touch [Registration (CD)]. 5. Touch [Manual]. 6. Press the Start Key to let the copier produce a test pattern. 7.
(3) Adjustment of the Upper Right Door (Multi Bypass Unit) If the Right Door has been removed and reinstalled, the position of the actuator of Upper Right Door Set Sensor may deviate from the correct position. Hence, the necessity of the following adjustment. 1. Lifting the front end slightly, tighten the two mounting screws. NOTE At this time, only temporarily tighten these screws. 4002D220AB 2. Lightly close the Upper Right Door so that the Set Sensor actuator will not contact the frame.
(4) Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage Requirement With the Scanner fixed to the Scanner Drive Cables, there should be no gap between the Scanner/Mirrors Carriage Positioning Jig and the Scanner and also between the Scanner/ Mirrors Carriage Positioning Jig and the 2nd/3rd Mirror Carriage. Make this adjustment after either of the following procedures have been performed: • After the Scanner Drive Cable has been replaced.
4002D508AA 5. Press the Scanner and the 2nd/3rd Mirrors Carriage Assy tightly up against the Scanner Positioning Jigs. 6. Check that there is no clearance between the Scanner and the Scanner Positioning Jig, and between the 2nd/3rd Mirrors Carriage Assy and the Scanner Positioning Jig. If there is any clearance, adjust parallel alignment of the 2nd/3rd Mirrors Carriage Assy after this adjustment has been completed. 7. Tighten the two Scanner Positioning Screws.
(6) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller (D.B. Adjustment) Requirement The gap between the Doctor Blade and Sleeve Roller should be 0.6 + 0.03 - 0.05 mm. Adjustment Procedure 1. Slide out the Developer Unit and remove the PC Drum Charge Corona and PC Drum. 2. Remove two screws and the Developer Scattering Prevention Plate. 4002D224AA 3. Using a brush, whisk developer off the surface of the Sleeve Roller. 4002D225AA 4.
4. 4-1. MISCELLANEOUS INSTALLATION OF THE KEY COUNTER SOCKET (OPTION) 1. Remove the Right Cover. 2. Remove the Counter Cover. 4002D227AA 3. Swing down the Front Door and slide out the Developer Unit. 4. Remove three screws and the cover. NOTE Do not remove the belt mounting screw on the cover. 4002D075AB 5. Connect the Key Counter Socket connector. 6. Using one screw and nut, secure the counter socket.
4-2. MOUNTING THE ORIGINAL SIZE DETECTING SENSORS (OPTION) NOTE When an Original Size Detecting Sensor has been added, turn “ON” “Original Size Detecting Option” of “System Input” under the Tech. Rep. mode and make the “Orig. Size Adjustment.” ☞ D-80 1. Remove the Original Glass and EDH Glass. 2. Install the Original Size Detecting Sensor. FD3 (✽2) FD1 (✽1) (✽3) A CD2 (✽2) G 4002D268AB ✽ 1: Standard for the Except U.S.A.
4-3. FLASH MEMORY Software has conventionally been upgraded by replacing ROM on each board. This copier employs flash memory for the system control IC mounted on the Master Board and Image Processing Board. Its contents are reprogrammed easily by performing the following steps using the IC card (memory card), into which data has been previously downloaded. NOTES • NEVER remove or insert the memory card with the copier power turned ON.
10. Turn OFF the Power Switch. 11. Plug the power cord into the power outlet. 12. Turn ON the Power Switch. 13. Call the Tech. Rep. Mode to the screen. 14. Touch [ROM Version]. 15. Check to see if the printer version shown on the screen matches the version marked on the flash memory. (2) Rewriting the Image Processing Board Data 1. With the Power Switch in the OFF position, unplug the power cord from the power outlet. 2. Remove the Right Cover. 3. Close the Front Cover. 4.
Check Items • “Downloading Completed.” is shown. • The number shown to the left of “Language” matches that entered from the 10-Key Pad when the Power Switch is turned ON. • The Check Sum value matches the value given on the memory card. 11. If rewriting has been NG (as indicated by the Start key lighting up red), perform steps 12 and 13 and then start the procedure over, beginning with step 5. NOTE If the second rewriting fails, perform steps 12 and 13 and abandon the procedure. 12.
(3) Rewriting the ECC Board Data (option) 1. Unplug the power cord from the power outlet with the Power Switch OFF. 2. Remove the Rear Cover. 3. Insert the memory card into the ECC Board. 4002D538AB 4. Plug the power cord into the power outlet. 5. Turn ON the Power Switch. 6. This starts the rewriting sequence. NOTE D1 on the Master Board remains blinking while data is being rewritten. 4002D540AB 7. Check that D3 on the ECC Board turns ON. 8.
(4) Rewriting the Master Board, Image Processing Board, and ECC Board (Option) Simultaneously NOTE Steps 4 and 9 are to be performed only when the ECC Board (option) is mounted. 1. With the Power Switch in the OFF position, unplug the power cord from the power outlet. 2. Insert the memory card into the Image Processing Board. ☞ D-113 3. Insert the memory card into the Master Board. ☞ D-112 4. Insert the memory card into the ECC Board. ☞ D-115 5. Plug the power cord into the power outlet. 6.
4-4. REMOUNTING EPROM NOTE If the PW Board has replaced, be sure to remount EPROM from the old to new PW Board. If the PW Board has been replaced and EPROM has not been remounted, be sure to replace the PC Drum with a new one. EPROM contains no data in this case, so make entries again of numeric values given on the Adjust Label. (1) Remounting EPROM on the Master Board 1. Remove the Master Board. 2. Remove EPROM (IC101) from the new Master Board. 3.
(2) Remounting EPROM on the Image Processing Board 1. Remove the Image Processing Board. 2. Remove EPROM (IC400) from the new Image Processing Board. 3. Remove EPROM (IC400) from old Image Processing Board and remount it onto the new Image Processing Board. 4002D254AB A NOTE Note the alignment notch (A) on EPROM (IC400) when mounting the IC.
SWITCHES ON PWBs, TECH. REP.
CONTENTS 1. CONTROL PANEL KEYS AND TOUCH PANEL ............................................. S-1 1-1. Control Panel Keys .................................................................................. S-1 1-2. Explanation of the Touch Panel ............................................................... S-3 (1) Basis Screen ................................................................................... S-3 (2) Warning Screens ...........................................................................
1. 1-1.
1. HDD Lamp • Lights up to indicate that the Hard Disk Drive Kit (option) is being accessed. 2. Access Key • Press to enter the access number when Copy Track of the Administrator mode available. Press the access Key. 3. Energy Saver Key • Press to set machine into the Energy Saver mode. 4. Interrupt Key • Press to select the Interrupt mode. 5. Panel Reset Key • Press to set the machine into the initial mode, clearing all settings made on the control panel. 6. Clear Key • Clear the various numeric values. 7.
1-2. (1) Explanation of the Touch Panel Basis Screen The Basic screen is the initial screen that appears when the copier is turned ON. 1 2 3 5 4003P137CA 4 1. Supplementary Function Keys • The auxiliary, Density, Orig. Copy, and Basics keys are displayed. 2. Message Display • Shows the current machine status, operating instructions and precautions, and other data including the number of copies selected and the amount of paper still available for use. 3.
(2) Warning Screens The Warning screen may be a malfunction display, error display, warning display, or a caution display. Given when a malfunction occurs. E.g.: Malfunctions that can be identified with a specific code. 4003P200CA 4003P201CA Given when an error occurs. E.g.: Paper misfeed, door open, etc. Given when only a defective copy will be produced because of erroneous or illegal panel settings. E.g.: Unmatched paper size in Auto Paper.
2. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs 2-1. PWB Location PWB-S 4002S001AB 2-2. PWB-S (Tech. Rep. Setting Switches Board) 4002S002AB Symbol Name Description S25 Trouble Reset Switch Resets the malfunction display. S26 Tech. Rep. Switch Display the Tech. Rep. mode screen. PJ2 Initialize Switch Resets a misfeed, malfunction, and erratic display. TP1 Memory Clear Test Point Clears all data.
(1) Clearing Procedures 1. Turn OFF the Power Switch. 2. With the circuit across pins of PJ2 closed, turn ON the Power Switch. 3. Open the circuit in about 5 seconds. 4. Check that the message “Initialize Completed” is displayed on the Touch Panel and then touch the “OK” key. 1. Turn OFF the Power Switch. 2. With the circuit across TP1 and TP3 closed, turn ON the Power Switch. 3. Open the circuit in about 5 seconds. 4.
3. UTILITY MODE • Utility Mode is used to make various settings according to the user’s need. 3-1. Utility Mode selection Screen • Press the Utility key on the control panel. 4003P605CA 3-2. Utility Mode Function Tree Job Memory Input Image Memory Input Job/Image Mem. Input Meter Count Utility User’s Choice User’s Choice 1/6 User’s Choice 2/6 User’s Choice 3/6 User’s Choice 4/6 User’s Choice 5/6 User’s Choice 6/6 Administrator Mode Copy Track Copy Track Data Max.
3-3. Settings in the Utility Mode Touch Panel Display Setting Job/Image Men. Input Permits programming of various functions, including copying jobs. Meter Count Displays the counts of various counters. User’s Choice User’s Choice is used to make various settings according to the user’s need. Administrator Mode The entry of the “Administrator #” set using the Tech. Rep. mode permits the settings of the following functions. Toner Replenisher Replenishes the supply of toner.
2.
3. Settings in the User’s Choice Mode Touch Panel Display Original Default Copy Setting (The default is Highlighted ). Select the priority type of Original Copy setting selected automatically when the Power Switch is turned ON or Panel Reset key pressed. 1-Sided Language selected Mixed Original Detect 1-Sided 1-Sided 2-Sided 2-Sided Select the language of the Touch Panel messages.
Touch Panel Display Density Priority Setting (The default is Highlighted ). Specify the priority exposure mode that is selected automatically when the Power Switch is turned ON or the Panel Reset key pressed. Manual Auto Exposure Text/Photo Text Default Level Photo Auto: Select the priority exposure level in the Auto Exposure mode. Manual: Select the priority exposure level in the Manual Exposure mode.
Touch Panel Display Setting (The default is Highlighted ). “Smaller” Originals Select whether to enable or disable a copy cycle when it is initiated with an original of a small size that is not detectable by the system placed on the Original Glass. ON OFF ✽ Default: Metric areas OFF/Inch Areas ON. 4in1 Copy Order Date Printing Format Specify the default copying order in the 4in1 mode. 1 2 1 3 3 2 4 4 Select the delimiter and format for date printing. X X. X X.
Touch Panel Display Universal Tray Setting (The default is Highlighted ). Set the paper size for the Universal Tray. Size Input Auto Detect Special Paper Auto Panel Reset Energy Saver Mode Define the type of paper used for each paper source, or designate a particular paper source for special paper.
Touch Panel Display Auto Shut-Off Mode Setting (The default is Highlighted ). Select the time it takes the Auto Shut Off function, which shuts down the copier when the set period of time elapses after a copy cycle has been completed or the last key operated, to be activated. ✽ When a Printer Controller is not NOTE: • The option of “OFF” becomes available on the screen if “Yes” is connected. selected for “Disable Auto Shut off” of the “Administrator Mode” function.
(2) Administrator Mode • The entry of the “Administrator #” set using the Tech. Rep. mode permits the settings of the following functions. 1. Administrator Mode Function Setting Procedure 1. Press the Utility key. 2. Touch the “Administrator Mode” key. 3. Enter the Administrator number. 4. Select the appropriate function. 5. After the settings are complete, touch the “Enter” key to validate the settings. • Press the Panel Reset key. 2.
Touch Panel Display Setting (The default is Highlighted ). 100 Accounts The copy track data of the selected page is displayed. “No.”: Enter the set account number from the 10-Key Pad. “Total Count”: Displays the count of the Total Counter. “Size Count”: Displays the count of the Size Counter. “Copy Limit”: Enter the maximum number of copies that can be made from the 10-Key Pad. “Access Code”: Enter the access number, which can range from 0001 to 9999, from the 10-Key Pad.
4. TECH. REP. MODE • This mode is used by the Tech. Rep. to check, set, adjust, and/or program various service functions. 4-1. Tech. Rep. Mode Menu Screen 4003P602CA 4-2. Tech. Rep. Mode Function Setting Procedure 1. Press the Utility key. 2. Press the Meter Count key. 3. Press the following keys in this order: Stop → 0 → 0 → Stop → 0 → 1 4. Select the desired Tech. Rep. Mode function. • Press the Panel Reset key.
Tech. Rep. Mode Menu Function Tree Function Image Memory Tech. Rep. Choice Tech. Rep. Mode Opt. Mem. Check Memory Check Comp./Expansion I.R. → Mem. → Prn. → Printer F1: Paper Passage F2: HV Output F5: AIDC Sensor F8: ATDC Sensor F12: Test Pattern → 4-3. Hard Disk Format Hard Disk Check ECC Check Date/Time Check System Set FLS Paper Auto Paper Configuration Function Limit Touch Panel Adj.
~ I/O Check I.R. & EDH Check Tech. Rep. Mode Function (IR) Focus Check Zoom (CD) Zoom (FD)/Scale Scale (CD) Scanning Check Orig. Size Adjust Function (EDH) Position/Zoom (FD) Position (CD) S-ADF Mode (CD) S-ADF Mode (FD) Skew Check I/O Check (IR) I/O Check (EDH) Tech. Rep Choice Erasure Width ID in Photo Mode EDH Paper Passage 1-Sided 2-Sided Auto size Single Feed ROM Version RD Mode Level History Admin.
~ Tech. Rep.
4-4. (1) Setting in the Tech. Rep. Mode Function • This function allows the Tech. Rep. to make the various function tests and adjustments. Printer: Used for making the various function tests and adjustments for the printer. Image Memory: Used for making the various function tests and adjustments for image memory. Touch Panel Display F1: Paper Passage Operation A check is made for paper passage performance. 1. Select the paper source. 2.
Touch Panel Display Operation Memory Check Writes data in the image memory and reads it out to check for exact correspondence. The Touch Panel shows the percentage of processing completed of each diagnostic sequence and the number of diagnostic sequences carried out. If a fault is encountered, it gives the message of “NG” together with the address at which the fault occurred. 1. Press the Start key to start the diagnostic sequence. 2. Press the Stop key to stop the diagnostic sequence. Comp.
Touch Panel Display Operation Hard Disk Format Formats the Hard Disk. The Touch Panel shows the percentage of processing completed. If formatting has been normally completed, the panel gives the message of “OK”; if it has been abnormally terminated, the panel gives the message of “NG” together with the corresponding malfunction code. • Press the Start key to start the formatting sequence. Hard Disk Check Checks for proper connection and read/write operation of the Hard Disk.
(2) Tech. Rep. Choice • This function allows the Tech. Rep. to make various settings and adjustments. System Set: Choice functions relating to the printer. Printer: Choice functions relating to image memory. Controller Set: Choice functions relating to the Printer Controller. Touch Panel Display FLS Paper Setting (The default is Highlighted ). Set the size for FLS. F: 330.2 mm C: 203.2 mm Auto Paper Configuration Function Limit Touch Panel Adj. F: 330 mm C: 210 mm F: 330.2 mm C: 215.
Touch Panel Display Setting (The default is Highlighted ). Toner Empty Stop Select whether or not to inhibit copying when a toner-empty condition is detected. Disable Enable T/C Abnormal Select whether to enable or disable copying when an abnormal T/C is detected. Disable Enable Fusing (°C) Input T/C Auto Recover Set the temperature for fusing temperature control according to the operating environment and the type of paper used.
Touch Panel Display Peripheral Mode Setting (The default is Highlighted ). Select the type of external I/F operation. Mode 1 External I/F operation mode 1 Mode 2 External I/F operation mode 2 Mode 3 External I/F operation mode 3 ✽ After the setting has been made, touch “END” and turn OFF and ON the Power Switch. (3) System Input • This function allows the Tech. Rep. to change the fixed zoom ratios, set the paper size, define the marketing area, and make other settings.
(4) Counter • Shows the number of copies made on each paper size or type. 1. Open the counter menu screen. 2. Select the counter to be cleared. 3. Press the Clear key. 4. Touch “END”. Press the Interrupt key to undo the clearing operation, restoring the original count. 1. Touch the “Counter Reset” key. 2. Select the counters to be cleared all at once. 3. Touch “OK”.
Touch Panel Display Jam Setting Counts the number of misfeeds that have occurred at different locations in the copier. Display MCBJ System MCBJ Machine Only Manual Feed 1st Drawer 2nd Drawer 3rd Drawer 4tht Drawer Description Total Counter divided by the sum of all misfeedcounters (including misfeeds in the Finisher) Total Counter divided by the sum of machine misfeed counter (excluding misfeeds in the Finisher) No. of misfeeds that occurred at the Multi Bypass Tray No.
Touch Panel Display Setting Jam Display Fold Staple Finisher Needle Duplex Entrance Duplex Exit PM Description No. of misfeeds that occurred at the Folding Unit No. of misfeeds that occurred at the Stapling Unit No. of misfeeds that occurred in the Finisher, other than above No. of staple misfeeds that occurred. No. of misfeeds that occurred at the turnover/storage section of the Duplex Unit No.
Touch Panel Display Setting PM Display Description Staple 1 Staple 2 Punch Sort/Group Trans./Sepa. pass Ozone Filter No. of stapling sequences performed No. of stapling sequences performed (FN-105) No. of holes made (FN-105) No. of copies fed out in the Sort/Group mode No. of times a sheet of paper is fed through No. of times a sheet of paper is fed through ✽ See MAINTENANCE SCHEDULE (machine/options) for the applicable parts. Consumables Enter the count of the Waste Toner and Web Roller counters.
Touch Panel Display Setting Trouble Malfunction Code Description Malfunction Code Description C004E/F Cooling Fan C0210 C0042 Fusing Unit Fan C04X0 Exposure Lamp C0070/2 Toner Hopper Motor C05X0 Fusing Unit C0090 Dev.
Touch Panel Display Setting Trouble Malfunction Code Malfunction Code Description Description C1430 H. sysnc Trouble C1461/2 Serial GA Trouble C143E EDH Trouble C1499 IR Cooling Fan C1440 Gain Adjust Trouble C14XX IR Sequence Trouble C1441 CCD Trouble C1802 SPC Error Malfunction Code Description C1803 Memory Check Trouble C180X ECC Control Trouble C10A1/2, C11EX Communication (IR) C10A5/6, C11FX, C1326/34 Com. (Prin.
Touch Panel Display Scanning Check Setting Check the operations from image scanning to image processing. Normal: OK: Abnormal: NG See the following for details of “NG” display Display Action Optical Analog ✽ Check the optical system, change PWB-IA or B. Digital Change PWB-B. ✽ Made for correct alignment of the optical axis. Orig. Size Adjust Adjusts the threshold of original detection level. ✽ For details, see DIS/REASSEMBLY, ADJUSTMENT.
(8) RD Mode • Make the initial settings of the copier for the Data Terminal. 1. RD Mode Menu Function Tree e-mail System Set Modem CT-ID DT-ID Billing Center DT Setting TEL. No. (Setting Modem) Initial Transmission (Setting Modem) Mail Address (Setting e-mail) Billing RAM Clear YES NO CT-ID RD Mode Maint. Center ID Code DT-ID DT Setting TEL. No. (Setting Modem) Initial Transmission (Setting Modem) Mail Address (Setting e-mail) Call Completion Maint.
2. Setting in the RD Mode Touch Panel Display System Set Setting Set the control system. e-mail Modem Billing Center Displays the various setting screens. DT Setting Displays the setting screens for CT-ID, DT-ID, and telephone number. The mail address is also displayed if “e-mail” is set for System Set. CT-ID Enter the ID number of the Center PC from the 10-Key Pad. DT-ID Enter the ID number of the Data Terminal from the 10-Key Pad. TEL No.
Touch Panel Display Setting Date/Time Set Set the date and time-of-day for Date Printing. Common DT Displays the screens for communications settings. Dial Mode Sets the type of telephone line of the user. Tone Auto Receive Pulse Sets the auto reception function. YES (9) NO Level History • Displays the various level histories. Touch Panel Display Setting Fuser (Upper) Displays the current value of the fusing temperature. Fuser (Lower) Displays the current value of the fusing temperature.
(10) Admin. Mode • Makes the various settings. Touch Panel Display Setting Copy Track See User’s Choice. Copy Track Data See User’s Choice. Max. Copy Sets See User’s Choice. Administrator # Input Set an ID number for opening the “Administrator Mode” screen of Utility Mode from the 10-Key Pad. Data send See User’s Choice. Telephone number of Copy Track on the LAN See User’s Choice. (11) Finisher • Checks the Finisher for operation and makes necessary adjustments.
5. SECURITY MODE • Allows the Tech. Rep. to set the various counters. 5-1. Security Mode Menu Screen 4003P603CA 5-2. Security Mode Setting Procedure 1. Show the Tech. Rep. mode menu screen. 2. Press the following keys in this order: Stop → 9 3. Select the particular function. • Press the Panel Reset key.
5-3. Settings in the Security Mode Touch Panel Display Key Counter Setting (The default is Highlighted ). Set to “ON” if a Key Counter is plugged in. NOTE: • If “OFF” is set, copies can be made without having to plugging the Key Counter into the socket. ON Plug-In Counter OFF Select the condition by which the Counter count is increased. Copy Cycles Copy Made Size Counter Select the size of the paper to be counted by the Size Counter.
Touch Panel Display Vendor Mode Setting (The default is Highlighted ). Set the initial screen according to the type of vendor mounted on the copier. Coin OFF Admin. Unit Card Select the model of the Data Controller mounted on the copier.
6. ADJUST MODE • Used at the factory for making adjustments. NOTE: • Use only when the RAM Board has been replaced. If any of the adjustment values has been changed, be sure to enter the value in the label affixed to the copier. 6-1. Adjust Mode Menu Screen 4003P604CA 6-2. Adjust Mode Setting Procedure 1. Show the Tech. Rep. mode menu screen. 2. Press the following keys in this order: Stop → Start 3. Select the desired function. • Press the Panel Reset key.
6-3. Adjust Mode Function Tree Adjust Mode Printer Registration (CD) Registration (CD) PHC beam Adjust Image Density ATDC Control Separator Charge LD Bias Leading Edge Erase Trailing Edge Erase Loop Adjustment Vg adjust Image Reader Zoom (CD) Zoom (FD)/Manual Scale (FD) Scale (CD) EDH Zoom (FD)/EDH Feed (2) Feed (FD) Feed (CD) S-ADF Feed (FD) S-ADF Feed (CD) Regist. Loop (1) Regist.
6-4. Settings in the Adjust Mode Printer: Adjust functions relating to the printer. I.R.: Adjust functions relating to the I.R. EDH: Adjust functions relating to the EDH. Touch Panel Display Registration (CD) Setting (The default is Highlighted ). Adjust registration in the CD direction on the engine side. Setting -8.2 ................................ 0 ...............................+8.
Touch Panel Display Leading Edge Erase Setting (The default is Highlighted ). Select whether to enable or disable the leading edge erase. 0 to 5 ( 3 mm ) Trailing Edge Erase Select whether to enable or disable the trailing edge erase. 0 to 5 ( 3 mm ) Loop Adjustment Set the length of the loop to be formed in paper before the Synchronizing Rollers. Setting -3 ................................... 0 ..................................
Touch Panel Display Feed (FD) Setting (The default is Highlighted ). Set the correction value for the original scanning position in the FD direction when the EDH is used. -4.0 to +4.0 ( 0.0 mm ) Feed (CD) Set the correction value for the original scanning position in the CD direction when the EDH is used. -3.0 to +3.0 ( 0.0 mm ) S-ADF Feed (FD) Set the correction value for the original scanning position in the FD direction in the single feed mode. -4.0 to +4.0 ( 0.
TROUBLESHOOTING 13430
CONTENTS 1. INTRODUCTION ............................................................................................. T-1 1-1. Reading the Text ..................................................................................... T-1 2. I/O CHECK ...................................................................................................... T-1 2-1. Controlled Parts Check Procedure .......................................................... T-1 2-2. I/O Check List ....................................
C0924: 1st Drawer Lift-Up Motor’s failure to turn ............................ T-53 (13) C0900: 3rd Drawer Paper Lift-Up Sensor malfunction C0904: 3rd Drawer Paper Lift-Up Motor’s failure to turn C0950: 4th Drawer Paper Lift-Up Sensor malfunction C0954: 4th Drawer Paper Lift-Up Motor’s failure to turn ................. T-55 (14) C0990: Main Tray lifting motion failure C0994: Main Tray Elevator Motor’s failure to turn ...........................
1. INTRODUCTION 1-1. Reading the Text 1. The paper transport failure troubleshooting procedures are given according to the symptom. First identify the location where the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward. 2. Make checks in the numerical order of steps and, if an item is checked okay, go to the next step.
2-2. I/O Check List • The following screen is only typical and the port data shown does not necessarily represent the actual one. [IR] 4002T003CA [IR] Symbol Panel Display Parts/Signal Name Operation Characteristics/Panel Display 1 0 Input Board IC No. Port No. CN/PJ No. — — PJ6B-1 — — PJ6B-14 PC53 Orig. Size S1 Original Size Detect- Original ing Sensor FD1 present PC54 Orig.
• The following screens are only typical and the port data shown does not necessarily represent the actual one.
[Printer] Symbol Panel Display Parts/Signal Name Operation Characteristics/Panel Display 1 PC10 1st Drawer Set 1st Drawer Set Sen- In position sor 0 Out of position Input Board IC No. Port No. CN/PJ No.
Symbol Panel Display Parts/Signal Name Operation Characteristics/Panel Display 1 PC124 4th Drawer (PF208) PC135 Cabinet 0 Input Board IC No. Port No. CN/PJ No.
Symbol Panel Display Parts/Signal Name Operation Characteristics/Panel Display 1 PC113 Input Board IC No. Port No. CN/PJ No. Control Board (PWB-A) IC1 PD6 PJ9A-5 IC1 PB3 PJ7A-5A Leading Paper Leading Edge Edge Sensor 3 Paper present Paper not present Elev.
Symbol Panel Display Parts/Signal Name Operation Characteristics/Panel Display 1 PC23 0 Input Board IC No. Port No. CN/PJ No.
3. 3-1. PAPER TRANSPORT FAILURE Paper Misfeed When a paper misfeed occurs, the Touch Panel shows the corresponding message, misfeed location, and paper location.
3-2.
3-3. Types of Misfeed Detection and Detection Timings • The following lists the types of misfeed detection and detection timings for different misfeed locations. • The symbol “L” (for the leading edge) and “T” (for the trailing edge) given in ( ) indicate the particular edge of the paper detected by the sensor. NOTE For the types of misfeed detection and detection timings of options, see the relevant option service manual.
Type Detection Start Detection Leading edge detection by Paper Turnover Feed Entry SenExit Sensor during turnover exit sor (T) Paper Exit Sensor (L) Trailing edge detection by Paper Exit Sensor during turnover exit Paper Exit Sensor (L) Paper Exit Sensor (T) Leading edge detection by Turnover/Exit Sensor Turnover Feed Entry Sensor (L) Turnover/Exit Sensor (L) Leading edge detection by Turnover/Exit Sensor (L) Duplex Unit Turnover Entry Sensor Duplex Unit Turnover E
3-4.
Copier Paper Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action 1 Paper meets product specifications. NO Change paper. 2 Paper is curled, wavy, or damp. YES Change paper. Instruct user in correct paper storage. 3 Edge Guide and Trailing Edge Stop are at correct position to accommodate paper. NO Set. 4 Paper Take-Up Roll is dirty with paper dust, deformed, or worn. YES Clean or change. 5 Paper Lifting Plate is dirty or deformed.
• Paper is stopped in the Vertical Transport Section. Step Check Result Action 1 Vertical Transport Rollers are dirty with paper dust, deformed, or worn. NO Change paper. 2 Paper take-up guide plate or vertical transport guide plate is dirty or deformed. YES Clean or change. 3 I/O check for 1st Drawer Paper Take-Up Sensor YES Change Master Board.
(2) Multi Bypass Misfeed Relevant Electrical Parts Transport Roller Sensor (PC2) Manual Feed Paper Empty Sensor (PC18) Upper Vertical Transport/Manual Feed Motor (M6) Manual Feed Paper Pick-Up Solenoid (SL5) Master Board (PWB-A) PJ18 CN29 3 2 1 PC18 1 2 3 3 2 1 PWB-A PJ2A-1(DC5V) PJ2A-2(GND) PJ2A-3(PC18 ON) CN205 1 1 2 2 3 3 SL5 PJ2 3 2 1 PC2 PJ2A-4(DC24V) PJ2A-5(SL5 ON) PJ2A-6(SL5 OFF) CN19 1 2 3 4 4 3 2 1 PJ4A-11A(DC5V) PJ4A-12A(GND) PJ4A-13A(PC2 ON) PJ106 M6 1 2 3 PJ5A-7A(1U) PJ5A-8A(1
Multi Bypass Misfeed Troubleshooting Procedures • Paper is not detected. Step Check Result 1 I/O check for Manual Feed Paper Empty Sensor operation: the voltage across PJ2A-3 on Master Board and GND is DC0V when the sensor is unblocked and DC5V when the sensor is blocked. YES Change Master Board. Action NO Correct actuator. Change sensor. • Paper is not taken up at all. Step Check Result Action 1 Paper meets product specifications. NO Change paper. 2 Paper is curled, wavy, or damp.
(3) Transport/Separator Misfeed Relevant Electrical Parts Transport Roller Sensor (PC2) Synchronizing Roller Sensor (PC1) Transport Roller Motor (M8) Synchronizing Roller Motor (M9) PJ2 3 2 1 PC2 PJ1 3 2 1 PC1 Suction Fan Motor (M17) Separator Finger Solenoid (SL4) Master Board (PWB-A) PWB-A CN19 1 2 3 4 4 3 2 1 PJ4A-11A(DC5V) PJ4A-12A(GND) PJ4A-13A(PC2 ON) CN20 1 2 3 3 2 1 PJ4A-1B(DC5V) PJ4A-2B(GND) PJ4A-3B(PC1 ON) PJ108 M8 1 2 3 M9 1 2 3 PJ5A-4B(U) PJ5A-5B(V) PJ5A-6B(W) PJ109 PJ5A-7B(U
Transport/Separator Misfeed Troubleshooting Procedures • Paper is stopped at the Synchronizing Rollers. Step Check Result Action 1 Synchronizing Rollers are dirty with paper dust, deformed, or worn. YES Clean or change. 2 The length of the loop formed before the Synchronizing Rollers is okay. NO Adjust loop length. 3 I/O check for Synchronizing Roller Sensor operation: the voltage across PJ4A-3B on Master Board and GND is DC0V when the sensor is unblocked and DC5V when the sensor is blocked.
• Paper is stopped at the Transport Rollers. Step Check Result Action 1 Transport Rollers are dirty with paper dust, deformed, or worn. YES Clean or change. 2 Transport Roller Motor turns when the Start key is pressed. NO Correct drive coupling. Change motor or Master Board.
(4) Fusing/Exit Misfeed Relevant Electrical Parts Paper Exit Sensor (PC9) Fusing Motor (M2) Exit/Duplex Switching Solenoid (SL3) Master Board (PWB-A) PWB-A PJ109 M2 4 3 2 1 PJ7A-2A(M2 ON) PJ7A-1A(M2 LOCK) PJ9 PC9 CN30 3 2 1 1 11 2 10 3 9 PJ9A-1A(DC5V) PJ9A-2A(GND) PJ9A-3A(PC9 ON) 11 1 CN203 CN22 SL3 1 1 2 2 1 2 7 6 7 1 PJ9A-1B(DC24V) PJ9A-2B(SL3 ON) 4002C04TAA Fusing/Exit Misfeed Troubleshooting Procedures • Paper is stopped at the Fusing Unit.
(5) PF-208 Paper Take-Up Misfeed Relevant Electrical Parts rd 3 Drawer Paper Take-Up Sensor (PC117) 3rd Drawer Paper Take-Up Motor (M122) 4th 4th Drawer Paper Take-Up Motor (M123) Vertical Transport Motor (M121) Control Board (PWB-A): PF-208 Master Board (PWB-A) Drawer Paper Take-Up Sensor (PC125) Paper Leading Edge Sensor 3 (PC113) Paper Leading Edge Sensor 4 (PC118) PWB-A(PF-208) PJ101 M121 3 2 1 M122 3 2 1 M123 3 2 1 PJ3A-3(W) PJ3A-2(V) PJ3A-1(U) PJ102 PJ3A-6(W) PJ3A-5(V) PJ3A-4(U) PJ103
PF-208 Paper Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action 1 Paper meets product specifications. NO Change paper. 2 Paper is curled, wavy, or damp. YES Change paper. Instruct user in correct paper storage. 3 Edge Guide and Trailing Edge Stop are at correct position to accommodate paper. NO Set. 4 Paper Lifting Plate is dirty or deformed. YES Clean or change. 5 Paper Separator Pad is dirty with paper dust, deformed, or worn.
• Paper is stopped at the Vertical Transport Rollers. Step Check Result Action 1 Vertical Transport Rollers are dirty with paper dust, deformed, or worn. YES Clean or change. 2 Paper take-up guide plate or vertical transport guide plate is dirty or deformed. YES Clean, correct, or change. 3 Vertical Transport Motor turns when the Start key is pressed with the cabinet selected. NO Correct drive coupling. Change motor or Control Board. Change Master Board.
(6) PF-115 Paper Take-Up Misfeed Relevant Electrical Parts rd 3 Drawer Paper Take-Up Sensor (PC117) Paper Leading Edge Sensor 3 (PC113) Paper Leading Edge Sensor 4 (PC118) 3rd Drawer Paper Take-Up Motor (M122) Vertical Transport Motor (M121) Control Board (PWB-A): PF-115 Master Board (PWB-A) PWB-A(PF-115) PJ101 M121 3 2 1 M122 3 2 1 PJ3A-3(W) PJ3A-2(V) PJ3A-1(U) PJ102 PJ3A-6(W) PJ3A-5(V) PJ3A-4(U) PJ2 PC113 3 2 1 PC118 3 2 1 PC117 3 2 1 PJ9A-4(GND) PJ9A-5(PC113 ON)) PJ9A-6(DC5V) PJ3 PJ9A-
PF-115 Paper Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action 1 Paper meets product specifications. NO Change paper. 2 Paper is curled, wavy, or damp. YES Change paper. Instruct user in correct paper storage. 3 Paper Lifting Plate is dirty or deformed. YES Clean or change. 4 Paper Separator Pad is dirty with paper dust, deformed, or worn. YES Clean or change. 5 Paper take-up guide plate is dirty or deformed. YES Clean or change.
(7) Duplex Paper Take-Up Misfeed Relevant Electrical Parts Turnover Feed Entry Sensor (PC7) Turnover Feed Jam Sensor (PC8) Turnover/Exit Sensor (PC27) Duplex Unit Turnover Entry Sensor (PC112) Turnover Feed Jam Sensor (PC131) Horizontal Transport Entry Sensor (PC132) Horizontal Transport Jam Sensor (PC133) Horizontal Transport Exit Sensor (PC134) Turnover Motor (M10) Vertical Transport Motor (M121) Duplex Unit Turnover Motor (M130) Horizontal Transport Motor (M131) Turnover Roller Retraction Solenoid (SL
Duplex Paper Take-Up Misfeed Troubleshooting Procedures • Paper is stopped at the turnover section. Step Check Result Action 1 Rollers at the turnover section are dirty, deformed, or worn. YES Clean or change. 2 Guide plate at the turnover section is dirty or deformed. YES Clean, correct, or change. 3 A torn piece of paper is left at the turnover section. YES Clean.
• Paper is stopped at the horizontal transport section. Step Check Result Action 1 Horizontal Transport Rollers are dirty with paper dust, deformed, or worn. YES Clean or change. 2 Horizontal transport guide plate is dirty or deformed. YES Clean, correct, or change. 3 I/O check for Horizontal Transport Entry Sensor operation: the voltage across PJ12A-6 on Control Board and GND is DC5V when the sensor is unblocked and DC0V when the sensor is blocked. YES Change Control Board.
4. MALFUNCTIONS The copier’s CPU is equipped with a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code on the Touch Panel. Resetting a Malfunction • Press the Trouble Reset Switch on the Tech. Rep. Setting Switches Board to reset fusingand Exposure Lamp-related malfunctions. • For any other malfunctions, open and close the Front Door or turn OFF and ON the Power Switch. 4-1.
Code Description C004C Ventilation Fan Motor’s failure to turn Detection Timing • The Lock signal remains HIGH for a continuous period of 1.5 sec. or more after the lapse of 10 sec. after the motor has started turning. • The Lock signal remains LOW for a continuous period of 1.5 sec. or more after the lapse of 10 sec. after the motor has stopped turning. C004E Power Supply Unit Cool- The Lock signal remains HIGH for a continuous period ing Fan Motor 1’s failure of 1.5 sec.
Code Description Detection Timing C0500 Warming-up failure The surface temperature of the Upper Fusing Roller does not reach a specified level even after the lapse of a predetermined period of time during warming-up as detailed below: • From room temperature to 90°C: Within 180 sec. • From 90°C to 140°C: Within 140 sec. • From 140°C to 170°C: Within 135 sec. The copier fails to complete its warm-up cycle within 135 sec. after the temperature has reached 170°C.
Code Description Detection Timing C0910 2nd Drawer Paper Lift-Up • The 2nd Drawer Paper Lift-Up Sensor is not blocked Sensor malfunction (LOW) even after the lapse of 5 sec. after the 2nd Drawer Paper Lift-Up Motor has started turning. • The 2nd Drawer Paper Lift-Up Sensor is not activated even when the 2nd Drawer Paper Lift-Up Motor Pulse Sensor detects 150 edges of rotation detection pulses after the 2nd Drawer Paper Lift-Up Motor has started turning.
Code Description Detection Timing C0B00 C0B02 Transport mechanism C0B03 malfunction C0B04 C0B20 C0B21 Stapling Unit drive system malfunction C0B24 C0B30 C0B31 C0B34 Paper Aligning MechaC0B35 nism malfunction C0B36 C0B38 C0B48 Neat copy stack transport mechanism malfunction C0B49 See the relevant option service manual.
Code Description Detection Timing C0BC0 C0BC1 Paper folding mechanism C0BC2 malfunction C0BC3 See the relevant option service manual. C0BF0 Control system malfunction C0D50 Duplex Horizontal Transport Motor malfunction C0E00 Main Erase Lamp’s failure to turn ON • The Main Erase Lamp Malfunction signal remains LOW for a continuous 1-sec. period while the Main Erase Lamp remains OFF. • The Main Erase Lamp Malfunction signal remains HIGH for a continuous 1-sec.
Code Description C1334 Duplex take-up print command error Detection Timing • A Duplex take-up print command is not received for the paper to be taken up from the Duplex after the paper has moved past the horizontal transport, but before it reaches the Transport Roller.
4-2. (1) Troubleshooting Procedures by Malfunction Code C0000: Fusing Motor’s failure to turn C0010: PC Drum Drive Motor’s failure to turn Relevant Electrical Parts Fusing Motor (M2) PC Drum Drive Motor (M21) Master Board (PWB-A) PWB-A PJ121 M21 5 4 3 2 1 M2 4 3 2 1 PJ7A-5A(M21 FR) PJ7A-4A(M21 LOCK) PJ7A-3A(M21 START) PJ102 PJ7A-2A(M2 LOCK) PJ7A-1A(M2 START) GND DC24V 4002C08TAA C0000 Step Check Result Action 1 Fusing Motor turns when the Start key is pressed. NO Correct drive coupling.
(2) C0040: Suction Fan Motor’s failure to turn C004C: Ventilation Fan Motor’s failure to turn Relevant Electrical Parts Suction Fan Motor (M17) Ventilation Fan Motor (M18) Master Board (PWB-A) CN22 M18 CN118 1 7 PWB-A 3 3 2 2 1 1 5 6 7 3 2 1 PJ9A-5B(M18 LD) PJ9A-6B(GND) PJ9A-7B(DC24V) CN117 M17 1 2 3 4 1 2 3 4 DC24V GND PJ13A-1B(M17 LOCK) PJ13A-2B(M17 H/L) 4002C09TAA C0040 Step Check Result 1 Suction Fan Motor turns when the malfunction is reset.
(3) C0042: Fusing Unit Cooling Fan Motor’s failure to turn Relevant Electrical Parts Fusing Unit Cooling Fan Motor (M23) Power Supply Board (PWB-C) CN30 CN123 M23 1 2 3 3 2 1 1 11 9 3 10 2 11 1 PWB-C PJ13C-1 (DC24V) PJ13C-2 (GND) PJ13C-3 (M23 LD) 4002C24TAA C0042 Step Check Result 1 Fusing Unit Cooling Fan Motor rotation: the voltage across PJ13C-1 on Power Supply Board and GND is DC24V (during high-speed rotation) and DC16V (during low-speed rotation) after the malfunction has been reset.
(4) C0045: IR Cooling Fan Motor malfunction C0046: PH Cooling Fan Motor 1 malfunction C0047: PH Cooling Fan Motor 2 malfunction Relevant Electrical Parts PH Cooling Fan Motor 2 (M19) PH Cooling Fan Motor 1 (M22) IR Cooling Fan Motor (M52) SCP Board (PWB-IC) PWB-IC CN122 M22 1 2 3 PJ4IC-1(DC24V) PJ4IC-2(GND) PJ4IC-3(M22 LD) 3 2 1 CN152 M52 1 2 3 PJ4IC-4(DC24V) PJ4IC-5(GND) PJ4IC-6(M52 LD) 3 2 1 CN119 M19 1 2 3 PJ4IC-7(DC24V) PJ4IC-8(GND) PJ4IC-9(M19 LD) 3 2 1 4002C10TAA T-39
C0045 Step Check Result Action 1 IR Cooling Fan Motor rotation: the voltage across PJ4IC-4 on SCP Board and GND is DC24V (during high-speed rotation) and DC12V (during low-speed rotation) after the malfunction has been reset. NO 2 IR Cooling Fan Motor rotation: the voltage across PJ4IC-6 on SCP Board and GND is DC5V after the malfunction has been reset. YES Change SCP Board. NO Check motor for installation. Change motor. Change SCP Board.
(5) C0049: Paper source option Vertical Transport Cooling Fan Motor malfunction Relevant Electrical Parts Vertical Transport Cooling Fan Motor (M132) Control Board (PWB-A) PWB-A (CABINET) CN18 1 2 3 M132 3 2 1 PJ14A-1(DC24V) PJ14A-2(GND) PJ14A-3(M132 LOCK) 4002C27TAA C0049 Step Check Result 1 Vertical Transport Cooling Fan Motor rotation: the voltage across PJ14A-1 on Power Supply Board and GND is DC24V after the malfunction has been reset.
(6) C004E: Power Supply Unit Cooling Fan Motor 1’s failure to turn C004F: Power Supply Unit Cooling Fan Motor 2’s failure to turn Relevant Electrical Parts Power Supply Unit Cooling Fan Motor 1 (M16) Power Supply Unit Cooling Fan Motor 2 (M15) Master Board (PWB-A) Power Supply Board (PWB-C) CN115 1 2 3 M15 3 2 1 PWB-A PJ6A-11(DC24V) PJ6A-12(GND) PJ6A-13(M15 LD) PWB-C PJ3C-1 (DC24V) PJ3C-2 (GND) PJ3C-3 (M16 LD) M16 4002C23TAA C004E Step Check Result 1 Power Supply Unit Cooling Fan Motor 1 rota
C004F Step Check Result Action 1 Power Supply Unit Cooling Fan Motor 2 rotation: the voltage across PJ6A-11 on Power Supply Board and GND is DC24V after the malfunction has been reset. NO Change Master Board. 2 Power Supply Unit Cooling Fan Motor 2 rotation: the voltage across PJ6A-13 on Power Supply Board and GND is DC5V after the malfunction has been reset. YES Check motor for installation. Change motor. NO Change Master Board.
(7) C0072: Main Hopper Toner Replenishing Motor’s failure to turn C0090: Developing Unit Drive Motor’s failure to turn Relevant Electrical Parts Toner Bottle Home Position Sensor (PC21) Developing Unit Drive Motor (M1) Main Hopper Toner Replenishing Motor (M13) Sub Hopper Toner Replenishing Motor (M14) Master Board (PWB-A) PWB-A PJ101 M1 4 3 2 1 PJ7A-7A(M1 LOCK) PJ7A-6A(M1 START) DC24V GND CN114 1 2 M14 2 1 CN10 1 2 3 4 1 2 3 4 PJ7A-1B(DC24V) PJ7A-2B(M14 ON) 24 24 CN113 1 2 M13 2 1 PJ11A-
C0072 Step Check Result 1 Toner Bottle turns when the Toner Bottle is turned a half turn and the Front Door is closed. NO 2 I/O check for Toner Bottle Home Position Sensor operation: the voltage across PJ11A-5 on Master Board and GND is DC5V (Toner Bottle at home position) and DC0V (Toner Bottle at a position other than home) when step 1 is performed. YES Change Master Board. NO Check sensor for installation. Correct detecting plate. Change sensor.
(8) C0210: Image Transfer/Paper Separator Corona charge leak detected Relevant Electrical Parts PC Drum Charge/Developing Bias HV (HV1) Master Board (PWB-A) PJ2HV1 HV1 PJ1HV1 8 7 6 5 4 3 2 1 PWB-A PJ12A-4B(SCD) PJ12A-5B(Sep BIAS) PJ12A-6B(Sep REM) PJ12A-7B(Tra REM) PJ12A-8B(Dev BIAS) PJ12A-9B(Dev REM) PJ12A-10B(GRID) PJ12A-11B(C.G.REM) 1 2 GND DC24V 4002C12TAA C0210 Step Check Result 1 The Image Transfer/Paper Separator Coronas Unit is installed properly. NO Correct installed position.
(9) C0400: Exposure Lamp’s failure to turn ON C0420: Exposure Lamp turning ON at abnormal timing Relevant Electrical Parts Exposure Lamp (FL51) Inverter Board (UN51) Lamp Flat Cable (PWB-IF) FL51 Image Processing Board (PWB-B) Power Supply Board (PWB-C) SCP Board (PWB-IC) UN51 CN2UN51-1 CN2UN51-2 F1 CN1UN51-1 CN1UN51-2 CN1UN51-3 PWB-B PWB-IF PJ1IF-4 PJ1IF-3 PJ1IF-2 PJ1IF-1 PJ2IF-4(ON-OFF) PJ2IF-3(DC24V) PJ2IF-2(GND) PJ2IF-1(GND) PJ5B-1(ON-OFF) PJ301B-14(GND) PJ301B-15(DC24V) PWB-C PJ9C-3(GND)
(10) C0500: Warming-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature Relevant Electrical Parts Upper Fusing Roller Heater Lamp (H1) Lower Fusing Roller Heater Lamp (H2) Upper Fusing Roller Thermistor (TH1) Lower Fusing Roller Thermistor (TH2) TH1 CN11 CN217 1 2 3 4 TH2 Upper Fusing Roller Thermostat (TS1) DC Power Supply Main (PU1) Master Board (PWB-A) 4 3 2 1 CN218 1 2 3 4 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1
C0500, C0510 Step Check Result Action 1 Upper Fusing Roller Heater Lamp turns ON when the Power Switch is turned ON. YES Correct thermistor for mounting position and/or clean. 2 Lower Fusing Roller Heater Lamp turns ON when the malfunction is reset with the surface temperature of Lower Fusing Roller Heater Lamp is 140°C or less as indicated on “Level History” under the Tech. Rep. mode. NO Check step 7 and onward. 3 Upper and Lower Fusing Roller Thermistors are installed properly.
C0520 Step Check Result Action 1 Upper Fusing Roller Heater Lamp is ON even after the copier has completed warming up. Or Lower Fusing Roller Heater Lamp is ON when the surface temperature of Lower Fusing Roller Heater Lamp is 140°C or more as indicated on “Level History” under the Tech. Rep. mode. YES Change DC Power Supply Main. 2 Upper and Lower Fusing Roller Thermistors are installed properly. NO Reinstall. 3 Upper and Lower Fusing Roller Thermistors are dirty. NO Clean.
(11) C0602: Cable unwound C0650: SHOME signal error Relevant Electrical Parts Scanner Motor (M51) Image Processing Board (PWB-B) Scanner Reference Position Sensor (PC51) SCP Board (PWB-IC) PWB-B PJ51 3 2 1 PC51 PJ306B-10(GND) PJ306B-9(PC51 ON) PJ306B-11(DC5V) PWB-IC PJ151 M51 1 2 3 PJ3IC-1 (U) PJ3IC-2 (V) PJ3IC-3 (W) 4002C14TAB T-51
C0602 Step Check Result Action 1 Scanner moves as moved manually. NO Correct drive coupling. Rewind cables. 2 Connector on SCP Board is connected properly: PJ3IC on PWB-IC. NO Connect. 3 Scanner Motor turns when the Start key is pressed. NO Correct drive coupling. Change motor or SCP Board. 4 Connector on Image Processing Board is connected properly: PJ306B on PWB-B. NO Connect. 5 I/O check for Scanner Reference Position Sensor YES Change Image Processing Board. NO Correct actuator.
(12) C0910: 2nd Drawer Paper Lift-Up Sensor malfunction C0914: 2nd Drawer Lift-Up Motor’s failure to turn C0920: 1st Drawer Paper Lift-Up Sensor malfunction C0924: 1st Drawer Lift-Up Motor’s failure to turn Relevant Electrical Parts 2nd 1st Drawer Set Sensor (PC10) Drawer Set Sensor (PC11) 2nd Drawer Lift-Up Motor Pulse Sensor (PC13) 1st Drawer Lift-Up Motor Pulse Sensor (PC12) 2nd Drawer Paper Lift-Up Sensor (PC15) 1st Drawer Paper Lift-Up Sensor (PC14) 2 nd 1st Drawer Lift-Up Motor (M11) Master
C0910, C0914 Step Check Result 1 Lift-Up Motor turns when the 2nd Drawer is slid out and then back in. NO Action 2 2nd Drawer Lift-Up Motor rotation: the voltage across PJ3A-13B on Master Board and GND is DC0V (motor deenergized) and DC24V (motor YES Change motor. NO Change Master Board. YES Change Master Board. NO Correct drive coupling. Change sensor. Correct drive coupling. energized) after the 2nd Drawer has been slid back in.
(13) C0900: 3rd Drawer Paper Lift-Up Sensor malfunction C0904: 3rd Drawer Paper Lift-Up Motor’s failure to turn C0950: 4th Drawer Paper Lift-Up Sensor malfunction C0954: 4th Drawer Paper Lift-Up Motor’s failure to turn Relevant Electrical Parts 3rd Drawer Paper Lift-Up Sensor (PC115) 4th Drawer Paper Lift-Up Sensor (PC119) 3rd Drawer Set Sensor (PC121) 4th Drawer Set Sensor (PC122) 3rd Drawer Lift-Up Motor Pulse Sensor (PC123) 4th Drawer Lift-Up Motor Pulse Sensor (PC124) 3rd Drawer Paper Lift-Up M
C0900, C0904 Step Check Result 1 Lift-Up Motor turns when the 3rd Drawer is slid out and then back in. NO Action 2 3rd Drawer Paper Lift-Up Motor rotation: the voltage across PJ5A-3B on Control Board and GND is DC0V (motor deenergized) and DC24V YES Change motor. NO Change Control Board. YES Change Control Board. NO Correct drive coupling. Change sensor. Correct drive coupling. (motor energized) after the 3rd Drawer has been slid back in.
(14) C0990: Main Tray lifting motion failure C0994: Main Tray Elevator Motor’s failure to turn Relevant Electrical Parts 3rd Drawer Paper Lift-Up Sensor (PC115) 3rd Drawer Paper Empty Sensor (PC116) Lower Position Overrun Detecting Sensor (PC137) Elevator Lower Position Sensor (PC139) Elevator Motor Pulse Sensor (PC142) Elevator Motor (M126) Cabinet Transport Board (PWB-H) Control Board (PWB-A): PF-115 DC5V PJ26 PWB-H 1 2 3 PC137 PJ2H-2A PJ1H-10A PWB-A (PF-115) PJ7A-2A(PC137 ON) PJ29 1 2 3 PC1
C0990 Step Check Result 1 I/O check for 3rd Drawer Paper Lift-Up Sensor operation: the voltage across PJ8A-2 on Control Board and GND is DC5V (sensor unblocked) and DC0V (sensor blocked). YES Change Control Board. NO Change sensor. I/O check for Lower Position Overrun Detecting Sensor operation: the voltage across PJ7A-2A on Control Board and GND is DC5V (sensor unblocked) and DC0V (sensor blocked). YES Change Control Board. NO Change sensor or Cabinet Transport Board. Change flat cable.
(15) C0996: Main Tray lock release failure C0997: Shift Gate malfunction Relevant Electrical Parts Shift Gate Position Sensor (PC136) rd 3 Drawer Set Sensor (PC144) Shift Gate Motor (M128) DC5V PJ35 1 2 3 PC136 3rd Drawer Lock Solenoid (SL112) Cabinet Transport Board (PWB-H) Control Board (PWB-A): PF-115 PWB-H PJ1H-11B PJ7A-1B(PC136 ON) PJ2H-1B GND PJ36 1 2 M128 PJ1H-10B PJ1H-9B PJ2H-2B PJ2H-3B PJ17 PC144 PJ7A-2B(+) PJ7A-3B(-) PWB-A (PF-115) PJ10A-2(GND) PJ10A-3(PC144 ON) PJ10A-4(DC5V) 3 2 1
C0996 Step Check Result 1 3rd Drawer Lock Solenoid operation: the voltage across PJ10A-6 on Control Board and GND is DC24V (solenoid deenergized) and DC0V (solenoid energized) when the Paper Descent key is pressed and the Main Tray completes its descent motion. YES Change solenoid. Action NO Change Control Board.
(16) C0998: Shifter return failure C099C: Shift Motor’s failure to turn Relevant Electrical Parts Shifter Home Position Sensor (PC140) Shifter Return Position Sensor (PC141) Shift Motor Pulse Sensor (PC143) DC5V PJ27 PC143 1 2 3 PC141 1 2 3 PC140 1 2 3 Shift Motor (M127) Cabinet Transport Board (PWB-H) Control Board (PWB-A): PF-115 PWB-H PJ1H-9A PJ7A-3A(PC143 ON) PJ2H-3A PJ31 PJ1H-5A PJ2H-7A PJ32 PJ1H-4A PJ7A-7A(PC141 ON) PWB-A (PF-115) PJ7A-8A(PC140 ON) PJ2H-8A GND PJ37 M127 1 2 PJ1H-8
C0998 Step Check Result 1 I/O check for Shifter Return Position Sensor operation: the voltage across PJ7A-7A on Control Board and GND is DC5V (sensor unblocked) and DC0V (sensor blocked). YES Change Control Board. NO Change sensor or Cabinet Transport Board. Change flat cable. I/O check for Shifter Home Position Sensor operation: the voltage across PJ7A-8A on Control Board and GND is DC5V (sensor unblocked) and DC0V (sensor blocked). YES Change Control Board.
(17) C0D50: Duplex Horizontal Transport Motor malfunction Relevant Electrical Parts Horizontal Transport Motor (M131) PJ25 M131 7 6 5 4 3 2 1 Control Board (PWB-A) CN8 12 11 10 9 8 7 6 5 4 3 2 1 PWB-A (Cabinet) 12 11 10 9 8 7 6 5 4 3 2 1 PJ12A-13(GND) PJ12A-12(DC5V) PJ12A-10(GND) PJ12A-9(DC24V) PJ12A-8(M131 CLK) PJ12A-7(M131 LOCK) PJ12A-5(M131 REM) PJ12A-1(GND) 4002C25TAA C0D50 Step Check Result Action 1 Horizontal Transport Motor turns when the Start key is pressed.
(18) C0E00: Main Erase Lamp’s failure to turn ON Relevant Electrical Parts Main Erase Lamp (LA2) Master Board (PWB-A) CN30 LA2 PJ74 1 11 3 2 1 7 8 5 4 PWB-A PJ9A-7A (LA2 REM) 11 1 DC24V 4002C20TAA C0E00 Step Check Result 1 Main Erase Lamp ON: the voltage across PJ9A-7A on Master Board and GND is DC24V (lamp OFF) and DC0V (lamp ON) when the Start key is pressed. YES 2 Main Erase Lamp ON: the voltage across PJ9A-7A on Master Board and GND is DC24V in the standby state. YES Change lamp.
(19) C0F24: AIDC Sensor contamination correction failure Relevant Electrical Parts AIDC Sensor Board (PWB-G) Master Board (PWB-A) CN10 CN41 PWB-G AIDC 1 2 3 3 2 1 1 1 10 10 11 11 12 12 PWB-A PJ7A-5B(AIDC LED) PJ7A-6B(GND) PJ7A-7B(AIDC OUT) 24 24 4002C21TAA C0F24 Step Check Result Action 1 PJ7A, CN10, and CN41 are plugged securely into Master Board. NO 2 Photosensor/LED of the AIDC Sensor are contaminated. YES Clean. NO Change AIDC Sensor Board. Change Master Board.
(20) C0F32: ATDC Sensor malfunction C0F33: Abnormally low T/C as detected by ATDC Sensor Relevant Electrical Parts ATDC Sensor (UN2) Master Board (PWB-A) CN10 PJ7 UN2 ATDC 1 2 3 4 1 1 15 16 17 18 15 16 17 18 PWB-A PJ7A-8B(CONTROL) PJ7A-9B(DC24V) PJ7A-10B(OUT) PJ7A-11B(GND) 24 24 4002C22TAA C0F32, C0F33 Step Check Result 1 PJ7A on Master Board, CN10, and PJ7 on the sensor are properly connected. NO Plug them in securely.
(21) C10XX to C18XX • These malfunctions are concerned with faulty symptoms relating to software, hardware, and communications. Code Action C10XX C11XX C12XX 1. Reset the malfunction and turn OFF and ON the Power Switch. 2. If the same malfunction persists, check cables and connectors for proper connection. 3. If they are okay, change Image Processing Board, Memory Board, or Hard Disk Drive. C12CX 1. Run “Hard Disk Format” selected in the following sequence: Tech. Rep. Mode → Function → Image Memory.
Code Action C1401 C1402 C1410 C1426 C1428 C1429 C142A C1430 1. Reset the malfunction. 2. If the same malfunction persists, change the Image Processing Board. C143E See the option service manual. C1440 1. 2. 3. 4. C1441 1. Reset the malfunction. 2. Check that the Original Glass is properly installed. 3. Check for extraneous light and check to see if the CCD Assy and mirrors are installed at the correct positions. 4. If the same malfunction is detected again, change Image Processing Board. C1450 1.
(22) Copier does not turn ON. Relevant Electrical Parts Power Switch (S1) Front Door Interlock Switch (S21) Upper Left Door Interlock Switch (S22) Main Relay (RY1) DC Power Supply Main (PU1) DC Power Supply Sub (PU2) Power Supply Board (PWB-C) Master Board (PWB-A) • Main Relay does not turn ON.
Step 9 Check Result Power Supply Board operation: the voltage across PJ5C-3 on Power Supply Board and GND is AC10V when Power Switch is turned ON. T-70 Action NO Change Power Supply Board. YES Check Main Relay.
5. IMAGE FAILURE 5-1. Image Failure Troubleshooting • In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting procedures classified by image failures.” • If any image failure has occurred, first make the initial checks, then proceed to the corresponding image failure troubleshooting procedure. 5-2. Initial Checks • Determine if the failure is attributable to a basic cause or causes.
5-3. Troubleshooting Procedures Classified by Image Failure • Image Failure Samples 1. Blank copy 2. Black copy 3. Low image density 4. Foggy background 5. Black streaks or bands 6. Black spots 7. Blank streaks or bands 8. Void areas 9. Smear on back 10. Uneven image density 11. Gradation reproduction failure 12. Rough image 13. Periodically uneven image 14. Traces of PC Drum Paper 15.
(1) Blank copy Section Engine IR (2) Step Check Result 1 Developing Unit is installed in position. NO Install correctly. Action 2 There is drive to the Developing Unit. NO Correct or change drive coupling. 3 Image Transfer Corona wire is installed properly. NO Install properly. 4 Wiring between HV and Image Transfer Corona is connected. YES Change HV. NO Connect. 5 Dust-proof shutter is in correct position. NO Correct.
(3) Low image density Section Engine IR (4) Check Result 1 Image Transfer Corona is dirty. YES Clean or change. Action 2 Wiring between HV and Image Transfer Corona is connected. NO Connect. 3 Developing bias contact is dirty or deformed. YES Clean or change. 4 PH lens is dirty. YES Clean. 5 Wiring between HV and developing bias is connected. NO Connect. 6 ATDC Sensor gain value is correct. NO Re-input. 1 Shading position is correct. NO Correct IR shading position.
(6) Black streaks or bands Section Step (7) Result Action PC Drum is dirty. YES Clean or change. 2 Cleaning Blade has correct lateral movement. NO Correct lateral movement mechanism. 3 Cleaning Blade is curled upward or deteriorated. YES Change. 4 Comb Electrode and grid mesh are dirty. YES Clean or change. 5 Upper Fusing Roller is dirty. YES Clean. 6 PH Unit window is dirty. YES Clean. 1 Mirrors and lens are dirty. YES Clean. 2 Original Glass is dirty or scratchy.
(8) Blank streaks or bands Section Engine IR (9) Step Check Result 1 PC Drum is scratchy and dirty. YES Clean or change. Action 2 PC Drum Paper Separator Fingers are dirty or deformed. YES Clean of change. 3 PC Drum is properly grounded. NO Clean or change PC Drum ground plate. 4 Image Transfer Corona wire is dirty. YES Clean or change. 5 Comb Electrode and grid mesh are dirty. YES Clean or change. 6 Upper Fusing Roller is scratchy or dirty. YES Clean or change.
(10) Smear on back Section Engine Step Check Result Action 1 Suction Belts are dirty. YES Clean. 2 Image Transfer Corona is dirty. YES Clean. 3 Image Transfer Guide Plate is dirty. NO Clean. 4 Pre-Fusing Guide Plate is dirty. YES Clean. 5 Fusing Rollers are dirty. YES Clean or change. 6 Toner spilled over area inside copier. YES Clean. (11) Uneven image density Section Engine IR Step Check Result Action 1 PC Drum is properly grounded.
(13) Rough image Section Engine Step Check Result Action 1 Foreign matter and caked toner inside Developing Unit and DB. YES Remove foreign matter and caked toner. Change developer. 2 Image Transfer Corona wire is dirty or deteriorated. YES Clean or change. 3 Wiring between HV and Image Transfer Corona is connected. YES Change HV. NO Connect. Wiring between CCD Assy and Image Processing Board is connected. YES Change CCD Assy. Change Image Processing Board. NO Connect.
6. RESETTING THE MAINTENANCE CODE DISPLAY 6-1. Details of Maintenance Codes Code M2 The count of “Waste Toner” of the Consumables counter reaches a predetermined value before the setting value. M3 The count of “Web” of the Consumables counter reaches the setting value. 6-2. (1) Description Resetting the Maintenance Code Display Entering the Tech. Rep. Mode 1. Press the Utility key. 2. Touch Meter Count. 3. Press the following keys in this order: Stop → 0 → 0 → Stop → 0 → 1. 4.
Copyright 2000 MINOLTA Co., Ltd. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA Co., Ltd.
