Develop D1531iD Service Manual Download

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FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.03
01.04.23

P-1

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.

Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to
alert against unsafe practices.

• The following graphic symbols are used to give instructions that need to be observed.

Used to call the service technician’s attention to what is graphically represented
inside the marking (including a warning).

Used to prohibit the service technician’s from doing what is graphically repre-
sented inside the marking.

Used to instruct the service technician’s to do what is graphically represented
inside the marking.

1-1.

Warning

1. Always observe precautions.

2. Before starting the procedures, be sure to unplug the power cord.

WARNING

CAUTION

WARNING

• Parts requiring special attention in this product will include a label containing the

mark shown on the left plus precautionary notes. Be sure to observe the pre-
cautions.

• Be sure to observe the “Safety Information” given in the Operator’s Manual.

• This product contains a high-voltage unit and a circuit with a large current

capacity that may cause an electric shock or burn.

• The product also contains parts that can jerk suddenly and cause injury.
• If this product uses a laser, laser beam leakage may cause eye damage or

blindness.

Summary of Contents for D1531iD

Page 1: ... GENERAL FOR Di151 00 03 14 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 4007 7990 11 00051800 14413 SERVICE MANUAL GENERAL Di151 SERVICE MANUAL GENERAL D 1531iD D 1831iD ...

Page 2: ...FrameMaker Ver5 5E PC Di152 Di183 GENERAL 01 08 27 GENERAL 14413 ...

Page 3: ......

Page 4: ...TION G 5 2 1 Installation Site G 5 2 2 Power Source G 5 2 3 Grounding G 5 3 PRECAUTIONS FOR USE G 6 3 1 To ensure that the copier is used in an optimum condition G 6 3 2 Operating Environment G 6 3 3 Power Requirements G 6 3 4 Note G 6 4 HANDLING OF CONSUMABLES G 7 5 OTHER PRECAUTIONS G 8 6 SYSTEM OPTIONS G 9 ...

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Page 6: ...0 Sheets Mirror Scanning MT HG System Comb Electrode 1 DC Negative Corona with Scorotron System Roller Image Transfer Paper Separator Fingers and Charge Neutralizing Plate Heat Roller Charge Neutralizing Brush A3L 11 17 Paper Source Drawer Manual Bypass Type Plain Paper 60 to 90 g m2 Transparencies Thick Paper 91 to 157 g m2 Postcards Recycled Paper 60 to 90 g m2 Dimensions Maximum Width Length 29...

Page 7: ...wer Consumption full system Max Current Consumption full system 24 V 14 4 W 900 W 110 V 970 W 120 V 1090 W 127 V 1180 W 220 V 990 W 230 V 1050 W 240 V 1120 W 110 V 8 9 A 120 V 9 1 A 127 V 9 3 A 220 V 4 5 A 230 V 4 6 A 240 V 4 7 A POWER REQUIREMENTS 110 V 120 V 127 V 220 V to 240 V 50 60 Hz Temperature 10 to 30 C with a fluctuation of 10 C or less per hour Humidity 15 to 85 RH with a fluctuation of...

Page 8: ...s 20 sheets Recycled Paper 60 to 90 g m2 50 sheets Dimensions Maximum Width Length 297 432 mm Minimum Width Length 90 140 mm Size A3L B4L FLS A4L A4C B5L B5C A5C 11 17 11 14 8 1 2 14 8 1 2 11L 8 1 2 11C 8 1 2 5 1 2 DOCUMENT ALIGNMENT CAPACITY POWER REQUIREMENTS MAX POWER CONSUMPTION DIMENSIONS WEIGHT OPERATING ENVIRONMENT Center 50 sheets 80 g m2 DC24 V DC5 V supplied from copier 9 W or less W 245...

Page 9: ...sheets 10 sheets Thick Paper 91 to 157 g m2 Postcards Recycled Paper 60 to 90 g m2 150 sheets A4C L 75 sheets except A4C L Stacking height up to 22 mm 100 sheets A4C L 50 sheets except A4C L Dimensions Maximum Width Length 297 432 mm Minimum Width Length 90 140 mm 140 140 mm Application Mode Exit Tray of the machine Job Tray Fax and Copier Copier Fax Printer and Copier Copier Printer Fax Copier an...

Page 10: ...make sure that the capacity of the outlet is not exceeded Use a power source with little voltage fluctuation Never connect by means of a multiple socket any other appliances or machines to the outlet being used for the copier Ensure that the copier does not ride on the power cord or communication cable of other electrical equipment and that it does not become wedged into or underneath the mecha ni...

Page 11: ...ear the copier Do not place a vase or vessel containing water on the copier Be sure to turn OFF the power switch at the end of the workday or upon power failure Use care not to drop paper clips staples or other small pieces of metal into the copier 3 2 Operating Environment The operating environmental requirements of the copier are as follows Temperature 10 to 30 C Humidity 15 to 85 RH Rate of tem...

Page 12: ... children Do not touch the PC Drum with bare hands The same sized paper is of two kinds short grain and long grain Short grain paper should only be fed through the copier crosswise long grain paper should only be fed lengthwise If your hands become soiled with toner wash them with soap and water Do not throw away any used consumables PC Drum starter toner etc They are to be collected Do not burn b...

Page 13: ...ch as when working around the printerhead or PC Drum be sure first to unplug the power cord of the copier from the outlet If the job requires that the power cord be left plugged in observe the following precau tions 1 Take off your watch ring and any other reflective object and wear laser protective gog gles 2 Keep users away from the job site 3 Do not bring a highly reflective tool into the laser...

Page 14: ...M172AC 7 5 6 4 3 2 1 1 Plug In Counter 2 Original Cover OC 5 3 Automatic Document Feeder AF 10 4 Multiple Bypass MB 5 5 Copy Desk 6 Paper Feed Cabinet PF 120 7 Data Terminal DT 201 only for USA 8 Job Tray JS 202 Illustration none 9 Sifting Unit OT 103 Illustration none 10 Memory M16 4 M32 3 Illustration none 11 Mechanical Counter CNT1 Illustration none ...

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Page 16: ...FrameMaker Ver5 5E PC Di152 Di183 MECHANICAL ELECTRICAL 01 09 05 MECHANICAL ELECTRICAL 14413 ...

Page 17: ......

Page 18: ...l M 17 11 MEMORY STORAGE IMAGE PROCESSING SYSTEM M 18 11 1 Laser Exposure Process M 19 12 DEVELOPING UNIT SECTION M 20 12 1 Developing Unit Drive Mechanism M 21 12 2 Sleeve Magnet Roller M 22 12 3 Developing Bias M 22 12 4 ATDC Sensor M 23 1 ATDC Sensor Automatic Adjustment M 23 12 5 Toner Replenishing Mechanism M 24 12 6 Toner Replenishing Control M 25 12 7 T C Recovery Mode M 26 12 8 Toner Bottl...

Page 19: ...SE SECTION M 42 19 FUSING UNIT SECTION M 43 19 1 Fusing Unit Drive Mechanism M 44 19 2 Fusing Rollers Pressure Mechanism M 44 19 3 Fusing Temperature Control M 45 19 4 CPM Control M 45 20 JOB TRAY JS 202 Option M 46 20 1 Tray Selecting Mechanism M 47 20 2 Tray Full Detecting Mechanism M 48 20 3 Job Tray Paper Detecting Mechanism M 48 21 SHIFTING UNIT OT 103 Option M 49 21 1 Exit Position Shifting ...

Page 20: ...FrameMaker Ver5 5E PC Di152 Di183 MECHANICAL ELECTRICAL 01 09 05 M 1 1 CROSS SECTIONAL VIEW 1 IR Section 2 Fusing Unit 3 Imaging Unit 4 Paper Take Up Feed Section 5 PH Section 2 1 3 4 5 4021M001AA ...

Page 21: ...ough appropriate correction before being output to the PH Image Pro cessing 5 PH Image Processing After going through corrections the digital image signal is converted to a corresponding electrical signal D A conversion that controls the intensity of the light from the laser diode 6 Laser Exposure The laser beam strikes the surface of the PC Drum forming an electrostatic latent image 7 Developing ...

Page 22: ... on the paper 12 Cleaning Residual toner on the surface of the PC Drum is scraped off The toner is then recycled back to the Developing Unit 13 Main Erase Light is directed to the surface of the PC Drum to neutralize any surface potential remain ing there after cleaning 14 Paper Transport The paper is fed to the Fusing Unit 15 Fusing The developed image is permanently fused to the paper by a combi...

Page 23: ...i183 MECHANICAL ELECTRICAL 01 09 05 M 4 3 DRIVE SYSTEM 1 Scanner Motor M5 2 Main Motor M1 4021M003AA 1 2 Paper Exit Roller Gear Transport Roller Gear Fusing Roller Gear PC Drum Synchronizing Roller Clutch Paper Take Up Roller Gear ...

Page 24: ...Motor M1 Paper Take Up Solenoid SL1 Synchronizing Roller Sensor PC1 Synchronizing Roller Clutch CL1 Developing Bias VB DC Developing Bias VB AC Image Transfer Bias Image Transfer Bias Exit Paper Sensor PC3 Power Supply Cooling Fan Motor M4 Full speed Speed reduction Full speed Speed reduction Fusing Cooling Fan Motor M3 150 C Warm up completed Predrive 4021M510CA ...

Page 25: ...lly resets the CPU thereby restarting the logic circuit and mechanism 5 1 Watchdog Function Post Processing The following processing is performed if a faulty condition is detected in the CPU When the copier CPU is found faulty All CPUs are reset and the system is restarted If the CPU is found faulty during a copy cycle the system attempts to feed all sheets of paper out of the copier before restar...

Page 26: ...control voltage is varied to bring Vg Vb to an appropriate level according to the following settings Tech Rep Choice ID Adjustment Tech Rep Choice VG Adjustment User s Choice Print Density IU Life Counter Paper type To stabilize image transfer Image transfer output control The image transfer output is varied to bring the image transfer current to an appropriate level according to the following con...

Page 27: ...RICAL 01 09 05 M 8 7 IMAGING UNIT I U The IU integrates the PC Drum Developing Unit PC Drum Charge Corona and the PC Drum Cleaning Mechanism all in one body 4021M006AB 4021M007AB PC Drum Developing Unit PC Drum Cleaning Mechanism PC Drum Charge Corona ...

Page 28: ...TRICAL 01 09 05 M 9 7 1 Imaging Unit IU Drive Mechanism The IU is driven by the Main Motor Elevtrical Component Control Signal Forward Rotation Backward Rotation OFF Wiring Diagram M1 PWB A PJ7A 5 L L H 17 G PWB A PJ7A 7 H L H Main Motor M1 4021M008AB ...

Page 29: ...on which an electrostatic latent image is formed 8 1 PC Drum Drive Mechanism The PC Drum is rotated by drive from a motor Elevtrical Component Control Signal Forward Rotation OFF Wiring Diagram M1 PWB A PJ7A 5 L H 17 G PWB A PJ7A 7 H H 1139M007AA PC Drum Aluminum Base Charge Generation Layer Charge Transport Layer PC Drum Cross Section 1167M007AA Main Motor M1 4021M009AA PC Drum ...

Page 30: ...er5 5E PC Di152 Di183 MECHANICAL ELECTRICAL 01 09 05 M 11 8 2 Grounding of the PC Drum The potential on the surface of the PC Drum exposed to the light is grounded to the frame 4021M010AA Frame PC Drum Ground Plate ...

Page 31: ...has a scorotron grid to deposit a charge evenly across the surface of the PC Drum The corona unit has a comb electrode that discharges only toward the grid mesh thus minimizing the amount of ozone produced Elevtrical Component Control Signal ON OFF Wiring Diagram HV1 PWB A PJ8A 8 L H 5 C 4021M011AA Comb Electrobe Grid Mesh ...

Page 32: ...152 Di183 MECHANICAL ELECTRICAL 01 09 05 M 13 10 IMAGE READING SECTION 1 Scanner Motor M5 2 CCD Board PWB J 3 Size Reset Switch S10 4 Scanner 5 2nd 3rd Mirrors Carriage 6 Scanner Home Position Sensor PC6 4021M012AB 5 6 1 2 3 4 ...

Page 33: ...rrected that occurs due to variations in sensitivity of each CCD chip and the light distribution varying along the length of the Exposure Lamp The data obtained through actually illuminating the shading sheet with the Exposure Lamp is compared with the shading sheet reading reference value white max data value to make the necessary correction 4 Zoom Processing The synchronous timing of the input d...

Page 34: ...he binding generally fails to come flush against the glass so that the copy of these areas is gener ally too dark The Auxiliary Reflector reduces this problem by reflecting light from the Exposure Lamp onto these areas of the original 2 Exposure Lamp LA2 A fluorescent lamp is used to illuminate the original 3 1st Mirror Directs the light reflected off the original to the 2nd Mirror 4021M013AA 3 1 ...

Page 35: ...ment Mechanism The Scanner is driven by the Scanner Motor 2 2nd 3rd Mirrors Carriage Movement Mechanism The 2nd 3rd Mirrors Carriage moves at a speed half that of the Scanner thereby keeping constant the optical path length between the original and the CCD Board 4021M014AB Scanner Motor M5 Scanner 2nd 3rd Mirrors Carriage CCD Board PWB J ...

Page 36: ...d by varying the period of the motor drive pulse that is timed with the reference clock The distance over which the Scanner travels is controlled by the number of motor drive pulses that correspond to each paper size and zoom ratio Elevtrical Component Control Signal ON OFF Wiring Diagram M5 PWB C JP5C 1 to 4 Pulse output 11 B High Speed Low Speed Period ...

Page 37: ...MECHANICAL ELECTRICAL 01 09 05 M 18 11 MEMORY STORAGE IMAGE PROCESSING SYSTEM Based on the image data output from the IR a laser light is projected onto the surface of the PC Drum to form a corresponding latent image 4021M015AA PH Unit ...

Page 38: ...gnal determines the laser emission timing for each main scanning line 5 The surface of the PC Drum is illuminated by the laser beam corresponding to the image data which forms an electrostatic latent image Elevtrical Component Control Signal ON OFF Wiring Diagram M2 PWB A PJ13A 3 L H 8 D 4021M016AA PC Drum SOS Mirror SOS Board LD Board PWB B Polygon Motor M2 PC Drum SOS Sensor SOS Signal SOS Mirro...

Page 39: ... changing the image to a visible developed one 1 Spent Toner Recycling Coil 2 PC Drum Charge Corona 3 Spent Toner Conveying Screw 2 4 Cleaning Blade 5 Spent Toner Conveying Screw 1 6 PC Drum Paper Separator Finger 7 PC Drum Protective Shutter 8 PC Drum 9 Sleeve Magnet Roller 10 1st Toner Conveying Roller 11 ATDC Sensor UN1 12 2nd Toner Conveying Roller 13 3rd Toner Conveying Roller 14 Spent Toner ...

Page 40: ...nism The rollers are driven through a gear train from the motor Elevtrical Component Control Signal Forward Rotation OFF Wiring Diagram M1 PWB A PJ7A 5 L H 17 G PWB A PJ7A 7 H H 4021M008AB Sleeve Magnet Roller 3rd Toner Conveying Roller 1st Toner Conveying Roller 2nd Toner Conveying Roller Main Motor M1 ...

Page 41: ...Roller Vb DC is applied to prevent toner from sticking to the background of the image Vb AC is applied to enhance good separation of toner from carrier The amount of toner sticking to the surface of the PC Drum is varied according to the dif ference in potential between the voltage Vi on the surface of the PC Drum and Vb DC Large difference A greater amount of toner sticks Small difference A small...

Page 42: ...AA 2nd Toner Conveying Roller ATDC Sensor UN1 With the copier set in the ATDC Sensor Automatic Adjustment mode press the Start key The developer is mixed The ATDC Sensor converts the reference T C 14 to a corresponding voltage value and outputs it Does the output voltage fall within the range from 2 36 to 2 44 V YES NO The voltage input to the ATDC Sensor from the Master Board at this time is fixe...

Page 43: ...there is a Metering Chamber provided in the outer race of the coupling 3 When the Toner Bottle turns toner in the Metering Chamber drops 4 Toner from the metering chamber is conveyed by the Toner Conveying Screw into the Developer Mixing Chamber 5 The Toner Conveying Screw is turned by the motor Elevtrical Component Control Signal ON OFF Wiring Diagram M6 PWB A PJ19A 6 L H 4 B 4021M020AB 4021M021A...

Page 44: ... C is less than 14 toner replenishing is determined according to the B W value Toner is replenished until T C becomes 14 The greater the value of B W in the table the higher the B W ratio high image density original T C ratio B W ratio toner replenishing More than 14 not supply 13 5 to 14 More than 2000 supply 13 to 13 5 More than 1000 supply 12 5 to 13 More than 500 supply 12 to 12 5 More than 50...

Page 45: ...eplenished for 30 sec to complete the A toner empty condition is detected T C recovery mode T C is less than 8 A toner empty stop condition results and the initiation of any new copy cycle is prohibited A toner empty condition is reset when the Front Cover is opened and closed after a T C of 10 or more is detected with the supply of toner replenished A toner empty stop condition is reset when the ...

Page 46: ...hanism The Toner Bottle is at its home position where it remains stationary when its Toner Sup ply Port faces up This position is detected by a sensor Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC7 PWB A PJ19A 10 L H 4 B 4021M024AA Toner Supply Port Toner Bottle Home Position Sensor PC7 ...

Page 47: ...HANICAL ELECTRICAL 01 09 05 M 28 13 PAPER TAKE UP FEED SECTION 1 Paper Size Detecting Board PWB I 2 Paper Size Detecting Sensor S11 3 Paper Empty Sensor PC4 4 Paper Take Up Roll 5 Separator Roll 6 Paper Lifting Plate 4021M025AA 4 5 6 3 2 1 ...

Page 48: ... that the drawer has been slid in position 13 2 Paper Empty Detection Mechanism The Paper Empty Sensor detects a paper empty condition in the drawer Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC5 PWB A PJ15A 10 L H 1 I Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC4 PWB A PJ6A 6 L H 1 I 4021M026AA Drawer Set Sensor PC5 1167M073AD Paper Emp...

Page 49: ...in the feeding direction of the paper are detected and the copier CPU determines the paper size based on the combi nation of the two readings The width CD of the paper is detected when the lever that is operatively connected to the Edge Guide activates or deactivates the Paper Size CD Detection Sensor The length FD of the paper is detected when the lever that is operatively connected to the Traili...

Page 50: ... 2 L ON ON Activated A4C 8 1 2 11 C ON A5C 5 1 2 8 1 2 C ON ON ON A5L 5 1 2 8 1 2 L ON ON ON Activated A4C 8 1 2 11 C ON FLS ON ON FLS ON ON ON ON A4L 8 1 2 11 L Elevtrical Component Control Signal ON OFF Wiring Diagram PWB I SW1 PWB A PJ15A 1 L H 2 H PWB I SW2 PWB A PJ15A 2 L H PWB I SW3 PWB A PJ15A 3 L H PWB I SW4 PWB A PJ15A 4 L H Elevtrical Component Control Signal Activated Deactivated Wiring...

Page 51: ...nt of friction on the front side of the sheet of paper taken up and fed through the space between the Paper Take Up Roll and Separator Roll is the same as that on the backside of the sheet of paper allowing the paper to be properly fed into the machine When two or more sheets of paper are taken up The coefficient of friction between the paper and the Separator Roll is greater than that between the...

Page 52: ...peated a given number of times Elevtrical Component Control Signal Forward Rotation OFF Wiring Diagram M1 PWB A PJ7A 5 L H 17 G PWB A PJ7A 7 H H Elevtrical Component Control Signal ON OFF Wiring Diagram SL1 PWB A PJ5A 2 L H 1 I Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC1 PWB A PJ6A 3 L H 1 F No of Paper Take Up Retry Sequences Paper Take Up Retry 2 ON OFF Start Key...

Page 53: ...ake up from the Manual Bypass is transmitted from a motor via the Sole noid 14 2 Paper Detection Mechanism The Sensor detects a sheet of paper on the Manual Bypass 4021M028AA Main Motor M1 Manual Bypass Solenoid SL2 Manual Feed Paper Sensor PC2 4021M029AA 4021M061AA When Paper is not Present When Paper is Present Manual Feed Paper Sensor PC2 Paper ...

Page 54: ... PWB A PJ7A 5 L H 17 G PWB A PJ7A 7 H H Elevtrical Component Control Signal ON OFF Wiring Diagram SL2 PWB A PJ4A 2 L H 1 B Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC2 PWB A PJ4A 5 L H 1 A H L Paper Set Paper drawing in sequence completed Start Key ON ON OFF ON OFF Manual Bypass Solenoid SL2 Manual Feed Paper Sensor PC2 Main Motor M1 4021M511CA ...

Page 55: ...hanism Drive for paper take up from the Multiple Bypass is transmitted from a motor via the Sole noid 1 Paper Take Up Roll 2 Multiple Bypass Solenoid SL21 3 Multiple Bypass Paper Empty Sensor PC21 4021M031AA 1 3 2 4021M032AA Main Motor M1 Paper Take Up Roll Multiple Bypass Solenoid SL21 Multiple Bypass Paper Empty Sensor PC21 ...

Page 56: ... is accomplished when the drive from the motor is transmitted to the cam through a solenoid to rotate the cam 4021M033AA Drive from Main Motor Paper Take Up Roll Multiple Bypass Solenoid SL21 Cam Ascent Descent Motion Main Motor M1 is energized Paper Take Up Roll is turned Multiple Bypass Solenoid SL21 Energized Cam Rotates Tray Raised Multiple Bypass Solenoid SL21 Deenergized Paper take up Multip...

Page 57: ...M1 PWB A PJ7A 5 L H 17 G PWB A PJ7A 7 H H Elevtrical Component Control Signal ON OFF Wiring Diagram SL21 PWB A PJ4A 2 L H 17 F Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC21 PWB A PJ4A 5 L H 17 F 4021M034AA When Paper is not Present When Paper is Present 4021M035AA Multiple Bypass Paper Empty Sensor PC21 Paper H L Paper Set Start Key ON ON OFF ON OFF Multiple Bypass ...

Page 58: ... reach the Synchronizing Roller Sensor within a given period of time after the sequence has been started The paper take up sequence is then performed again These paper take up sequences are repeated a given number of times No of Paper Take Up Retry Sequences Paper Take Up Retry 2 ON OFF Multiple Bypass Solenoid SL21 H L Synchronizing Roller Sensor PC1 1st Paper Take Up Retry Sequence Successful pa...

Page 59: ...the amount of charge A negative charge is applied to the Image Transfer Roller to return toner sticking to the Image Transfer Roller to the PC Drum It is performed in the following timings A copy cycle is started and completed The Power Switch is turned ON A misfeed or a malfunction is reset Paper Separation The PC Drum Paper Separator Fingers mechanically separate paper from the surface of the PC...

Page 60: ...aning Blade the PC Drum is turned backward by turning the Main Motor backward when the cumulative time through which the PC Drum has turned reaches a predetermined value When the PC Drum is turned backward a backlash in gears prevents drive from being transmitted to other drive mechanisms Cumulative Time Through Which PC Drum Has Been Driven PC Drum Backward Rotation Time Approx 330 sec 50 ms 4021...

Page 61: ...voltage applied by the Charge Neutralizing Sheet A negative charge is applied to the Charge Neutralizing Sheet to neutralize a positive charge on the surface of the PC Drum The Main Erase then illuminates the surface of the PC Drum to neutralize the charge left on it Elevtrical Component Control Signal ON OFF Wiring Diagram LA1 PWB A PJ7A 12 L H 4 A 4021M040AA Main Erase LA1 Charge Neutralizing Sh...

Page 62: ... developed image to the paper by applying heat and pressure to the toner and paper 1 Paper Exit Roller 2 Transport Roller 3 Fusing Paper Separator Finger 4 Exit Paper Sensor PC3 5 Right Fusing Roller 6 Pressure Spring 7 Fusing Heater Lamp H1 8 Thermistor TH1 9 Thermoswitch TS1 10 Left Fusing Roller 4021M041AD 2 4 1 3 5 10 9 8 7 6 ...

Page 63: ... Rollers Pressure Mechanism To ensure that there is a certain width of area of contact between the Right and Left Fus ing Rollers a pressure spring is used to press the Lower Fusing Roller up against the Upper Fusing Roller 4021M042AA Main Motor M1 Right Fusing Roller Left Fusing Roller 4021M043AA Right Fusing Roller Left Fusing Roller Pressure Spring ...

Page 64: ... cumulative number of copies made through continuous copy cycles exceeds 30 the paper take up interval is made longer thereby allowing the temperatures of the Fusing Rollers at different spots to be uniform Continuous copy cycle Continuous copy cycles run with an interval of 2 min or less between cycles Machine Condition or Paper Type Mode 1 Mode 2 Mode 3 Standby 180 C 180 C 170 C 170 C Plain pape...

Page 65: ... M 46 20 JOB TRAY JS 202 Option 1 Job Tray 2 Main Board PWB A 3 Paper Empty Sensor PC35 4 Full Detecting Sensor PC34 5 Upper Home Position Sensor PC32 6 Lower Home Position Sensor PC33 7 Paper Detecting Board PWB B 8 Bin Switching Motor M1 4021M045AC 2 3 4 5 6 7 8 1 ...

Page 66: ...cted by a motor and a sensor Elevtrical Component Control Signal ON OFF Wiring Diagram M1 PWB A PJ2A 1 to 4 Pulse output 16 A Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC32 PWB A PJ4A 3 L H 16 B PC33 PWB A PJ4A 6 L H When feeding paper into the Exit Tray Copier When feeding paper into the Job Tray fax printer 4021M047AB 4021M046AB Upper Home Sensor PC32 Activated Bin...

Page 67: ...per is fed into the Exit Tray Job Tray in the raise position the indicator lamp on the Paper Detecting Board lights to warn the user that there is paper in the Job Tray A sensor is provided for detecting paper in the Job Tray Elevtrical Component Control Signal Activated Deactivated Wiring Diagram PC34 PWB A PJ4A 9 L H 16 C Elevtrical Component Control Signal Activated Deactivated Wiring Diagram P...

Page 68: ...FrameMaker Ver5 5E PC Di152 Di183 MECHANICAL ELECTRICAL 01 09 05 M 49 21 SHIFTING UNIT OT 103 Option 1 Main Board PWB A 2 Home Sensor S31 3 Shift Motor M1 4021M053AB 1 2 3 ...

Page 69: ...along a straight path is fed straight into the Shifting Unit without being shifted sideways as the Exit Roller turns Shifted Feeding When the trailing edge of the paper transported to the exit section moves past the Fusing Roller the Shift Motor is energized to move the Transport Roller sideways The paper is fed into the Shifting Unit as it is shifted sideways The Exit Roller is moved sideways by ...

Page 70: ...CTRICAL 01 09 05 M 51 Elevtrical Component Control Signal Forward Rotation Backward Rotation OFF Wiring Diagram M1 PWB A PJ2A 1 to 4 Pulse output 16 C Elevtrical Component Control Signal Activated Deactivated Wiring Diagram S31 PWB A PJ3A 3 L H 17 D ...

Page 71: ...nit to the outside to prevent the Power Supply Unit temperature from running high The cooling fan motor is turned at full speed when the Main Motor turns and at a speed reduction during other timings thereby making the machine quieter without sacrificing cooling performance Elevtrical Component Control Signal ON OFF Wiring Diagram M4 PWB A PJ19A 1 analog voltage output H 11 I 4021M057AA Power Supp...

Page 72: ...suction force to help stabilize paper transport Ozone produced from the PC Drum Charge Corona is absorbed by the Ozone Filter from the air drawn by a fan motor to the outside The fan motor is turned at full speed during a print cycle and at a speed reduction during other timings thereby making the machine quieter without sacrificing cooling perfor mance Elevtrical Component Control Signal ON OFF W...

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Page 74: ...he service technician s attention to what is graphically represented inside the marking including a warning Used to prohibit the service technician s from doing what is graphically repre sented inside the marking Used to instruct the service technician s to do what is graphically represented inside the marking 1 1 Warning 1 Always observe precautions 2 Before starting the procedures be sure to unp...

Page 75: ...ng 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 con nected Be sure the power outlet meets or exceeds the specified capacity A part marked with the symbol shown on the left carries a high voltage Touch ing it could result in an electric shock or burn Be s...

Page 76: ...ing or grounding and result in a mal function electric shock or injury Take great care to avoid personal injury from possible burrs and sharp edges on the parts frames and chassis of the product When moving the product or removing an option use care not to injure your back or allow your hands to be caught in mechanisms Wherever feasible keep all parts and covers mounted when energizing the product...

Page 77: ...period of time Avoid dusty locations and places exposed to oil or steam Avoid working positions that may block the ventilation ports of the product Replace a rundown battery with the same type as specified in the manufac turer s parts manual Before installing a new battery make sure of the correct polarity of the installa tion or the battery could burst Dispose of used batteries according to the l...

Page 78: ... recom mandé par le constructeur Mettre au rebut les batteries usagées conformément aux instructions du fabricant Denmark ADVARSEL Lithiumbatteri Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med batteri af samme fabrikat og type Levér det brugte batteri tilbage til leverandøren Finland Sweden VAROlTUS Paristo voi räjähtää jos se on virheellisesti asennettu Vaihda paristo ainoast...

Page 79: ...nly instructs you to replace the whole PWB or functional unit and does not give trou bleshooting procedures applicable within the defective unit All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions The procedures preclude possible malfunctions due to noise and other external causes 3 Preca...

Page 80: ...Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed While the product is energized do not unplug or plug connectors into the circuit boards or harnesses Never use flammable sprays near the copier A used battery should be disposed of according to the local regulations and never be dis carded casually or left unattended at the user s pre...

Page 81: ...Avoid checking the IC directly with a multimeter use connectors on the Board Never create a closed circuit across IC pins with a metal tool Before unplugging connectors from the P W Boards make sure that the power cord has been unplugged from the outlet When removing a Board from its conductive bag or conductive case do not touch the pins of the ICs or the printed pattern Place it in position by h...

Page 82: ...scratch the surface of the PC Drum Do not apply chemicals to the surface of the PC Drum Do not attempt to wipe clean the surface of the PC Drum If however the surface is contaminated with fingerprints clean it using the following proce dure A Place the PC Drum into one half of its carton 1076D001 B Gently wipe the residual toner off the surface of the PC Drum with a dry Dust Free Cotton Pad Turn t...

Page 83: ...t Precautionary Information on the PC Drum Inside the Imaging Cartridge Use care not to contaminate the surface of the PC Drum with oil base solvent finger prints and other foreign matter Do not scratch the surface of the PC Drum Do not attempt to wipe clean the surface of the PC Drum C Soak a small amount of either ethyl alcohol or iso propyl alcohol into a clean unused Dust Free Cot ton Pad whic...

Page 84: ...FrameMaker Ver5 5E PC Di152 Di183 DIS REASSEMBLY ADJUSTMENT 01 09 03 DIS REASSEMBLY ADJUSTMENT 10230 ...

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Page 86: ... 3 3 MAINTENANCE SCHEDULE D 16 3 4 PAPER TAKE UP TRANSPORT SECTION D 18 1 Removal of the Paper Separator Roll Assy and Paper Take Up Roll D 18 2 Cleaning of the Paper Separator Roll D 18 3 Cleaning of the Paper Take Up Roll D 18 4 Cleaning of the Right and Left Synchronizing Rollers D 19 5 Removal of the Paper Dust Remover Assy D 19 6 Cleaning of the Paper Dust Remover D 20 7 Cleaning of the Bypas...

Page 87: ...MENT D 51 4 1 ADJUSTMENT JIGS AND TOOLS USED D 51 4 2 TIMING BELT TENSION ADJUSTMENT D 51 4 3 ACCESSING THE FUNCTION TECH REP CHOICE AND ADJUST MODE D 52 1 Function Mode D 52 2 Tech Rep Choice Mode D 52 3 Adjust Mode D 52 4 4 ELECTRICAL IMAGE ADJUSTMENT D 53 1 Edge Erase Adjustment Leading Trailing and Top Bottom Edges D 53 2 Loop Length Adjustment 1st and 2nd Trays Bypass Tray D 54 3 Printer CD R...

Page 88: ...ker Ver5 5E PC Di152 Di183 DIS REASSEMBLY ADJUSTMENT 01 09 03 iii 1 Remounting the EEPROM U29 D 68 2 Installation of the Plug In Counter Socket Option D 69 3 Installation of the Mechanical Counter Option D 70 ...

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Page 90: ...ION Laser Aperture of the Print Head Unit This product employs a Class 3b laser diode that emits an invisible laser beam The laser diode and the scanning polygon mirror are incorporated in the print head unit The print head unit is NOT A FIELD SERVICE ITEM Therefore the print head unit should not be opened under any circumstances Semiconductor laser Maximum average radiation power 26 4 µW Waveleng...

Page 91: ... the CDRH regulations and must be attached to laser products marketed in the United States All Areas Denmark CAUTION Use of controls adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure Semiconductor laser Maximum power of the laser diode 5 mW Wavelength 770 795 nm CAUTION Use of controls adjustments or performance of procedu...

Page 92: ...in suurin teho 5 mW Aallonpituus 770 795 nm VARNING Om apparaten används på annat sätt än i denna bruksanvisning specificerats kan använ daren utsättas för osynlig laserstrålning som överskrider gränsen för laserklass 1 Halvledarlaser Den maximala effekten för laserdioden 5 mW Våglängden 770 795 nm VARNING Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad Betrakta ej strålen ...

Page 93: ...be used select ones with a lens conforming to the above specifications When a disassembly job needs to be performed in the laser beam path such as when working around the printerhead and PC Drum be sure first to turn the copier OFF If the job requires that the copier be left ON take off your watch and ring and wear laser protective goggles A highly reflective tool can be dangerous if it is brought...

Page 94: ...Di152 Di183 01 09 03 D 5 2 SERVICE INSTRUCTIONS 2 1 IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS 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 4022D028AA Thermoswitch 1 TS1 250 V 7 5 A 125 V 15 A ...

Page 95: ...omes unavoidably necessary to disassemble any of these assemblies and units disassembly may be done provided that the conditions permitting reassembly are met Note also that when two or more screws are used on the part in question only one repre sentative screw may be marked with red paint 2 Variable Resistors on Board Do not turn the variable resistors on boards for which no adjusting instruction...

Page 96: ... Ver 5 5E PC DIS REASSEMBLY ADJUSTMENT FOR Di152 Di183 01 09 03 D 7 3 DISASSEMBLY REASSEMBLY 3 1 DOORS COVERS AND EXTERIOR PARTS IDENTIFICATION AND REMOVAL PROCEDURES 1 2 3 4 5 6 7 9 10 11 12 13 14 16 17 18 15 8 ...

Page 97: ...t 8 Left Cover Remove no 3 Remove no 5 Remove no 14 Remove five Left Cover mounting screws 9 Upper Cover Remove no 3 Remove no 5 Remove no 14 Remove no 8 Remove two screws and two Upper Cover mounting screws 10 Rear Inside Cover Remove no 3 Remove no 5 Remove no 14 Remove no 8 Remove no 9 Remove no 4 Remove two Rear Inside Cover mounting screws 11 ADF Glass Remove two ADF Glass mounting screws 12 ...

Page 98: ...ow 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 PWB J PU3 PWB R2 PU1 HV1 PWB I PWB A PU2 PWB C PWB R1 PWB A Job Tray JS 202 Option Shifting Unit ...

Page 99: ... Assy Remove two screws and the PWB I Assy PWB I PWB J CCD Board D 23 Remove the CCD Unit as a unit PWB R1 Fusing Board Remove the Fusing Unit PWB R1 PWB R2 Pre Image Transfer Board Open the Right Door PWB R2 PU1 DC Power Supply D 13 PU2 Inverter Board D 23 PU3 Control Panel Remove two control panel mounting screws Remove two ground wire mounting screws Remove one flat cable and unplug one connect...

Page 100: ...r Cover Left Cover Upper Cover Right Inside Cover and Rear Inside Cover 2 Remove the PWB Cover Assy 3 Unplug all connectors from the Master Board except for PJ20 and from the Control Board 4 Remove the harness from seven wiring saddles and two edge covers 3 Unplug all connectors but PJ20 from the Master Board 4 Remove four screws and the Master Board 3 Unplug all connectors from the Control Board ...

Page 101: ...1 09 03 D 12 7 Remove ten screws and the PWB Assy 5 Unplug three connectors from the High Voltage Unit and remove the harness from one wiring saddle 6 Remove the harness from one wiring saddle 8 Remove the harness from one wiring saddle of the High Voltage Unit cover ...

Page 102: ...Upper Cover 9 Remove nine screws and the High Voltage Unit cover 10 Unplug two connectors from the High Voltage Unit 11 Remove two screws and the High Voltage Unit 2 Unplug two connectors of the Hopper Assy 3 Remove two Hopper mounting screws on the right 4 Remove two Hopper mounting screws on the left and the Hopper Assy 5 Remove three screws and the Power Supply Right Cover ...

Page 103: ...the Power Supply Left Cover 7 Unplug one connector and remove the harness from one edge cover 8 Unplug one connector and remove the harness from one wiring saddle 9 Unplug one connector and remove the harness from one wiring saddle 10 Unplug three connectors and remove the har ness from two wiring saddles ...

Page 104: ...FrameMaker Ver 5 5E PC DIS REASSEMBLY ADJUSTMENT FOR Di152 Di183 01 09 03 D 15 11 Remove two screws 12 Remove two screws 13 Remove four screws and the DC Power Supply ...

Page 105: ...s Separator Roll Assy Multiple Bypass 150 4658 0151 XX 1 D 42 Double feed Paper Dust Remover Assy 1 40 4021 0151 XX 1 D 19 IU Life Failure to remove toner off completely filming Right Synchronizing Roller D 19 Dirty image Left Synchronizing Roller D 19 Dirty image Bypass Transport Roller D 20 Paper misfeed Optical Section Mirrors and lens 80 D 21 IR Scanner rails bushings 80 D 22 Original Glass 80...

Page 106: ... separated from PC Drum Fusing Section Fusing Unit 100 V system 150 4021 0321 XX 1 D 37 Image Trans fer Roller Fusing Unit 200 V system 150 4021 0322 XX 1 D 37 1 Replace at 40K for recommended plain paper Clean when the Paper Dust Remover is full of paper dust for paper of other types 2 The life of the Imaging Unit except for the Ozone Filter is determined by the period of time through which the P...

Page 107: ...l Assy 3 Press down the Paper Lifting Plate 4 Snap off one C clip from the Paper Take Up Roll Assy 5 Slide the Paper Take Up Roll Assy to the rear so that it can be pulled off the bushing at the front 6 Snap off one C clip and remove the Paper Take Up Roll 1 Remove the Paper Separator Roll Assy 2 Using a soft cloth dampened with alcohol wipe the Paper Separator Roll clean of dirt 1 Slide out the 1...

Page 108: ...he 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 dampened with alcohol wipe the Right and Left Synchronizing Rollers clean of dirt 2 Remove two screws and the stopper 3 Remove the 1st Tray 5 Remove three screws and the Paper Dust Remover Assy ...

Page 109: ...ve the Imaging Unit 2 Remove two screws unplug one connector and remove the Bypass Transport Roller Assy 1 Remove the Paper Dust Remover Assy 2 Using a brush whisk dust and dirt off the Paper Dust Remover 3 Using a soft cloth dampened with alcohol wipe the Bypass Transport Roller clean of dirt 4 Using a soft cloth dampened with alcohol wipe the rolls clean of dirt ...

Page 110: ...ass 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 dampened with alcohol wipe the Original Glass and ADF Glass clean of dirt 1 Remove the Original Glass 2 Using a soft cloth dampened with alcohol wipe the mirrors clean of dirt ...

Page 111: ...r Rails Bushings 3 Using a soft cloth dampened with alcohol wipe the Lens clean of dirt 3 Remove the Lens cover 4 Using a soft cloth dampened with alcohol wipe the CCD Sensor clean of dirt 1 Remove the Original Glass 2 Using a soft cloth dampened with alcohol wipe the Scanner rails bushings clean of dirt NOTE After the Scanner rails bushings have been cleaned apply oil copier lubricant A or FLOIL ...

Page 112: ...foam seal and mylar one each at the front and rear NOTE Ready a new foam seal and mylar and affix them after the procedure 3 Unplug one connector 4 Remove three screws and the CCD Unit NOTE NEVER attempt to loosen or remove screws that are not specified when removing the CCD Unit Reinstallation of the CCD Unit Temporarily secure the CCD Unit with each of the screws at the center of each slot After...

Page 113: ...mounting screws to which no red paint has been applied 4 Remove one screw and the cable holder 5 Remove the flat cable from the Inverter Board and then remove the Scanner 6 Unplug one connector from the Inverter Board 7 Remove two screws and the Inverter Board 8 Remove two screws and the Exposure Lamp ...

Page 114: ...ar Cover Left Cover Right Cover Original Glass and ADF Glass 2 Remove the Scanner NOTE Remove the two red painted screws to remove the Scanner in this step 3 Remove two screws and the Exposure Lamp 4 Loosen three screws to free the Scanner Motor Assy 5 Unhook the spring from the cable hooks at the front and rear 6 Remove the front cable from the cable pulley ...

Page 115: ... D 26 7 Remove the rear cable from the cable pulley 8 Snap off one C ring from the front side of the pul ley assy 9 Snap off one C ring from the rear side of the pul ley assy 10 Remove the belt and the pulley assy 11 Remove two screws and the pulley 12 Remove the rear cable ...

Page 116: ...ront cable pulley of the pulley assy from side A toward side B and then secure the cable with tape NOTE Make sure that no part of the cable rides on the other Rear Front 4022D003AA Bead Position Rear Front Bead Position Winding Direction on Side B A B Winding Direction on Side A A B Winding Direction on Side B Winding Direction on Side A 3 Secure the pulley to the rear cable pulley using two screw...

Page 117: ...and hook the spring onto the frame 7 Wind the cable in the rear 8 Secure the cables at the front and rear with a spring 4 Mount the pulley assy using two C rings 4022D006AB 4022D007AB 4022D008AB 9 Temporarily secure the Scanner to the front and rear cables 10 Perform the Focus Positioning of the Scanner and 2nd 3rd Mirrors Carriage D 64 4022D009AA ...

Page 118: ... of the PH Window 1 Remove the Front Cover Rear Cover Left Cover and Upper Cover 3 Remove one flexible harness and unplug one connector from the Master Board 4 Remove the harness from one edge cover and one wiring saddle 5 Remove one screw and the ground wire NOTE To remove the ground wire remove the screw installed on the copier side 6 Remove three screws and the PH Unit 2 Wipe the PH window clea...

Page 119: ...oping Assy 1 Open the Right Door 2 Open the Front Door 3 Remove two screws and holding onto the handle of the IU take off the IU NOTE Before installing the IU be sure to fully open the Right Door If the IU is installed with the Right Door left ajar the PC Drum protective shutter will not open interfer ing with the Image Transfer Roller gear thus pro ducing noise When inserting the IU do that slowl...

Page 120: ... on both ends marked with A in the illustration on the left of the Cleaning Assy in the direction of arrow and turn to take off the Clean ing Assy A A 5 Unplug one connector of the Main Erase 6 Remove two screws and the pivot shaft 7 Remove the PC Drum NOTE When the PC Drum has been replaced apply a coat of toner to the surface of the PC Drum D 34 8 Remove two screws and the Main Erase ...

Page 121: ...remove it from the side bracket 11 Slide out the PC Drum Charge Corona in the direction of the arrow 12 Remove three screws the Charge Neutralizing Sheet and Cleaning Blade NOTE When securing the Cleaning Blade and Charge Neutralizing Sheet tighten screws in the order of one on one edge one at the center and one on the other edge When the Cleaning Blade has been replaced apply a coat of toner to t...

Page 122: ...ws and the Developer Scatter ing Prevention Plate 16 Using a brush whisk dust and dirt off the surface of the Developer Scattering Prevention Plate 17 Dump the developer How to Dump Developer Dump developer on the Sleeve Roller by turning the gear in the direction of the arrow with the Developing Unit tilted as shown Note at this time that turning the gear backward could damage the mylar for clean...

Page 123: ... Image Transfer Guide Plate 3 Application of Toner NOTE Perform these steps when the PC Drum and or Cleaning Blade have been replaced 18 Pour one packet of developer NOTE Shake the packet of developer well before pouring When the developer has been replaced run ATDC Sensor Automatic Adjustment D 61 ...

Page 124: ...per 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 Area to which toner is to be applied 4021U057AA 20 30 mm 10 15 mm 20 25 mm PC Drum 3 Hold both ends of the PC Drum with your both hands and turn the PC Drum a half turn in the direction of the...

Page 125: ...rn to remove the Pre Image Transfer Upper Guide Plate NOTE When reinstalling the fixing bracket make sure that the hook of the fixing bracket fits into the slot in the Pre Image Transfer Upper Guide Plate 2 Using a soft cloth dampened with alcohol wipe the Pre Image Transfer Lower Guide Plate clean of dirt 2 Using a soft cloth dampened with alcohol wipe the Charge Neutralizing Plate clean of dirt ...

Page 126: ...p free the control panel without removing one flat cable and two ground wires and unplugging one connector 2 Remove the Front Cover Rear Cover and Rear Right Cover 2 Disassembly of the Fusing Unit Removal of the Thermoswitch 3 Unplug two connectors of the Fusing Unit 4 Open the Right Door 5 Remove four screws and the Fusing Unit 1 Remove two screws and the thermoswitch ...

Page 127: ...ng Roller Removal of the Fusing Heater Lamp 2 Unhook the pressure springs at the front and rear 3 Remove two shoulder screws two washers and the Right Roller Assy 4 Remove the Right Roller 5 Remove the Pressure Lever Assemblies at the front and rear 6 Remove two screws and the Fusing Entrance Guide Plate ...

Page 128: ...Lamp from the cover 8 Remove the thermistor harness from the cover 9 Remove one mounting screw from the front of the Heater Lamp 10 Remove one screw and the cover NOTE When reinstalling the cover allow two tabs on the cover to be caught in the frame 11 Remove one screw and the rear lamp holder 12 Remove the Fusing Heater Lamp ...

Page 129: ...pring at the front of the Guide Assy 16 Remove the Guide Assy NOTE When removing and reinstalling the Guide Assy use care not to allow the sensor lever spring to be unhooked 17 Remove one screw and the Paper Separator Fin ger Assy NOTE When reinstalling the Paper Separator Finger Assy allow six tabs to be caught in the frame 18 Remove two screws and the mounting bracket 19 Remove the idle gear ...

Page 130: ...off the retaining ring at the front of the Left Fusing Roller and remove the washer and bush ing 21 Snap off the retaining ring in the rear of the Left Fusing Roller and remove the gear 22 Remove the collar 23 Remove the bushing 24 Remove the Left Fusing Roller 25 Remove one screw and the Thermistor ...

Page 131: ... BYPASS MB 5 OPTION 1 Removal of the Separator Roll Assy 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 the Separator Roll Assy 1 Remove two screws and the cover 3 Remove two screws and the Bypass Transport Roller Assy ...

Page 132: ...ion Procedure Temporarily secure the Multiple Bypass using four screws Install the positioning pin at the location shown in the illustration Use the positioning pin furnished as an acces sory with the Multiple Bypass Close the Right Door and correctly position the Multiple Bypass using the positioning pin Tighten the four Multiple Bypass mounting screws to specified torque ...

Page 133: ...NT FOR Di152 Di183 01 09 03 D 44 6 Remove four screws and the Paper Take Up Assy 7 Snap off one C ring and remove the gear 8 Snap off one C ring 9 Snap off one C ring and remove the Paper Take Up Roll Assy 10 Snap off one C ring and remove the roll ...

Page 134: ...e paper Take Up Roll 1 Open the Right Door 2 Remove two screws and the Separator Roll Assy NOTE When attempting to reinstall the Separator Roll Assy try to move the assy in the direction of the arrow 3 Using a soft cloth dampened with alcohol wipe the Separator Roll clean of dirt 1 Open the Right Door 2 Remove the Separator Roll Assy 3 Using a soft cloth dampened with alcohol wipe the Paper Take U...

Page 135: ...the control panel Front Cover Rear Cover Right Cover and Right Inside Cover 2 Remove two screws and the fan cover 3 Remove one screw and the Mechanical Counter if the copier is so equipped 4 Remove one Sensor Assy mounting screw 5 Unplug two connectors 6 Remove the harness from two edge covers and remove the Sensor Assy 7 Unplug two connectors ...

Page 136: ...SEMBLY ADJUSTMENT FOR Di152 Di183 01 09 03 D 47 8 Unplug one connector and remove the harness from one edge cover 9 Remove two screws and the PWB Assy 10 Unplug four connectors 11 Remove two screws two PWB Supports and the Main Board ...

Page 137: ... 2 Paper Detecting Board 1 Remove the control panel Rear Cover and Right Cover 2 Unplug one harness connector and remove the harness from one edge cover 3 Press the tabs to remove the Paper Detecting Board Assy from the Front Cover 4 Remove one screw and the Paper Detecting Board ...

Page 138: ... panel Front Cover Rear Cover Right Cover and Right Inside Cover 2 Remove two screws and the fan cover 3 Remove one screw and the Mechanical Counter if the copier is so equipped 4 Remove one screw and the Motor Assy 5 Unplug two connectors and remove the harness from the guide 6 Unplug one connector from the Main Board 7 Remove the harness from one edge cover ...

Page 139: ...rameMaker Ver 5 5E PC DIS REASSEMBLY ADJUSTMENT FOR Di152 Di183 01 09 03 D 50 8 Remove two screws and the Main Board Assy 9 Unplug two connectors 10 Remove two screws two PWB Supports and the Main Board ...

Page 140: ...ing Jigs PC Positioning Jig 4 2 TIMING BELT TENSION ADJUSTMENT Scanner Motor Timing Belt Adjustment 4022D010AA 4022D011AA 4022D012AA 4022D030AA 1 Loosen three screws and move the Scanner Motor Assy to the right or left to give tension to the spring NOTE Give tension to the spring with the pulley in correct mesh with the timing belt 2 Using a torque driver tighten the screws to a torque of 2 kg cm ...

Page 141: ...s order Stop 0 0 Stop 0 1 3 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 1 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 0 1 3 Press the Stop key and th...

Page 142: ...ge Erase Adjustment mode 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 key to validate the entry Adjustment Instructions To 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 trailing edge an...

Page 143: ...hown on the Display enter the code number 8 from the 10 Key Pad and press the Start key to enter the Loop Length Adjustment 1st Tray mode 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 key to validate the entry Adjustment Instructions Adjust by changing the setting value until the problems of variations in the amount of le...

Page 144: ... 6 With AJ shown on the Display enter the code number 1 from the 10 Key Pad and press the Start key to enter the Printer CD Registration Adjustment mode 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 Start key to validate the entry Adjustment Instructions If width A on the test print is longer than the specifications increas...

Page 145: ...djustment 6 With AJ shown on the Display enter the code number 2 from the 10 Key Pad and press the Start key to enter the Printer FD Registration Adjustment mode 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 Start key to validate the entry Adjustment Instructions If width B on the test print is longer than the specification...

Page 146: ...eviation If the deviation between width A on the test print and that on the copy falls outside the specified range perform the following steps to make an adjustment 7 With AJ shown on the Display enter the code number 5 from the 10 Key Pad and press the Start key to enter the Scanner CD Registration Adjustment mode 8 Press the Clear key to clear the current setting value 9 Enter the new setting va...

Page 147: ...viation If the deviation between width B on the test print and that on the copy falls outside the specified range perform the following steps to make an adjustment 7 With AJ shown on the Display enter the code number 5 from the 10 Key Pad and press the Start key to enter the 2Scanner CD Registration Adjustment mode 8 Press the Clear key to clear the current setting value 9 Enter the new setting va...

Page 148: ...the 10 Key Pad and press the Start key to enter the Scanner CD Zoom Adjustment mode 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 Start key to validate the entry Adjustment Instructions If the length on the copy is longer than the actual one decrease the setting value If the length on the copy is shorter than the actual one...

Page 149: ...s the Start key to enter the Scanner FD Zoom Adjustment mode 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 Start key to validate the entry Adjustment Instructions If the length on the copy is longer than the actual one decrease the setting value If the length on the copy is shorter than the actual one increase the setting v...

Page 150: ...removed from the copier Adjustment Procedure 1 Enter the Function mode 2 With F shown on the Display enter the code number 8 from the 10 Key Pad to set the copier into the ATDC Sensor Automatic Adjustment mode 3 Press the Start key This automatically runs the ATDC Sensor Automatic Adjustment sequence for about three minutes 4 After the F8 operation has been completed check the adjustment value and...

Page 151: ...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 copy using the Manual Bypass 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 copy falls outside the specified range adjust the position of the Guide Plate Unit Adjust so that ...

Page 152: ...ad 3 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 copy using the Multiple Bypass 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 copy falls outside the specified range adjust the positio...

Page 153: ...r 2 Press the 2nd 3rd Mirrors Carriage tightly up against the jigs 4022D014AA Rear 2nd 3rd Mirrors Carriage Jig Jig 3 Loosen the set screw of the cable holding plate and turn the adjusting screw as necessary to eliminate clearance between the 2nd 3rd Mirrors Carriage and the Scanner Mirrors Carriage Posi tioning Jigs 4022D015AB Adjusting Screw Fixing Screw 4 Press the Scanner tightly up against th...

Page 154: ...CD Zoom Adjust ment D 59 If the measured value falls outside the specified range perform the following step to make an adjustment 3 Loosen three CCD Unit mounting screws slide the CCD Unit to the right or left and secure it in position Adjustment Instructions If the length on the copy is longer than the actual one move the CCD Unit to the right If the length on the copy is shorter than the actual ...

Page 155: ...oper Scattering Prevention Plate 4 Install the Ds Collar Positioning Jigs NOTE Ready a PC Positioning Jig Pivot Shaft sepa rately It can be ordered For details see the Parts Manual 4022D018AC Ds Collar Positioning Jigs PC Positioning Jig 6 Remove three screws and the Doctor Blade 4022D019AA 7 Using a small piece of paper remove developer from the shaded area on the surface of the Sleeve Roller and...

Page 156: ...ller and Doctor Blade 4022D021AB 12 Press the Doctor Blade tightly up against the Db Gap Adjusting Jigs and keeping that position tighten the screws in the order of at the front at the center and in the rear NOTE The Doctor Blade mounting screws have been coated with lock paint and the job must be com pleted within 30 min It the job extends more than that time change the screws for new ones 4022D0...

Page 157: ... new one EEPROM U29 must be demounted from the old PWB C and remounted on the new PWB C Remove the EEPROM U29 from the new Control Board and mount the EEPROM U29 of the old Control Board to the new Control Board New EEPROM Old EEPROM New Control Board Old Control Board 4022D031AA NOTE Note the alignment notch marked with A on the EEPROM U29 when mounting the IC 1171D049AA A A ...

Page 158: ...023AA 2 Using two screws secure the counter mounting bracket 4022D024AA 3 Connect the Plug In Counter Socket connector 4 Using two screws secure the counter socket 4022D025AA 5 Using two screws secure the Plug In Counter cover NOTE When the Plug In Counter Socket is mounted set Plug In Counter of the Security mode to 1 For details see SWITCHES ON PWBs TECH REP SETTINGS 4022D026AA ...

Page 159: ...Cover 2 Cut out the knockout from the Right Cover 4021D001AA 3 Using one screw secure the Mechanical Counter to its mounting bracket 4021D002AA 4 Connect the Mechanical Counter connector 5 Using one screw secure the Counter Assy NOTE When the Mechanical Counter is mounted set Mechanical Total Counter of the Security mode to 1 For details see SWITCHES ON PWBs TECH REP SETTINGS 4021D003AA ...

Page 160: ...FrameMaker Ver5 5E PC Di152 Di183 SWITCHES ON PWBs TECH REP SETTINGS 01 07 26 SWITCHES ON PWBs TECH REP SETTINGS 17196 ...

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Page 162: ...on Setting Procedure S 14 3 3 Setting in the Tech Rep Mode S 15 1 Control Panel LED Check S 15 2 Function S 15 3 Tech Rep Choice S 16 4 Counter Mode S 18 5 ATDC Sensor Output S 21 6 Level History S 21 7 ROM Version S 21 8 Administrator No Input S 22 9 Change Fixed Zoom S 22 10 Marketing Area Setting S 22 11 Memory Clear S 23 12 Total Clear S 23 13 ADF Document Passage Test S 23 14 ADF Original Gla...

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Page 164: ...HES ON PWBs TECH REP SETTINGS 01 07 26 S 1 1 CONTROL PANEL KEYS AND TOUCH PANEL 1 1 Control Panel Keys 4021S002CA 1 2 3 4 5 6 7 8 9 10 11 Metric area 4021S003CA 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Inch area 4021S001CA ...

Page 165: ... the copier Malfunction indicator Lights up when malfunction occurs in the copier 13 Maintenance indicator Blinks or lights up when the time approaches that copier needs maintenance service 14 Add Paper indicator Lights up when paper source currently selected for use runs out of paper 15 Add Toner indicator Lights up when toner will soon run out 16 Bypass Tray Size Select key Press to select the s...

Page 166: ...rt a print cycle Press to validate the setting just made The key lights up green when the copier is ready to make copies orange when it is not ready to make copies 27 Enter key Press to validate the setting just made 28 Zoom key Press to select a zoom ratio from among those fixed ratio available as standard 29 Auto Paper Auto Size key Press to select either Auto Paper or Auto Size 30 Paper key Pre...

Page 167: ...e U 5 Administrator Mode Code No Function Code No Function C 1 Mixed Orig C18 Density ADF C 2 Paper Priority C19 Print Density C 3 Copy Priority C20 Paper Auto Detection 1st Tray C 4 Density Priority C21 Paper Auto Detection 2nd Tray C 5 Density Level Auto C22 Paper Auto Detection 3rd Tray C 6 Density Level Manual C23 Paper Auto Detection 4th Tray C 7 Output Priority C24 Paper Auto Detection 5th T...

Page 168: ... screen reappears 3 Setting in the User s Choice Mode Code No Setting The default is C 1 Mixed Orig Select the priority Mixed Original Detection mode that is automatically selected when the Power Switch is turned ON or Panel Reset key pressed C 2 Paper Priority Select the priority paper size or paper source that is automatically selected when the copier is set into the Auto Size or Manual mode Ini...

Page 169: ...ss Mode Select whether to enable or disable crisscross sorting automatically C 9 4in1 Copy Order Specify the default copying order in the 4in1 mode C10 Book Binding Position Select whether to the copier scan the left hand side page Left bound or the right hand side page Right bound first when it scans an open book Highlighted Setting 1 2 Description Auto Manual Photo Manual 0 Setting 0 2 Descripti...

Page 170: ... to be activated C16 Energy Saver Select the time it takes the copier to enter the Energy Saver mode after a copy cycle has been completed or the last key operated C17 Auto Shut OFF 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 Note The option of 0 ca...

Page 171: ...y C25 Paper Size Detection Select the paper size detection method for the 1st Tray If paper of a nonstandard size is to be used select 1 Size input is made using U 4 C26 Paper Type 1st Tray Select the type of paper loaded in the 1st Tray C27 Paper Type Bypass Tray Select the type of paper loaded in the Bypass Tray Highlighted Setting Description When the standard original text etc is used 1 To giv...

Page 172: ...or 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 value in the FD direc tion 4 Press the Clear key to reset the currently set value 5 Enter the new value from the 10 Key Pad 6 Press the Start key Then the Display will show the currently set value in the CD direc tion 7 Press the Clear key to reset the currently set value 8 Ent...

Page 173: ...art 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 shows 6 Enter the code assigned to the desired subfunction from the 10 Key Pad 1 or 2 7 Press the Start Key Exiting the Mode Press the Panel Reset key until the initial screen reappears 2 Administrator Mode Function Tree U 5 Administrator M...

Page 174: ...e 1 Enter 1 from the 10 Key Pad Display A 1 2 Press the Start key to show the current setting value 3 Press the Clear key to reset 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 A 2 Input Account Using the 10 Key Pad enter a 3 digit access number that can range from 001 to 999 The access number corres...

Page 175: ...y Pad 6 Press the Start key to validate the new access number just entered If the new access number just entered already exists Err appears on the Display and then the Display blanks out In this case perform steps 5 and 6 again A 5 Total Counter Display by Account Display the count of the Total Counter for each account Procedure 1 Enter 5 from the 10 Key Pad Display A 5 2 Press the Start key This ...

Page 176: ... 1 Maintenance Counter Count c 2 IU Life Stop c 3 ID Adjustment c 4 VG Adjustment c 5 Leading Edge Erase Adjustment c 6 Trailing Edge Erase Adjustment c 7 Top Bottom Edge Erase Adjustment c 8 Loop Length Adjustment 1st Tray c 9 Loop Length Adjustment 2nd Tray c10 Loop Length Adjustment Bypass Tray c11 Priority FLS Setting 3 Counter cnt 1 PM Counter 2 Maintenance Counter 3 IU Life Counter 4 Applica...

Page 177: ... 0 1 3 Enter the code number corresponding to the function to be used from the 10 Key Pad Code No 0 to 14 20 4 Press the Start Key Exiting the Mode Press the Panel Reset key until the initial screen reappears Tech Rep Mode 9 Marketing Area Setting 20 Serial No Display Sn 10 Memory Clear CLr 11 Total Clear tCL 13 ADF Original Glass Check AdF 14 Scanner Drive Check ccd 8 Change Fixed Zoom 12 ADF Doc...

Page 178: ...r transport path is checked without involving any printing action This test is used to check for a paper misfeed and transport path Procedure 1 Select the paper source 2 Press the Start key to start the paper passage cycle 3 Press the Stop key to stop the paper passage cycle F 2 HV Output This test is for factory adjustment only and should NOT be used F 8 ATDC Sensor Automatic Adjustment Adjusts t...

Page 179: ... is C 1 Maintenance Counter Count Select the counting method of the maintenance counter It is used as guidelines for the number of copies to be made before the next maintenance time C 2 IU Life Stop Select whether to prohibit copying or not when the IU Counter reaches a life value C 3 ID Adjustment Set the central value of image density This function is used when image density is not satisfactory ...

Page 180: ...ler when a skew or misfeed occurs 1st Tray C 9 Loop Length Adjustment 2nd Tray Adjust the length of the loop formed before the Synchronizing Roller when a skew or misfeed occurs 2nd Tray C10 Loop Length Adjustment Bypass Tray Adjust the length of the loop formed before the Synchronizing Roller when a skew or misfeed occurs Bypass Tray C11 Priority FLS Setting Set the size for FLS Highlighted Setti...

Page 181: ...t parts of the copier The count should be cleared when the corresponding PM part is replaced 2 Maintenance Counter Enter a value for the maintenance counter for any given part The count is based on a countdown system and when the set value is counted down to 0 the Maintenance Indicator lights If counting continues after 0 a minus sign is appended to the value shown on the Display NOTE The above co...

Page 182: ...to automatically set 40 000 The value 40 000 is the starting value from which it is counted down No value can be set from the 10 Key Pad NOTES There are some discrepancies between the count and the actual number of copies made The setting made in c 2 of Tech Rep Choice determines the copying operation after the life value has been reached If Copying prohibited is selected nc2 is displayed and the ...

Page 183: ...image transfer voltage Warm up failure Abnormally low fusing temperature Abnormally high fusing temperature Scanner Home Sensor malfunction Tray Selecting Motor malfunction Shift Motor malfunction ATDC Sensor malfunction ATDC adjustment failure ASIC memory malfunction Polygon Motor malfunction HSYNC detection failure EEPROM malfunction Exposure Lamp malfunction Display Description 1 2 3 4 5 6 7 8 ...

Page 184: ...l screen reappears 7 ROM Version This function displays the ROM version It is used when upgrading the F W or the PWB is replaced with a new one The version is displayed in the order of the copier controller and engine The version consists of 12 digits each being displayed sequentially as the image density key darker the digits flow in the left direction Procedure 1 Press the Start key to display t...

Page 185: ... Press the Zoom key to select the specific zoom ratio to be changed 3 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 Display shows Err rejecting the entry The old zoom ratio will reappear on the Display 1 sec later 10...

Page 186: ... reappear 3 Turn OFF and ON the Power Switch 13 ADF Document Passage Test This function is used to check for correct document passage through the ADF when a document misfeed occurs Procedure 1 Load a paper stack in the Document Feeding Tray 2 Press the Start key to let the ADF start feeding the paper 3 Press the Stop key to stop the sequence For details see the relevant option service manual List ...

Page 187: ...evant option service manual 15 Scanner Move Check This function is used to check the drive for the Scanner It is also used when securing the Scanner in position with the fixing pin for transportation of the machine Procedure Press the Start key This will move the Scanner to the left and stop 16 Serial No Display This function is used to display the serial number consisting of 8 digits Procedure Pr...

Page 188: ... 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 Display shows Err rejecting the entry The old setting value will reappear on the Disp...

Page 189: ...ut having to plug the Key Counter into the socket 4 Total Counter Set to 1 if a Total Counter is plugged in Size Counter Count Mode Size other than those set Set size Total Counter Count Mode 0 1 2 0 1 2 Total Counter 1 1 2 2 Size Counter Not Count 1 1 2 Highlighted Setting Description 1 Copy per 1 copy cycle 1 Multiple count up according to the paper size and copying mode 2 0 Setting Description ...

Page 190: ... Key Pad If any value outside the available setting range is entered the Display shows Err rejecting the entry The old setting value will reappear on the Display 1 sec later 7 Press the Start key to validate the new setting value just entered Exiting the Mode Press the Panel Reset key until the initial screen reappears Code No Description 1 Printer CD Registration adjustment 2 Printer FD Registrat...

Page 191: ...adjustment Adjust the zoom ratio in the FD direction on the Scanner IR side It is used when the PH Unit or the Scanner Drive Cables have been replaced or when the Scanner has been removed 5 Scanner CD Registration adjustment Adjust registration in the CD direction on the Scanner IR side It is used when the PH Unit or CCD Unit has been replaced 6 Scanner FD Registration adjustment Adjust registrati...

Page 192: ...nsor Gain Manual adjustment Adjust the ATDC Sensor voltage It is used when an IU of another machine is to be used or the T C con trol voltage is to be changed The value to which F 8 ATDC Sensor Automatic Adjustment has been adjusted is to be the setting value 11 Be sure to set to 1 whenever Memory Clear has been effected on the 18 cpm machine 12 Test Print This function is used to produce a test p...

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Page 194: ...FrameMaker Ver 5 5E PC Di152 Di183 TROUBLESHOOTING 01 09 04 TROUBLESHOOTING 14390 ...

Page 195: ......

Page 196: ...045 Fusing Cooling Fan Motor malfunction T 24 3 C004E Power Supply Cooling Fan Motor malfunction T 25 4 C0070 Toner Replenishing Motor malfunction T 26 5 C0210 Abnormal image transfer voltage T 27 6 C0500 Warm up failure C0510 Abnormally low fusing temperature C0520 Abnormally high fusing temperature T 28 7 C0650 Faulty Scanner Home Position Sensor T 30 8 C0B60 Bin Switching Motor malfunction T 31...

Page 197: ...47 4 Foggy background or rough image T 49 5 Black streaks or bands T 51 6 Black spots T 52 7 Blank streaks or bands T 53 8 Void areas T 54 9 Smear on back T 55 10 Uneven image density T 56 11 Gradation reproduction failure T 58 12 Periodically uneven image T 59 6 OTHER ERROR CODES T 60 ...

Page 198: ...tion 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 E g Pattern 1 E g Pattern 2 Step Check Result Action 1 NO 2 Step Check Result Action 1 YES NO 2 Go to the next step if you answered YES Go to the next step i...

Page 199: ...H L of the paper take up related sensors and the Exit Paper Sensor are monitored to detect a sheet of paper left in the copier All drives are brought to an immediate stop when a sheet of paper misfeed or left in the copier is detected 2 2 Paper Misfeed When a paper misfeed occurs the control panel shows the misfeed location and paper location LED No Code Misfeed Paper Location Action Ref Page 1 J0...

Page 200: ... 5th Tray T 11 7 J2 Misfeed at the PC Drum T 13 7 J3 Misfeed at the Fusing Unit T 16 8 J80 Original misfeed ADF Separator See option service manual J81 Original misfeed ADF registration J83 Original misfeed ADF exit 1 7 J Paper left PC1 T 7 7 Paper left PC3 T 16 2 Paper left 2nd Tray Paper Take Up Sensor T 11 3 Paper left 3rd Tray Paper Take Up Sensor T 11 4 Paper left 4th Tray Paper Take Up Senso...

Page 201: ...nizing Roller Sensor PC2 Manual Feed Paper Sensor PC3 Exit Paper Sensor Symbol Name PC12 2nd Tray Paper Take Up Sensor PC12 3rd Tray Paper Take Up Sensor PC12 4th Tray Paper Take Up Sensor PC12 5th Tray Paper Take Up Sensor Symbol Name PC3 Registration Sensor PC4 Separator Sensor PC5 Paper Exit Sensor PC4 PC3 PC5 PC3 PC1 PC2 PC12 PC12 PC12 PC12 Paper Path 4022T504AA ...

Page 202: ...m J2 misfeed at Fusing Unit J3 paper left J Open the Right Door or slide out the 1st Tray remove all sheets of paper misfeed and left inside and close the Right Door Paper wedged at Manual Bypass Tray byp Pull the paper wedged out of the tray Removing the paper will reset the misfeed display Misfeed in the option J02 J03 J04 J05 J1 J80 J81 and J83 Remove all sheets of paper mis feed and left insid...

Page 203: ...on Misfeed at the PC Drum Misfeed at the Fusing Unit Type Detection Start Paper Detection Misfeed at 1st Tray J01 Paper Take Up Solenoid SL1 energized Synchronizing Roller Sensor PC1 L Misfeed at Manual Bypass Tray J06 Manual Bypass Solenoid SL2 energized Synchronizing Roller Sensor PC1 L Misfeed at Multiple Bypass Tray J06 Multiple Bypass Solenoid SL21 energized Synchronizing Roller Sensor PC1 L ...

Page 204: ...ypass Solenoid SL21 Master Board PWB A Step Check Result Action 1 Paper meets product specifications NO Change paper 2 Paper is curled wavy or damp YES Change paper Instruct user to load paper that meets product specifications 3 Edge Guide and Trailing Edge Stop are at correct position to accommo date paper NO Adjust as necessary CN26 PC1 ANODE Multiple Bypass MANUAL BYPASS SECTION DRAWER SECTION ...

Page 205: ...Master Board copier PWB A pin and GND Voltage across PJ5A 2 and GND In standby DC24 V When pressed DC0 V NO Change Paper Take Up Solenoid SL1 8 Synchronizing Roller Sensor PC1 is operational Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the sensor is blocked Voltage across PJ6A 3 and GND When blocked DC5 V When unblocked DC0 V NO Change Synchronizing Roller Sen ...

Page 206: ... PJ4A 5 and GND When unblocked DC5 V When blocked DC0 V NO Change Manual Feed Paper Sen sor PC2 7 Synchronizing Roller Sensor PC1 is operational Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the sensor is blocked Voltage across PJ6A 3 and GND When blocked DC5 V When unblocked DC0 V NO Change Synchronizing Roller Sen sor PC1 YES Change Master Board copier PWB A S...

Page 207: ...Multiple Bypass Solenoid SL21 6 Paper Take Up Roll Multiple Bypass Tray is dirty scratchy deformed or worn YES Clean or change 7 Separator Roll Multiple Bypass Tray is dirty scratchy deformed or worn YES Clean or change 8 Synchronizing Roller Sensor PC1 is operational Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the sensor is blocked Voltage across PJ6A 3 and G...

Page 208: ...J6A 2 GND PJ6A 1 PC1 ANODE PWB A Master Board PJ18A PJ1A PWB A 2nd Tray 3rd Tray 4th Tray PF 120 Synchronizing Roller Sensor 13 13 13 SL11 CN53 PJ3A 2A GND PJ3A 1A SL11 ON PJ1A PJ2APJ1A SL11 CN53 PJ3A 2A GND PJ3A 1A SL11 ON PJ1A PJ2APJ1A PJ2APJ1A PJ3A 2B PC12ON PJ53 PC12 Paper Take Up Sensor PJ3A 3B DC5 V PJ3A 1B GND PWB A PF 120 PJ3A 2B PC12ON PJ53 PC12 Paper Take Up Sensor PJ3A 3B DC5 V PJ3A 1B ...

Page 209: ...ke Up Solenoid SL11 operation check The voltage across PJ3A 1A on Con trol Board PF 120 PWB A and GND changes from DC0 V to DC24 V when the Start key is pressed YES Change Paper Take Up Solenoid SL11 NO Change Control Board PF 120 PWB A 9 Paper Take Up Sensor PC12 oper ation check The voltage across PJ3A 2 on Con trol Board PF 120 PWB A and GND is DC 5 V when the sensor is unblocked and DC 0 V whe...

Page 210: ...ller Clutch CL1 Master Board PWB A Step Check Result Action 1 Synchronizing Rollers are dirty scratchy deformed or worn YES Clean or change the Synchronizing Rollers Clean or change the Paper Dust Remover 2 Loop length is set to an appropriate value NO Adjust loop length using Tech Rep Choice For details see DIS REASSEM BLY ADJUSTMENT PC1 ANODE PWB A Master Board TRANSPORT SECTION FUSING SECTION S...

Page 211: ... The following voltage is supplied to the Synchronizing Roller Clutch CL1 Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the Start key is pressed Voltage across PJ5A 4 and GND In standby DC24 V When pressed DC0 V YES Change Synchronizing Roller Clutch CL1 NO Change Master Board copier PWB A Step Check Result Action 1 Image Transfer Roller is dirty YES Clean or ch...

Page 212: ...orn or dam aged YES Clean or change 2 The following voltage is supplied to the Fusing Cooling Fan Motor M3 Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the Start key is pressed Voltage across PJ10A 4 and GND During decelerated rotation DC8 V During full speed rotation DC24 V YES Change Fusing Cooling Fan Motor M3 NO Change Master Board copier PWB A ...

Page 213: ...aged YES Clean or change 2 Fusing Paper Separator Fingers are dirty scratchy deformed or worn YES Clean or change the Fusing Paper Separator Fingers or change spring 3 Fusing Rollers are dirty scratchy deformed or worn YES Clean or change Step Check Result Action 1 Exit guide plate is dirty scratchy deformed worn or damaged YES Clean or change 2 Transport Roller is dirty scratchy deformed or worn ...

Page 214: ...ion 4 Exit Paper Sensor PC3 is opera tional Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the sensor is blocked Voltage across PJ10A 3 and GND When blocked DC5 V When unblocked DC0 V NO Change Exit Paper Sensor PC3 YES Change Master Board copier PWB A ...

Page 215: ...us 3 5 sec period while the Toner Bottle is turning The Toner Bottle Home Position Sensor PC7 outputs a LOW signal for a continuous 2 sec period while the Toner Bottle is turning C0210 Abnormal image transfer voltage The image transfer voltage remains more than 100 V for a continuous given period of time while the PC Drum remains stationary C03FF Improperly set Adjust Mode 11 An incorrect setting ...

Page 216: ...e Bin Switching Motor M1 has started turning forward the Bin Switching Motor is kept deenergized for a given period of time and then energized again to turn back ward The Upper Home Position Sensor PC32 does not go LOW after the motor has started turning back ward The Upper Home Position Sensor PC32 does not go HIGH at a time 1 sec after the Bin Switching Motor M1 has started turning forward When ...

Page 217: ...ome Sensor S31 is LOW at a timing immedi ately before the Shift Motor M1 starts turning back ward The Home Sensor S31 is LOW after the lapse of a given period of time after the Shift Motor M1 has started turning backward C0F32 Faulty ATDC Sensor The measurement taken by the ATDC Sensor UN1 at a time 2 5 sec after the Main Motor M1 has started turning is less than 3 greater than 4 98 V The measurem...

Page 218: ...t of timing A LOW Polygon Motor M2 Lock signal is not detected for a continuous given period of time while the rotation of the Polygon Motor remains stabilized Faulty Lock signal A LOW Polygon Motor M2 Lock signal is detected for a given period of time or more when the Polygon Motor remains deenergized C13F0 Faulty HSYNC Laser scanning system malfunction The SOS Sensor does not detect a rising edg...

Page 219: ...11 Set Adjust Mode 11 correctly and then turn OFF and ON the Power Switch For details see SWITCHES ON PWBs TECH REP SETTINGS C0500 Warm up failure Turn ON the Power Switch with the Stop key held down C0510 Abnormally low fusing temperature C0520 Abnormally high fusing tempera ture C0650 Faulty Scanner Home Position Sensor Turn OFF and ON the Power Switch C0B60 Bin Switching Motor malfunction C0F32...

Page 220: ...ollowing voltage is supplied to the Main Motor M1 when the Start key is pressed Check voltage across a Master Board copier PWB A pin and GND when the Start key is pressed Voltage across PJ7A 6 and GND DC5 V when Main Motor M1 is in standby state DC0 V when Main Motor M1 is energized Voltage across PJ7A 5 and GND DC5 V when Main Motor M1 is in standby state DC0 V when Main Motor M1 is energized NO ...

Page 221: ...cross a Master Board copier PWB A pin and GND when the Power Switch is turned ON Voltage across PJ10A 4 and GND DC8 V during rotation at deceler ated speed DC24 V during rotation at full speed YES Change Fusing Cooling Fan Motor M3 3 The following voltage is supplied to the Fusing Cooling Fan Motor M3 Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the Power Switc...

Page 222: ...ss a Master Board copier PWB A pin and GND when the Power Switch is turned ON Voltage across PJ19A 1 and GND DC8 V during rotation at deceler ated speed DC24 V during rotation at full speed YES Change Power Supply Cooling Fan Motor M4 3 The following voltage is supplied to the Power Supply Cooling Fan Motor M4 Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the Po...

Page 223: ...r PC7 is operational Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the Toner Replenishing Motor M6 turns Voltage across PJ19A 10 and GND DC0 V when unblocked DC5 V when blocked NO Change Toner Bottle Home Posi tion Sensor PC7 3 The following voltage is supplied to the Toner Replenishing Motor M6 Check Procedure Check voltage across a Master Board copier PWB A pi...

Page 224: ...ck Result Action 1 C0210 reappears when the Power Switch is turned OFF and ON YES Change High Voltage Unit HV1 Change Master Board PWB A PWB A Master Board DEVELOPING SECTION HV1 High Voltage Unit Developing Bias Image Transfer VG Voltage Charge Neutralizing Cloth Photo Conductor Not Use P C I T _REM P C I T _REM I T Control I T Control I T Voltage Monitor I T Voltage Monitor 4022T529AA ...

Page 225: ...3 NO Go to step 2 2 Fusing Heater Lamp H1 is open cir cuited Check Procedure Check the resistance across both ends of the Fusing Heater Lamp H1 The Fusing Heater Lamp is open cir cuited if the resistance is infinity YES Change Fusing Heater Lamp H1 3 Thermoswitch 1 TS1 is operational Check Procedure Check the resistance across both ends of the Thermoswitch 1 TS1 The Thermoswitch 1 is open circuite...

Page 226: ...ES Change Thermistor TH1 6 The following voltages are supplied from the Master Board copier PWB A Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the Power Switch is turned ON Voltage across PJ10A 7 and GND DC24 V when Fusing Heater Lamp H1 is OFF DC0 V when Fusing Heater Lamp H1 is ON Voltage across PJ10A 10 and GND DC24 V when Fusing Heater Lamp H1 is OFF DC0 V ...

Page 227: ...the Scanner by hand to check for smooth operation NO Remove foreign matter and other obstacle Clean the Scanner rails Clean or change the Scanner bush ings Reinstall Scanner 3 Scanner Home Position Sensor PC6 is operational Check Procedure Check voltage across a Control Board copier PWB C pin and GND when the sensor is blocked Voltage across PJ18C 2 and GND DC5 V when unblocked DC0 V when blocked ...

Page 228: ...tch is turned ON NO Change Bin Switching Motor JS 202 M1 2 Tray is moved as the Bin Switching Motor JS 202 M1 operates NO Reinstall motor unit 3 Upper Home Position Sensor JS 202 PC32 is operational Check Procedure Check voltage across a Main Board JS 202 PWB A pin and GND when the sensor is blocked Voltage across PJ4A 3 and GND DC0 V when unblocked DC5 V when blocked NO Change Upper Home Position...

Page 229: ...Home Position Sensor JS 202 PC33 is operational Check Procedure Check voltage across a Main Board JS 202 PWB A pin and GND when the sensor is blocked Voltage across PJ4A 6 and GND DC0 V when unblocked DC5 V when blocked NO Change Lower Home Position Sen sor PC33 YES Change Master Board copier PWB A ...

Page 230: ... Shift Motor OT 103 M1 2 Exit Roller operates as the Shift Motor OT 103 M1 is energized NO Reinstall motor unit 3 Home Sensor OT 103 S31 is oper ational Check Procedure Check voltage across a Main Board OT 103 PWB A pin and GND when the sensor is blocked Voltage across PJ3A 3 and GND DC5 V when blocked DC0 V when unblocked NO Change Home Sensor OT 103 S31 YES Change Master Board copier PWB A S31 O...

Page 231: ...ith for eign matter such as paper dust other than developer YES Clean ATDC Sensor UN1 3 Foreign matter such as paper dust is trapped in the Developer Mixing Chamber YES Remove foreign matter from the Developer Mixing Chamber 4 The following voltages are supplied from the Master Board copier PWB A Check Procedure Check voltage across a Master Board pin and GND when the Power Switch is turned ON DC5...

Page 232: ...he connection between Master Board copier PWB A and Control Board copier PWB C is loose YES Make good connection between Master Board copier PWB A and Control Board copier PWB C NO Change Control Board copier PWB C Change Master Board copier PWB A Relevant Electrical Parts Control Board copier PWB C Step Check Result Action 1 C1200 reappears when the copier is turned OFF and ON again Check Procedu...

Page 233: ...OFF and ON the Power Switch to check to see if C1300 C13F0 reap pears YES Go to step 2 2 Polygon Motor M2 connector PJ13A is loose YES Reconnect connector PJ13A 3 The following voltage is supplied to the Polygon Motor M2 Check Procedure Check voltage across a Master Board copier PWB A and GND when the Start key is pressed Voltage across PJ13A 3 and GND DC5 V while Polygon Motor M2 is in standby st...

Page 234: ...l Board copier PWB C Step Check Result Action 1 C1468 reappears when the copier is turned OFF and ON again Check Procedure Turn OFF and ON the Power Switch to check to see if C1468 reappears YES Go to step 2 2 Memory U29 on Control Board copier PWB C is loose YES Reinstall memory U29 NO Change Control Board copier PWB C ...

Page 235: ... 04 T 38 15 C14A3 IR fluorescent lamp fault Relevant Electrical Parts Exposure Lamp LA2 Inverter Board copier PU2 Control Board copier PWB C PWB J CCD IR SECTION Exposure Lamp PU2 Inverter Board PWB C Control Board Not Use Not Use Not Use Not Use 4022T535AA ...

Page 236: ...Board copier PU2 connec tor is loose YES Reconnect NO Change Exposure Lamp LA2 4 CCD Board copier PWB J connec tor is loose YES Reconnect 5 The following voltage is supplied from the Control Board copier PWB C Check Procedure Check voltage across a Control Board copier PWB C pin and GND when the Power Switch is turned ON Voltage across JP16C 4 and GND DC24 V when Exposure Lamp LA2 is OFF DC0 V whe...

Page 237: ...Switch is turned ON YES Go to step 2 NO Go to step 3 2 The malfunction is temporarily reset when the Power Switch is turned OFF and ON with the Stop key held down YES Perform the troubleshooting proce dure according to the malfunction code JP2UN2 JP4C 1 29 30 2 PJ11C 1 29 30 2 PJ1A PWB A Master Boad PWB C Control Boad UN2 Control Panel Main Switch Fusing Unit Interlock Switch Fusing Heater Lamp Th...

Page 238: ...t of DC24 V to Master Board copier PWB A Check Procedure Check voltage across a Master Board copier PWB A pin and GND when the Power Switch is turned ON Voltage across PJ2A 2 and GND DC0 V when the Power Switch is OFF DC24 V when the Power Switch is turned ON NO Check Front Door Inter lock Switch S3 Check Right Door Inter lock Switch S4 Change DC power Supply PU1 6 Check of output of DC 5 V to Mas...

Page 239: ... product specifi cations NO Change paper for one that meets specifications Instruct user to use paper that meets specifications and is recommended 3 Paper is damp YES Change paper for one that is dry Then instruct user to use paper that meets specifica tions and in how to store paper Original 4 Original is placed correctly NO Reposition original Instruct user in how to place original correctly 5 O...

Page 240: ...T 43 Determine if the failure is attributable to an input system IR or output system engine Check Result Action Copy made at a reduced ratio Input system Output system Original 1177T03YA Full size copy Reduced copy 1177T04YA Full size copy Reduced copy 1177T05YA ...

Page 241: ...ure Samples 1 Blank copy 2 Black copy 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 reproduc tion failure 12 Periodically uneven image 4022T542 ...

Page 242: ... current contact is dirty broken or bent YES Clean correct or change 7 Developing bias contact is dirty broken or bent YES Clean correct or change 8 High Voltage Unit HV1 connec tors CN1HV1 and CN2HV1 are loose YES Reconnect 9 The following voltage is supplied from the Master Board copier PWB A Check Procedure Check voltage across a Master Board pin and GND when the Start key is pressed Voltage ac...

Page 243: ...ltage across PJ8A 8 and GND DC14 V in standby state DC0 V when Start key is pressed YES Change IU Change PH Unit Change High Volt age Unit HV1 NO Change Master Board copier PWB A Input system 1 Exposure Lamp turns ON when the Power Switch is turned ON NO Go to step 3 2 Exposure Lamp is abnormally lit flickers or abnormally dark when the Power Switch is turned ON NO Go to step 4 3 Inverter Board co...

Page 244: ... High Voltage Unit HV1 connectors CN1HV1 and CN2HV1 are loose YES Reconnect 6 ATDC Sensor UN1 is dirty with foreign matter such as paper dust other than developer YES Clean 7 The following voltages develop from the ATDC Sensor UN1 Check Procedure Check voltage across a Master Board pin and GND when the Power Switch is turned ON DC5 39 V to 8 15 V across PJ7A 8 and GND DC1 41 V to 4 98 V across PJ7...

Page 245: ...et reading portion the por tion on the backside of the Original Glass to which Original Width Scale is affixed is dirty YES Clean 2 CCD Board copier PWB J connector is loose YES Reconnect 3 Control Board copier PWB C connec tor PJ1A is loose YES Reconnect NO Change Control Board copier PWB C Change Master Board copier PWB A ...

Page 246: ...UN1 Check Procedure Check voltage across a Master Board pin and GND when the Power Switch is turned ON DC5 39 V to 8 15 V across PJ7A 8 and GND DC1 41 V to 4 98 V across PJ7A 10 and GND NO Change ATDC Sensor UN1 and then change developer 7 The following voltage is supplied from the Master Board copier PWB A Check Procedure Check voltage across a Master Board pin and GND when the Start key is press...

Page 247: ...re Lamp is abnormally lit flickers or abnormally dark when the Start key is pressed NO Go to step 7 6 Inverter Board copier PU2 connector CN1PU2 is loose YES Reconnect NO Change Exposure Lamp LA2 7 CCD Board copier PWB J connector PJ7C is loose YES Reconnect NO Change Inverter Board PU2 Change Control Board copier PWB C ...

Page 248: ...r scratchy YES Clean or change 6 PH window of the PH Unit is dirty or scratchy YES Clean or change NO Change IU Input system 1 Original Glass is dirty scratchy worn or damaged YES Clean or change 2 Shading sheet reading portion the por tion on the backside of the Original Glass to which Original Width Scale is affixed is dirty YES Clean 3 Scanner mirrors are dirty scratchy or damaged YES Clean or ...

Page 249: ...dirty or scratchy YES Clean or change 5 Tip of the Fusing Paper Separator Fin ger is dirty scratchy deformed worn or damaged YES Clean or change Fus ing Paper Separator Fingers and finger springs 6 Image condition changes after VG Adjustment has been made YES Readjust For details see SWITCHES ON PWBs TECH REP SET TINGS Input system 1 Original Glass is dirty or scratchy YES Clean 2 CCD Board copier...

Page 250: ...or change 5 PH window of the PH Unit is dirty scratchy or damaged YES Clean or change NO Change IU Input system 1 Original Glass is dirty scratchy worn or damaged YES Clean or change 2 Shading sheet reading portion the por tion on the backside of the Original Glass to which Original Width Scale is affixed is dirty YES Clean 3 Scanner mirrors are dirty scratchy or damaged YES Clean or change 4 CCD ...

Page 251: ... deformed worn or damaged YES Clean or change 6 Toner is even on Sleeve Magnet Roller NO Adjust DB For details see DIS REASSEMBLY ADJUSTMENT 7 Developer is not even in the Developer Mixing Chamber of IU YES Even out developer in the Developer Mixing Chamber 8 DB of IU is plugged with foreign matter such as paper dust YES Remove foreign matter 9 Image Transfer Roller is dirty scratchy deformed worn...

Page 252: ...side copier YES Clean interior 2 Toner is present along the paper path YES Clean 3 Right Fusing Roller is dirty scratchy or damaged YES Clean or change 4 Image Transfer Roller is dirty YES Clean or change 5 Grid bias contact is dirty scratchy deformed worn or damaged YES Clean correct or change NO Change High Voltage Unit HV1 Change Master Board copier PWB A ...

Page 253: ...xing Chamber of IU YES Even out developer in the Developer Mixing Chamber NO Change IU Change Master Board copier PWB A Input system 1 Original Glass is dirty scratchy worn or damaged YES Clean or change 2 Shading sheet reading portion the por tion on the backside of the Original Glass to which Original Width Scale is affixed is dirty YES Clean 3 Scanner mirrors are dirty scratchy or damaged YES C...

Page 254: ...5 5E PC Di152 Di183 TROUBLESHOOTING 01 09 04 T 57 Section Step Check Result Action Input system 9 Control Board copier PWB C connec tor PJ1A is loose YES Reconnect NO Change CCD Unit Change Control Board copier PWB C ...

Page 255: ... UN1 and developer YES Change Master Board copier PWB A Input system 1 Original Glass is dirty scratchy worn or damaged YES Clean or change 2 Shading sheet reading portion the portion on the backside of the Original Glass to which Original Width Scale is affixed is dirty YES Clean 3 Scanner mirrors are dirty scratchy or dam aged YES Clean or change 4 Exposure Lamp LA2 is dirty YES Clean or change ...

Page 256: ...curely fastened using the dedicated fixing screws NO Secure in position 2 Scanner Motor M5 drive mechanism is dirty or damaged YES Clean or change 3 Timing belt of the scanner drive mecha nism is dirty with foreign matter or out of correct position YES Remove foreign mat ter or reinstall belt 4 Scanner drive mechanism pulley is dirty with foreign matter scratchy deformed worn or damaged YES Remove...

Page 257: ...rn OFF and ON the Power Switch oL Front Door Right Door or Side Door is open Close the open door or lower the ADF oU ADF is raised oA ADF document take up door is open H11 Scan image memory over Turn OFF and ON the Power Switch H2 The length of the paper set does not match that of the paper actually taken up and fed in Load paper of the correct size again according to the set paper size Turn OFF a...

Page 258: ... Turn OFF and ON the Power Switch Blank Mechanical total counter not con nected Connect the mechanical total counter and then turn OFF and ON the Power Switch Change setting in Security mode For details see SWITCHES ON PWBs TECH REP SETTINGS nc1 Maintenance Counter count value reached the set count of the Mainte nance Counter is reached Enter a count value again For details see SWITCHES ON PWBs TE...

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