sm field di152 di183

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Di152/Di183

Service Manual[Field Service]

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INDEX (FIELD SERVI

DIS/REASSEMBLY,

ADJUSTMENT

SWITCHES ON PWBsTECH. REP. SETTING

TROUBLESHOOTING

SAFETY PRECAUTIO

INSPECTION AND SE

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1. SAFETY PRECAUTIONS FOR INSPECT

SERVICE

When performing inspection and service procedures, observe the to prevent accidents and ensure utmost safety.

Depending on the model, some of the precautions given in the follo

Different markings are used to denote specific meanings as detaile

Indicates a potentially hazardous situation could result in death or serious injury.

Indicates a potentially hazardous situation may result in minor or moderate injury. It malert against unsafe practices.

The following graphic symbols are used to give instructions that ne

Used to call the service technicians attention to what is grainside the marking (including a warning).

Used to prohibit the service technicians from doing what issented inside the marking.

Used to instruct the service technicians to do what is grapinside the marking.

1-1. Warning

1. Always observe precautions.

WARNING

CAUTION

WARNING

Parts requiring special attention in this product will includemark shown on the left plus precautionary notes. Be surecautions.

Be sure to observe the Safety Information given in the O

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11. Restore all parts and harnesses to their original positions.

1-2. Caution

1. Precautions for Service Jobs.

2. Precautions for Servicing with Covers and Parts Removed.

To promote safety and prevent product damage, make sureturned to their original positions and properly secured indles in order to avoid hot parts, high-voltage parts, sharp

crushed. To promote safety, make sure that all tubing and other ins

returned to their original positions. Make sure that floating on the circuit boards are at their correct distance and pos

CAUTION

A toothed washer and spring washer, if used originally, mOmitting them may result in contact failure which could caor fire.

When reassembling parts, make sure that the correct scrused in the correct places. Using the wrong screw could lthreads, poorly secured parts, poor insulating or groundinfunction, electric shock or injury.

Take great care to avoid personal injury from possible burrthe parts, frames and chassis of the product.

When moving the product or removing an option, use carback or allow your hands to be caught in mechanisms.

Wherever feasible, keep all parts and covers mounted whproduct.

If energizing the product with a cover removed is absolutetouch any exposed live parts and use care not to allow yocaught in the moving parts. Never leave a product in this

Never place disassembled parts or a container of liquid ofalling into, or the liquid spilling inside, the mechanism coushock or fire.

Never use a flammable spray near the product. This could Make sure the power cord is unplugged before removing

boards or plugging in or unplugging connectors.

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3. Precautions for the Working Environment.

4. Precautions for Handling Batteries. (Lithium, Nickel-Cadmium, et

5. Precautions for the Laser Beam. (Only for Products Employing a

6. Precautions for storage the toner or imaging cartridge.

1-3. Other Precautions

When handling circuit boards, observe the HANDLING of PWBs. The PC Drum is a very delicate component. Observe the precauti

DLING OF THE PC DRUM because mishandling may result in se Note that replacement of a circuit board may call for readjustments

ular items, or software installation.

The product must be placed on a flat, level surface that is Never place this product or its parts on an unsteady or tilt

servicing.

Provide good ventilation at regular intervals if a service joconfined space for a long period of time.

Avoid dusty locations and places exposed to oil or steam. Avoid working positions that may block the ventilation por

Replace a rundown battery with the same type as specifie

turers parts manual. Before installing a new battery, make sure of the correct ption or the battery could burst.

Dispose of used batteries according to the local regulatiothem at the users premises or attempt to try to discharge

Removing the cover marked with the caution label could l

sure to the laser beam, resulting in eye damage or blindnethe power cord before removing this cover.

If removing this cover while the power is ON is unavoidabtective laser goggles that meet specifications.

Make sure that no one enters the room when the machine When handling the laser unit, observe the Precautions fo

Equipment.

Be sure to keep the toner or imaging cartridge out of the ing the imaging cartridge or ingesting its contents is harm

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1-4. Used Batteries Precautions

ALL AreasCAUTION

Danger of explosion if battery is incorrectly replaced.Replace only with the same or equivalent type recommended by the Dispose of used batteries according to the manufacturers instruction

GermanyVORSICHT!

Explosionsgefahr bei unsachgemem Austausch der Batterie.Ersatz nur durch denselben oder einen vom Hersteller empfohlenen Entsorgung gebrauchter Batterien nach Angaben des Herstellers.

FranceATTENTION

Il y a danger dexplosion sil y a remplacement incorrect de la batteriRemplacer uniquement avec une batterie du mme type ou dun typmand par le constructeur.

Mettre au rebut les batteries usages conformment aux instructions

DenmarkADVARSEL!

Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering.Udskiftning m kun ske med batteri af samme fabrikat og type.Levr det brugte batteri tilbage til leverandren.

Finland, SwedenVAROlTUS

Paristo voi rjht, jos se on virheellisesti asennettu.Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin.Hvit kytetty paristo valmistajan ohjeiden mukaisesti.

VARNING

Explosionsfara vid felaktigt batteribyte.Anvnd samma batterityp eller en ekvivalent typ som rekommenderatillverkaren.Kassera anvnt batteri enligt fabrikantens instruktion.

N

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1-5. Precautions for Service

When performing inspection and service procedures, observe the to prevent mishandling of the machine and its parts.

Depending on the model, some of the precautions given in the follo1. Precautions Before Service When the user is using a word processor or personal computer fro

same line, take necessary steps to prevent the circuit breaker fromloads.

Never disturb the LAN by breaking or making a network connectioninstalling or removing networking hardware or software, or shutting

devices without the knowledge and express permission of the netwthe shop supervisor.

2. How to Use this Book< DIS/REASSEMBLY, ADJUSTMENT > To reassemble the product, reverse the order of disassembly unles

< TROUBLESHOOTING >

If a component on a PWB or any other functional unit including a mtext only instructs you to replace the whole PWB or functional unit ableshooting procedures applicable within the defective unit.

All troubleshooting procedures contained herein assume that thereharnesses and cords and all connectors are plugged into the right

The procedures preclude possible malfunctions due to noise and o

3. Precautions for Service Check the area surrounding the service site for any signs of dama

repair. Keep all disassembled parts in good order and keep tools under co

be lost or damaged. After completing a service job, perform a safety check. Make sure

and screws are returned to their original positions. Do not pull out the toner hopper while the toner bottle is turning. T

damaged motor or locking mechanism. If the product is to be run with the front door open, make sure that

the locked position. Do not use an air gun or vacuum cleaner for cleaning the ATDC Se

sors, as they can cause electrostatic destruction. Use a blower brucontaining these sensors is to be cleaned first remove the sensor

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4. Precautions for Dis/Reassembly Be sure to unplug the copier from the outlet before attempting to s The basic rule is not to operate the copier anytime during disassem

necessary to run the copier with its covers removed, use care not to

be caught in revolving parts such as the timing belt and gears. Before attempting to replace parts and unplug connectors, make scord of the copier has been unplugged from the wall outlet.

Be sure to use the Interlock Switch Actuating Jig whenever it is necInterlock Switch with the covers left open or removed.

While the product is energized, do not unplug or plug connectors ior harnesses.

Never use flammable sprays near the copier. A used battery should be disposed of according to the local regula

carded casually or left unattended at the users premises. When reassembling parts, make sure that the correct screws (size

washer are used in the correct places.

5. Precautions for Circuit Inspection Never create a closed circuit across connector pins except those sp

on the printed circuit. When creating a closed circuit and measuring a voltage across coin the text, be sure to use the GND wire.

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6. Handling of PWBs< During Transportation/Storage > During transportation or when in storage, new P.W. Boards must n

removed from their protective conductive bags.

Do not store or place P.W. Boards in a location exposed to direct sperature. When it becomes absolutely necessary to remove a Board from its

case, always place it on its conductive mat in an area as free as potricity.

Do not touch the pins of the ICs with your bare hands. Protect the PWBs from any external force so that they are not ben

< During Inspection/Replacement > Avoid checking the IC directly with a multimeter; use connectors o Never create a closed circuit across IC pins with a metal tool. Before unplugging connectors from the P.W. Boards, make sure th

been unplugged from the outlet. When removing a Board from its conductive bag or conductive cas

pins of the ICs or the printed pattern. Place it in position by holding

Board. When touching the PWB, wear a wrist strap and connect its cord toplace whenever possible. If you cannot wear a wrist strap, touch a charge static electricity before touching the PWB.

Note that replacement of a PWB may call for readjustments or resitems.

7. Handling of Other Parts

The magnet roller generates a strong magnetic field. Do not bring disk, magnetic card, or CRT tube.

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NOTES

Even when the PC Drum is only locally dirtied, wipe the entire sur

Do not expose the PC Drum to direct sunlight. Clean it as quickly a

interior illumination.

If dirt remains after cleaning, repeat the entire procedure from the

time.

9. Handling of the Imaging Cartridge Only for Products Employing an Imaging Cartridge.

< During Transportation/Storage > The storage temperature is in the range between 20C and +40C In summer, avoid leaving the Imaging Cartridge in a car for a long

< Handling > Store the Imaging Cartridge in a place that is not exposed to direc

< Precautionary Information on the PC Drum Inside the Imaging Car Use care not to contaminate the surface of the PC Drum with oil-b

prints and other foreign matter

C. Soak a small amount of eithepropyl alcohol into a clean, uton Pad which has been foldNow, wipe the surface of thetinuous movement from its reedge and off its surface one

Never move the Pad back and

1076D003

D. Using the SAME face of the dure explained in the latter hentire surface of the PC DrumAlways OVERLAP the areas complete turns of the PC Druate for cleaning.

1076D004

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DIS/REASSEMB

ADJUSTMENT

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CONTENTS1. SAFETY INFORMATION ........................................................

1-1. LASER SAFETY .............................................................

1-2. INTERNAL LASER RADIATION .....................................1-3. LASER SAFETY LABEL .................................................1-4. LASER CAUTION LABEL ...............................................1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPM

2. SERVICE INSTRUCTIONS ....................................................2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKER2-2. PARTS WHICH MUST NOT BE TOUCHED ..................

(1) Red Painted Screws ...............................................(2) Variable Resistors on Board ...................................

3. DISASSEMBLY/REASSEMBLY .............................................3-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFI

AND REMOVAL PROCEDURES ...................................3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECT

COMPONENTS ..............................................................

(1) Removal of the Master Board .................................(2) Removal of the Control Board ................................(3) Removal of the High Voltage Unit ..........................(4) Removal of the DC Power Supply ..........................

3-3. MAINTENANCE SCHEDULE .........................................3-4. PAPER TAKE-UP/TRANSPORT SECTION ...................

(1) Removal of the Paper Separator Roll Assy andPaper Take-Up Roll ................................................

(2) Cleaning of the Paper Separator Roll .....................(3) Cleaning of the Paper Take-Up Roll .......................(4) Cleaning of the Right and Left Synchronizing Roller(5) Removal of the Paper Dust Remover Assy ............(6) Cleaning of the Paper Dust Remover .....................

(7) Cleaning of the Bypass Transport Roller ................3-5. OPTICAL SECTION .......................................................(1) Cleaning of the Original Glass and ADF Glass ......(2) Cleaning of Mirrors .................................................(3) Cleaning of the Lens ...............................................

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(3) Application of Toner ................................................(4) Replacement of the ATDC Sensor .........................

3-8. IMAGE TRANSFER SECTION .......................................(1) Removal of the Image Transfer Roller Assy ...........

(2) Cleaning of the Pre-Image Transfer Lower Guide P(3) Cleaning of the Charge Neutralizing Plate .............

3-9. FUSING SECTION .........................................................(1) Removal of the Fusing Unit ....................................(2) Disassembly of the Fusing Unit ..............................

3-10.MULTIPLE BYPASS (MB-5): OPTION ...........................(1) Removal of the Separator Roll Assy .......................

(2) Removal of the Paper Take-Up Roll .......................(3) Cleaning of the Separator Roll/Paper Take-Up Roll (4) Cleaning of the Paper Take-Up Roll .......................

3-11.JOB TRAY (JS-202): OPTION .......................................(1) Removal of the Main Board ....................................(2) Paper Detecting Board ...........................................

3-12.SHIFTING UNIT (OT-103): OPTION ..............................(1) Removal of the Main Board ....................................4. ADJUSTMENT ........................................................................

4-1. ADJUSTMENT JIGS AND TOOLS USED ......................4-2. TIMING BELT TENSION ADJUSTMENT .......................4-3. ACCESSING THE FUNCTION, TECH. REP. CHOICE, A

ADJUST MODE ..............................................................

(1) Function Mode ........................................................(2) Tech. Rep. Choice Mode ........................................(3) Adjust Mode ............................................................

4-4. ELECTRICAL/IMAGE ADJUSTMENT ............................(1) Edge Erase Adjustment (Leading, Trailing, and Top

Edges) ....................................................................(2) Loop Length Adjustment (1st and 2nd Trays, Bypas

(3) Printer CD Registration Adjustment ........................(4) Printer FD Registration Adjustment ........................(5) Scanner CD Registration Adjustment .....................(6) Scanner FD Registration Adjustment .....................(7) Scanner CD Zoom Adjustment ...............................

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(1) Remounting the EEPROM (U29) ............................(2) Installation of the Plug-In Counter Socket (Option) (3) Installation of the Mechanical Counter (Option) .....

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1. SAFETY INFORMATION

1-1. LASER SAFETY

This is a digital machine certified as a class 1 laser product. There

danger from a laser, provided the machine is serviced according tomanual.

1-2. INTERNAL LASER RADIATION

*:Laser Aperture of the Print Head Unit

This product employs a Class 3b laser diode that emits an invisiblediode and the scanning polygon mirror are incorporated in the prin

The print head unit is NOT A FIELD SERVICE ITEM. Therefore, th

should not be opened under any circumstances.

Semiconductor laser

Maximum average radiation power(*) 26.4 W

Wavelength 770-795 nm

La

th

This figure Shows the view inside the Right Doorwith the Imaging Unit removed.

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the U.S.A., Canada

(CDRH Regulation)

This machine is certified as a Class I Laser product under Radiatiodard according to the Food, Drug and Cosmetic Act of 1990. Com

for Laser products marketed in the United States and is reported tDevices and Radiological Health (CDRH) of the U.S. Food and Drthe U.S. Department of Health and Human Services (DHHS). This does not produce hazardous laser radiation.

The label shown to page D-4 indicates compliance with the CDRHbe attached to laser products marketed in the United States.

All Areas

Denmark

CAUTION

Use of controls, adjustments or performance of procedures other ththis manual may result in hazardous radiation exposure.

Semiconductor laser

Maximum power of the laser diode 5 mW

Wavelength 770-795 n

CAUTION

Use of controls, adjustments or performance of procedures other ththis manual may result in hazardous radiation exposure.

Semiconductor laser

Maximum power of the laser diode 5 mW

Wavelength 770-795 n

ADVARSEL

Usynlig Laserstrling ved bning, nr sikkerhedsafbrydere er ude audsttelse for strling. Klasse 1 laser produkt der opfylder IEC6082

Halvlederlaser

Laserdiodens hjeste styrke 5 mW

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1-3. LASER SAFETY LABEL

A laser safety labels is attached to the outside of the machine as s

1-4. LASER CAUTION LABEL

A laser caution label is attached to the inside of the machine as sh

4

For Europe

For United Sta

4022D038CA

Laser safety

CLASS 1 LASER PR

LASER KLASSE 1 PR

4022D501AA

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2. SERVICE INSTRUCTIONS

2-1. IDENTIFICATION OF FUSES AND CIRCUIT B

Control Board (PWB-C)125 V 3 A

DC Power Supply (PU1)100 V system 125 V 15 A (F2)200 V system 250 V 6.3 A (F2)

Therm250 V

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2-2. PARTS WHICH MUST NOT BE TOUCHED

(1) Red Painted Screws

Purpose of Application of Red PaintRed painted screws show that the assembly or unit secured can onlythe factory and shall not be readjusted, set, or removed in the field.If it becomes unavoidably necessary to disassemble any of these asdisassembly may be done provided that the conditions permitting reaNote also that when two or more screws are used on the part in quesentative screw may be marked with red paint.

(2) Variable Resistors on Board

Do not turn the variable resistors on boards for which no adjusting inADJUSTMENT.Other Screws not Marked with Red Paint

PH Unit PH Unit base plate

Left side face Right side face

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3. DISASSEMBLY/REASSEMBLY

3-1. DOORS, COVERS, AND EXTERIOR PARTS:

AND REMOVAL PROCEDURES

9

10

11

17

18

8

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No. Part Name Removal Procedure

1 Original Cover Pull the Original Cover straight up.

2 Original Glass

Remove no. 18.Remove two holding br

the Original Glass.

3 Control PanelRemove two control panel mounting screwground wire mounting screws.Remove unplug one connector.

4 Right Inside CoverRemove no. 5.Remove one Right Insidescrew.

5 Front Cover Remove no. 3.

Open the Front Door andCover mounting screws.

6 Front DoorOpen the Front Door and remove one bandSnap off one C-clip.

7 1st TraySlide out the 1st Tray.Remove the fixingand left.

8 Left Cover

Remove no. 3.Remove no. 5.Remov

five Left Cover mounting screws.

9 Upper CoverRemove no. 3.Remove no. 5.Removno. 8.Remove two screws and two Uppscrews.

10 Rear Inside CoverRemove no. 3.Remove no. 5.Removno. 8.Remove no. 9.Remove no. 4.Inside Cover mounting screws.

11 ADF Glass Remove two ADF Glass mounting screws.

12 Left Hinge Remove no. 14.Remove three Left Hing

13 Right Hinge Remove no. 14.Remove three Right Hi

14 Rear Cover Remove six Rear Cover mounting screws.

15 Rear Right CoverRemove no. 14.Remove one Rear Righscrew.

16Multiple BypassCover (when theoption is mounted)

Remove two Multiple Bypass Cover mount

17 Right DoorRemove no. 14.Remove no. 15.Rem

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3-2. REMOVAL OF CIRCUIT BOARDS AND OTHE

COMPONENTS

When removing a circuit board or other electrical component, refe

FOR HANDLING THE PWBs and follow the corresponding remov The removal procedures given in the following omit the removal ofscrews securing the circuit board support or circuit board.

Where it is absolutely necessary to touch the ICs and other electricboard, be sure to ground your body.

PW

PWB-I

PWB-A

PU2

PWB-C

PWB-R1

PWB-AJob Tray (JS-202): OptionShifting Unit (OT-103): Option

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Job Tray (JS-202): Option

Shifting Unit (OT-103): Option

(1) Removal of the Master Board

1. Remove the Rear Cover.

2. Remove 12 screws and the PWB Cover Assy.

Symbol Part Name Removal Proce

PWB-A Master Board D-10

PWB-C Control Board D-11

PWB-I Paper Size DetectingBoard

Remove the Rear Cover.RemoRemove two screws and the PWB

PWB-J CCD Board D-23 Remove the CCD Unit as a unit

PWB-R1 Fusing Board Remove the Fusing Unit.PWB

PWB-R2Pre-Image Transfer

BoardOpen the Right Door.PWB-R2

PU1 DC Power Supply D-13

PU2 Inverter Board D-23

PU3 Control PanelRemove two control panel mountintwo ground wire mounting screwscable and unplug one connector.

HV1 High Voltage Unit

D-11


PWB-A Main Board D-46

PWB-B Paper Detecting Board D-48


PWB-A Main Board D-49

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(2) Removal of the Control Board

1. Remove the Rear Cover.2. Remove the PWB Cover Assy.

(3) Removal of the High Voltage Unit

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, Inside Cover, and Rear Inside Cover.

2. Remove the PWB Cover Assy.3. Unplug all connectors from the Master Board (except for PJ20) a

Board.4. Remove the harness from seven wiring saddles and two edge co

3. Unplug all connectors (but PBoard.

4. Remove four screws and th

3. Unplug all connectors from4. Remove six screws and the

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7. Remove ten screws and the PWB Assy.

5. Unplug three connectors froUnit and remove the harnessaddle.

6. Remove the harness from o

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(4) Removal of the DC Power Supply

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, a

9. Remove nine screws and thcover.

10. Unplug two connectors fromUnit.

11. Remove two screws and th

2. Unplug two connectors of th3. Remove two Hopper mount

right.

4. Remove two Hopper mountand the Hopper Assy.

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6. Remove four screws and thCover.

7. Unplug one connector and from one edge cover.

8. Unplug one connector and from one wiring saddle.

9. Unplug one connector and from one wiring saddle.

10 Unplug three connectors an

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11. Remove two screws.

12. Remove two screws.


3 3 MAINTENANCE SCHEDULE

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3-3. MAINTENANCE SCHEDULE

Parts

MaintenanceCycle

(K)

PartNo.

Qty

Ref.

Page

Counter(*3

)

AssociatedProblems

Clean

Replac

e

Roll(1stTray)

Whena

malfunction

occurs

150

4021-3012-XX

1

D-18

1stTray

Papertake-upfailur

e,dou-

blefeed

rRollAssy

150

4658-0151-XX

1

D-18

Doublefeed

perTake-UpRo

ll

s)

150

4687-3257-XX

1

D-42

BypassTray

Papertake-upfailur

e,dou-

blefeed

paratorRollAssy

s)

150

4658-0151-XX

1

D-42

Doublefeed

moverAssy(*1)

40

4021-0151-XX

1

D-19

IULife

Failuretoremoveto

neroff

completely,filming

zingRoller

D-19

Dirtyimage

ngRoller

D-19

Dirtyimage

rtRoller

D-20

Papermisfeed

80

D-21

IR

shings

80

D-22

80

D-21

Whena

malfunction

occurs

D-29

Imagenoise(white

lines)

Whena

malfunction

40

1

D-30

Imagenoise(white

lines)

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MParts

MaintenanceC

ycle

(K)

PartNo.

Qty

Ref.

Page

Counte

r(*3)

AssociatedP

roblems

Clean

Re

place

eringPrevention

Plate

40

D-33

IULife

ingSheet

40

4163-4302-XX

1

D-32

ferUpperGuide

Plate

40

D-34

rope)

150

1156-4118-XX

1

D-31

easotherthanE

urope)

300

D-31

Ozone

Filter

RollerAssy

150

4021-0315-XX

1

D-36

Image

Trans-

ferRoller/

Fusing

Unit

ferLowerGuide

Plate

Whena

malfunction

occurs

D-36

Dirtyimage

ingPlate

D-36

Misfeeddueto

papernot

properlysepara

tedfrom

PCDrum

0-Vsystem)

150

4021-0321-XX

1

D-37

Image

Trans-

ferRoller/

Fusing

Unit

0-Vsystem)

150

4021-0322-XX

1

D-37

dedplainpaper.CleanwhentheP

aperDustRemoverisfullofpaperdustfo

rpaperofothertypes.

ceptfortheO

zoneFilter)isdeterm

inedbytheperiodof

timethroughwhichth

ePCDrumhasturned(as

cetraveled).Themaintenancecyc

leinthetablerepresentsthenumberofco

piesmadeinthestandard

differdepend

ingonconditionsinwhichthecopiersare

usedamongdifferen

tusers.

3-4 PAPER TAKE-UP/TRANSPORT SECTION

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3-4. PAPER TAKE-UP/TRANSPORT SECTION

(1) Removal of the Paper Separator Roll Assy and Paper Take

(2) Cleaning of the Paper Separator Roll

1. Slide out the 1st Tray.

2. Remove two screws and thRoll Assy.

3. Press down the Paper Liftin4. Snap off one C-clip from the

Assy.5. Slide the Paper Take-Up Ro

that it can be pulled off the

6. Snap off one C-clip and remUp Roll.

1. Remove the Paper Separat2. Using a soft cloth dampene

the Paper Separator Roll cl

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(4) Cleaning of the Right and Left Synchronizing Rollers

1. Remove the Imaging Unit.

(5) Removal of the Paper Dust Remover Assy

1. Remove the Imaging Unit.

4. Remove one screw and the Synchronizing Roller Sensor Assy.

NOTE

Do not unplug the sensor harness connector.

2. Using a soft cloth dampene

the Right and Left Synchrondirt.

2. Remove two screws and th3. Remove the 1st Tray.

(6) Cleaning of the Paper Dust Remover

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( ) g p

(7) Cleaning of the Bypass Transport Roller

1. Remove the Imaging Unit.2. Remove two screws, unplug one connector, and remove the Byp

Assy.

1. Remove the Paper Dust Re2. Using a brush, whisk dust a

Dust Remover.

3. Using a soft cloth dampenethe Bypass Transport Rolle

4 Using a soft cloth dampene

3-5. OPTICAL SECTION

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3 5 O C S C O

(1) Cleaning of the Original Glass and ADF Glass

(2) Cleaning of Mirrors

(3) Cleaning of the Lens

1. Remove the Original Glass.

2. Remove 15 screws and the CCD Unit cover.

1. Using a soft cloth dampene

the Original Glass and ADF

1. Remove the Original Glass2. Using a soft cloth dampene

the mirrors clean of dirt.


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(4) Cleaning of the CCD Sensor

1. Remove the Original Glass.2. Remove 15 screws and the CCD Unit cover.

(5) Cleaning of the Scanner Rails/Bushings

3. Using a soft cloth dampenethe Lens clean of dirt.

3. Remove the Lens cover.

4. Using a soft cloth dampenethe CCD Sensor clean of d

1. Remove the Original Glass2. Using a soft cloth dampene

the Scanner rails/bushings

NOTE

(6) Removal of the CCD Unit

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1. Remove the Original Glass.2. Remove 15 screws and the CCD Unit cover.

(7) Removal of the Scanner, Exposure Lamp, and Inverter Boa

1. Remove the control panel, Front Cover, Rear Cover, and Origina2. Remove the foam seal and mylar, one each at the front and rear.

NOTE

Ready a new foam seal and mylar and affix them after the proced

3. Unplug one connector.

4. Remove three screws and t

NOTE

NEVER attempt to loosen or

are not specified when remo

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3. Remove two Scanner mounno red paint has been appli

4. Remove one screw and the5. Remove the flat cable from

and then remove the Scann

6. Unplug one connector from7. Remove two screws and th


(8) Removal of the Scanner Drive Cables

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1. Remove the control panel, Front Cover, Rear Cover, Left Cover, RGlass, and ADF Glass.

2. Remove the Scanner.

NOTE

Remove the two red painted screws to remove the Scanner in this


4. Loosen three screws to free

Assy.

5. Unhook the spring from thefront and rear.

6. Remove the front cable from

7. Remove the rear cable from

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8. Snap off one C-ring from thley assy.

9. Snap off one C-ring from thley assy.

10. Remove the belt and the pu

11 Remove two screws and th

(9) Winding of the Scanner Drive Cables

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1. Wind the cable around the rear cable pulley of the pulley assy fromand then secure the cable with tape.

2. Wind the cable around the front cable pulley of the pulley assy frB and then secure the cable with tape.

NOTE

Make sure that no part of the cable rides on the other.

Rear

Front

Bead Position

Rear

FrontB

Winding Directionon Side A

B

Winding Direction on S

4. Mount the pulley assy using

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5. Wind the cable at the front.6. Hook the spring onto the cable hook and hook the spring onto th

7. Wind the cable in the rear.

8. Secure the cables at the front and rear with a spring.

4022D006AB

4

3-6. PH

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(1) Removal of the PH Unit

1. Remove the control panel, Front Cover, Rear Cover, Left Cover, a2. Remove the PWB Cover Assy.

(2) Cleaning of the PH Window1. Remove the Front Cover, Rear Cover, Left Cover, and Upper Cov

3. Remove one flexible harnesconnector from the Master

4. Remove the harness from oone wiring saddle.

5. Remove one screw and the

NOTE

To remove the ground wire, r

installed on the copier side.


2. Wipe the PH window clean cloth.

3-7. Imaging Unit (IU)

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NOTE

When loading developer as part of the IU replacement procedure

developer, remove the Toner Bottle and run ATDC Sensor Automa

twice to allow toner in the Spent Toner Recycling Duct and Toner C

Developer Mixing Chamber before removing the IU.

(1) Removal of the IU

(2) Disassembly of the IU

1. Open the Right Door.

2. Open the Front Door.3. Remove two screws and, hoof the IU, take off the IU.

NOTE

Before installing the IU, be su

Right Door.

If the IU is installed with the R

PC Drum protective shutter wing with the Image Transfer R

ducing noise.

When inserting the IU, do tha

you are sure that the drum ge

part, push the IU all the way

step is done all at once, the d

damaged.

Handle

1. Remove one screw in the reremove the harness cover.

3. Remove two screws at the

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4. Widen flaps on both ends (illustration on the left) of the

direction of arrow and turn ting Assy.

A

A

5. Unplug one connector of th

6. Remove two screws and th7. Remove the PC Drum.

NOTE

When the PC Drum has beecoat of toner to the surface o

D-34

9. Remove the Ozone Filter.

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10. Turn the holder in the rear iarrow to remove it from the

11. Slide out the PC Drum Chadirection of the arrow.

12. Remove three screws, the CSheet, and Cleaning Blade.

NOTE

When securing the CleaningNeutralizing Sheet, tighten sc

one on one edge, one at the

the other edge.

When the Cleaning Blade ha

apply a coat of toner to the s

Drum.

D-34

13. Using a soft cloth dampeneth P S t Fi


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14. Using a soft cloth dampenethe Ds Collars clean of dirt.

15. Remove three screws and ting Prevention Plate.

16. Using a brush, whisk dust aof the Developer Scattering

17. Dump the developer.

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(4) Replacement of the ATDC Sensor1. Divide the IU into the Cleaning Assy and Developing Assy.2. Remove the Developer Scattering Prevention Plate and dump de

4. Install the ATDC Sensor.

5. Pour developer.6. Reinstall the Developer Scattering Prevention Plate.7. Mount the Cleaning Assy to the Developing Assy.8. Install the IU in the copier and run F8 operation.9. Enter the adjustment value on the Adjust Label.

4021U057AA

20-30

mm

10 - 15 mm 20 - 25 mm

PC Drum

3. Hold both ends of the PC Dhands and turn the PC Dru

direction of the arrow.

4021U009AA

3. Unplug one connector, andand the ATDC Sensor.

3-8. IMAGE TRANSFER SECTION

(1) Removal of the Image Transfer Roller Assy

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( ) g y


(2) Cleaning of the Pre-Image Transfer Lower Guide Plate


(3) Cleaning of the Charge Neutralizing Plate


2. Loosen one fixing bracket m3. Turn to remove the Pre-Ima

Guide Plate.

NOTE

When reinstalling the fixing b

that the hook of the fixing bra

the Pre-Image Transfer Uppe

2. Using a soft cloth dampenethe Pre-Image Transfer Lowof dirt.

2. Using a soft cloth dampenethe Charge Neutralizing Pla

NOTE

Use care not to allow the Ima

be touched with alcohol. Do not allow the soft cloth to

the Charge Neutralizing Plate

3-9. FUSING SECTION

(1) Removal of the Fusing Unit

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1. Remove the control panel.

NOTE In this step, free the control panel without removing one flat cable

and unplugging one connector.

2. Remove the Front Cover, Rear Cover, and Rear Right Cover.

(2) Disassembly of the Fusing Unit

3. Unplug two connectors of th

4. Open the Right Door.5. Remove four screws and th


2. Unhook the pressure spring

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rear.

3. Remove two shoulder screw

the Right Roller Assy.

4. Remove the Right Roller.

5. Remove the Pressure Levefront and rear.

7. Remove the harness in theLamp from the cover.

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8. Remove the thermistor harn

9. Remove one mounting screHeater Lamp.


NOTE

When reinstalling the cover, cover to be caught in the fram


12 Remove the Fusing Heater

13. Snap off one retaining ring.

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14. Unhook the spring in the re

15. Unhook the spring at the fro16. Remove the Guide Assy.

NOTE

When removing and reinstall

use care not to allow the sen

unhooked.

17. Remove one screw and theger Assy.

NOTE

When reinstalling the Paper

Assy, allow six tabs to be cau

20. Snap off the retaining ring aFusing Roller and remove ting

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ing.

21. Snap off the retaining ring iFusing Roller and remove t

22. Remove the collar.

23. Remove the bushing.24. Remove the Left Fusing Ro

3-10. MULTIPLE BYPASS (MB-5): OPTION

(1) Removal of the Separator Roll Assy

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(2) Removal of the Paper Take-Up Roll

2. Remove the harness from one cord clamp.

1. Open the Right Door.2. Remove two screws and th


4. Unplug two connectors.

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7. Snap off one C-ring and rem

8. Snap off one C-ring.

9. Snap off one C-ring and remUp Roll Assy.

10 Snap off one C-ring and rem

11. Snap off one C-ring and onthe paper Take-Up Roll.

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(3) Cleaning of the Separator Roll/Paper Take-Up Roll

1. Open the Right Door.2. Remove two screws and th

NOTE

When attempting to reinstall

Assy, try to move the assy in

arrow.

3. Using a soft cloth dampenethe Separator Roll clean of

3-11. JOB TRAY (JS-202): OPTION

(1) Removal of the Main Board

1 Remove the control panel Front Cover Rear Cover Right Cover

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1. Remove the control panel, Front Cover, Rear Cover, Right CoverCover.


3. Remove one screw and the(if the copier is so equipped

4. Remove one Sensor Assy m


6. Remove the harness from tremove the Sensor Assy.

8. Unplug one connector and from one edge cover.

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10. Unplug four connectors.

11. Remove two screws, two PWMain Board.

(2) Paper Detecting Board

1. Remove the control panel, Rear Cover, and Right Cover.

2. Unplug one harness conne

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p gharness from one edge cov

3. Press the tabs to remove thBoard Assy from the Front C

4. Remove one screw and theBoard.

3-12. SHIFTING UNIT (OT-103): OPTION

(1) Removal of the Main Board

1. Remove the control panel, Front Cover, Rear Cover, Right Cover

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Cover.


3. Remove one screw and the(if the copier is so equipped


5. Unplug two connectors and

from the guide.


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10. Remove two screws, two PWMain Board.

4. ADJUSTMENT

4-1. ADJUSTMENT JIGS AND TOOLS USED

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1. Press the Meter Count key.

2. Press the following keys in this order: Stop 0 0 Stop 03. Enter the code number 1 from the 10-Key Pad.4. Press the Start key.

(2) Tech. Rep. Choice Mode

1. Press the Meter Count key.2. Press the following keys in this order: Stop 0 0 Stop 0

3. Enter the code number 2 from the 10-Key Pad.4. Press the Start key.

(3) Adjust Mode

1. Press the Meter Count key.2. Press the following keys in this order: Stop 0 0 Stop 03. Press the Stop key and then the Start key.

4-4. ELECTRICAL/IMAGE ADJUSTMENT

(1) Edge Erase Adjustment (Leading, Trailing, and Top/Bottom

Requirement

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Requirement

NOTE

This adjustment is made when a request is made from the user to

sponding erase width.

1. Enter the Tech. Rep. Choice mode.

2. With c-- shown on the Display, enter the code number 5 from press the Start key to enter the Leading Edge Erase Adjustment

3. Press the Clear key to clear the current setting value.4. Enter the setting value from the 10-Key Pad and press the Start

entry.

Adjustment InstructionsTo make the edge erase width smaller, decrease the setting value.To make the edge erase width greater, increase the setting value.

5. Following the same procedure, set the erase width on the trailingedge.

Mode Code No.

Tech. Rep. Choice

5 (leading edge)

0 t6 (trailing edge)

7 (top/bottom)

Adjust the erase width on theA), trailing edge (width B), an(width C).

Default Setting: 4 mm

C

C

A B 4022D503AA

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(3) Printer CD Registration Adjustment

Requirement

Adjust so that width A on the

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NOTES

This adjustment is made when the PH Unit has been replaced.

Load the 1st Tray with A4C or 8-1/2 11C paper.

1. Enter the Adjust mode.2. With AJ- shown on the Display, enter the code number 12 from3. Press the Paper key to select the 1st Tray.4. Press the Start key.

Then, a test print will be produced.5. Check to see if width A on the test print falls within the specified If width A falls outside the specified range, perform the following adjustment.

6. With AJ- shown on the Display, enter the code number 1 frompress the Start key to enter the Printer CD Registration Adjustm

7. Press the Clear key to clear the current setting value.8. Enter the new setting value from the 10-Key Pad and press the S

entry.

Adjustment InstructionsIf width A on the test print is longer than the specifications, increase

Specifications Mode Code No.

A4C: 20 2.0 mm;8-1/2 11C: 11.2 2.0 mm

Adjust 1

Adjust so that width A on thefalls within the specified rang

A

4686D504AA

(4) Printer FD Registration Adjustment

Requirement

Adjust so that width B on the

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NOTES

This adjustment is made when the PH Unit has been replaced.


1. Enter the Adjust mode.2. With AJ- shown on the Display, enter the code number 12 from3. Press the Paper key to select the 1st Tray.4. Press the Start key.

Then, a test print will be produced.5. Check to see if width B on the test print falls within the specified If width B falls outside the specified range, perform the following adjustment.

6. With AJ- shown on the Display, enter the code number 2 frompress the Start key to enter the Printer FD Registration Adjustm


entry.

Adjustment InstructionsIf width B on the test print is longer than the specifications, decrease


10 1.5 mm Adjust 2

jfalls within the specified rang

B

4022D502AA

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(6) Scanner FD Registration Adjustment

Requirement

Adjust so that the deviation b

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NOTES

This adjustment is made when the PH Unit has been replaced and

tration Adjustments (CD and FD) and Scanner Zoom Adjustment This adjustment is made when the CCD Unit has been replaced a

Position Adjustment.


1. Enter the Adjust mode.

2. With AJ- shown on the Display, enter the code number 12 from3. Press the Paper key to select the 1st Tray.4. Press the Start key. Then, a test print will be produced.5. Place the test print produced on the Original Glass and make a c6. Align the test print (original) with the copy and check for deviation

If the deviation between width B on the test print and that on the specified range, perform the following steps to make an adjustme

7. With AJ- shown on the Display, enter the code number 5 frompress the Start key to enter the 2Scanner CD Registration Adjus



0 1.5 mm Adjust 6

test print and that on the copified range.

B

4022D502AA

(7) Scanner CD Zoom Adjustment

Requirement Adjust so that the amount of error falls within 1.0 % of the length Adjust so that the following specifications are met when the length

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j g p g

mm.

NOTE

This adjustment is made when the CCD Unit has been replaced aafter CCD Unit Position Adjustment.

1. Place a scale on the Original Glass in parallel with the Original W

copy.

3. Enter the Adjust mode.4. With AJ- shown on the Display, enter the code number 3 from

press the Start key to enter the Scanner CD Zoom Adjustment 5. Press the Clear key to clear the current setting value.6. Enter the new setting value from the 10-Key Pad and press the S

entry.

Adjustment InstructionsIf the length on the copy is longer than the actual one, decrease the If the length on the copy is shorter than the actual one, increase the If a single adjustment procedure does not successfully bring the amo

Zoom Ratio Specifications Mode Code No.

Full size (1.00) 200 2.0 mm Adjust 3

2. Measure the length of the s

If the amount of error falls orange, perform the followingadjustment.

(8) Scanner FD Zoom Adjustment

Requirement Adjust so that the amount of error falls within 1.0 % of the length Adjust so that the following specifications are met when the length

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j g p g

mm.

NOTE

This adjustment is made when the Scanner Drive Cables have be

1. Place a scale on the Original Glass in parallel with the Original L

a copy.

3. Enter the Adjust mode.4. With AJ- shown on the Display, enter the code number 4 from

press the Start key to enter the Scanner FD Zoom Adjustment 5. Press the Clear key to clear the current setting value.6. Enter the new setting value from the 10-Key Pad and press the S

entry.

Adjustment InstructionsIf the length on the copy is longer than the actual one, decrease the If the length on the copy is shorter than the actual one, increase the If a single adjustment procedure does not successfully bring the amospecified range repeat steps 3 though 6

Zoom Ratio Specifications Mode Code No.

Full size (1.00) 300 3.0 mm Adjust 4

2. Measure the length of the sIf the amount of error falls o

range, perform the followingadjustment.

(9) ATDC Sensor Automatic Adjustment (F8)

NOTES

This adjustment is made when the developer has been replaced.

Make this adjustment with the Toner Bottle removed from the copi

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1. Enter the Function mode.2. With F- shown on the Display, enter the code number 8 from t

the copier into the ATDC Sensor Automatic Adjustment mode.3. Press the Start key. This automatically runs the ATDC Sensor Automatic Adjustment

three minutes.

4. After the F8 operation has been completed, check the adjustmenthe Adjust Label.

(10) Manual Bypass Registration Adjustment

Requirement

Adjust so that the deviation btest print and that on the cop

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NOTES


tration Adjustments (CD and FD) and Scanner Zoom Adjustment

This adjustment is made when the CCD Unit has been replaced a


Load the 1st Tray with A4C paper.

1. Enter the Adjust mode.2. With AJ- shown on the Display, enter the code number 12 from3. Press the Paper key to select the 1st Tray.4. Press the Start key. Then, a test print will be produced.5. Place the test print produced on the Original Glass and make a c

Bypass Tray.6. Align the test print (original) with the copy and check for deviationIf the deviation between width A on the test print and that on the specified range, adjust the position of the Guide Plate Unit.

test print and that on the cop

ified range. Specifications: 0 2.0 mm

A

4686D504AA

Adjustment InstructionsIf with A of the copy is longer th

print, move the Guide Plate UnIf with A of the copy is shorter tprint, move the Guide Plate Un

(11) Multiple Bypass Registration Adjustment (MB-5): Option

Requirement

Adjust so that the deviation btest print and that on the cop

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NOTES

This adjustment is made when the Multiple Bypass has been remo


tration Adjustments (CD and FD) and Scanner Zoom Adjustment

This adjustment is made when the CCD Unit has been replaced a


Load the 1st Tray with A4C paper.

1. Enter the Adjust mode.2. With AJ- shown on the Display, enter the code number 12 from3. Press the Paper key to select the 1st Tray.4. Press the Start key. Then, a test print will be produced.

5. Place the test print produced on the Original Glass and make a cBypass Tray.6. Align the test print (original) with the copy and check for deviation

If the deviation between width A on the test print and that on the specified range, adjust the position of the Guide Plate Unit.

test print and that on the cop

ified range. Specifications: 0 2.0 mm

A

4686D504AA

Adjustment Instructions

If with A of the copy is longer thprint, turn the adjusting screw cIf with A of the copy is shorter tprint, turn the adjusting screw c

4-5. OTHER ADJUSTMENTS

(1) Adjustment of the Position of the Scanner and 2nd/3rd Mir

1. Fit the Scanner/Mirrors Carin the space between the SRear

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p

3rd Mirrors Carriage.

4022D013AA

Rear

2. Press the 2nd/3rd Mirrors Cagainst the jigs.

4022D014AARear

2nd/3rd Mirrors Carriage

JigJig

3. Loosen the set screw of theand turn the adjusting screweliminate clearance betweeCarriage and the Scanner/Mtioning Jigs.

4022D015AB

AdjustingScrew

Fixing Screw

4. Press the Scanner tightly utighten the set screw of the the specified torque.

Scanner

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(3) Adjustment of the Gap between the Doctor Blade and Slee

ment)

Requirement The gap between the Doctor Blade and the Sleeve Roller should b

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set using the jigs).

1. Remove the IU.2. Separate the Cleaning Assy from the Developing Assy.3. Remove the PC Drum, Main Erase, PC Drum Charge Corona As

5. Remove three screws and the Developer Scattering Prevention P

4. Install the Ds Collar PositioNOTE

Ready a PC Positioning Jig (

rately. (It can be ordered. F

Parts Manual.)

4022D018AC

Ds Collar Positioning Jigs

PC Positioning Jig


4022D019AA

7. Using a small piece of papefrom the shaded area on th

Sleeve Roller and put it in tChamber.

8. Vacuum the developer left oPiece of paper

10. Install the Db Gap Adjustingbetween the Sleeve Roller a

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11. Put the Developing Assy and Cleaning Assy together.

4022D021AB

12. Press the Doctor Blade tigh

Gap Adjusting Jigs and, keetighten the screws in the ordat the center, andin th

NOTE

The Doctor Blade mounting s

coated with lock paint and th

pleted within 30 min. It the jo

that time, change the screws

4022D022AB

4-6. MISCELLANEOUS

(1) Remounting the EEPROM (U29)

NOTE

When the Control Board (PWB-C) is replaced with a new one, EE

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demounted from the old PWB-C and remounted on the new PWB-

Remove the EEPROM (U29) from the new Control Board and mount the old Control Board to the new Control Board.

New EEPROM Old EEP

New Control Board Old Control Board

NOTE

Note the alignment notch ma

EEPROM (U29) when mount

1171D049AA

A

A

(2) Installation of the Plug-In Counter Socket (Option)

1. Cut out the knockout from t

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4022D023AA

2. Using two screws, secure thbracket.

4022D024AA

3. Connect the Plug-In Counte4. Using two screws, secure t

4022D025AA

5. Using two screws, secure tcover.

NOTE

When the Plug-In Counter S

Plug-In Counter of the Secudetails, see SWITCHES ON

SETTINGS.)4022D026AA

(3) Installation of the Mechanical Counter (Option)

1. Remove the control panel, Front Cover, Rear Cover, and Right C

2. Cut out the knockout from t

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4021D001AA

3. Using one screw, secure thto its mounting bracket.

4021D002AA

4. Connect the Mechanical Co5. Using one screw, secure th

NOTE

When the Mechanical Count

Mechanical Total Counter o

1. (For details, see SWITCTECH. REP. SETTINGS.)

4021D003AA

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SWITCHES ON P

TECH. REP. SETT

CONTENTS1. CONTROL PANEL KEYS AND TOUCH PANEL ....................

1-1. Control Panel Keys .........................................................2. UTILITY MODE .......................................................................

2-1. Settings in the Utility Mode .............................................U ili M d S i P d

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2-2. Utility Mode Setting Procedure .......................................(1) Users Choice Mode (Display: U-1) ........................(2) Drum Dehumidify Mode (Display: U-2) ...................(3) Toner Replenisher Mode (Display: U-3) .................(4) Custom Size Input Mode (Display: U-4) .................(5) Administrator Mode (Display: U-5) .........................

3. TECH.REP.MODE ..................................................................3-1. Tech.Rep.Mode Menu Function Tree .............................3-2. Tech.Rep.Mode Function Setting Procedure ..................3-3. Setting in the Tech.Rep.Mode ........................................

(1) Control Panel LED Check .......................................(2) Function ..................................................................(3) Tech.Rep.Choice ....................................................

(4) Counter Mode .........................................................(5) ATDC Sensor Output ..............................................(6) Level History ...........................................................(7) ROM Version ..........................................................(8) Administrator No. Input ...........................................(9) Change Fixed Zoom ...............................................(10) Marketing Area Setting ...........................................

(11) Memory Clear .........................................................(12) Total Clear ..............................................................(13) ADF Document Passage Test ................................(14) ADF Original Glass Check ......................................(15) Scanner Move Check .............................................(16) Serial No. Display ...................................................

4. SECURITY MODE ..................................................................4-1. Settings in the Security Mode .........................................4-2. Security Mode Setting Procedure ...................................4-3. Setting in the Security Mode ...........................................

1. CONTROL PANEL KEYS AND TOUCH

1-1. Control Panel Keys

1 2 3

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91011

12 13 14 15 16 17 18 19

2262728293031

No. Name Description

1 Printer Lamp Lit while data received from personalprinted

2 Job Input key Press to select the Job Input mode. T

be programmed

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be programmed.3 Meter Counter key Press to display the Total Counter or

4 Neg.Pos. key Press to copy an original with the origments reversed.

5 Original key Press to select the Mixed Orig. or Botion.

6 Copy key Press to select the 2in1 or 4in1 functi7 Erase key Press to select the erase position.

8 Finishing key Press to select the finishing function.

9 File Margin key Press to select the File Margin mode

10 X/Y Zoom key Press to make a copy with different zoX (horizontal) and Y (vertical) directio

11 Job Recall key Press to recall either one of the two join memory.

12 Paper Misfeed indicator Lights up when a paper misfeed occu

Malfunction indicator Lights up when malfunction occurs in

13 Maintenance indicator Blinks or lights up when the time appneeds maintenance service.

14 Add Paper indicator Lights up when paper source currentlruns out of paper.

15 Add Toner indicator Lights up when toner will soon run ou

16 Bypass Tray SizeSelect key

Press to select the size of the paper lTray.

17 Zoom () key Press to change the zoom ratio in t50 % and 200 % in 1 % increments

What is shown on the Display chanof copies to be made to the zoom r

18 Display Shows the number of copies to be maand other setting data

No. Name Description

24 Clear key Press to reset the number of copies t

25 Stop key Press to stop a print cycle. Press to stop a scanning sequence

26 Start key Press to start a scanning sequence

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26 Start key Press to start a scanning sequence Press to start a print cycle. Press to validate the setting just ma The key lights up green when the co

copies, orange when it is not ready

27 Enter key Press to validate the setting just mad

28 Zoom key Press to select a zoom ratio from amavailable as standard.

29 Auto Paper/Auto Sizekey

Press to select either Auto Paper or A

30 Paper key Press to select the paper size.

31 Auto/Photo key Press to adjust the image density of t

2. UTILITY MODE

Utility Mode is used to make various settings according to the user

2-1. Settings in the Utility Mode

Code No Description

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2-2. Utility Mode Setting Procedure

1. Hold down the Panel Reset key for 3 seconds.2. Using the 10-Key Pad, enter the code corresponding to the desire

Code No.: 1 to 53. Press the Start key.

Press the Panel Reset key.

(1) Users Choice Mode (Display: U-1)

Users Choice is used to make various settings according to the us

1. Settings in the Users Choice Mode

Code No. DescriptionU-1 Users Choice Mode

U-2 Drum Dehumidify Mode

U-3 Toner Replenisher Mode

U-4 Custom Size Input Mode

U-5 Administrator Mode

Code No. Function Code No.

C-1 Mixed Orig. C18 Density (ADF

C-2 Paper Priority C19 Print Density

C-3 Copy Priority C20 Paper Auto D

C-4 Density Priority C21 Paper Auto De

C-5 Density Level (Auto) C22 Paper Auto DC-6 Density Level (Manual) C23 Paper Auto D

C-7 Output Priority C24 Paper Auto D

2. Users Choice Mode Setting Procedure

1. Hold down the Panel Reset key for 3 seconds.2. Enter 1 from the 10-Key Pad. (Display: U-1)3. Press the Start key.4. Enter the corresponding code number from the 10-Key Pad.

5 Press the Start key Then the Display will show the current settin

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5. Press the Start key. Then, the Display will show the current settin6. Press the Clear key to reset the current setting value.7. Enter the new setting value from the 10-Key Pad.8. Press the Start key. This will validate the new setting value just e

If any value outside the available setting range is entered, the Disrejecting the entry. (The old setting value will reappear on the Di

Press the Panel Reset key until the initial screen reappears.

3. Setting in the Users Choice Mode

Code No. Setting (The default is

C-1

Select the priority Mixed Original Detection modselected when the Power Switch is turned ON opressed.

C-2

Select the priority paper size or paper source thselected when the copier is set into the Auto Siz

Highligh

Setting 0

Description Mixed Orig. enabled Mix

Setting Description Setting

0123

45

7

A3 (L)B4 (L)A4 (L)B5 (L)

A5 (L)FLS (L)A4 (C)B5 (C)

121314

16202122

LegLettInvoLett

Invo1st 2nd3rd

6

15


C-4

Select the priority exposure mode selected wheturned ON or Panel Reset key pressed.

Highligh

Setting 10

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C-5

Select the priority exposure level in the Auto Exp

C-6

Select the priority exposure level in the Manual

C-7

Select the priority finishing type.

C-8

Select whether to enable or disable crisscross s

C-9

Specify the default copying order in the 4in1 mo

Setting 1

Description Auto Manual

Setting 0

Description Lighter Normal

1

Setting 1 2

Description

Step 1 Step 2 Step 3

Lighter

3

Setting 1

Description Non-Sort Sort

0

Setting

Description Enabled

0

Setting 0

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C18

Adjust the copy image density level when the AD

Highligh

Setting Description

When the standard original (text0

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C19

Set the image density level for printing

C20 to 24

Select the system of measurement of the papersize detection.

Initial setting: Metric area 1/Inch area 0C20: 1st Tray C21: 2nd Tray C22: 3rd TrayC23: 4th Tray C25: 5th Tray

C25

Select the paper size detection method for the 1nonstandard size is to be used, select 1. SizeU-4.

C26

Select the type of paper loaded in the 1st Tray.

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(2) Drum Dehumidify Mode (Display: U-2)

Removes dewdrops that have formed on the surface of the PC Dru1. Hold down the Panel Reset key for 3 seconds.2. Enter 2 from the 10-Key Pad. (Display: U-2)3. Press the Start key. The Drum Dry sequence will be stopped aft

time.

(3) Toner Replenisher Mode (Display: U-3)

Supply of toner is replenished. The replenishing sequence is stopperiod of time or when a required level of toner-to-carrier ratio is re

1. Hold down the Panel Reset key for 3 seconds.2. Enter 3 from the 10-Key Pad. (Display: U-3)3. Press the Start Key.

(4) Custom Size Input Mode (Display: U-4)

Input the size of the paper loaded in the 1st Tray. (This is necessanonstandard size is to be used.)

1. Hold down the Panel Reset key for 3 seconds.2. Enter 4 from the 10-Key Pad. (Display: U-4)3 Press the Start key Then the Display will show the currently set

C28 to 33

C20: 1st Tray C21: 2nd Tray C22: 3rd Tray

C23: 4th Tray C25: 5th Tray C23: Multiple By

Enables Auto Paper (selection). Switching.

1 Disables Auto Paper. Enables A

2 Disables Auto Paper. Disables A

0

(5) Administrator Mode (Display: U-5)

The entry on the Administrator No. Input set using the Tech. Rep.tings of the following functions.

1. Administrator Mode Function Setting Procedure

1. Hold down the Panel Reset key for 3 seconds.2 Enter 5 from the 10 Key Pad (Display: U 5)

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2. Enter 5 from the 10-Key Pad. (Display: U-5)3. Press the Start Key.4. Enter the Administrator number from the 10-Key pad.5. Press the Start Key. (Display: Ad ) If a mismatch is detected of the administrator number, the Display 6. Enter the code assigned to the desired subfunction from the 10-K

7. Press the Start Key. Press the Panel Reset key until the initial screen reappears.

2. Administrator Mode Function Tree

U-5: AdministratorMode

Ad1: Copy Track

Ad2: Disable Auto Shut OFF

A-1: Co

A-2: In

A-3: D

A-4: C

A-5: To

b

A-6: To fo

3. Setting in the Administrator Mode


U-5

Allows for setting two functions, Copy Track an

OFF.Ad

Highligh

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Ad1

Allows for making the six different subfunctions.

Ad2

Select whether to allow the option 0 to be selefunction no.17.

1. Enter 2 from the 10-Key Pad.2. Press the Start key to show the current setti3. Press the Clear key to reset the current sett4. Enter the new setting value from the 10-Key

5. Press the Start key to validate the new settin

A-1

Select whether to enable or disable Copy Track.accounts can be controlled under Copy Track.)

1. Enter 1 from the 10-Key Pad. (Display: A-2. Press the Start key to show the current setti3. Press the Clear key to reset the current sett4. Enter the new setting value from the 10-Key5. Press the Start key to validate the new settin

Using the 10-Key Pad, enter a 3-digit access nufrom 001 to 999. The access number corresponnumber.

Setting 0

Description Authorized N

Setting 0

Description Copy Track enabled Cop

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3. TECH.REP.MODE

This mode allows the Tech. Rep. to set adjust, and/program variou

3-1. Tech.Rep.Mode Menu Function Tree

---0: Control Panel LED Check

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---: Tech.Rep.Mode

---1: Function F-

F-1 : Paper PassagF-2 : HV OutputF-8 : ATDC SensorF12: Test Pattern O

---2: Tech.Rep.Choice c--

c-1 : Maintenance c-2 : IU Life Stopc-3 : ID Adjustmenc-4 : VG Adjustmec-5 : Leading Edgec-6 : Trailing Edge c-7 : Top/Bottom E

c-8 : Loop Length Ac-9 : Loop Length Ac10: Loop Length Ac11: Priority FLS S

---3: Counter cnt

--1: PM Counter--2: Maintenance C--3: IU Life Counte--4: Application Co--5: Jam Counter--6: Trouble Counte--7: Paper Size Co

---4: ATDC Sensor Output

---5: Level HistoryVg (grid voltage)Vb (developing bias

---9: Marketing Area Setting

~---8: Change Fixed Zoom

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3-2. Tech.Rep.Mode Function Setting Procedure

1. Press the Meter Count key.2. Press the following keys in this order:Stop 0 0 Stop 0 1

3. Enter the code number corresponding to the function to be used Code No.: 0 to 14,20

4. Press the Start Key.


---: Tech.Rep.Mode

-20: Serial No. Display Sn

-10: Memory Clear CLr

-11: Total Clear tCL

-13: ADF Original Glass Check AdF

-14: Scanner Drive Check ccd

-12: ADF Document Passage Test doc

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(3) Tech.Rep.Choice

This function allows the Tech. Rep. to make various settings and a1. Enter the code number corresponding to the function to be used 2. Press the Start key to display the current setting value.3. Press the Clear key to clear the current setting value.4. Enter the new setting value from the 10-Key Pad.5. Press the Start key to validate the new setting value just entered

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5. Press the Start key to validate the new setting value just enteredIf any value outside the available setting range is entered, the Disrejecting the entry. (The old setting value will reappear on the Di



C-1

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C-6

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g3. Press the Paper key to select the display of another counter.4. Call the counter count to be cleared on the Display.5. Press the Clear Key.

Press Interrupt key to undo the clearing operation, restoring the o6. Press the Start Key.


Code No. Setting

--1

Counts the frequency of use of each of the diffecopier.The count should be cleared when the corresporeplaced.

Enter a value for the maintenance counter (for aThe count is based on a countdown system andcounted down to 0, the Maintenance Indicator If counting continues after 0, a minus sign (-) isvalue shown on the Display.

NOTE

The above counting method varies depending

Display Description Display De

123

45

Bypass Tray1st Tray2nd Tray

3rd Tray4th Tray

678

910

5th TrayADFIR

Ozone FilterImage Transf

Code No. Setting

Show the count of the IU Life Counter.The count is based on a countdown system andafter 0, a minus sign (-) is appended to the val

play.The count is controlled according to the period o

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--3

the PC Drum has turned and, when a near-life vMaintenance Indicator blinks.1. Press the Start key to display the current co2. Press the Clear key to clear the current cou

If the current count is mistakenly cleared, prto restore the count just cleared.3. Press the Start key to automatically set 40,

40,000 is the starting value from which it is No value can be set from the 10-Key Pad.

NOTES

There are some discrepancies between the c

number of copies made.

The setting made in c-2 of Tech. Rep. Choic

copying operation after the life value has been

If Copying prohibited is selected, nc2 is dis

tenance Indicator lights steadily.

--4

The count is made according to the application.

Counts the number of misfeeds that have occurtions in the copier.

Display Description

12

No. of copies made.No. of printed pages produced throug

Display Description

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(5) ATDC Sensor Output

This function displays a T/C ratio representing the current ATDC S It is used for checking the T/C when image density is not good. It is not possible to change or reset the sensor output data.


(6) Level History

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(6) Level History

This function displays the grid voltage and developing bias voltage It is not possible to change or reset the voltage data.1. Press the Start key to display the current grid voltage (Vg).

2. Press the Zoom down key to display the current developing biasPress the Zoom up key to return to the display of the current gr


(7) ROM Version

This function displays the ROM version. It is used when upgrading the F/W or the PWB is replaced with a n The version is displayed in the order of the copier controller and e The version consists of 12 digits, each being displayed sequentially

key (darker) (the digits flow in the left direction).1. Press the Start key to display the first 3 digits of the total 12.2. Press the image density key (darker). Then, the leftmost digit wi

instead, a new fourth digit will appear.Press the image density key (darker) a number of times to view tversion.

Pressing the image density key (lighter) will reverse the display of 3. Press the Zoom down key to display the version of the engine R

Follow the same steps as those given above. Pressing the Zoom up or down key selects the display of the RO

copier controller or engine. Press the Panel Reset key until the initial screen reappears.

(8) Administrator No. Input

Set an ID number for opening the Administrator Mode screen of 10-Key Pad.

1. Press the Start key to alternately display the current administrato2. Press the Clear key to clear the current administrator number.

3. Enter the new administrator number from the 10-Key Pad. The nof 6 digits, ranging from 000000 to 999999.

4 Press the Start key to validate the new administrator number just

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4. Press the Start key to validate the new administrator number just

(9) Change Fixed Zoom

Change a fixed zoom ratio to a desired value. The ratios of 50 %, 100 %, and 200 % cannot be changed.

1. Press the Start key to display the fixed zoom ratio.2. Press the Zoom key to select the specific zoom ratio to be chang3. Press the Clear key to clear the zoom ratio selected.4. Enter the new zoom ratio from the 10-Key Pad.5. Press the Start key to validate the new zoom ratio just entered.

If any value outside the allowable setting range is entered, the Di

rejecting the entry. (The old zoom ratio will reappear on the Disp

(10) Marketing Area Setting

Set the marketing area.1. Press the Start key to display the current marketing area setting.

2. Press the Clear key to clear the current marketing area setting va3. Enter the new setting value from the 10-Key Pad.4. Press the Start key to validate the setting value just entered.

Setting Description0 MSJ

1 MC

2 ME

3 China

4 Other areas

(11) Memory Clear

This function is used to clear all data except that of the various ele1. Press the Start key to display CLr on the Display.2. Press the Start key to blank out the Display.

Then, CLr will reappear.

3. Turn OFF and ON the Power Switch.

(12) Total Clear

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(12) Total Clear

This function is used to clear all data of the various electronic coun1. Press the Start key to display tCL on the Display.2. Press the Start key to blank out the Display.

Then, tCL will reappear.3. Turn OFF and ON the Power Switch.

(13) ADF Document Passage Test

This function is used to check for correct document passage throudocument misfeed occurs

: Cleared : Not cleared*1: Except Copy Track, Input Account, and Total Counter D*2: Except Marketing Area Setting and Serial No. Display.

DoorOpen/Close

MemoryClear

Jam display

Trouble display

Erratic operation/display

Utility (*1)

Tech.Rep.Mode (*2)

Security

Adjust

Job programs

Electronic counters

Clearing

Data Cleared

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4. SECURITY MODE

Allows the Tech. Rep. to set the various counters.

4-1. Settings in the Security Mode

Code No. Description--1 Total Counter Count Mode

2 Si C t C t M d

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4-2. Security Mode Setting Procedure1. Set the machine into the Tech. Rep. Mode.2. Press the following keys in this order:

Stop 9 (Display: SCU).3. Enter the code number corresponding to the subfunction to be us

Code No.: 1 to 4

4. Press the Start key to display the current setting value.5. Press the Clear key to clear the current setting value.6. Enter the new setting value from the 10-Key Pad.7. Press the Start key to validate the new setting value just entered

If any value outside the available setting range is entered, the Disrejecting the entry. (The old setting value will reappear on the Di


--2 Size Counter Count Mode

--3 Key Counter

--4 Total Counter

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5-3. Setting in the Adjust Mode


--1

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--2

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--8

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TROUBLESHOO

CONTENTS1. INTRODUCTION ....................................................................

1-1. Reading the Text ............................................................2. PAPER TRANSPORT FAILURE ............................................

2-1. Paper Misfeed Detection ................................................

(1) Outline ....................................................................2-2. Paper Misfeed .................................................................2-3. Misfeed Detection Sensor Layout ...................................2 4 T f Mi f d D i d D i Ti i

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2-4. Types of Misfeed Detection and Detection Timings .......3. MISFEED TROUBLESHOOTING PROCEDURES ................

3-1. Misfeed at Copier Paper Take-Up J01 and Misfeed at By3-2. Misfeed at Paper Feed Cabinet Paper Take-Up and

Transport Section J02, J03, J04, J05, J1 (PF-120) ........3-3. Misfeed at PC Drum J2 ...................................................3-4. Misfeed at Fusing Unit J3 ...............................................

4. MALFUNCTION ......................................................................4-1. Detection Timing by Malfunction Code ...........................4-2. Resetting Procedure by Malfunction Code .....................4-3. Troubleshooting Procedures by Malfunction Code .........

(1) C0000: Main Motor malfunction ..............................(2) C0045: Fusing Cooling Fan Motor malfunction ......(3) C004E: Power Supply Cooling Fan Motor malfuncti(4) C0070: Toner Replenishing Motor malfunction ......(5) C0210: Abnormal image transfer voltage ...............(6) C0500: Warm-up failure

C0510: Abnormally low fusing temperatureC0520: Abnormally high fusing temperature ..........(7) C0650: Faulty Scanner Home Position Sensor ......(8) C0B60: Bin Switching Motor malfunction ...............(9) C0B80 Shift Motor malfunction ...............................(10) C0F32: Faulty ATDC Sensor

C0F33: Improperly adjusted ATDC Sensor ............

(11) C1038: Engine connection failure ...........................(12) C1200: Faulty ASIC/memory ..................................(13) C1300: Polygon Motor malfunction (startup failure,

(3) Low image density ..................................................(4) Foggy background or rough image .........................(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 ................................

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( ) p(12) Periodically uneven image ......................................

6. OTHER ERROR CODES .......................................................

1. INTRODUCTION

1-1. Reading the Text

1. The paper transport failure troubleshooting procedures are givensymptom. First identify the location where the paper is present afor that particular location. For malfunction troubleshooting, start

onward.2. Make checks in the numerical order of steps and, if an item is ch

next step.

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Step Check Result

1 NO2

Step Check Result

1 YES

NO

2

Go to the nexYES.

Go to the nex

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LED No. Code Misfeed/Paper Location

2/3 J1 Misfeed on paper transport path between Pand PC12 (3rd Tray)

3/4 Misfeed on paper transport path between PC(3rd Tray) and PC12 (4th Tray)

4/5 Misfeed on paper transport path between PC(4th Tray) and PC12 (5th Tray)

7 J2 Misfeed at the PC Drum

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7 J3 Misfeed at the Fusing Unit

8 J80 Original misfeed: ADF Separator

J81 Original misfeed: ADF registration

J83 Original misfeed: ADF exit

1/7 J Paper left: PC1

7 Paper left: PC3

2 Paper left: 2nd Tray Paper Take-Up Sensor

3 Paper left: 3rd Tray Paper Take-Up Sensor

4 Paper left: 4th Tray Paper Take-Up Sensor5 Paper left: 5th Tray Paper Take-Up Sensor

8 Paper left: ADF

6 byp Paper left: Manual Bypass Tray

2-3. Misfeed Detection Sensor Layout

PC4*

PC3*

PC5*

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Copier

Paper Feed Cabinet (option)

Symbol Name

PC1 Synchronizing Roller Sensor

PC2 Manual Feed Paper Sensor

PC3 Exit Paper Sensor

Symbol Name

PC12* 2nd Tray Paper Take-Up Sensor

Paper Path

Misfeed Location Rese

Misfeed inthe copier

Misfeed at 1st Tray J01,misfeed at Multiple Bypass Tray J06,misfeed at Manual Bypass Tray J06,

misfeed at PC Drum J2,misfeed at Fusing Unit J3,paper left J - -

Open the Rthe 1st Tray,paper misfe

close the Ri

Paper wedged at Manual Bypass Tray byp Pull the pap

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Paper wedged at Manual Bypass Tray byp Pull the paptray. (Removreset the mis

Misfeed in the option:

J02, J03, J04, J05, J1, J80, J81, and J83

Remove all

feed and leftand lower oreconnect th

2-4. Types of Misfeed Detection and Detection T

The following list the types of misfeed detection and detection timifeed locations.

The symbol L (for the leading edge) and T (for the trailing edgethe particular edge of the paper detected by the sensor.

NOTE For the types of misfeed detection and detection timings of options

option service manual.

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Type Detection Start Pa

Misfeed at 1st TrayJ01

Paper Take-Up Solenoid (SL1)energized

Synchron(PC1) (L)

Misfeed at ManualBypass Tray J06

Manual Bypass Solenoid (SL2)energized

Synchron(PC1) (L)

Misfeed at MultipleBypass Tray J06

Multiple Bypass Solenoid (SL21)energized

Synchron(PC1) (L)


Misfeed at PC DrumJ2

Synchronizing Roller Sensor (PC1)(L)

Exit Pape

Synchronizing Roller Sensor (PC1)

(L)

Synchron

(PC1) (T)


Misfeed at FusingUnit J3

Synchronizing Roller Sensor (PC1)(T)

Exit Pape

3. MISFEED TROUBLESHOOTING PROC

3-1. Misfeed at Copier Paper Take-Up J01 and M

Tray J06

Relevant Electrical PartsSynchronizing Roller Sensor (PC1)Manual Feed Paper Sensor (PC2)Paper Take-Up Solenoid (SL1)

Manual Bypass SolenoMultiple Bypass SolenMaster Board (PWB-A

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CN26

Multiple Bypass

MANUAL BYPASS SECTION

DRAWER SECTION

TRANSPORT SECTION

Multiple

Bypass Solenoid

Manual FeedBypass Soleno

sm field di152 di183

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