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FrameMaker Ver.5.5(PC) Di251/Di351 TROUBLESHOOTING
05.03.01

T-10

3-2.

Size Error

• The following warning screen appears if the actual size of the paper loaded in a paper

source differs from the paper size set for that particular paper source.

✽

1st to 5th Drawer: A size error is indicated by a highlighted paper source in the copier

overview display.

<Resetting the Size Error Display>
• Press the Panel Reset key.
• Slide out the drawer, then slide it back in, or load paper in the Manual Bypass Tray.

<Causes of a Size Error>
• Wrong paper size settings have been made.
• The user loads paper of a size different from what is set for the paper source.
• Two or more sheets of paper are being taken up and fed in.

1st to 5th Drawer

Manual Bypass

4011T546CA

4011T547CA

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Summary of Contents for Di251

Page 1: ...Di251 Di351 SERVICE MANUAL GENERAL 4011 7990 11 ...

Page 2: ...INDEX GENERAL GENERAL MECHANICAL ELECTRICAL ...

Page 3: ...GENERAL ...

Page 4: ...allation Site G 9 3 2 Power Source G 9 3 3 Grounding G 9 4 PRECAUTIONS FOR USE G 10 4 1 To ensure that the copier is used in an optimum condition G 10 4 2 Operating Environment G 10 4 3 Power Requirements G 10 4 4 Note G 10 5 HANDLING OF CONSUMABLES G 11 6 OTHER PRECAUTIONS G 12 7 SYSTEM OPTIONS G 13 ...

Page 5: ...Performance Stan dard according to the Food Drug and Cosmetic Act of 1990 Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health CDRH of the U S Food and Drug Administration of the U S Depart ment of Health and Human Services DHHS This means that the device does not produce hazardous laser radiation CAUTION The use...

Page 6: ... Di251 775 795 nm Di351 ADVARSEL Usynlig laserstråling ved åbning når sikkerhedsafbrydere er ude af funktion Undgå udsættelse for stråling Klasse 1 laser produkt der opfylder IEC60825 sikkerheds kravene Dansk Dette er en halvlederlaser Laserdiodens højeste styrke er 5 mW Di251 15 mW Di351 og bølgelængden er 770 795 nm Di251 775 795 nm Di351 LUOKAN 1 LASERLAITE VAROITUS Laitteen käyttäminen muulla ...

Page 7: ...n halvledarlaser Den maximala effekten för laserdioden är 5 mW Di251 15 mW Di351 och våglängden är 770 795 nm Di251 775 795 nm Di351 ADVERSEL Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisning kan brukeren utsettes för unsynlig laserstrålning som overskrider grensen for laser klass 1 Dette en halveder laser Maksimal effekt till laserdiode er 5 mW Di251 15 mW Di351 og bφlg...

Page 8: ...side the copy machine as shown below Please read the following for your own protection Opening the cover indicated by the Caution label may expose you to harmful laser radiation which could cause damage or loss of eyesight Do not open the cover when the power is on Caution 1166O234AA ...

Page 9: ...atteri Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten Brukte batterier kasseres i henhold til fabrikantens instruksjoner Sweden only VARNING Explosionsfara vid felaktigt batteribyte Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren Kassera använt batteri enligt fabrikantens instruktion Finland only VAROlTUS Paristo voi räjäh...

Page 10: ...ial paper 2nd Drawer 500 Sheets Plain paper 35 CPM 25 CPM Standard Mirror Scanning Slit Exposure 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 L Paper Source 1st Drawer Manual Feed Tray Type Plain paper 60 to 90 g m2 Transparencies Thick paper 91 to 1...

Page 11: ...00 Variable 25 to 400 in 0 1 increments LENS EXPOSURE LAMP FUSING TEMPERATURE Through Lens F 4 0 f 62 mm Fluorescent Lamp 190 C Exposure Lamp Rating Fusing Roller Heater Lamp Rating Max Power Consumption full system Max Current Consumption full system 24 V 20 W 35 CPM 800 W 25 CPM 800 W 230 V 1450 W Metric area 35 CPM 25 CPM 6 A Inch area 35 CPM 25 CPM 11 5 A POWER REQUIREMENTS 230 V 50 60 Hz Temp...

Page 12: ...tric area 35 CPM W 632 mm D 707 mm H 647 mm 25 CPM W 594 mm D 707 mm H 647 mm Inch area 35 CPM W 25 D 27 3 4 H 25 1 2 25 CPM W 23 1 2 D 27 3 4 H 25 1 2 Metric area 35 CPM 60 5 kg 25 CPM 58 7 kg Inch area 35 CPM 133 1 2 lb 25 CPM 129 1 2 lb ...

Page 13: ...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 nism Make the followi...

Page 14: ...ot 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 4 2 Operating Environment The operating environmental requirements of the copier are as follows Temperature 10 to 32 C Humidity 15 to 85 RH Rate of temperature change 10 ...

Page 15: ...e 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 bury in the ground or thro...

Page 16: ... 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 beam path during the ser...

Page 17: ...y Cabinet PF 117 9 Copy Table 10 Copy Desk 11 Printer Controller Pi3502 12 8MB 16MB 32MB Memory 13 Data Terminal DT 103 14 Finisher FN 109 15 Finisher FN 110 16 Job Tray JS 201 17 Shift Tray OT 102 18 Option Tray JS 100 19 Mailbin Finisher FN 504 1166O014AA 1166O007AA 1 2 3 4015O025AB 4015O028AB 5 4015O027AA 4015O029AA 1166O190AA 1166O191AB 6 7 10 8 9 4002O099AA 4002O102AA 1166O012AA 1166O011AA 40...

Page 18: ...MECHANICAL ELECTRICAL ...

Page 19: ...inal Size Detection M 18 11 3 Original Size Detection Timing M 19 12 PH SECTION M 20 12 1 Laser Emission Timing M 21 13 DEVELOPING UNIT M 22 13 1 Sleeve Magnet Roller M 23 13 2 Developing Bias M 23 13 3 ATDC Sensor M 24 1 ATDC Sensor Automatic Adjustment M 24 2 Toner Replenishing Control M 24 3 Toner Empty Control T C Recovery Mode M 25 13 4 Toner Bottle Home Position Detection Mechanism M 26 13 5...

Page 20: ...2 Synchronizing Roller Drive Mechanism M 38 17 IMAGE TRANSFER AND PAPER SEPARATION M 39 17 1 PC Drum Paper Separator Fingers M 39 18 PC DRUM CLEANING M 40 19 ERASE LAMP M 41 20 FUSING UNIT M 42 20 1 Fusing Unit Drive Mechanism M 43 20 2 Fusing Temperature Control M 44 1 Temperature Control Table during Standby State and Copy Cycle M 44 20 3 CPM Control M 44 21 PAPER EXIT UNIT M 45 22 OTHER UNITS A...

Page 21: ...ller 8 Fusing Transport Roller 9 Right Fusing Roller 10 Image Transfer Roller 11 Synchronizing Roller 12 Manual Bypass Tray 13 Manual Feed Paper Take Up Roll 14 Paper Separator Pad 15 Paper Take Up Roll 16 Imaging Cartridge I C 17 PH Unit 18 Left Fusing Roller 4011M001AA 2 3 1 4 5 6 7 8 9 10 11 13 14 15 16 17 18 12 ...

Page 22: ...he laser light is controlled 5 Laser Exposure A laser beam strikes the surface of the PC Drum creating an electrostatic latent image 6 Development Negatively charged toner adheres to the latent image on the PC Drum surface creating a visible image AC DC negative bias voltages are applied to the Sleeve Magnet Roller thereby prevent ing toner from sticking to the background Toner scraped off by the ...

Page 23: ...k to the Developing Unit 12 Erase The PC Drum is exposed to light which effectively neutralize any residual charge on the surface of the PC Drum 13 Fusing Heat and pressure applied by the Right and Left Fusing Rollers fuse toner on the paper 14 Paper Exit Feeds paper out of the copier onto the Exit Tray ...

Page 24: ...M 4 3 DRIVE SYSTEM 1 Scanner Motor M10 2 Main Motor M2 3 I C Motor M1 1 3 2 4011M002AA ...

Page 25: ... Solenoid SL1 Polygon Motor M5 Synchronizing Roller Sensor PC2 Synchronizing Clutch CL1 Paper Exit Sensor PC3 I C Motor M1 Laser Drum Charge Bias Image Transfer Bias Developing Bias Full speed Full speed 170 Full speed Full speed 1 When the Main Motor or I C Motor remains energized for a continuous 300 ms period 2 When the Main Motor and I C Motor remain deenergized for a continuous 10 s period Ha...

Page 26: ...erates erratically If a copier CPU overruns All CPUs including those of the options are reset and a restart sequence is performed If the overrun occurs during a copy cycle the copier tries to feed all sheets of paper out of itself before resetting the CPU Any sheet of paper that could not be fed out of the copier is detected as a sheet of paper left when the restart sequence is later carried out I...

Page 27: ...s I C Thermistor is used to detect temperature and according to the detected temperature Vg Vb is corrected PC Drum deterioration correction To compensate for degraded sensitivity caused by a deterio rating PC Drum Vg is corrected according to the period of time during which the PC Drum has turned 1171M028AA PC Drum Charge Corona PC Drum Revolution Counter I C Thermistor TH2 Grid Voltage Vg Develo...

Page 28: ...IDGE I C This copier employs an Imaging Cartridge I C in this manual The I C contains a PC Drum Developing Unit PC Drum Charge Corona and a Cleaning Unit as one unit Toner Supply Port 1171M002AA 1171M003AA ATDC Sensor UN2 ...

Page 29: ...d and closed the copier deter mines whether the I C is new or one which has been used previously The copier monitors the I C life by storing in memory the period of time during which the PC Drum has turned The data is cleared when a new I C is installed in the copier Electrical Component Control Signal ON OFF Wiring Diagram M1 PJ5A 3 L H 5 G 4011M021AA PC Drum Drive Gear Hopper Drive Gear I C Moto...

Page 30: ...rt layer 8 1 Grounding of the PC Drum The potential of the areas on the surface of the PC Drum exposed to the laser light is grounded to the frame 1139M007AA 1167M007AA PC Drum Cross Section Gear PC Drum Charge Transport Layer Charge Generation Layer Aluminum Base 1171M005AA Ground Plate Shaft Ground Point PC Drum ...

Page 31: ...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 Electrical Component Control Signal ON OFF Wiring Diagram Drum charging output PJ15A 4A L H 6 E 1171M006AB PC Drum PC Drum Charge Corona 1171M008AC Comb Electrode Grid Mesh ...

Page 32: ...na is absorbed from the air which is being drawn out of the copier by the Ozone Fan Motor by the ozone filter located beneath the motor Electrical Component Control Signal ON OFF Wiring Diagram M8 PJ10A 4 H L 8 F 4011M025AA I C Ozone Fan Motor M8 Ozone Filter ...

Page 33: ...nsor PC14 4 Original Size Detecting Sensor 4 UN6 5 Exposure Lamp LA2 6 Original Size Detecting Sensor 6 UN8 7 Scanner Motor M10 8 Original Size Detecting Sensor 1 UN3 9 Original Size Detecting Sensor 2 UN4 10 Original Size Detecting Sensor 3 UN5 11 Scanner Home Position Sensor 1 PC12 12 Size Reset Switch S6 13 CCD2 Board CCD2 14 Lens 15 Scanner 16 Scanner Home Position Sensor 2 PC13 17 2nd 3rd Mir...

Page 34: ...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 Electrical Component Control Signal ON OFF Wiring Diagram LA2 CN13BCR 1 L H 14 B 1167M089AA 2 Exposure Lam...

Page 35: ...g signal the board converts it to 8 bit image data A D conversion It further makes various corrections Compresses the image data stores it and uncompresses it The image memory has a standard capacity of 32MB for the 35 cpm copier and the 25 cpm copier and 16MB for the 20 cpm copier and can be expanded up to 64MB optional 20 cpm copier U S A and Canada Only 3 PH Emits a laser beam according to the ...

Page 36: ...en the AF 9 is used 2 2nd 3rd Mirrors Carriage Moving Mechanism The 2nd 3rd Mirrors Carriage travels at a speed half that of the Scanner thereby keeping constant the optical path length between the original and PC Drum Electrical Component Control Signal Forward Rotation Backward Rotation Wiring Diagram M10 CN3BCR 1 to 3 Pulse output 14 C Electrical Component Control Signal Activated Deactivated W...

Page 37: ... inch areas standard for the metric areas Electrical Component Control Signal Activated Deactivated Wiring Diagram UN3 CN2DSN 4 L H 17 D UN4 CN5BCR 7 L H 14 A UN5 CN5DSNS 4 L H 17 E UN6 CN6BCR 4 L H 15 B UN7 CN3DSNS 1 L H 17 E UN8 metric CN8BCR 4 L H 15 C UN8 inch CN4DSN 4 L H 15 F 4011M011AA Original Size Detecting Sensor 5 UN7 Original Size Detecting Sensor 3 UN5 Original Size Detecting Sensor 4...

Page 38: ...iven level or higher of inten sity 11 2 Original Size Detection The copier CPU determines the correct original size based on the combination of sta tuses of the original either present or absent as detected by the original size detecting sensors Detected by sensor Original Size UN3 UN4 UN5 UN6 UN7 UN8 S1 S2 S3 S4 S5 S6 S7 S8 S9 11 17 A3L A4L A4C A5L B4L B5L B5C Letter L Letter C Legal 1136M020AA ...

Page 39: ...d the Size Reset Switch is actuated Or when the Start key is pressed with the Original Cover Detecting Sensor unblocked Resets size readings When the Original Cover is raised and the Size Reset Switch is just deactuated from the actuated state Electrical Component Control Signal ON OFF Wiring Diagram S6 CN9BCR 2 L H 15 D Electrical Component Control Signal Activated Deactivated Wiring Diagram PC14...

Page 40: ...PH SECTION Image data sent from the memory section is corrected and based on the corrected data a laser light is projected onto the surface of the PC Drum to form a corresponding latent image 1167M022AA PH Unit ...

Page 41: ...on timing A to B LD activation B to C LD OFF C to D Laser beam exposure area according to the image data Electrical Component Control Signal Energized Deenergized Wiring Diagram M5 PJ9A 3 L H 7 G 1167M024AD Polygon Mirror f θ Lens Polygon Motor M5 SOS Mirror Cylindrical Lens Collimator Lens Laser Diode Board PWB B PC Drum SOS Sensor 1171M038AA PC Drum SOS Mirror SOS Sensor SOS Signal A B C D ...

Page 42: ...developed one 1 Spent Toner Recycling Coil 2 PC Drum Charge Corona 3 Spent Toner Feed Roller 2 4 Cleaning Blade 5 Spent Toner Feed Roller 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 UN2 12 2nd Toner Conveying Roller 13 3rd Toner Conveying Roller 14 Spent Toner Recycling Duct 1 2 3 4 5 6 7 8 9 10 11 12...

Page 43: ... Sleeve Magnet Roller to prevent toner from sticking to the background of the image The amount of toner attracted onto the surface of the PC Drum depends on how much lower the PC Drum surface potential Vi is than Vb i e potential difference When the potential difference is large a greater amount of toner is attracted When the potential difference is small a smaller amount of toner is attracted Ele...

Page 44: ...ing Data V Control Details More than 19 Less than 1 41 Defective ATDC Sensor 14 to 19 2 32 to 1 41 Toner replenished for 0 ms 13 to 14 2 50 to 2 32 Toner replenished for 54 ms at intervals of approx 1 s 12 to 13 2 68 to 2 50 Toner replenished for 150 ms at intervals of approx 1 s 10 to 12 3 10 to 2 68 Toner replenished for 378 ms at intervals of approx 500 ms 7 to 10 3 92 to 3 10 Passed onto the T...

Page 45: ...enish ing Motor is energized to replenish the supply of toner into the Developing Unit If T C is not recovered to a level of 13 or higher 2 50 V or less within a given period of time a toner empty condition results Given period of time 35 cpm copier 150 s 25 20 cpm copier approx 209 s 20 cpm copier U S A and Canada Only ...

Page 46: ...er supply port should face up 13 5 Toner Bottle Vibration Mechanism When the dents in the Toner Bottle move past the protrusion of the Bottle Holder the Toner Bottle is vibrated to prevent some of the toner from remaining unconsumed in the bottle Electrical Component Control Signal Activated Deactivated Wiring Diagram PC10 PJ15A 4B L H 4 to 5 F 4011M004AA Toner Bottle Home Position Sensor PC10 113...

Page 47: ...enished each time the Sub Hopper Toner Empty Switch S4 provided in the Sub Hopper is actuated and deactuated Electrical Component Control Signal Energized Actuated Deenergized Deactuated Wiring Diagram M6 PJ15A 1B L H 5 F S4 PJ3A 15B L H 5 H 4011M020AA Toner Bottle Main Hopper Toner Replenishing Motor M6 Sub Hopper Sub Hopper Toner Empty Switch S4 Magnet 1171M021AA Sub Hopper ...

Page 48: ...r the copier has entered the T C recovery mode a toner empty condition is detected Given period of time 35 cpm copier 150 s 25 20 cpm copier approx 209 s If T C drops below 7 as a result of making additional copies after the toner empty con dition has been detected of the Sub Hopper a defective ATDC Sensor results and the copier displays the corresponding malfunction code 20 cpm copier U S A and C...

Page 49: ...of the drawer blocks the 1st Drawer Set Sensor and the copier determines that the drawer has been slid into position Electrical Component Control Signal Activated Deactivated Wiring Diagram PC6 PJ3A 5B L H 6 H Paper Size Detecting Board PWB I Paper Take Up Roll 4011M006AC Paper Size Detecting Sensor CD S5 Light Blocking Plate 4011M007AB 1st Drawer Set Sensor PC6 ...

Page 50: ... near empty condition is detected sensor is blocked the Paper Level LED starts blinking A paper empty condition results when about 50 more sheets of paper are used after the paper near empty condition has been detected Electrical Component Control Signal Activated Deactivated Wiring Diagram PC4 PJ15A 14A L H 6 E Electrical Component Control Signal Activated Deactivated Wiring Diagram PC5 PJ3A 2B L...

Page 51: ...the length of the paper FD while the Paper Size Detecting Sensor CD detects the width of the paper CD A lever is connected to the Trailing Edge Stop of the 1st Drawer while another lever is connected to the Edge Guide of the drawer These levers activate and deactivate the Paper Size Detecting Sensor CD and the switches on the Paper Size Detecting Board The combination of ON or OFF or activated or ...

Page 52: ... L H H H H A4C H H H H H B5L Letter L G Letter L Executive L 8 10 L H H H L L Letter C H H H L H Invoice L H H L L L A4C G Letter C 8 10 C H H L L H A5L H L L H H B5C B6L Executive C L H L L H A5C A6L Invoice C Electrical Component Control Signal Activated Deactivated Wiring Diagram PWB I 1 PJ15A 6B L H 6 F PWB I 2 PJ15A 7B L H 6 F PWB I 3 PJ15A 8B L H 6 F PWB I 4 PJ15A 9B L H 6 F S5 PJ3A 8B L H 6...

Page 53: ...sheet of paper taken up and fed through the space between the Paper Take Up Roll and Separator Pad is the same as that on the backside of the sheet of paper allowing the paper to be properly fed into the copier When two or more sheets of paper are taken up The coefficient of friction between the paper and the Sepa rator Pad is greater than that between the sheets of paper which allows only the top...

Page 54: ...ach the Synchronizing Roller Sensor within a given period of time after the paper take up sequence has been started This sequence is repeated a given number of times 3 Paper Take Up Interval Control To minimize the occurrence of a paper misfeed due to improper paper separation the interval between two paper take up sequences is automatically varied according to the type and size of paper being use...

Page 55: ... feed If the Double Feed Detecting Board detects a sheet of paper the copier retards the start of paper take up sequence for the subsequent sheet of paper a period of time equivalent to about 10 mm Electrical Component Control Signal Activated Deactivated Wiring Diagram PWB H PJ4A 2 L H 6 G Double Feed Detecting Board PWB H Paper Take Up Roll 4011M010AA ...

Page 56: ... for detecting a paper empty condition of the Manual Bypass Tray Electrical Component Control Signal Energized Deenergized Wiring Diagram CL2 PJ2A 9A L H 4 I Electrical Component Control Signal Activated Deactivated Wiring Diagram PC8 PJ2A 7B L H 4 H 4011M023AB Main Motor M2 Manual Feed Paper Take Up Roll Manual Feed Paper Take Up Sensor PC8 Manual Bypass Tray Manual Feed Paper Take Up Clutch CL2 ...

Page 57: ...of the paper transport section 16 1 Paper Dust Remover Paper dust attracted from the paper to the surface of the Synchronizing Roller is trans ferred onto the Paper Dust Remover Synchronizing Roller 4011M018AA Synchronizing Clutch CL1 1171M026AB Paper Dust Remover Synchronizing Roller Synchronizing Roller Sensor PC2 ...

Page 58: ...or the Synchronizing Rollers is provided by the Main Motor through the Synchro nizing Clutch Electrical Component Control Signal Energized Deenergized Wiring Diagram CL1 PJ3A 2A L H 5 I Main Motor M2 Synchronizing Clutch CL1 Synchronizing Roller 1167M064AA ...

Page 59: ...ive image transfer voltage is applied to the roller Paper Separation To neutralize any charge left on the paper to which the image has been transferred a negative voltage is applied to the Charge Neutralizing Plate 17 1 PC Drum Paper Separator Fingers The PC Drum Paper Separator Fingers mechanically separate paper from the surface of the PC Drum to ensure good and positive paper separation Electri...

Page 60: ...aper dust from being compacted on the edge of the Cleaning Blade the PC Drum is turned backward as soon as a copy cycle is completed if the drum has been driven for more than a given period of time Given period of time 35 cpm copier 170 s 25 20 cpm copier 240 s 20 cpm copier U S A and Canada Only 1171M015AA Cleaning Blade PC Drum 1171M016AA Toner Conveying Rollers Recycling Duct Spent Toner Feed R...

Page 61: ...ive charge on the surface of the PC Drum which is positively charged by the Image Transfer Roller The Erase Lamp then illumi nates the surface of the PC Drum to further neutralize it Electrical Component Control Signal All lamps ON Standby ON Wiring Diagram LA1 PJ10A 7 L H 8 F 1171M009AD Erase Lamp LA1 I C PC Drum 1171M010AD PC Drum PC Drum Charge Corona Sleeve Magnet Roller Erase Lamp LA1 Charge ...

Page 62: ... to the paper 1 Paper Exit Roller 2 Fusing Unit Pressure Lever 3 Fusing Transport Roller 4 Paper Exit Sensor PC3 5 Fusing Paper Separator Finger 6 Right Fusing Roller 7 Fusing Roller Heater Lamp H1 8 Left Fusing Roller 9 Fusing Roller Thermostat TS1 10 Fusing Paper Separator Finger 4011M014AB 1 4 3 2 7 9 6 8 10 5 ...

Page 63: ...rive from the Main Motor is transmitted via a gear train to the Left Fusing Roller Electrical Component Control Signal Energized Deenergized Wiring Diagram M2 PJ5A 1 L H 4 to 5 F 4011M017AB Main Motor M2 Left Fusing Roller Paper Exit Roller ...

Page 64: ...ze width of 250 mm or less is used to run a multi copy cycle the temperature on the edges of the Fusing Rollers over which no part of the paper passes tends to run high which can damage the copier To prevent this the paper feed interval is made greater CPM control is activated when the number of copies made on special paper of the small size as counted with an internal counter exceeds 30 If no spe...

Page 65: ...paper which has been transported from the Fusing Unit out of the copier The Charge Neutralizing Brush touches the surface of the sheet of paper being fed out to neutralize any static charge left on it Charge Neutralizing Brush Paper Exit Roller 4011M027AA ...

Page 66: ...er functions as well as counter values When replacing PWB A therefore it is necessary to remount IC3 NOTE When replacing PWB A Master Board care should be used not to change IC3 together with the board For details see DIS REASSEMBLY ADJUSTMENT 22 2 Flash Memory To respond to the need of upgrading software data is written in flash memory using the controller ...

Page 67: ...to blow outside air against the I C thereby preventing low ID and a foggy background from occurring due to an increased temperature of the developer Electrical Component Control Signal Energized Deenergized Wiring Diagram M9 PJ15A 13B L H 6 F 1171M032AB I C I C Cooling Fan Motor M9 ...

Page 68: ...aws air from the area around the Fusing Unit to the outside to prevent the copier interior temperature from running high Electrical Component Control Signal Energized Deenergized Wiring Diagram M3 PJ3A 3A L H 5 I Fusing Unit Cooling Fan Motor M3 4011M015AA ...

Page 69: ...rom the area around the Power Supply Unit to the outside to pre vent the temperature of the unit from running high Electrical Component Control Signal Energized Deenergized Wiring Diagram M4 PJ10A 1 L H 8 F 4011M016AA Power Supply Unit PU1 Power Unit Cooling Fan Motor M4 ...

Page 70: ...Copyright 2001 MINOLTA ME GmbH Printed in Germany Use of this manual should be strictly supervised to avoid disclosure of confidential information MINOLTA ME GmbH 4011 7990 11 ...

Page 71: ...Di251 Di351 SERVICE MANUAL FIELD SERVICE 4011 7991 11 ...

Page 72: ...parts always use the genuine parts specified in the manufac turer s parts manual Installing a wrong or unauthorized part could cause dielec tric breakdown overload or undermine safety devices resulting in possible electric shock or fire Replace a blown electrical fuse or thermal fuse with its corresponding genuine part specified in the manufacturer s parts manual Installing a fuse of a different m...

Page 73: ...ectrical leakage could result in an electric shock or fire Never connect the ground wire to a gas pipe water pipe telephone ground wire or a lightning conductor Modifying this product in a manner not authorized by the manufacturer may result in a fire or electric shock If this product uses a laser laser beam leakage may cause eye damage or blindness To promote safety and prevent product damage mak...

Page 74: ... place disassembled parts or a container of liquid on the product Parts falling into or the liquid spilling inside the mechanism could result in an electric shock or fire Never use a flammable spray near the product This could result in a fire Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors Always use the interlock switch a...

Page 75: ...Removing the cover marked with the following caution label could lead to possi ble exposure to the laser beam resulting in eye damage or blindness Be sure to unplug the power cord before removing this cover If removing this cover while the power is ON is unavoidable be sure to wear protective laser goggles that meet specifications Make sure that no one enters the room when the machine is in this c...

Page 76: ...sageés conformément aux instructions du fabricant Denmark ADVARSEL Lithiumbatteri Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med bat teri af samme fabrikat og type Levér det brugte batteri tilbage til leverandøren Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten Brukte batterier ka...

Page 77: ...rou 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 Check the area surrounding the service site for any signs of damage wear or need of repa...

Page 78: ...rds 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 premises When reassembling parts make sure that the correct screws size type and toothed washer are used in the correct places If it becomes necessary to replace the thermal fuse or any other fuse mount...

Page 79: ...r 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 holding only the edges of the Board When touchin...

Page 80: ... 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 Handling of the PC Drum 1 Place the PC Drum into one half of its carton 1076D001 2 Gently wipe the residual toner off the surface of the PC Drum with a dry Dust Free Cotton Pad A Turn the PC Drum so that the area of ...

Page 81: ...rtridge 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 3 Soak a small amount of either ethyl alcohol or iso propyl alcohol into a clean unused Dust Free Cot ton Pad which has been folded over into quarters Now wipe the surface of the...

Page 82: ...INDEX FIELD SERVICE DIS REASSEMBLY ADJUSTMENT SWITCHES ON PWBs TECH REP SETTINGS TROUBLESHOOTING INSTALLATION ...

Page 83: ...Di251 Di351 Allgemein Mechanik Elektrik Rev 1 1 0 03 01 I 1 INSTALLATION 3 ...

Page 84: ...paper feed unit to the copy table 13 1 2 6 Attaching the paper feed unit to the copy desk 14 1 3 INSTALLATION JS 100 15 1 3 1 Unpacking 15 1 3 2 Installing the Third Tray 15 1 3 3 INSTALLATION JS 201 18 1 3 4 Unpacking 18 1 3 5 Job tray installation 19 1 3 6 Copy Tray Set up 21 1 4 INSTALLATION OT 102 Shift Tray 22 1 4 1 Unpacking 22 1 4 2 Shift Tray Installation 23 1 4 3 Copy Tray Setting up 25 1...

Page 85: ...in the 2 sided original mode 47 1 7 6 Checking the Document Stop Position 47 1 7 7 Adjusting the Document Stop Position 48 1 7 8 Adjusting the Document Stop Position 48 1 7 9 Checking and adjusting the document stop position in the single feed copy mode 49 1 7 10 Checking the Document Stop Position 49 1 7 11 Adjusting the Document Stop Position 50 1 7 12 Checking and adjusting the position of the ...

Page 86: ...y 64 1 8 10 Removing the Rail 64 1 9 INSTALLATION FN 504 65 1 9 1 Unpacking 65 1 9 2 Attaching the Finisher set pin 67 1 9 3 Attaching the pipe 67 1 9 4 How to remove the pipe 68 1 9 5 Installing the transport unit 68 1 9 6 Adjusting the height of the Finisher 69 1 9 7 Connecting the cable 71 1 9 8 Attaching the labels 71 1 9 9 Adjusting the placement of the punch hole 72 1 9 10 Attaching the hold...

Page 87: ...necting the Paper Feed Unit to the Copier 84 1 11 4 Connecting the Paper Feed Unit to the Paper Feed Unit 86 1 11 5 Changing the Paper Size of the Paper Feed Unit 88 1 11 6 Changing the Paper Size of the Paper Feed Unit Fixed Cassette 90 1 11 7 Paper Size Input for the Fixed Cassette 91 1 11 8 Affixing the Labels 92 1 11 9 Adjust the Paper Reference Position 93 ...

Page 88: ...Di251 DI351 Rev 1 1 0 03 01 I 6 ...

Page 89: ...keep the imaging unit in a horizontal position when handling it 1 1 1 Unpacking Remove the imaging unit from the box and check that it contains the following items 1 Imaging unit 1 2 Installation instructions 1 1 1 2 Imaging Unit Installation 1 Remove the seal from the imaging unit 1 2 Seal ...

Page 90: ...e the lock lever and open the right cover 4 Shake the new imaging unit horizontally 5 Align the green labels on both ends of the new imaging unit with the green labels on the rails of the copier and position the imaging unit Grasp the handles to position the imaging unit and push it into the copier Sponge Tape ...

Page 91: ... the right cover NOTE Return the used imaging unit to the service center to ensure efficient use of the earth s natural resources Do not dispose of the unit and be sure to return it to the serviceman 1 1 3 When removing the imaging unit 1 Grasp the green handles and gently pull out the imaging unit NOTE Be especially careful when handling the imaging unit It may be damaged if it is dropped ...

Page 92: ...crews 3 5 Adjusters 2 6 Fixing plates 4 7 Flat head screws 4 8 Grounding plates inside 2 9 Grounding plate right front 1 10 Grounding plate screws 3 1 2 2 Unpacking the Copy Desk 1 Copy desk 1 2 Stabilizers A 2 3 Stabilizer B 1 4 Stabilizers screws 1 5 Adjusters 2 6 Fixing plates 4 7 Flat head screws 4 8 Grounding plates inside 2 9 Grounding plate right front 1 1 2 3 4 5 6 7 8 9 10 ...

Page 93: ...I 5 Di251 Di351 Rev 11 0 0 03 01 10 Grounding plate screws 3 1 2 3 4 5 6 7 8 9 10 ...

Page 94: ...front corner to the copy table copy desk at the positions shown in the illustrations at the left using a grounding plate screw for each plate 2 Using one screw for each stabilizers attach the two stabilizers A and stabilizer B to the copy table or copy desk at the positions shown in the illustration below 3 Attach the two adjusters to the copy table or copy desk at the positions shown in the illus...

Page 95: ...h is not enclosed Caution Be sure to set the adjusters as specified Failure to set the adjusters correctly may cause the unit to become unbalanced and fall possibly resulting in serious injuries 1 2 5 Attaching the paper feed unit to the copy table 1 Place the paper feed unit on top of the copy table so that the rubber feet on the paper feed unit are correctly aligned on the copy table ...

Page 96: ...g connections to the copier refer to Connecting the Op tional Paper Feed Unit to the Copier in the Setup Instructions for the paper feed unit 1 2 6 Attaching the paper feed unit to the copy desk 1 Place the paper feed unit on top of the copy desk ensuring that the two are aligned properly with each other 2 Using the four enclosed fixing plates and fixing plate screws secure the paper feed unit to ...

Page 97: ... Unpack the Third Tray and check that the following components are contained in the box 1 Exit Tray 1 2 Front Cover 1 3 Rear Cover 1 4 Third Tray 1 5 Screw 4 x 10 mm 2 Remove tape and other fixing brackets 1 3 2 Installing the Third Tray 1 Open the Finisher Cover 1 2 3 4 5 ...

Page 98: ... Di251 Di351 Rev 1 1 0 0 03 01 2 Remove one screw from the Dummy Cover 3 Secure the Third Tray using two screws and connect the Hookup Cord to the Finisher 4 Install the Front Cover 5 Install the Rear Cover ...

Page 99: ...I 11 Di251 Di351 Rev 11 0 0 03 01 6 Fit the Exit Tray 7 Close the Finisher Cover ...

Page 100: ...ing 1 Remove the job tray unit and the accessory box 2 Verify the following accessories are in the accessory box 1 Screws 4 mm x 8 mm 3 2 Mounting frame 1 3 Decorative cover 1 4 Copy tray 1 5 Auxiliary tray 1 6 Spring 2 3 Remove the tape from the job tray unit 1 2 3 4 5 6 ...

Page 101: ...ove the rear paper exit cover 1 screw and free the harness that is attached to the backside of the cover NOTE Make sure that the harness does not fall inside the main unit 3 Cut off the treaded tires from only the two Exit Rolls on both sides of the machine 4 Use two accessory screws 4 x 8 mm to secure the mounting frame ...

Page 102: ...he copier harness and plug in the copier harness at the rear of the and the copier NOTE Install the job tray unit rear side and front end so the pins pass through the holes in the parts indicated by the arrows Make sure that the harness is plugged in correctly and that the harness does not become caught between the job tray unit and the copier 7 Use an accessory screw 4 x 8 mm to secure the job tr...

Page 103: ... Set up 1 Reverse the Auxiliary tray and set the spring into place 2 Attach the accessory auxiliary tray to the copier in alignment with the hole at two place in the copier 3 Attach the accessory copy tray by aligning the three tabs of the tray with the three insertion holes of the main unit ...

Page 104: ...Remove the shift tray unit and accessory box 2 Verify the following accessories are in the accessory box 1 Screw 4 mm x 8 mm 4 2 Mounting frame front 1 3 Mounting frame rear 1 4 Decorative cover 1 5 Copy tray 1 3 Remove the tape and securing materials 1 2 3 4 5 Tape Tape Securing material ...

Page 105: ... attached to the backside of the cover NOTE Make sure that the harness does not fall inside the copier 3 Cut off the treaded tires from the Exit Rolls of the machine 4 Use three screws 4 8 mm to secure the rear end of the mounting frames front rear from the front side of the copier as shown NOTE Install the mounting frame so the pins pass through the holes at the rear side of the copier ...

Page 106: ...t the rear of the unit NOTE Install the shift tray unit front end so the pin passes through the hole in the part indicated by the arrow Make sure that the harness is plugged in correctly and that the harness does not become caught between the shift tray unit and the copier 7 Use an accessory screw 4 x 8 mm to secure the shift tray unit at the front 8 Press on the decorative cover ...

Page 107: ...I 19 Di251 Di351 Rev 11 0 0 03 01 1 5 3 Copy Tray Setting up Install the accessory copy tray in the shift tray unit ...

Page 108: ...s not to raise the unit 2 Verify the packing contents 1 Automatic duplex unit 1 2 Unpacking and setting up instructions 1 1 6 2 Automatic Duplex Unit Setting up 1 Turn off the power and disconnect the power cord and interface cable from the copier Open the manual feed table 2 Remove the Duct Cover for Di251 only 3 Peel off the polyester film as shown UNPACKING SETTING UP INSTRUCTIONS ...

Page 109: ...n for transfer Keep them in a safe location and be careful not to lose them 6 Align the bottom hooks and the drive gear of the unit with the mounting site on the copier and mount the duplex unit NOTE Make sure that the drive gears of the duplex unit and copier are correctly and fully engaged 7 Tighten the accessory screws the two screws are pre installed in the screw holes and secure the unit to t...

Page 110: ...NOTE After the automatic duplex unit is installed opening the duplex unit may unbalance the copier or cause it to shift position due to the added weight Be sure to switch the tension after installation 2 Reinstall the exit tray 1 6 4 Reference Gap Adjustment 1 Access the service mode screen Refer to the service manual 2 Press the stop key and then immediately press the start key The Adjust Mode wi...

Page 111: ...uch Test Print 6 Touch Duplex and press the start key Measure margins A and B on the copy Standard Values A4C 10 0 mm 3 0 mm Letter C 10 0 mm 3 0 mm If the measured width is not within the standard values use the following procedure for adjustment A B Main scanning direction Secondary Scanning Direction ...

Page 112: ...0 03 01 7 After pressing the Clear key you can change the value using the key pad Use the key to change between and 8 Touch OK to complete the setting 9 Make another test copy and check the image once again 1 2 3 4 5 6 7 8 9 0 C ...

Page 113: ...ATION AF 9 1 7 1 Unpacking ADF Kit I shown below must be installed when installing the ADF Original Glass for AF 9 1 1 7 2 Installing ADF Kit 1 Remove the caps two 2 Remove the Upper Front Cover two screws 3 Remove the Original Cover brackets two ...

Page 114: ...1 Rev 1 1 0 0 03 01 4 Remove the Upper Left Cover two screws 5 Remove the Original Glass 6 Remove the Right Rear Cover 7 Remove the Rear Upper Cover two screws 8 Press the Original Glass toward the rear of the copier ...

Page 115: ... Glass Support furnished with the ADF 10 Press ADF Glass Assy up against the Glass support and secure it in position two screws Use the screws that have been removed in step 4 to secure the assy in position Use the ADF Glass Assy furnished with the ADF 11 Install the Original Cover brackets at the locations shown one screw each Use the screw which has been removed in step 3 for A Use the screw con...

Page 116: ...uded 1 ADF Glass Assy 1 2 Glass support 1 3 Tray 1 4 Holder 1 5 Screw 3 6mm Black 3 Screw 4 8mm Silver 3 1 7 4 Installation 1 Remove the Right Rear Cover 2 Unplug the connector that is connected to the copier NOTE Tidy up the connector which has been removed to ensure that it does not interfere with the subsequent steps 1 2 3 4 5 ...

Page 117: ...nnect the two connectors of the Automatic Document Feeder and install the ground wire Screw 4x8 Silver 5 Insert the tie band fitted to the cable of the Automatic Document Feeder into the frame of the copier to secure the cable in position 6 Secure the ADF Screw 4x8 Silver 7 Cut out the knockout shown in the illustration 8 Reinstall the cover which has been removed ...

Page 118: ...ference line in the feeding direction B FD 2 Load the test chart in the ADF and make a full size copy 3 Check that the lengths of the reference lines reproduced on the copy A CD and B FD meet the following specifications Reference Line Registration Specifications A CD 200 2 0 mm B FD 300 4 5 mm If the length of the line reproduced on the copy falls outside the specified range make the Registration...

Page 119: ...stration Adjustment 1 Access the Tech Rep Mode menu on the Touch Panel For details on how to access the menu see the Service Manual 2 Touch Tech Rep Choice 3 Touch Scan through ADF 4 Touch Zoom adjust 5 Touch CD Copier or FD Copier Level History ...

Page 120: ... a copy again and check for correct zoom 1 7 7 Checking for Registration 1 Prepare a test chart A3 as shown Draw a straight reference line at a point 20 mm from the rear edge and another at a point 20 mm from the top edge of the chart 2 Load the test chart in the ADF and make a full size copy 3 Check that the margins reproduced on the copy meet the following specifications Margin Registration Spec...

Page 121: ... 8 Registration Adjustment 1 Access the Tech Rep Mode menu on the Touch Panel For details on how to access the menu see the Service Manual 2 Touch Tech Rep Choice 3 Touch Scan through ADF 4 Touch Registration 5 Touch CD or FD Level History ...

Page 122: ...unit 1 mm 24 dots 7 Press the Clear key 8 Press the key to change the sign to select either or 9 Enter the numeric value from the 10 Key Pad 10 Touch END to go back to the initial screen Make a copy again and check for correct registration Registration CD Registration FD direction direction direction direction ...

Page 123: ...ling 1 Remove the Rear Cover two screws of the copier 2 Tighten the two Shoulder Screws that come with the document feeder into the holes in the rear 3 Lift the Duplexing Document Feeder up and set it onto the copier so that the screws mentioned above fit into the holes of both hinges NOTE When mounting the Duplexing Document Feeder be careful to hold it by the top and bottom sides 1 2 3 ...

Page 124: ...rews completely with a screwdriver so that they will not come loose NOTE Tighten the Shoulder Screws until there is no clearance between the hinges and the copier body 5 Remove all the tape from the Duplexing Document Feeder Remove the plastic bag from the Hookup Cord 6 Install the exit tray 7 Secure the screw from underneath the unit Tapes ...

Page 125: ...the following modes Auto Paper Select One sided Original One sided Copy 3 Place a sheet of A4 or Letter paper crosswise onto the Document Feed Tray 4 Press the start key and open the paper guide F1 as soon as the paper is fed into the unit and the scanning starts 5 After the paper is fed onto the Original Glass open the Duplexing Document Feeder gently NOTE If the Duplexing Document Feeder is open...

Page 126: ... Left Hinge 2 If the paper on the Original Glass leans like a shift the right side of the Duplexing Document Feeder toward the rear side If the original leans like b shift the right side of the Duplexing Document Feeder toward the front side Then tighten the shoulder head screws 1 8 4 Checking and adjusting the document stop position in the 1 side original mode 1 Set the copier into the following ...

Page 127: ...p Position Measure the distance the edge of the sheet deviates in the c or d direction from the edge of the Original Scale Recommended Within 1 mm in the C direction from the edge of the Original Scale If the distance is out of tolerance carry out the following procedure Adjusting the Document Stop Position 1 Access the initial Tech Rep Mode screen Refer to the Service Manual for the procedure 2 T...

Page 128: ...mode 6 After pressing the Clear key use the key pad to enter the adjustment Use the key to switch between and Adjusts in direction C Adjusts in direction D 7 Press the Panel Reset Key to display the Service Mode screen and touch the Stop key Check the document stop position again Panel Reset ...

Page 129: ...s the scanning for the 2nd side of the original starts 4 After the paper is fed onto the Original Glass open the Duplexing Document Feeder gently NOTE When the Duplexing Document Feeder is opened quickly the paper will be knocked out of position 1 8 6 Checking the Document Stop Position Measure the distance the edge of the sheet deviates in the c or d direction from the edge of the Original Scale ...

Page 130: ...4 Touch Original Stop Position 1 8 8 Adjusting the Document Stop Position 1 Select the 2 Side Set mode 2 After pressing the Clear key use the key pad to enter the adjustment Use the key to switch between and Adjusts in direction C Adjusts in direction D 3 Press the Panel Reset Key to display the Service Mode screen and touch the Stop key Check the document stop position again Level History Panel R...

Page 131: ...and the scanning starts open the paper guide F1 immediately 4 After the paper is fed onto the Original Glass open the Duplexing Document Feeder gently NOTE When the Duplexing Document Feeder is opened quickly the paper will be knocked out of position 1 8 10 Checking the Document Stop Position Measure the distance the edge of the sheet deviates in the c or d direction from the edge of the Original ...

Page 132: ...reen Refer to the Service Manual for the procedure 2 Touch Tech Rep Choice 3 Touch ADFR 4 Touch Original Stop Position 5 Select the Single Feed Set mode 6 After pressing the Clear key use the key pad to enter the adjustment Use the key to switch between and Adjusts in direction C Adjusts in direction D Level History ...

Page 133: ...pier into the following modes Auto Paper Select One sided Original One sided Copy 2 Place a sheet of A4 or Letter paper crosswise onto the Document Feed Tray 3 Press the Start Key and openthe paper guide F1 as soon as the scanning starts 4 After the paper is fed onto the Original Glass open the Duplexing Document Feeder gently NOTE When the Duplexing Document Feeder is opened quickly the paper wil...

Page 134: ... 0 mm To the front More than 5 0 mm To the back 1 8 15 Checking and adjusting the position of the guide plate in the single feed copy mode 1 Set the copier into the following mode Auto Paper Select One sided Original One sided Copy 2 Insert a sheet of A4 or Letter size paper crosswise into the Single Feed Tray along the Rear Paper Guide 3 When the paper feeds automatically and the scanning starts ...

Page 135: ...D Scale Allowable deviation 4 0 1 0 mm 1 8 17 Adjusting the Position of the Single Feed Copy Move the Guide Plate to the front or back as necessary to meet the above requirements Less than 3 0 mm To the front More than 5 0 mm To the back 1 8 18 Securing the stoppers Remove the shoulder screws one each at the right and left hand side in the rear of the copier and tighten these shoulder screws into ...

Page 136: ...copier to the height of the finisher the copy desk or the copy table and additional paper feed units or the large capacity cabinet must be installed 1 Copier Paper Feed Unit three drawers Copy Table 2 Copier Paper Feed Unit one drawer Large Capacity Cassette 3 Copier Paper Feed Unit one drawer Copy Desk ...

Page 137: ...nd then check that the following accessories are also enclosed 1 Rail guide 1 2 Rail 1 3 Stabilizing pin 1 4 Magnet 1 5 Horizontal transport unit 1 6 Horizontal transport unit mounting base 1 7 Tray 1 8 Protective guide 1 9 Labels 2 10 Screws 3 11 Setup instructions this manual 1 1 2 3 4 5 6 7 8 9 10 ...

Page 138: ...I 50 Di251 Di351 Rev 1 1 0 0 03 01 2 Remove all tape and packing brackets On the FN 109 NOTE Do not remove these parts Packing bracket Tape Packing bracket Packing bracket ...

Page 139: ...e the copier unnecessarily If it is necessary to move the copier follow the procedure described under Removing the rail on page I 57 After moving the copier perform the operations described in Installing the Horizontal Transport Unit and Installing the Stabilizing Pin and Rail NOTE Do not remove these parts Packing bracket Packing bracket Tape ...

Page 140: ...as shown in the illustration If the large capacity cabinet copy table or copy desk is installed attach the rail guide at the same location NOTE Be sure to fit the correct side of the rail guide onto the copier and make sure that it snaps into place 4 Insert one end of the rail into the rail guide on the copier 5 Slide the other end of the rail installed in step 3 into the rail guide on the finishe...

Page 141: ...holes at two places in the copier 3 Mount the Horizontal Transport Unit on the exit section of the copier 4 Open the cover of the Horizontal Transport Unit and fit the shaft of the Horizontal Transport Unit into position as illustrated 5 Make sure that the gears on the Horizontal Transport Unit and the Finisher are in positive engagement with each other Then secure the Horizontal Transport Unit wi...

Page 142: ...then remove the lower front cover two screws of the finisher 3 Lift the finisher s two caster covers up and then pull them off 4 Without turning the adjusting bolt lower bolt on the caster loosen the securing bolt upper bolt and then turn the adjusting bolt lower bolt as indicated below to adjust the height of the finisher Two rear casters If the stabilizing pin is too high Turn the bolt clockwise...

Page 143: ...lts lower bolts tighten the four securing bolts upper bolts 7 Re install the caster covers and the lower front cover two screws 1 9 5 Connecting the Hookup Cord Insert the connector on one end of the hookup cord into the connector on the horizontal transport unit and then insert the connector on the other end of the hookup cord into the connector on the copier 1 9 6 Installing the Tray and Protect...

Page 144: ...I 56 Di251 Di351 Rev 1 1 0 0 03 01 1 9 7 Affixing the Labels Affix the enclosed operation labels 1 Label for the copier AFR 17 Label for ADF AF 9 For Copier For ADF ...

Page 145: ...ishing 4 Touch Hole Punch so that its background changes to black 5 Press the Start key 6 Fold the paper that is fed out in half and check that the punched holes are aligned Standard position 2 mm If the punched holes are not at their standard positions adjust the hole punching position Mixed Orig Detection Memory Free Memory Free Select a finishing mode Use SELECT POSITION to Select the hole punc...

Page 146: ...n check that the punched holes are aligned NOTE If the punched holes are not at their standard positions adjust the hole punching position 1 9 10 Removing the Rail 1 Pinch together the rail stoppers on the left side of the finisher to release them 2 Disconnect the two hookup cords 3 Remove the horizontal transport unit from the finisher and then place it on top of the copier 4 Carefully pull the f...

Page 147: ...ION FN 504 1 10 1 Unpacking 1 Remove the main unit Finisher transport unit and accessories from the box 2 Remove all other plastic wrappings tape and packing materials FINISHER main unit Cushion Label Tape Tape wait to remove during the installation ...

Page 148: ... a large capacity unit or Copy Desk in order to install the Finisher Make sure that the unit is set up on a level surface After the setting up procedures have been completed do not move the entire system unless absolutely necessary If for some reason it should become necessary to move the system first remove the horizontal transport unit and then remove the pipe from both the Finisher and the copi...

Page 149: ...ding to the copier as shown in the diagram NOTE The black guide rail molding will click into place when properly installed 2 Insert one end of the pipe into the insertion guide that is attached to the side of the Tray NOTE The black guide rail molding will click into place when properly installed 3 Set the finisher with the main unit by inserting one end of the pipe that was used in STEP 2 into th...

Page 150: ...ng the transport unit 1 Cut off the treaded tires from the Exit Rolls of the machine 2 Install the feeder attachment of the transport unit onto the main unit NOTE Be sure to align the pins 2 located on the bottom of the feeder attachment with the holes 2 of the main unit during installation 3 Mount the horizontal transport unit on the exit section of the copier 4 Open the cover of the horizontal t...

Page 151: ...Separate the Finisher from the copier 2 Check to make sure that the horizontal transport unit is not leaning If the horizontal transport unit appears to be leaning use the following procedure to adjust the standing position of the unit 3 Loosen the front and back wing bolts 2 located on the right side of the Finisher and use the adjust bolt to adjust the height If the horizontal transport unit app...

Page 152: ... the gap using the following instructions 6 Remove the covers from the casters 7 Loosen the front and back wing bolts 2 and use the adjust bolt to adjust the gap a b turn the adjust bolt clockwise a b turn the adjust bolt counter clockwise 8 After the gap has been adjusted tighten the front and back wing bolts 2 and set the adjust bolts Replace the covers onto the casters Adjust bolt Wing bolts ...

Page 153: ...f the mail bin with the holes of the copier 9 to install the mail bin 1 10 7 Connecting the cable 1 Remove the panel cover from the copier unit 2 Connect two cables to the copier as shown 1 10 8 Attaching the labels Attach the labels that came with the Finisher 1 Label 1 for the copier 2 Label 2 for the ADF 1 2 2 AFR 17 AF 9 for the copier for the ADF ...

Page 154: ...main unit s Tray1 are finished 1 Select the A4 horizontal tray 2 Touch the Non Sort key 3 Touch the Hole Punch key 4 Touch Select Position 5 Select the position of the punch hole 6 Press the Start key Mixed Orig Detection Memory Free Memory Free Memory Free Select a finishing mode Use SELECT POSITION to Select the hole punching positon Memory Free OFF ...

Page 155: ...oor and remove the cover of the Finisher as shown in the illustration 10 Using a coin or similar instrument loosen the screw as shown in the illustration 11 Using the green lever move the hole punch guide left or right in order to adjust the hole punch position Use the measuring scale above the green lever as a guide to determine the amount of the adjustment 12 Retighten the screw and output anoth...

Page 156: ... 01 1 10 10 Attaching the holder for the instruction manual Place the holder in the position shown in the illustration NOTE If a holder has already been installed onto the copier reposition it as shown in the illustration to the left ...

Page 157: ...ng plate 4 2 Flat head screw 4 3 L shaped stopper 1 4 Stopper 4 5 Stopper cover 2 6 Thumbscrew short 4 7 Thumbscrew long 2 8 Power supply harness 1 2 Remove the tape from each parts 3 Pull out the tray and remove the packing material NOTE Be sure to remove the packing material before setting the copier onto the Cabinet 4 Return the tray to its original position 1 2 3 4 5 6 7 8 Tape Tape Tape Cushi...

Page 158: ...stoppers in the positions shown in the figure 2 Install the stopper covers over the 2 front stoppers 3 Use the Long thumbscrews to install the L shaped stopper to the rear side of the cabinet 1 11 3 Support Adjustment Unscrew the 3 supports on the front and right side of the main unit firmly against the floor ...

Page 159: ... in position if they are out of the harness holder 2 Aligning the rubber feet of the Paper Feed Unit with the positioning pins of the Large Capacity Cabinet mount the unit onto the cabinet 3 Holding the four carrying handles of the main copier unit align the rubber feet and setting pins of the optional cassette and set the copier on the cassette 4 Use the flat head screw and fixing plates to secur...

Page 160: ... to the Powe Supply harness The connector of the P S harness can be connected to any receptacle 9 Reinstall all covers into positions 1 11 5 Paper Size Setting The initial setting is for A4C 1 Push in the front and rear edges of the trays as far as they will go 2 Change the positions of the rear and side edge guide plates shown in the figure to adjust the paper size One screw in each location Remo...

Page 161: ...binet 5 Refer to the following chart and set the dip switches to adjust the size 6 Reinstall the cover 1 11 6 Attaching the paper size label Affix the paper size label and cassette number label included in the main unit s package in the locations show in the diagram SW1 1 2 3 4 Letter C OFF OFF OFF OFF A4 C ON OFF OFF OFF B5 L OFF ON OFF OFF ON 1 2 3 4 Cassette number label Label ...

Page 162: ...r C paper and close it Select this drawer as the paper source and 1 sided 2 sided copying 2 Access the initial Rep Mode screen Refer to the Service Manual for the procedure 3 Press the stop key and then immediately press the start key 4 Touch Printer 5 Touch the key for the direction to be adjusted 6 Touch Test Print ...

Page 163: ...the following procedure for adjustment 8 Touch OK to complete the setting 9 Touch the key representing the drawer selected as the paper source 10 After pressing the Clear key you can change the value using the key pad Use the key to change between and 11 Touch OK to complete the setting 12 Make another test copy and check the image once again A Main scannning direction 1 2 3 4 5 6 7 8 9 0 C ...

Page 164: ...Remove the large capacity cabinet from the box and make sure that the following accessories are contained in the box 1 Fixing plate 4 2 Flat head screw 4 3 Bracket 1 4 Screw 2 5 Harness 1 6 Power supply harness 1 with core 1 7 Power supply harness 2 1 8 Label PF 118 only 1 1 2 3 4 5 6 7 ...

Page 165: ...Grasp the front and rear handles of the copier and set it on the paper feed unit 3 Slightly pull out the paper drawers of the copier s paper feed unit and the optional paper feed unit and then secure the optional paper feed unit to the copier using the enclosed fixing plates and flat head screws Cushion ...

Page 166: ... the rear Cover from the Paper Feed Unit 3 Remove the bracket from the Paper Feed Unit for Di251 and Di351 4 Connect the Harness furnished with the Paper Feed Unit to the copier and the Paper Feed Unit NOTE Push the Harness into a recess in the rear as illustrated to ensure easy and proper installation of the Bracket in the subsequent step ...

Page 167: ...of the Bracket 6 Accessing through the hole in the Bracket connect the connector white portion of Power Supply Harness 1 with a core 7 Connect the connector black portion of Power Supply Harness 1 with a core to the copier NOTE The connector of Power Supply Harness 1 with a core may be connected to any one of the receptacles on the copier 8 Reinstall the rear Cover of each unit 9 Reinstall the con...

Page 168: ...Unit 4 Connect the Harness furnished with the Paper Feed Unit to the Paper Feed Unit NOTE Push the Harness into a recess in the rear as illustrated to ensure easy and proper installation of the Bracket in the subsequent step Connect the Harness furnished with the Paper Feed Unit to the copier NOTE Push the Harness into a recess in the rear as illustrated to ensure easy and proper installation of t...

Page 169: ... bottom of the Bracket 6 Accessing through the hole in the Bracket connect the connector white portion of Power Supply Harness 1 with a core 7 Connect the connector black portion of Power Supply Harness 1 with a core to the connector black portion of Power Supply Harness 2 without core 8 Connect the connector black portion of Power Supply Harness 2 without core to the copier 9 Reinstall the rear C...

Page 170: ...pier 1 12 5 Changing the Paper Size of the Paper Feed Unit 1 Pull out the drawer of the Paper Feed Unit and press down the paper lifting plate until it locks 2 Adjust the front rear edge guide plates and the trailing edge guide plate to the size of the paper that will be loaded ...

Page 171: ... paper that the top of the stack is higher than the mark Be careful not to touch the surface of the paper take up rollers If they have been touched wipe them with a soft dry cloth Be sure the paper is not curled when it is loaded Make sure that the front rear edge guide plates are pressed tightly up against the edges of the paper stack ...

Page 172: ...r lifting plate 4 Refer to the following chart and replace the two springs according to the desired paper size NOTE The replacement springs are stored in the bottom of the front side of the paper feed unit Always set the springs so the upper end of the spring fits into the metal clips of the lifting plate and the lower end fits into the cutout in the bottom of the drawer Paper Size Spring Paper Si...

Page 173: ...paper size CAUTION When installing the edge guides make sure that the fingers fitted to the front rear edge guides are on top of the paper loaded in the cassette 6 Load paper and close the drawer 1 12 7 Paper Size Input for the Fixed Cassette 1 Access the service mode screen Refer to the service manual for the procedure 2 Touch System Input 3 Touch Paper Size Input 4 Select the position where the ...

Page 174: ...351 Rev 1 1 0 0 03 01 5 Touch the paper size to be set 6 Touch END 7 Touch Panel Reset to display the service mode screen 1 12 8 Affixing the Labels Affix the enclosed label for the paper size at the position shown ...

Page 175: ...ith A4 paper 2 Press the stop key and then immediately press the start key 3 Touch Printer 4 Touch Registration CD 5 Touch Test Print 6 Touch the key representing the drawer selected as the paper source and then press the start key Output the test print Standard Values A4C 10 0 2 0 mm Letter C 10 0 2 0 mm ...

Page 176: ...print again and check for correct registration If the width of the measure margin does not meet its standard width follow the instructions described below For Universal Open the paper drawer for the Cassette that needs to be adjusted and then remove all of the paper Loosen the two screws of the drawer watching the scale on the adjusting plate inside the drawer move the guide plate as necessary Aft...

Page 177: ...e cassette that needs to be adjusted and then remove all of the paper Loosen five screws of the drawer Then watching the scale on the adjusting plate move the guide plate as necessary After the adjustment has been made tighten the screws and then produce a test print to check again ...

Page 178: ...I 90 Di251 Di351 Rev 1 1 0 0 03 01 ...

Page 179: ...DIS REASSEMBLY ADJUSTMENT 10230 ...

Page 180: ...TICAL SECTION D 13 1 Removal of the PH Unit D 13 2 Removal of the CCD Unit D 16 3 Cleaning of the Scanner Rails Bushings D 16 4 Cleaning of the Mirrors D 17 5 Cleaning of the Lens D 17 6 Cleaning of the Original Glass D 17 7 Removal of the Scanner D 18 8 Removal of the Scanner Drive Cables D 19 9 Winding of the Scanner Drive Cables D 20 2 6 IMAGE TRANSFER SECTION D 24 1 Removal of the Image Transf...

Page 181: ...3 Loop Adjustment D 37 4 Edge Erase D 38 5 Registration CD Printer D 41 6 Registration FD Printer D 43 7 Registration IR D 45 8 Zoom Adjust IR D 49 9 IR Erasure Width D 53 10 Book Center Erase D 54 3 6 FOCUS POSITIONING OF THE SCANNER AND 2ND 3RD MIRRORS CARRIAGE D 55 4 MISCELLANEOUS D 57 4 1 INSTALLATION OF THE KEY COUNTER SOCKET OPTION D 57 4 2 REMOUNTING THE EEPROM IC3A D 58 4 3 ADJUST DATA INP...

Page 182: ...sembly 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 into the laser beam path Use utmost care when handling tools on the user s premise...

Page 183: ...ssemblies 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 instructions are given in ADJUSTMENT 3 Other Screws Although not ma...

Page 184: ...SASSEMBLY REASSEMBLY 2 1 DOORS COVERS AND EXTERIOR PARTS IDENTIFICATION AND REMOVAL PROCEDURES 4011D113CA 4011D114CA 19 7 1 2 3 4 6 8 9 10 15 12 16 17 18 23 33 32 29 28 26 27 21 31 25 20 24 5 11 22 30 13 14 34 ...

Page 185: ...he Front Cover 13 Multi Purpose Cassette Slide out the Multi Purpose Cassette Pushing the tab on the right rail pull out the cassette 14 Fixed Paper Size Cassette 1 Slide out the Fixed Paper Size Cassette Pushing the tabs on both the right and left rails pull out the cassette 15 Upper Cover Remove two screws that secure the Upper Cover 16 Control Panel Remove no 11 Remove no 17 Remove no 16 Remove...

Page 186: ... Cover 30 Connector Cover Unhook one tab and remove the Connector Cover 31 Harness Cover Remove one screw that secures the Harness Cover 32 Lower Rear Cover Remove no 31 Remove no 30 Remove no 28 Remove three screws that secure the Lower Rear Cover 33 Upper Rear Cover Remove no 31 Open no 7 Remove three screws that secure the Upper Rear Cover 34 Rear Upper Cover Remove two screws that secure the R...

Page 187: ...ow the corre sponding 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 4011D115CA CCD2 PWB A MFB2 PWB M PWB N BCR INV PWB F UN1 PU3 PWB R PWB R2 PWB R2 PWB H PU2 PU1 P...

Page 188: ...B R PWB R2 Pre Transfer Guide Plate Register Board 1 Open the Side Cover and remove the Vertical Transport Unit PWB R2 PWB R2 Pre Transfer Guide Plate Register Board 2 Open the Side Cover Remove the I C Remove one screw and the PWB Cover PWB R2 BCR BCR Board Remove the Left Rear IR Cover Remove three screws and the Harness Cover BCR MFB2 MFB2 Board Remove the Rear Upper Cover Remove the Upper Rear...

Page 189: ...r 900 1164 3515 XX 1 D 11 lower 900 1164 3508 XX 1 D 11 Side Cover Ventilation Fan Section 75 D 12 Other PM Parts 1 Optical Section Mirrors and lens 150 D 17 IR 2 Scanner rails bushings 75 D 16 IR 1 Original Glass 75 D 17 Image Transfer Section Image Transfer Roller Assy 150 4011 0313 XX 1 D 24 Other PM Parts 2 Comb Electrode 75 1 D 24 Other PM Parts 1 Pre Transfer Guide Plate 75 1 D 25 Ozone Filt...

Page 190: ...s made The following table lists the life counter values of different models based on the standard copying mode 2 Controlled with the Total Counter NOTES K 1 000 copies The contents of this maintenance schedule are subject to change without notice For part numbers see Parts Manual and Parts Modification Notice Model Copying Mode Life Counter 25 cpm copier A4C 3 copies per job 67000 35 cpm copier A...

Page 191: ...011D007AA 2 Lock the Paper Lifting Plate 3 Snap off one C clip of the Paper Take Up Roll Assy 4 Slide the Paper Take Up Roll Assy to the rear so that it can be pulled off the bushing at the front 4011D008AA 5 Snap off one C clip and remove the Paper Take Up Roll 4108D035AA 1 Open the Side Cover 4011D009AA 2 Remove the Paper Dust Remover Assy 4011D010AB ...

Page 192: ...nd dirt off the Paper Dust Remover Assy 4011D011AA 1 Open the Side Cover 4011D009AA 4011D012AA 2 Snap off two retaining rings E type and the upper and lower Synchronizing Roller gears 3 Remove one screw and the ground plate 4011D013AA NOTE When reinstalling the ground plate make sure that the ground plate is in contact with the side faces of the bushings Bushings Ground Plate 4011D014AB ...

Page 193: ...p off one retaining ring E type unplug one connector and remove the Synchronizing Clutch 6 Remove one washer and two wave washers 7 Unhook one spring snap off two retaining rings E type and remove the upper and lower Synchro nizing Roller bushings NOTE When reinstalling the bushings make sure that the flanges of the bushings are on the outside 4011D017AA 4011D018AB 1 Using a soft cloth dampened wi...

Page 194: ...eft Hinge Cover 4011D025AB 2 Remove screws 14 or 12 and the Shield Cover NOTE The number of screws used differs according to the applicable marking area The illustration shows only one representative screw Be sure to remove all screws that secure the Shield Cover 4011D027AA 4011D027AC 3 Unplug four connectors of the MFB2 Board 4 Remove the harness from two cord clamps and one wiring saddle 5 Unplu...

Page 195: ...interfere with other parts Part A of the illustration When reinstalling the MFB2 Board Assy hook two tabs and press the tab marked with C up against the mating part Parts B and C of the illustration When connecting the connector to the Master Board and fixing the MFB2 Board Assy to the PWB support as part of the procedure of reinstalling the assy position the assy as you look at it from the left h...

Page 196: ...ers 12 Remove six screws and the PWB A Assy 4011D029AB 13 Remove one screw and the Flexible Harness Guide 4011D030AB 14 Remove five screws and the Reinforcement Bracket 4011D031AA 15 Unplug one connector from the Power Switch 16 Remove the harness from one edge cover four wiring saddles and two cord clamps 4011D032AA ...

Page 197: ...ing of the Scanner Rails Bushings 17 Remove three screws and the mounting bracket 18 Remove four screws and the PH Unit 4011D033AA 1 Remove the Original Glass 2 Unhook the tabs of the cover in order of A B C and D and remove the cover A D D B C 4011D034AA 3 Unplug two connectors of the CCD Unit 4 Remove two screws and the CCD Unit 4011D035AA 1 Remove the Original Glass 2 Using a soft cloth wipe cl...

Page 198: ...ens 6 Cleaning of the Original Glass 1 Remove the Original Glass 2 Wipe clean the Mirrors with a soft cloth 1167D017AC 1 Remove the CCD Unit 2 Wipe clean the Lens with a soft cloth 1167D018AB 1 Wipe clean the Original Glass with a soft cloth 1171D050AA ...

Page 199: ...in the illustration 4011D037AA 4011D038AA 4 Remove one screw and unplug the connector of the Exposure Lamp 5 Remove the flat cable of the Exposure Lamp 4011D039AA 6 Remove one screw and the Lamp Fixing Bracket 7 Slide the Exposure Lamp to the front and remove it Rear 4011D040AA Front 4011D041AB 8 Remove two screws and the Scanner ...

Page 200: ...one connector and remove the Original Size Detecting Sensor Option for the inch areas 4011D043AA 7 Remove the cover See step 2 of 2 Removal of the CCD Unit of 2 5 OPTICAL SECTION 8 Remove four screws and the Reinforcement Bracket 4011D044AD 4011D045AA 9 Snap off one retaining ring E type and remove one mounting screw from the front pulley and slide the pulley to the rear 10 Snap off one retaining ...

Page 201: ...on shown in the illustration Front 1167D051AC 2 Wind the hook end of the Scanner Drive Cable two turns counterclockwise from the rear side to the front 1167D052AD Cable on Hook End 1167D053AD 3 Wind the bead end of the cable four turns clock wise from the front to the rear Then secure the cable with tape NOTE Make sure that no part of the cable rides on the other Cable on Bead End ...

Page 202: ...d pulley C and fit the fixed bead at a posi tion about 5 5 mm from the Scanner rail 4011D049AC pulley C pulley D 7 Wind the hook end of the cable around pulley A and pulley B 4011D102AA pulley A pulley B 8 Install the cable guide fit the hook end of the cable into the groove in the cable guide and hook the spring 4011D050AA Cable Guide 9 Position the round bead of the cable black at the position s...

Page 203: ...the other 1167D055AD Cable on Bead End 12 Slide the pulley toward the rear and fit one retain ing ring E type 13 Pushing the pulley tightly up against the retaining ring E type secure the pulley with one screw 4011D051AA 14 Wind the fixed bead end of the cable around pul ley H and pulley G and fit the fixed bead at a posi tion about 5 5 mm from the Scanner rail pulley H pulley G 4011D052AC 15 Wind...

Page 204: ... Perform the Focus Positioning of the Scanner and 2nd 3rd Mirrors Carriage See 3 6 FOCUS POSITIONING OF THE SCANNER AND 2ND 3RD MIRRORS CAR RIAGE NOTE Whenever the Scanner Drive Cables have been removed be sure to make the following adjustment CD of Zoom Adjust IR 16 Fit the hook end of the cable into the groove in the Cable Guide and hook the spring 4011D053AA Cable Guide 4011D106AB Front Rear 40...

Page 205: ...age Transfer Roller Assy NOTE Do not touch the surface of the Image Transfer Roller directly with bare hands 4011D057AA 1 Open the Side Cover 4011D009AA 2 Using a soft cloth dampened with alcohol wipe the Comb Electrode NOTES Make sure the alcohol does not touch the surface of the Image Transfer Roller When wiping the Comb Electrode make sure the cloth is not caught by the ends of the combs 4011D0...

Page 206: ...lter 4011D009AA 1 Open the Side Cover 2 Using a soft cloth dampened with alcohol wipe the Pre Image Transfer Guide Plate NOTE Make sure the alcohol does not touch the surface of the Image Transfer Roller 4011D059AB 1 Remove the Rear Lower Cover 2 Remove the Ozone Filter 4011D060AA ...

Page 207: ...Imag ing Cartridge part of the way out 3 Then grasp the handle on top of the cartridge and pull the cartridge out NOTE When installing the Imaging Cartridge push it all the way into the machine If the cartridge is not properly installed the PC Drum protective shutter of the cartridge may not be opened or may even be damaged 4011D061AA ...

Page 208: ...n the Side Cover 4011D009AA 2 Push the lever and open the Exit Cover 3 Unplug two connectors in the rear 4011D062AB 4 Close the Exit Cover remove two screws and slide out the Fusing Unit 5 Unplug one connector at the front and remove the Fusing Unit 4011D063AA ...

Page 209: ...ed insert a screwdriver through the hole in the Fusing Front Cover and move the ends of the flat spring in the direction of the arrow so that they rest on the bearing outer race side face 4011D064AB Where Fusing Front Cover is Mounted Where Ends of Flat Spring are Moved Ends of Flat Spring Bearing Outer Race Side Face 4 Remove one cord holder and the harness 4011D065AA 5 Remove two screws six cord...

Page 210: ...e harness from the harness guide and edge cover 11 Remove one screw one shoulder screw and the Paper Exit Cover Assy 4011D066AA 12 Remove three screws Coupling Gear Assy and gear 13 Remove three screws and the Drive Frame Assy 14 Unhook the spring to free the Rear Pressure Lever Assy 4011D070AB 15 Remove two screws and the Lever Assy 16 Unhook the spring to free the Front Pressure Lever Assy 17 Sn...

Page 211: ...D073AA 21 Snap off one retaining ring E type and remove the Rear Pressure Lever Assy and bearing 22 Remove the Right Fusing Roller 4011D074AB 23 Remove three screws frame spring and the lever 4011D075AB 4011D076AB NOTES Study the illustration for how the spring is installed After the spring has been installed move the lever in the direction of the arrow to make sure that it is returned by the tens...

Page 212: ...s been installed move the gear assy in the direction of the arrow to make sure that it is returned by the tension of the spring 26 Snap off one retaining ring and remove one washer and one wave washer 27 Remove one bearing each at the front and rear and then remove the Left Fusing Roller 4011D079AA 2 Remove three cord holder 3 Remove two screw and the Holder Assy 4011D080AB 4 Remove one screw and ...

Page 213: ... Automatically adjusted Control Panel D 35 Original Size Detecting Sensor Adjustment F7 1 D 36 Loop Adjustment D 37 Edge Erase D 38 Leading Trailing Right Left Registration CD Printer 1 sided 10 2 0 mm 2 sided 10 3 0 mm D 41 Registration FD Printer 10 2 0 mm D 43 Registration IR D 45 CD FD Zoom Adjust IR D 49 CD 200 2 0 mm FD 300 3 0 mm IR Erasure Width D 53 Book Center Erase D 54 1167D108AA ...

Page 214: ...ard replacement ROM RAM Board replacement Ref Page Check Item Touch Panel Adj Automatic adjustment D 35 Original Size Detecting Sensor Adjustment Automatic adjustment D 36 Loop Adjustment D 37 Edge Erase Leading Setting range 0 to 5 mm 7 D 38 Trailing Setting range 0 to 5 mm 8 Right Left Setting range 0 to 5 mm 9 Registration CD Printer 1 sided 10 2 0 mm 2 sided 10 3 0 mm 1 D 41 Registration FD Pr...

Page 215: ... 2 Loosen the two screws that secure the Scanner Motor Using a bar tension gage pull the motor to the right with a tension of 1000 g 50 g and at the same time tighten the mounting screws NOTE The adjustment must be made with the belt teeth in mesh with the pulley grooves 4011D082AB ...

Page 216: ...screen For details see SWITCHES ON PWBs TECH REP SETTINGS 2 Touch Touch Panel Adj 3 Touch on screen 1 shown above NOTES At this time make sure that the very center of is touched with the tip of a ballpoint pen or similar device Use care not to damage the screen with the tip of a ballpoint pen 4 Touch on screen 2 shown above 5 Touch on screen 3 shown above 6 Touch on screen 4 shown above Initial Sc...

Page 217: ...ment ROM RAM Board replacement Adjustment Procedure 2 Call the Tech Rep Mode to the screen 3 Touch Function to display the Function menu 4 Touch F7 1 5 Press the Start key to run the Original Size Detecting Sensor Adjustment function 6 Turn OFF and ON the Power Switch NOTE The Start key remains lit up orange while this function is being run and lights up green as soon as the sequence is completed ...

Page 218: ...key to clear the current setting value 6 Enter the new setting value from the 10 Key Pad Use the Access Mode key or to change the or sign Setting Instructions Change the setting value as necessary until there are no variations in the amount of void image along the leading edge skewed feeding dog ear or misfeed 7 Touch END to validate the setting value NOTE Be sure to touch the END key before retur...

Page 219: ...e new setting value from the 10 Key Pad Setting Instructions To make the edge erase width width A smaller decrease the setting value To make the edge erase width width A greater increase the setting value 6 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid A 1171D003AA Set the e...

Page 220: ...ew setting value from the 10 Key Pad Setting Instructions To make the edge erase width width A smaller decrease the setting value To make the edge erase width width A greater increase the setting value 6 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid A 1171D004AA Set the eras...

Page 221: ...ting value from the 10 Key Pad Setting Instructions To make the edge erase width width A smaller decrease the setting value To make the edge erase width width A greater increase the setting value 6 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid A A 1171D005AA Set the erase wi...

Page 222: ... 2 Sided Touch Test Print and select Duplex At this time the 1st Drawer is selected 4 Press the Start key A test pattern will be produced 5 1 Sided Check to see if width A on the test pattern meets the specifications 2 Sided Check to see if width A on the second side of the 2 sided copy meets the specifications If width A falls outside the specified range perform the fol lowing steps for adjustmen...

Page 223: ... width A into the specified range try another setting value 10 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid 11 Perform the same steps to adjust for other paper sources Checking for 2 Sided for Each Paper Source In step 3 touch Test Print select the paper source and Duplex a...

Page 224: ...he 1st Drawer and a test pattern will be produced 5 Check to see if width A on the test pattern meets the specifications If width A falls outside the specified range perform the following steps for adjustment 6 Touch END to recall the Registration FD screen 7 Press the Clear key to clear the current setting value Specification Adjust Mode Setting Range 10 2 0 mm Registration FD 25 cpm copier 26 to...

Page 225: ... into the specified range try another setting value 9 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid Checking for Each Paper Source 1 Sided In step 3 touch Test Print select the paper source then press the Start key 2 Sided In step 3 touch Test Print select the paper source a...

Page 226: ...n the Original Glass and make a copy of it 3 Check to see if width A on the test pattern copy meets the specifications If width A falls outside the specified range perform these steps to make the adjustment 4 Call the Adjust Mode to the screen 5 Touch IR Registration and CD in that order 6 Press the Clear key to clear the current setting value Specification Adjust Mode Setting Range 10 2 0 mm Regi...

Page 227: ...g value greater than the current one If a single adjustment procedure does not successfully bring width A into the specified range try another setting value 8 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid 4011P259CA 4011D001AA Setting Value Use to change the or sign Use to c...

Page 228: ...inal Glass and make a copy of it 3 Check to see if width A on the test pattern copy meets the specifications If width A falls outside the specified range perform these steps to make the adjustment 4 Call the Adjust Mode to the screen 5 Touch IR Registration and FD in that order 6 Press the Clear key to clear the current setting value Specification Adjust Mode Setting Range 10 2 0 mm Registration F...

Page 229: ...g value greater than the current one If a single adjustment procedure does not successfully bring width A into the specified range try another setting value 8 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid 4011P259CA 4011D001AA Setting Value Use to change the or sign Use to c...

Page 230: ... Specification Adjust Mode Setting Range Full size 1 000 200 2 0 mm Zoom Adjust CD 0 990 to 1 010 1 Place a scale in parallel with the Original Width Scale and make a copy Note that the scale is perpendicular to the Original Length Scale Use the full size X1 000 mode and paper with a width of 200 mm or more If the scale is of plastic and transparent place a blank sheet of paper over it 1167D111AA ...

Page 231: ...rease the setting value If the scale on the copy is shorter than the actual scale increase the setting value If the measurement does not fall within the specifications through one setting try another setting 7 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid 4011P300CA 1167D069...

Page 232: ...ustment Procedure Zoom Ratio Specification Adjust Mode Setting Range Full size 1 000 300 3 0 mm Zoom Adjust FD 0 990 to 1 010 1 Place a scale in parallel with the Original Length Scale and make a copy Use the full size 1 000 mode and A3 or 11 17 paper If the scale is of plastic and transparent place a blank sheet of paper over it 1167D112AA 2 Measure the length of the scale on the copy to find the...

Page 233: ...rease the setting value If the scale on the copy is shorter than the actual scale increase the setting value If the measurement does not fall within the specifications through one setting try another setting 7 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid 4011P300CA 1167D069...

Page 234: ...the erase width along the four edges of the paper width A smaller decrease the setting value To make the erase width along the four edges of the paper width A greater increase the setting value 6 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting remains valid A A A A Set the erase width along...

Page 235: ...etting value from the 10 Key Pad Setting Instructions To make the erase width at the center of the paper width A smaller decrease the setting value To make the erase width at the center of the paper width A greater increase the setting value 6 Touch END to validate the setting value NOTE Be sure to touch END to return to the normal operating mode If the Panel Reset key is used the previous setting...

Page 236: ...justment Procedure 4 Press the 2nd 3rd Mirrors Carriage up against the jigs and make sure that there is no clearance at the front and rear ends 5 Press the Scanner tightly up against the jigs and keeping that condition tighten the setscrews of the cable holding plate 1 Remove the Exposure Lamp See steps 1 through 7 of 8 Removal of the Scan ner of 2 5 OPTICAL SECTION 2 Temporarily loosen the set sc...

Page 237: ...1D084AA 4011D055AB 2 Press the 2nd 3rd Mirrors Carriage up against the front and rear rails and check that there is no clearance at the front and rear ends 3 If there is any clearance turn the Scanner Drive Cable adjusting screws at the front and or rear as necessary to eliminate the clearance Front Rear 4 Move the 2nd 3rd Mirrors Carriage so that there is a distance of 15 5 mm between the 2nd 3rd...

Page 238: ... Mounting Bracket 4011D088AB 4 Remove the harness from one cord clamp and route it as shown in the illustration 4011D089AA 5 Connect the Key Counter Socket connector 6 Using two screws secure the counter socket 4011D090AA 7 Using two screws secure the Key Counter Cover NOTE When the Key Counter Socket is mounted set to ON the Key Counter available from the Security mode 4011D091AA ...

Page 239: ...re to replace the Imaging Cartridge with a new one at the same time 1 Remove the Master Board For details see 2 2 REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS 2 Demount the EEPROM IC3A from the new Master Board 3 Demount the EEPROM IC3A from the old Master Board and remount it onto the new Master Board 4011D092AA New EEPROM New Master Board Old EEPROM Old Master Board NOTE Note the al...

Page 240: ... been replaced NOTES Be sure to produce a Service Call Report before performing the above procedures If an option ADF Duplex Unit or add on cassette is mounted be sure to input the related Adjust data Adjust Data Entry Items IR Printer Registration CD Registration CD 1st Drawer Registration FD Registration 2 Sided 35 cpm copier Zoom Adjust CD Registration FD Zoom Adjust FD ...

Page 241: ...SWITCHES ON PWBs TECH REP SETTINGS 17196 ...

Page 242: ... Function Setting Procedure S 16 4 3 Tech Rep Mode Menu Function Tree S 17 4 4 Setting in the Tech Rep Mode S 18 1 Tech Rep Mode S 18 2 System Input S 21 3 Administrator Input S 22 4 Counter S 22 5 Function S 25 6 I O Check S 26 7 Movement Check S 26 8 RD Mode S 27 9 ROM Version S 28 10 Level History S 28 5 SECURITY MODE S 29 5 1 Security Mode Menu Screen S 29 5 2 Security Mode Setting Procedure S...

Page 243: ...ches S 36 8 UTILITY MODE S 37 8 1 Utility Mode selection Screen S 37 8 2 User s Choice Function Tree S 37 8 3 Settings in the Utility Mode S 38 9 SOFT SWITCH SET S 39 9 1 Soft Switch Initial Value Table S 39 9 2 Set Contents of Soft Switches S 40 ...

Page 244: ...s 5 Copy Key Press to select the Copy mode 6 Scan Key Press to select the Scanner mode 7 Access Mode Key Press to enter the access number when Copy Track of the Administrator mode available Press the access Key 8 Interrupt Key Press to select the Interrupt mode 9 Panel Reset Key Press to set the machine into the initial mode clearing all settings made on the control panel 10 Clear Key Clear the va...

Page 245: ...splay Shows the current machine status operating instructions and precautions and other data including the number of copies selected 3 Function Display Shows the basic function keys and the corresponding functions currently selected for use 4 Sub message Display Shows graphic representation of the operating status of a job 5 Set Function Shows graphic representation of the copying type currently s...

Page 246: ...cific code Error Display Given when an error occurs E g Paper misfeed door open etc 4011P274CA 4012P179CC Warning Display Given when only a defective copy will be produced because of erroneous or illegal panel settings E g Unmatched paper size in Auto Paper Caution Display Given when though further copier opera tion will be possible it could eventually result in a malfunction E g Toner near empty ...

Page 247: ...n 2 2 PWB A Master Board Symbol Name Description S1 Test Print Switch Produces the test pattern of Function F12 Procedure 1 Press S1 to let the copier start the output sequence 2 Press S1 a second time to stop the output sequence 4011D095AA PWB A PWB F 4011D093AA ...

Page 248: ...S 5 2 3 PWB F Control Panel Symbol Name Description SW37 Warm Restart Switch Used to enter the initial mode SW37 SW37 4011D095AA ...

Page 249: ...rom Tech Rep Mode 2 The description of the function is displayed when a Data Terminal is connected to the machine 4011P294CA User s Choice 1 6 User s Choice 2 6 User s Choice 3 6 User s Choice 4 6 User s Choice 5 6 User s Choice 6 6 Cofirmation Beep Alarm Volume Panel Cleaning Dehumidity Toner Replenisher Data Send Utility User s Choice Meter Count Copy Job Recall User Management Admin Management ...

Page 250: ... are complete touch the Enter key to validate the settings Exiting the Mode Touch the Exit key Touch Panel Display Setting User s Choice User s Choice is used to make various settings according to the user s need Meter Count Displays the counts of various counters Copy Job Recall Permits programming of various functions including copying jobs User Management Permits setting of the various User Man...

Page 251: ...r Multiple in 1 and Booklet Copy Zoom Auto Panel Reset Energy Save Mode User s Choice Mode User s Choice 3 6 Plug In Counter ID Key Reset Auto Power Off LCD Back light Off 4in1 Copy Order Density Priority User s Choice 4 6 Default Copy Output Levels Priority Density Output Priority Intelligent Sorting Output Tray User s Choice 5 6 Small Originals Scanner Dry User s Choice 6 6 Density ADF only ...

Page 252: ...ons configured with the copier and the settings made in Tech Rep Choice Auto Paper Auto Size Select the priority Auto mode Auto Paper or Auto Size selected when the Power Switch is turned ON or Panel Reset key pressed Drawer Priority Select the priority paper source that is automatically selected when the copier is set into the Auto Size or Manual mode Special Paper Define the type of paper used f...

Page 253: ...he panel automatically when the Access Mode key is pressed in the Copy Track mode or the Plug In Counter is unplugged Auto Power 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 Press the Clear key and Use the 10 Key Pad to set the time Note The opti...

Page 254: ...in the Auto Exposure mode Manual Select the priority exposure level in the Manual Exposure mode Priority Density Set the image density level for printing Output Priority Select the priority finishing type Note The contents of the display vary depending on the types of finishing options mounted on the machine Highlighted 2 1 3 4 3 1 2 4 Density Original Image Type Auto Manual Photo Text Photo Text ...

Page 255: ...lt setting 2 Small Originals Select whether to enable or disable a copy cycle when it is initiated with an original of a small size that is not detectable by the system placed on the Original Glass Default Metric areas OFF Inch Areas ON Scanner Dry Set the time of day to run a Scanner drying cycle Note When entering a value for Hours and Minutes and if it is a single digit number first enter a 0 D...

Page 256: ...splay Setting The default is Cofirmation Beep Select the volume of the beep that sounds when a key on the control panel is pressed or one on the Touch Panel is touched Alam Volume Select the volume of the alarm Panel Clearing Used to disable keys on the Touch Panel allowing the user to clean the Touch Panel without having to turning OFF the Power Switch Dehumidity Starts a dehumidifying sequence f...

Page 257: ...nistrator Set Displays the Max Copy Sets and Disable Auto Shut OFF screens Max Copy Sets Determine the number of copies or copy sets that can be set using the 10 Key Pad Disable Auto Shut Off Select whether to enable or disable the setting of the Auto Shut Off function available from User s Choice Copy Track Displays the various setting screens including Copy Track Copy Track Mode Select the numbe...

Page 258: ...unt number from the 10 Key Pad Total Count Displays the count of the Total Counter Size Count Displays the count of the Size Counter Copy Limit Enter the maximum number of copies that can be made from the 10 Key Pad Access Code Enter the access number which can range from 0001 to 9999 from the 10 Key Pad These data can be cleared with the Clear key 1000 Accounts The copy track data of the selected...

Page 259: ...ice functions 4 1 Tech Rep Mode Menu Screen 4 2 Tech Rep Mode Function Setting Procedure Procedure 1 Press the Utility key 2 Press the Meter Count key 3 Press the following keys in this order Stop 0 0 Stop 0 1 4 Select the desired Tech Rep Mode function Exiting the Mode Touch the Exit key 4011P296CA ...

Page 260: ...justment Image Density ATDC Sensor Gain VG Adjust Original Stop Position Registration Loop Registration Zoom Adjust Paper Size Input Change Fixed Zoom Machine Configuration Technical Memo Original Size Detecting Option Paper Jam PM Trouble Device Maintenance ADF Paper Passage Scanner Exp Lamp Check Scan through ADF Scanner ADFR Mail Bin Finisher Printer Finisher Sift Tray Job Tray F1 F2 F7 1 F8 F1...

Page 261: ...y for User Management of Util ity Notes Scanner Scanner Drum Dehumidify key is displayed Disable Dehumidify key is not displayed Function Limit Select whether to limit the functions to be set on the control panel or not Highlighted The measurement is rounded to the nearest standard inch or metric size Metric The measurement is rounded to the nearest standard metric size Inch Metric F 330 mm C 203 ...

Page 262: ...ollers Image Density Set the image density for the printer The value set for this function becomes the central value of Priority Density of User s Choice ATDC Sensor Gain Current Shows the current ATDC control voltage Set Set the ATDC control voltage Note Be sure to record this value when I C has been changed VG Adjust Vary the Vg voltage to set the desired image density Highlighted 0 to 5 mm 4 mm...

Page 263: ...ngth of the loop to be formed in the original fed off the ADF before the Registration Roller Touch Panel Display Setting The default is Registration Adjust registration in the main and sub scanning directions of the ADF Zoom Adjust Adjust the scanning zoom ratio in the main and sub scanning direc tions of the ADF Highlighted 7 7 Smaller Greater 0 5 mm 5 mm Smaller Greater 0 Highlighted Main Scanni...

Page 264: ... Center Erasure Adjust the center erase width Touch Panel Display Setting The default is Paper Size Input Set the paper size Procedure 1 Select the paper source 2 Select the paper size If a nonstandard size is to be used enter the paper size from the 10 Key Pad 3 Touch END to validate the new setting Change Fixed Zoom Change a fixed zoom ratio to a desired value Procedure 1 Touch the key of the fi...

Page 265: ...n a new I C is installed Clearing All Counts of a Counter Type at Once 1 Touch the Counter Reset key 2 Select the counters to be cleared all at once 3 Touch OK Touch Panel Display Setting The default is Machine Configuration Displays the machine configuration status Technical Memo Enter the serial number and other data Original Size Detecting Option Select ON when the optional Original Size Detect...

Page 266: ...DF Feed ADFR Scan through ADF Transport ADFR Reverse SADF Display Printer Engine Display Description I C Life 1 I C Life 2 1st Drawer 2nd Drawer 3rd Drawer 4th Drawer 5th Drawer No of A4C copies made translated from the period of time through which the I C motor has been energized No of A4C copies made translated in terms of A4C length from the total FD length copied No of sheets of paper fed from...

Page 267: ...rature Home Sensor Left Sensor LCC Transport Motor C0991 C0995 C0999 C099D LCC Lift 1 Limit LCC Lift Motor LCC Lift 2 Limit LCC Communication Malfunction Code Description Malfunction Code Description C0B00 C0B20 C0B30 C0B38 Transport Drive Motor Stapler Unit Paper Aligning Bar Unit Paper Standard Board Unit C0B48 C0B4A C0B4D C0B4E Pressure Motor 1 Unit Pressure Motor 2 Unit Assist Tray Unit Transa...

Page 268: ... paper source 2 Press the Start key to start the paper passage cycle 3 Press the Stop key to stop the paper passage cycle F2 This test is for factory adjustment only and should NOT be used F7 1 Original Size Detecting Sensor Adjustment Automatically adjusts the threshold level of the Original Size Detecting Sensor For details see DIS REASSEMBLY ADJUSTMENT F8 ATDC Sensor Automatic Adjustment This t...

Page 269: ...ion service manual Sift Tray Job Tray For details see Option service manual Touch Panel Display Setting ADF Paper Passage Makes a paper passage check through the ADF Procedure 1 Select the paper passage mode 2 Place paper on the Document Feed Tray 3 Press the Start key Scanner Checks the Scanner for operation Drives the CCD for factory adjustment only and should NEVER be used Turns ON the Exposure...

Page 270: ...of MAINT START to the Center Maintenance Displays the various setting screens DT Setting Displays the setting screens for CT ID DT ID and telephone number CT ID Enter the ID number of the Center PC from the 10 Key Pad DT ID Enter the ID number of the Data Terminal from the 10 Key Pad TEL No Enter the telephone number of the modem connected to the Center PC CT ID DT ID TEL DT Setting Initial Transm...

Page 271: ...of notifying the completion of service job to the Center RAM Clear Initializes the Data Terminal settings Common DT Displays the screens for communications settings Dial Mode Sets the type of telephone line of the user Auto Receive Sets the auto reception function Result Code Set the value according to the type of the modem on the copier Touch Panel Display Setting ATDC Set Displays the voltage se...

Page 272: ...arious counters 5 1 Security Mode Menu Screen 5 2 Security Mode Setting Procedure Procedure 1 Show the Tech Rep mode menu screen 2 Press the following keys in this order Stop 9 3 Select the particular function Exiting the Mode Touch the END key 4011P278CA ...

Page 273: ...o clear the current setting If the setting is accidentally cleared press the Interrupt key to undo the clearing operation 3 Enter the desired value from the 10 Key Pad 4 Touch Current 5 Press the Clear key to clear the current value If the current value is accidentally cleared press the Interrupt key to undo the clearing operation Plug In Counter Select the condition by which the Counter count is ...

Page 274: ...en according to the type of vender mounted on the copier Copying 1 Sided 2 Sided Size Size other than those set Set size Size other than those set Set size Total Mode Mode Mode Mode 1 2 3 1 2 3 1 2 3 1 2 3 Total 1 1 2 2 2 2 4 4 Size 0 1 1 2 0 2 2 0 2 Sided Total 0 0 1 1 2 1 1 4 2 Sided Size 0 0 0 1 1 4 Total by account 1 1 2 2 2 2 4 4 Size by account 0 1 1 2 0 2 2 4 Pulg in Counter Counting copies...

Page 275: ...rocedure 1 Show the Tech Rep mode menu screen 2 Press the following keys in this order Stop Start 3 Select the desired function Use the Access Mode key to enter a or sign Exiting the Mode Touch the END key 6 3 Adjust Mode Function Tree C1166P002CA Adjust Printer IR Registration CD Registration FD Registration Zoom Adjust ...

Page 276: ...ration FD Adjust registration in the FD direction on the engine side 35 CPM 25 CPM Touch Panel Display Setting Registration Adjust registration in the CD and FD direction on the IR side Zoom Adjust Adjust the zoom ratio in the CD and FD direction on the IR side 4 0 0 4 0 Smaller Greater 19 0 19 Smaller Greater 26 0 26 Smaller Greater Main scanning CD Sub scanning FD 72 dot 0 72 dot Smaller Greater...

Page 277: ...1 Initial Mode Menu Screen 7 2 Initial Mode Setting Procedure Procedure 1 Press the Warm Restart switch Then appears at the center on the left side of the screen 2 Enter 3 from the 10 Key Pad 3 Select the desired function Exiting the Mode Touch the Exit key 4011P297CA ...

Page 278: ...re to touch the exact center of the marking Total Clear Clears all of the electronic counters and Copy Track related data Marketing Area Set the marketing area Image Data Clear Clears the image data FAX Set Clear Clears the fax related settings For details see the FAX Service Manual Date Time Set Set the date and time of day for Date Printing Set the time zone Set the Daylight Svgs Time Summer tim...

Page 279: ... open close Trouble Reset Memory Clear Total Clear Misfeed display Malfunction display Fusing Others Erratic operation display Job Image User s Choice Tech Rep Mode Security Mode Touch Panel Adjust Copy Track function data Electronic Counter counts Clearing Method Data Cleared ...

Page 280: ...tion Screen Press the Utility key on the control panel 8 2 User s Choice Function Tree 4011P295CA Utility User s Choice Meter Count Copy Job Recall User Management Admin Management Protocol Trace Service Call Report Report Maintenance Mode Men contents File Display Soft Switch Set Memory Dump File Dump Touch Panel Adj ...

Page 281: ...pier produce currently set choice data of the various kinds Maintenance Mode Men contents For details see the FAX Service Manual File Display For details see the FAX Service Manual Soft Switch Set Soft Switch Set S 39 Memory Dump For details see the FAX Service Manual File Dump Produces hard copy data used for analysis of internal data Notes Before attempting to produce the hard copy data first en...

Page 282: ...t Sorting 413 14 FAX Mail Output Bin Specification PC Print Output Bin Specification PC Print Output Bin Specification Copy Output Bin Specification FAX Mail Output Bin Specification 414 A0 Image Compression When Reserving Capacity In The Copy Memory copy 415 6C Cofirmation Beep Alam Volume 416 60 Sound Volume Setting 3 Monitor Tone copy Orientation Of Images When Finisher Is Connected copy Overse...

Page 283: ... 1 7 Memory Recall OFF ON ON OFF selection for storing the image data and recalling the image after the end of copy ing 6 Mixed Original Detection OFF ON Selection of mixed original mode that has pri ority when the power is ON and the Panel Reset key is pressed 5 0 Fixed Setting change inhibit Mode Initial value 401 7 6 5 4 3 2 1 0 Bit 0 0 0 0 0 1 0 0 HEX 04 Bit Function Logic Description 0 1 7 2 ...

Page 284: ...her after data is received Printer PC prints are output successively each time data is received 1 Priority Application auto clear screen after panel reset Specifi cation Bit1 0 00 FAX Sets the initial status screen copy FAX AUTO or scanner 0 01 COPY 10 AUTO 11 Scanner Mode Initial value 403 7 6 5 4 3 2 1 0 Bit 0 0 0 0 0 0 0 1 HEX 01 Bit Function Logic Description 0 1 7 Multiple in 1 and Booklet Co...

Page 285: ...ing 1 minute steps 6 00000000 No Reset 5 00000001 1 min 4 3 11110000 240 min 2 11111111 30 sec 1 Other Setting inhibit 0 Mode Initial value 405 7 6 5 4 3 2 1 0 Bit 0 0 0 0 1 1 1 1 HEX 0F Bit Function Logic Description 0 1 7 Energy Save Mode Bit7 0 Setting of auto preheat time after the specified time from the end of copying or a key operation 1 minute steps 6 00000000 Setting inhibit 5 00000001 1 ...

Page 286: ...the setting becomes No 1 minute steps No FAX Auto power OFF With FAX Heater OFF Initial value for 25 cpm Copier and 35 cpm Copier 6 00000000 OFF 5 00000001 1 min 4 3 00001110 30 min 1 2 1 00111100 60 min 2 0 11110000 240 min Other Setting inhibit Mode Initial value 407 7 6 5 4 3 2 1 0 Bit 0 0 0 0 0 0 0 1 HEX 01 Bit Function Logic Description 0 1 7 LCD Back light Off Bit7 0 Setting of the back ligh...

Page 287: ...Other Setting inhibit 3 0 Fixed Setting change inhibit Mode Initial value 409 7 6 5 4 3 2 1 0 Bit 0 0 0 0 1 0 0 0 HEX 08 Bit Function Logic Description 0 1 7 4in1 Copy Order Bit7 6 Setting of image layout sequence for 4in1 copy operation 35 cpm Copier only 6 00 Pattern 1 01 Pattern 2 Other Setting inhibit 5 Density Priority AE Manual Density mode setting 4 1 Original Image Type Bit5 3 0000 Text Ph...

Page 288: ...3 0 0000 EXP 1 Setting of the manual density level selected when the mode is initialized and also the level selected when the mode is changed from auto density to manual density EXP1 Lighter EXP5 Normal EXP9 Darker 0001 EXP 2 0010 EXP 3 0011 EXP 4 0100 EXP 5 0101 EXP 6 0110 EXP 7 0111 EXP 8 1000 EXP 9 Other Setting inhibit Mode Initial value 411 7 6 5 4 3 2 1 0 Bit 0 0 0 0 0 0 0 0 HEX 00 Bit Funct...

Page 289: ... 0 Bit 0 0 0 1 0 1 0 0 HEX 14 Bit Function Logic Description 0 1 7 FAX Mail Output Bin Specifica tion Bit7 6 00 1st Drawer Setting of tray to exit FAX mail prints when a finisher is installed Option tray is effective when the option tray is installed 6 01 Elevator tray 10 Option tray 11 Setting inhibit 5 PC Print Output Bin Specification Bit5 4 00 1st Drawer Setting of tray to exit PC prints when ...

Page 290: ...riginal used 6 0101 0 5 5 0110 0 6 4 0111 0 7 1000 0 8 1001 0 9 1010 1 0 1011 1 1 1100 1 2 1101 1 3 Other Setting inhibit 3 0 Fixed Setting change inhibit Mode Initial value 415 7 6 5 4 3 2 1 0 Bit 0 1 1 0 1 1 0 0 HEX 6C Bit Function Logic Description 0 1 7 Cofirmation Beep Bit3 1 000 0 No tone Setting of sound volume of tone emitted when key is pressed 6 001 1 5 010 2 011 3 100 4 101 5 Other Sett...

Page 291: ...ge inhibit 1 Overseas Scanner File Format TIFF PDF Sets the file format used with an overseas scanner For maintenance use by the admin istrator 0 Disable Auto Shut Off NO YES Setting that enables or disables to select Dis abled setting for Auto Shut Off function Mode Initial value 417 7 6 5 4 3 2 1 0 Bit 0 1 1 0 0 0 1 1 HEX 63 Bit Function Logic Description 0 1 7 Max Copy Sets OFF ON Setting for p...

Page 292: ... 11 3 mm 4 I C Life Stop Specification Stop Do not stop Sets whether to stop or not stop a print opera tion when the imaging unit reaches the end of its life 3 I C Near End Of Life Display Setting Do not display Display Sets whether or not to display the fact that the imaging unit is approaching the end of its life 2 0 Fixed Setting change inhibit Mode Initial value 421 MC 7 6 5 4 3 2 1 0 Bit 0 0 ...

Page 293: ...ize to be counted by size counter 4 001 A3 3 010 A3 B4 011 A3 B4 FLS 100 A6 Other Setting inhibit 2 Copy Kit Counter Bit2 1 00 Mode 1 Do not count Sets whether or not the copy kit counter is to count and also whether or not copying is to be inhibited Mode 1 Does not count Mode 2 Counts Copying takes place when the set value is reached Mode 3 Counts Copying is inhibit when the set value is reached ...

Page 294: ...nfiguration Mixed Limited Sets whether or not the original size is to be rounded off for destination in the auto paper mode 6 FLS Paper Bit6 5 00 210 330 Setting of sizes handled as FLS 5 01 203 330 10 216 330 11 220 330 4 Copy Mode Limit copy YES NO Sets whether or not to inhibit setting of two sided copy in the priority copy mode 3 Small Originals Copy disabled Copy enable d Sets whether to enab...

Page 295: ...4 3 2 1 0 Bit 0 0 0 0 0 0 0 0 HEX 00 Bit Function Logic Description 0 1 7 to 3 Default Setting Country Classifi cation copy Bit7 5 Arbitrary setting Setting differs depending upon the country 2 to 0 Fixed Setting change inhibit Mode Initial value 430 7 6 5 4 3 2 1 0 Bit 0 1 1 1 1 0 0 0 HEX 78 Bit Function Logic Description 0 1 7 to 1 Overseas Scanner Timeout Time Bit7 0 Setting of overseas scanner...

Page 296: ...TROUBLESHOOTING 14413 ...

Page 297: ...33 1 C0000 Main Motor malfunction C0010 I C Motor malfunction C0045 Cooling Fan Motor malfunction C004C Ozone Fan Motor malfunction C004E Power Unit Cooling Fan Motor malfunction C0070 Main Hopper Toner Replenishing Motor malfunction T 33 2 C0214 Abnormal image transfer voltage T 36 3 C0500 Warming up failure C0510 Abnormally low fusing temperature C0520 Abnormally high fusing temperature T 37 4 C...

Page 298: ... 5 Black Streaks or Bands T 52 6 Black Spots T 53 7 Blank Streaks or Bands T 54 8 Void Areas T 55 9 Smear on Back T 56 10 Uneven Image Density T 57 11 Gradation Reproduction Failure T 58 12 Rough Image T 59 13 Periodically Uneven Image T 60 6 ABORT CODES T 61 6 1 List of Abort Codes T 61 ...

Page 299: ... the problem 2 Select I O Check from the Tech Rep Mode menu Then select the screen that con tains the electrical component picked out in step 1 above See Tech Rep Mode con tained in SWITCHES ON PWBs TECH REP SETTINGS 3 Check the input data to determine if the signal is correctly input Electrical Component Check Procedure Through Checking Input Data Example When a paper misfeed occurs in the paper ...

Page 300: ...n Characteris tics Panel Display Input Board IC No Port No CN PJ No 1 0 PC13 Scanner L Scanner Home Position Sensor 2 Blocked Unblocked MFB2 Board MFB2 CN14MFB2 27 PC12 Scanner HP Scanner Home Position Sensor 1 At home Not at home CN14MFB2 26 S6 Size reset S Size Reset Switch When closed When opened CN14MFB2 24 PC14 Orig cover detect ing S Original Cover Detecting Sensor Within 15 15 or more CN14M...

Page 301: ... Check Screens The following screen is only typical and it may be different from what is shown on each individual copier Printer 4011T540CA 4011T541CA BackUp Next 4011T543CA 4011T542CA Next BackUp BackUp Next ...

Page 302: ...6B to PJ15A 9B PC3 PC103 2nd Drawer Paper Near Empty Paper Near Empty Sensor Unblocked Blocked Control Board PWB A IC1A P86 PJ3A 11A PC2 PC102 Paper Empty Paper Empty Sen sor Paper not present Paper present IC1A P85 PJ3A 14A PC4 PC104 Side Cover Door Set Sensor When opened When closed IC1A PC2 PJ3A 7B SW D Drawer Detect Drawer Set Switch When PF 118 is used In position 3 displayed Out of position ...

Page 303: ...ontrol Board PWB A IC1A PB7 PJ3A 5A PC3 Paper Near Empty Paper Near Empty Sensor Unblocked Blocked IC1A P86 PJ3A 11A PC2 Paper Empty Paper Empty Sen sor Paper not present Paper present IC1A P85 PJ3A 14A PC4 Side Cover Door Set Sensor When opened When closed IC1A PC2 PJ3A 7B SW D Drawer Detect Drawer Set Switch When PF 118 is used In position 3 displayed Out of position 0 dis played IC1A PC0 PC1 PJ...

Page 304: ...or Paper present Paper not present IC4A P24 INTP3 CN4A 11 PPS1 PPS1S Paper Empty Sen sor 1 Paper present Paper not present IC4A P25 INTP4 ASCK CN3A 2 RS1 Paper Near Empty 1 Paper Near Empty Sensor 1 Blocked Unblocked IC4A P75 ANI5 CN6A 12 RS2 Paper Near Empty 2 Paper Near Empty Sensor 2 Blocked Unblocked IC4A P76 ANI6 CN5A 5 EMP Paper Empty Paper Empty Sen sor 2 Paper present Paper not present IC4...

Page 305: ...d IC2A P3 PJ3A 10B S4 Sub Hop per Sub Hopper Toner Empty Switch Toner not loaded 1 and 0 alternately displayed Toner loaded 0 dis played IC1A P06 PJ3A 15B PC10 Toner Bot tle Set Toner Bottle Home Position Sensor At home Not at home IC1A P40 PJ15A 4B PC2 Paper Pas sage Timing Roller Synchronizing Roller Sensor Paper present Paper not present IC1A P41 PJ3A 7A PC3 Exit Paper Exit Sensor Paper present...

Page 306: ...it T 18 8 Manual Bypass take up T 16 9 Duplex turnover Duplex take up T 26 10 1st Drawer take up T 14 11 Transport T 20 12 2nd Drawer take up T 20 13 3rd Drawer take up T 20 or T 23 14 4th Drawer take up T 20 or T 23 15 5th Drawer take up T 20 16 See the relevant option service manual 17 18 19 20 21 22 display Misfeed location display Paper location 4011T544CA 4011T545CA 1 2 3 20 5 6 7 8 9 10 12 1...

Page 307: ...ion and if it is intact replace the board Resetting the Display If the misfeed display is not reset by these procedures check the misfeed detecting sen sor at the paper location Misfeed in the copier Misfeed in the option Open the relevant door remove all sheets of paper misfed and left inside and then open and close the Side Cover Remove all sheets of paper misfed and left inside and then raise a...

Page 308: ... paper source in the copier overview display Resetting the Size Error Display Press the Panel Reset key Slide out the drawer then slide it back in or load paper in the Manual Bypass Tray Causes of a Size Error Wrong paper size settings have been made The user loads paper of a size different from what is set for the paper source Two or more sheets of paper are being taken up and fed in 1st to 5th D...

Page 309: ...er A fixed paper size cassette is standard for the 2nd Drawer of the 25 cpm and 35 cpm copier Paper Exit Sensor PC3 Synchronizing Roller Sensor PC2 Duplex Unit Trans port Sensor PC2 Duplex Unit Door Set Sensor PC1 Manual Feed Paper Take Up Sensor PC8 Paper Take Up Sensor PC101 4011T548CA ...

Page 310: ... take up fail ure detection Manual Feed Paper Take Up Clutch energized Synchronizing Roller Sensor L Paper left Power Switch ON Misfeed reset Manual Feed Paper Take Up Sensor activated Type Detection Start Detection Paper take up failure detec tion Paper Take Up Clutch ener gized Synchronizing Roller Sensor L Paper left Power Switch ON Misfeed reset Paper Take Up Sensor acti vated Type Detection S...

Page 311: ... edge detection by Duplex Unit Transport Sen sor Paper Exit Sensor T Duplex Unit Transport Sen sor L Paper take up failure detec tion Duplex Unit Transport Sen sor L Synchronizing Roller Sensor L Paper left Power Switch ON Misfeed reset Duplex Unit Transport Sen sor activated ...

Page 312: ...feed Relevant Electrical Parts 1st Drawer Paper Take Up Solenoid SL1 Synchronizing Roller Sensor PC2 Master Board PWB A PWB A PJ3A 8A DC5 V PJ3A 7A PC2 ON PJ3A 12B DC24 V PJ3A 13B SL1 ON PJ3A 6A GND CN6 10 5 4 3 2 1 1 6 7 8 9 10 CN10 1 2 2 1 3 2 1 PJ9 PC2 SL1 4011T513AA ...

Page 313: ...rty or deformed YES Clean or change 6 Paper Lifting Plate is dirty or deformed YES Clean or change 7 Separator Pad is dirty deformed or worn YES Clean or change 8 Paper take up guide plate is dirty or deformed YES Clean or change 9 1st Drawer Paper Take Up Solenoid operation check the voltage across CN10 1 on the side of Master Board and GND changes from DC24 V to DC0 V when the Start key is press...

Page 314: ...ler Sensor PC2 Manual Feed Paper Take Up Sensor PC8 Master Board PWB A PWB A PJ2A 9A CL2 ON PJ2A 8A DC24 V PJ2A 7B PC8 ON PJ2A 6B DC5 V PJ2A 8B GND 1 2 3 PJ40 PC8 3 2 1 PJ23 CL2 CN14 1 2 3 4 5 6 7 1 2 3 4 5 6 7 CN36 2 1 1 2 PJ3A 8A DC5 V PJ3A 7A PC2 ON PJ3A 6A GND CN6 10 5 4 3 2 1 1 6 7 8 9 10 3 2 1 PJ9 PC2 4011T514AA ...

Page 315: ...ed or worn YES Clean or change 5 Manual Feed Paper Take Up Sensor operation check through I O check NO Check actuator Change Manual Feed Paper Take Up Sensor 6 Manual Feed Paper Take Up Clutch operation check the voltage across CN14 2 on the side of Master Board and GND changes from DC24 V to DC0 V when the Side Cover is opened and closed YES Change Manual Feed Paper Take Up Clutch NO Change Maste...

Page 316: ... Roller Sensor PC2 Synchronizing Clutch CL1 Master Board PWB A PWB A PJ3A 13A DC5 V PJ3A 12A PC3 ON PJ3A 11A GND 3 2 1 PJ4 PC3 CN7 3 2 1 1 2 3 PJ3A 8A DC5 V PJ3A 7A PC2 ON PJ3A 6A GND PJ3A 2A CL1 ON PJ3A 1A DC24 V CN6 3 2 1 PJ9 PC2 10 9 5 4 3 2 1 1 2 6 7 8 9 10 CN23 2 1 1 2 3 2 1 PJ24 CL1 4011T515AA ...

Page 317: ...ion check the volt age across CN6 9 on the side of Master Board and GND changes from DC24 V to DC0 V when the Start key is pressed YES Change Synchronizing Clutch NO Change Master Board Step Check Result Action 1 Image Transfer Roller is dirty or deformed YES Clean or change 2 Charge Neutralizing Plate is dirty or deformed YES Clean or change 3 PC Drum Paper Separator Fingers are dirty or deformed...

Page 318: ...0 5 4 3 2 1 1 6 7 8 9 10 3 2 1 PJ9 PC2 CL1 3 2 1 PJ12 PC1 PJ1A PJ5A 4 PJ5A 3 PJ5A 2 PJ5A 1 PJ6A 1 PJ6A 2 PJ2A PJ3A 3A DC5 V PJ3A 4A GND PJ3A 5A PC1 ON PJ3A 14B CL1 REM PJ3A 13B DC24 V PWB A PF 118 PF 119 3rd Drawer CL1 3 2 1 PJ12 PC1 PJ1A PJ5A 4 PJ5A 3 PJ5A 2 PJ5A 1 PJ6A 1 PJ6A 2 PJ2A PJ3A 3A DC5 V PJ3A 4A GND PJ3A 5A PC1 ON PJ3A 14B CL1 REM PJ3A 13B DC24 V PWB A PF 118 PF 119 4th Drawer CL1 3 2 1...

Page 319: ...ate is dirty or deformed YES Clean or change 7 Paper Separator Roll is dirty deformed or worn YES Clean or change 8 Paper take up guide plate is dirty or deformed YES Clean or change 9 The voltage across PJ6A 1 on Control Board and GND is DC24 V YES Check step 11 and onward 10 Fuse is conducting YES Change Power Supply Unit NO Change fuse 11 Paper Take Up Motor drive check Vertical Transport Rolle...

Page 320: ...p Sensor operation check I O check of all Paper Take Up Sensors YES Check step 5 4 Paper Take Up Sensor operation check the voltage across PJ3A 5A on Control Board and GND is DC5 V when the sensor is blocked and DC0 V when the sensor is unblocked YES Change Control Board Change Master Board NO Check actuator Change Paper Take Up Sensor 5 Synchronizing Roller Sensor operation check through I O chec...

Page 321: ...d Drawer CN15 12 1 1 12 CN83 1 2 3 1 2 3 P2CL 1 2 3 PJ7 RSEN PWB A PF 117 CN7A 8 P1CL ON CN1A 15 CN1A 12 CN1A 10 CN1A 9 CN1A 7 CN1A 6 CN1A 5 CN1A 1 PJ2A 12 PJ2A 8 PJ2A 7 PJ2A 6 PJ2A 4 PJ2A 2 CN7A 7 DC24 V CN7A 6 P2CL ON CN7A 5 DC24 V CN7A 4 RCL ON CN7A 3 DC24 V CN7A 2 BCL ON CN7A 1 DC24 V CN4A 3 RSEN LED CN4A 11 PPS0 ON CN4A 10 DC5 V CN4A 12 PPS0 LED CN4A 2 RSEN ON CN4A 1 DC5 V RCL BCL P1CL 1 2 3 ...

Page 322: ...hange Paper Standby Position Sensor Change LCC Control Board Change Control Board 9 Paper transport operation check paper is transported up to Paper Standby Position Sen sor when the cassette is slid in with paper loaded only in Lift 2 YES Change LCC Control Board Change Control Board Change Master Board 10 Paper Take Up Clutch 1 operation check the voltage across CN7A 8 on LCC Control Board and G...

Page 323: ... Control Board and GND changes from DC24 V to DC0 V when the Start key is pressed YES Change Separator Clutch NO Change LCC Control Board Change Control Board Change Master Board Step Check Result Action 1 Vertical Transport Roller Roll is dirty deformed or worn YES Clean or change 2 Registration Sensor operation check through I O check NO Change Registration Sen sor Change LCC Control Board Chang...

Page 324: ...4 GND PJ2A 1A DC24 V PJ2A 2A GND PJ2A 3A M2 E PJ2A 4A M2 CLK PJ2A 5A M1 CW CCW PJ2A 6A M1 CLK PJ2A 7A M1 E PJ2A 5B DC5 V PJ2A 4B GND PJ2A 3B DUP SET PC1 PJ2A 2B PC2 ON PJ2A 1B DUP OPEN PC1 PJ1A 1 DC24 V PJ1A 2 GND PJ1A 3 DUP OPEN PC1 PJ1A 4 DUP SET PC1 PJ1A 5 GND PJ1A 6 DC 5V PJ1A 7 M1 CW CCW PJ1A 8 M1 CLK PJ1A 9 M1 E PJ1A 10 M2 CLK PJ1A 11 M2 E PJ1A 12 PC2 ON PJ3A 1 PJ3A 2 PJ3A 3 PJ3A 4 PJ2A 4 PJ...

Page 325: ... over Motor Change Duplex Unit Con trol Board NO Change Master Board 6 Duplex Unit Turnover Motor operation check the direction of rotation of Duplex Unit Turnover Motor changes from forward to backward dur ing a 2 sided copy run YES Check step 8 and onward 7 Duplex Unit Turnover Motor operation check the voltage across PJ1A 7 on Duplex Unit Con trol Board and GND changes from DC5 V to DC0 V durin...

Page 326: ... Trans port Sensor 5 Duplex Unit Transport Sensor operation check the voltage across PJ1A 12 on Duplex Unit Control Board and GND is DC0 V when the sensor is blocked and DC5 V when the sensor is unblocked YES Change Master Board NO Change Duplex Unit Con trol Board 6 Manual Feed Paper Take Up Clutch operation check the voltage across CN14 2 on the side of Master Board and GND changes from DC24 V t...

Page 327: ...continu ous 1 sec period or more while the Ozone Fan Motor remains energized C004E Power Unit Cooling Fan Motor malfunction The Lock signal remains HIGH or LOW for a continu ous 1 sec period or more while the Power Unit Cool ing Fan Motor remains energized C0070 Main Hopper Toner Replenishing Motor mal function The Toner Bottle Home Position Sensor remains blocked L for a continuous 2 sec period o...

Page 328: ... left The Scanner Home Position Sensor 1 is not blocked L even when the Scanner moves 4 mm to the right after the Scanner Home Position Sensor 1 has been unblocked H The Power Switch is turned ON Original Cover low ered or Start key pressed when the Scanner is at any position other than home The Scanner Home Position Sensor 1 is not blocked L even when the Scanner moves 469 5 mm to the right C0651...

Page 329: ...A0 Elevator Motor drive mal function C0F32 Faulty ATDC Sensor The value of data read by the ATDC Sensor is faulty ATDC Sensor reading is 19 or more or 7 or less C0F33 ATDC adjustment failure In an F8 ATDC control voltage automatic adjust ment operation the adjustment of ATDC control voltage is not completed within 1 min after the ATDC Sensor sampling In an F8 operation the control voltage falls ou...

Page 330: ...l Lock detection The Lock signal remains ON for a continuous 5 sec period while the Polygon Motor remains deener gized C133A Communications error G A Communications with the gate array for expansion I O the IC mounted on the Master Board fail C133B Communications error option I F The connection status of a finishing option is changed after the power has been turned ON C13C0 I C initialization fail...

Page 331: ...ower Unit Cooling Fan Motor M4 Main Hopper Toner Replenishing Motor M6 Toner Bottle Home Position Sensor PC10 Master Board PWB A M1 PJ2 1 2 3 4 5 M8 M2 PJ1 1 2 3 4 DC24 V GND PWB A PJ5A 1 M2 REM PJ5A 2 M2 LOCK PJ5A 4 M1 LOCK PJ5A 14 M1 F R PJ3A 5A M3 LOCK PJ3A 4A GND PJ15A 1B M6 ON PJ15A 2B GND PJ15A 3B GND PJ15A 4B PC10 ON PJ15A 5B DC5 V PJ5A 3 M1 REM PJ3A 3A M3 REM PJ10A 6 M8 LOCK PJ10A 5 GND PJ...

Page 332: ...ster Board Step Check Result Action 1 Cooling Fan Motor operation check the voltage across CN6 8 on the side of Master Board and GND changes from DC0 V to DC24 V when the Power Switch is turned ON YES Change Cooling Fan Motor NO Change Master Board Step Check Result Action 1 Ozone Fan Motor operation check the voltage across CN18 3 on the side of Master Board and GND changes from DC0 V to DC24 V w...

Page 333: ...e Toner Bottle Cover Sensor is unblocked under the above conditions YES Check step 3 2 Main Hopper Toner Replenishing Motor opera tion check the voltage across CN43 2 on the side of Master Board and GND changes from DC0 V to DC24 V when step 1 is performed YES Change Main Hopper Toner Replenishing Motor NO Change Master Board 3 Toner Bottle Home Position Sensor operation check through I O check YE...

Page 334: ...ster Board and GND remains DC1 2 V or less while the malfunction code is being dis played YES Change Master Board 3 The voltage across CN17 15 on the side of Master Board and GND remains DC0 9 V or more while the malfunction code is being dis played YES Change Master Board NO Change High Voltage Unit PWB A PJ15A 1A MONITOR PJ15A 3A I T CONTROL PJ15A 4A P C I T REM PU2 CN2PU2 7 MONITOR CN2PU2 5 I T...

Page 335: ... Heater Lamp H1 Fusing Roller Thermistor TH1 Fusing Roller Thermostat TS1 Fusing Roller Heater Lamp Fuse TF1 Side Cover Interlock Switch 2 S3 Power Supply Unit PU1 Master Board PWB A PWB A PJ5A 5 H1 REM PJ4PU1 5 H1 REM PJ2PU1 2N PJ2PU1 1L PJ5A 6 TH1 ON PJ5A 7 GND CN25 4 3 2 1 1 2 3 4 PU1 TH1 CN4 1 2 1 2 1A 2A 1B 2B S3 TS1 H1 TF1 CN3 1 2 1 2 4011T552AA ...

Page 336: ...r Lamp is conducting NO Change Fusing Roller Heater Lamp 5 Fusing Roller Thermostat is conducting NO Change Fusing Roller Thermostat 6 Fusing Roller Heater Lamp Fuse is conducting NO Change Fusing Roller Heater Lamp Fuse 7 There is continuity across 1A and 1B and across 2A and 2B when Side Cover Interlock Switch 2 is actuated YES Change Power Supply Unit Change Master Board NO Change Side Cover In...

Page 337: ...2 Scanner Home Position Sensor 2 PC13 Scanner Motor M10 BCR Board BCR MFB2 Board MFB2 Master Board PWB A PC12 BCR CN11BCR 1 PC12 ON CN11BCR 2 GND CN11BCR 3 DC5 V CN12BCR 1 PC13 ON CN12BCR 2 GND CN12BCR 3 DC5 V CN3BCR 3 CN1BCR CN3BCR 2 CN3BCR 1 CN33 1 2 3 1 2 3 PC13 CN32 1 2 3 1 2 3 M10 PJ31 1 2 3 MFB2 CN14MFB2 CN4MFB2 PWB A PJ1A CN28 1 32 1 32 4011T534AA ...

Page 338: ... blocked and DC5 V when the sensor is unblocked NO Change Scanner Home Position Sensor 1 6 Scanner Home Position Sensor 1 operation check the voltage across CN1BCR 26 on BCR Board and GND is DC0 V when the sensor is blocked and DC5 V when the sensor is unblocked YES Change BCR Board NO Change MFB2 Board Change Master Board 7 Scanner Home Position Sensor 2 operation check through I O check YES Chec...

Page 339: ...ontrol Board PWB A Master Board PWB A PJ1A PJ13A PJ2A PWB A 2nd Drawer PWB A PJ1A PWB A PF 118 PF 119 3rd Drawer CN15 12 1 1 12 CN83 1 2 3 1 2 3 PWB A PF 117 CN1A 15 CN1A 12 CN1A 10 CN1A 9 CN1A 7 CN1A 6 CN1A 5 CN1A 1 PJ2A 12 PJ2A 8 PJ2A 7 PJ2A 6 PJ2A 4 PJ2A 2 CN4A 8 GND CN4A 7 DC5 V CN4A 9 LS2 ON CN4A 5 GND CN4A 4 DC5 V CN5A 2 EMOT CCW CN5A 1 EMOT CW CN6A 6 HMOT CLK CN6A 5 DC5 V CN6A 4 HMOT SIG CN...

Page 340: ...YES Change LCC Control Board Change Control Board Change Master Board NO Check actuator Change Lift Up Sensor 1 3 LCC Lift Up Motor operation check LCC Lift Up Motor turns after the cassette has been slid into the copier YES Change Master Board 4 LCC Lift Up Motor operation check the voltage across CN5A 1 on LCC Control Board and GND changes from DC0 V to DC24 V while step 3 is being performed YES...

Page 341: ...nge Lift Up Sensor 2 3 LCC Lift Up Motor operation check LCC Lift Up Motor turns after the cassette has been slid into the copier YES Change Master Board 4 LCC Lift Up Motor operation check the voltage across CN5A 2 on LCC Control Board and GND changes from DC0 V to DC24 V while step 3 is being performed YES Change LCC Lift Up Motor NO Change LCC Control Board Change Control Board Change Master Bo...

Page 342: ...C Sensor and Master Board are connected properly NO Correct connection 2 The voltage across PJ6PU1 5 on Power Sup ply Unit and GND is DC5 V YES Change I C Change Master Board NO Change Power Supply Unit PWB A PU1 1 2 3 4 PJ18 UN2 PJ6A 1 UN2 CONTROL PJ6A 2 DC24 V PJ6A 3 UN2 ON PJ6A 4 GND PJ6PU1 5 DC5 V PJ7A 2 DC5 V CN11 12 11 10 9 8 7 1 1 2 3 4 5 6 12 CN50 1 2 3 4 8 1 2 3 4 8 4011T512AA ...

Page 343: ...nectors sequen tially and turn OFF and ON the Power Switch When C133A is detected check the connector of the corresponding paper source unit and if it is intact change the PWB A of the unit C133B 1 Reset the malfunction and turn OFF and ON the Power Switch 2 Check the connection between Master Board copier and Control Board Finisher 3 Unplug the connector between Master Board and Control Board and...

Page 344: ...e Power Supply Unit 4 DC5 V output check the voltage across PJ6PU1 6 on Power Supply Unit and GND changes from DC0 V to DC5 V when the Power Switch is turned ON NO Change Power Supply Unit 5 DC24 V output check Unplug CN1F on Panel Board The voltage across CN1F 1 on cable end and GND and the voltage across CN1F 2 on cable end and GND change from DC0 V to DC24 V when the Power Switch is turned ON N...

Page 345: ...allation site Paper 2 Recommended paper is used NO Instruct user 3 Paper is damp YES Change paper Instruct user in paper storage Original 4 Original not flat YES Correct 5 Faint original YES Instruct user 6 Highly transparent original OHP transparencies etc YES Instruct user 7 Dirty or scratched Original Glass YES Clean or change PM parts 8 PM parts relating to image for mation have reached the en...

Page 346: ... YES Clean or change 4 PH shutter the one located on the laser beam path between PH Assy and PC Drum opens and closes properly NO Correct 5 PC Drum protective shutter opens and closes properly NO Correct 6 Master Board and PH Assy are con nected properly YES Change I C Change PH Assy Change High Voltage Unit Change Master Board NO Correct IR 1 CCD2 Board and MFB2 Board are connected properly NO Co...

Page 347: ... ON is selected for Lighting Exposure Lamp YES Check step 5 and onward 2 The voltage across CN13BCR 1 on BCR Board and GND changes from DC24 V to DC0 V when step 1 is per formed again NO Change BCR Board Change MFB2 Board 3 An AC voltage is output from Inverter Board 1 to Exposure Lamp when step 1 is performed again YES Change Exposure Lamp NO Change Inverter Board 1 4 CCD2 Board and MFB2 Board ar...

Page 348: ...value is changed toward the plus side YES Make setting again 4 Select functions in the following order Tech Rep Mode Tech Rep Choice Printer The image problem is cor rected when the VG Adjust value is changed toward the plus side YES Make setting again NO Change I C Change PH Assy Change High Voltage Unit Change Master Board IR 1 Shading sheet is dirty YES Clean 2 CCD2 Board and MFB2 Board are con...

Page 349: ...h Rep Choice Printer The image problem is cor rected when the Image Density value is changed toward the minus side YES Make setting again 8 Select functions in the following order Tech Rep Mode Tech Rep Choice Printer The image problem is cor rected when the VG Adjust value is changed toward the minus side YES Make setting again NO Change I C Change PH Assy Change High Voltage Unit Change Master B...

Page 350: ... dirty or scratchy YES Clean or change NO Change I C Change Master Board IR 1 Mirror lens and or Original Glass are dirty YES Clean 2 Exposure Lamp is dirty YES Clean 3 CCD2 Board and MFB2 Board are connected properly NO Correct 4 MFB2 Board and Master Board are connected properly YES Change CCD Unit Change MFB2 Board NO Correct Typical Faulty Images 4011T520AA ...

Page 351: ... dirty or deformed YES Clean or change 6 Charge Neutralizing Sheet contact ter minal is dirty or deformed YES Clean or change 7 Erase Lamp is dirty YES Clean 8 Erase Lamp is conducting YES Change I C Change High Voltage Unit Change Master Board NO Change Erase Lamp IR 1 Original Glass is dirty YES Clean 2 CCD2 Board and MFB2 Board are connected properly NO Correct 3 MFB2 Board and Master Board are...

Page 352: ...tchy YES Clean or change 4 PH Assy window glass is dirty YES Clean NO Change I C Change Master Board IR 1 Shading sheet is dirty YES Clean 2 Mirror lens and or Original Glass are dirty YES Clean 3 CCD2 Board and MFB2 Board are connected properly NO Correct 4 MFB2 Board and Master Board are connected properly YES Change CCD Unit Change MFB2 Board NO Correct Typical Faulty Images 4011T522AA ...

Page 353: ...Change 3 Fusing Rollers are scratchy or deformed YES Clean or change NO Change I C Change Master Board IR 1 Original Glass is dirty YES Clean 2 CCD2 Board and MFB2 Board are connected properly NO Correct 3 MFB2 Board and Master Board are connected properly YES Change CCD Unit Change MFB2 Board NO Correct Typical Faulty Images 4011T523AA ...

Page 354: ...Smear on Back Section Step Check Result Action Engine 1 Paper path is dirty with toner YES Clean 2 Image Transfer Roller is dirty YES Clean 3 Fusing Rollers are dirty YES Clean Typical Faulty Images 4011T524AA ...

Page 355: ...er Board IR 1 Mirror lens and or Original Glass are dirty YES Clean 2 Shading sheet is dirty YES Clean 3 Exposure Lamp is dirty or deteriorated YES Clean or change 4 CCD2 Board and MFB2 Board are connected properly NO Correct 5 MFB2 Board and Master Board are connected properly YES Change CCD Unit Change MFB2 Board NO Correct Typical Faulty Images 4011T525AA ...

Page 356: ... or change NO Change I C Change Master Board IR 1 Mirror lens and or Original Glass are dirty YES Clean 2 Shading sheet is dirty YES Clean 3 CCD2 Board and MFB2 Board are connected properly NO Correct 4 MFB2 Board and Master Board are connected properly YES Change CCD Unit Change MFB2 Board NO Correct Typical Faulty Images 4011T526AA ...

Page 357: ...YES Clean or change 3 Toner has caked or is contaminated with foreign matter in Toner Hopper YES Remove foreign matter Change toner NO Change I C Change High Voltage Unit Change Master Board IR 1 CCD2 Board and MFB2 Board are connected properly NO Correct 2 MFB2 Board and Master Board are connected properly YES Change CCD Unit Change MFB2 Board NO Correct Typical Faulty Images 4011T527AA ...

Page 358: ... driven properly NO Correct or change drive coupling mechanism 5 PH Assy is installed properly YES Change I C Change Master Board NO Correct IR 1 Scanner Motor is driven properly NO Correct or change drive coupling mechanism 2 Scanner Drive Cables are wound prop erly NO Wind cables properly 3 Scanner rails are damaged or dirty with foreign matter YES Clean or change 4 CCD2 Board and MFB2 Board are...

Page 359: ...COD Board FPLAN Board CEN Board expansion memory OT 102 JS 201 FN 109 FN 110 FN 504 JS 100 Copy control system failure 0x00200000 to 0x002fffff MFB2 Board Operation system failure 0x00300000 to 0x003fffff MFB2 Board Touch Panel Panel Board Network function Web processing sys tem failure 0x00400000 to 0x004fffff MFB2 Board FPLAN Board CEN Board Conversion process ing system failure 0x00500000 to 0x...

Page 360: ...to 0x00dfffff MFB2 Board Scanner Home Position Sensor 1 Scanner Home Position Sensor 2 Printer sequence system failure 0x00e00000 to 0x00e000ff MFB2 Board FPLAN Board Pi3502 Printer sequence system failure 0x00e00100 to 0x00e001ff MFB2 Board FPLAN Board Pi3502 Printer sequence system failure 0x00e00200 to 0x00e002ff MFB2 Board FPLAN Board Pi3502 Printer sequence system failure 0x00e00300 to 0x00e0...

Page 361: ...Options Function sequence system failure 0x01100400 to 0x011004ff MFB2 Board OS message pro cessing system fail ure 0x02000000 to 0x020fffff MFB2 Board FPLAN Board CEN Board Network processing system failure 0x03000000 to 0x030fffff MFB2 Board FPLAN Board CEN Board ...

Page 362: ...Copyright 2001 MINOLTA ME GmbH Printed in Germany Use of this manual should be strictly supervised to avoid disclosure of confidential information MINOLTA ME GmbH 4011 7991 11 ...

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