Olivetti d-Copia 163MF Service Manual
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Olivetti d-Copia 163MF Service Manual

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See also: Operating Manual
Color Printer
d-Copia 163MF
d-Copia 164MF
SERVICE MANUAL
Code Y107330-8

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Summary of Contents for Olivetti d-Copia 163MF

  • Page 1 Color Printer d-Copia 163MF d-Copia 164MF SERVICE MANUAL Code Y107330-8...
  • Page 2 PUBLICATION ISSUED BY: Olivetti S.p.A. 77, Via Jervis - 10015 Ivrea (TO) Italy Copyright © 2007, Olivetti All rights reserved...

  • Page 3: Safety Precautions

    Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.
  • Page 4 Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

  • Page 5: Installation Precautions

    1.Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current....................•...

  • Page 6: Precautions For Maintenance

    2.Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 7 • Do not remove the ozone filter, if any, from the copier except for routine replacement..... • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself...................... •...
  • Page 8 This page is intentionally left blank.

  • Page 9: Table Of Contents

    CONTENTSONTENTS Specifications 1-1-1 Specifications ........................... 1-1-1 1-1-2 Parts names ............................. 1-1-4 Main body ..........................1-1-4 Operation panel ........................1-1-5 1-1-3 Machine cross section ........................1-1-6 Installation 1-2-1 Installation environment ........................1-2-1 1-2-2 Unpacking and installation ....................... 1-2-2 Installation procedure ......................1-2-2 Service Mode 1-3-1 Service mode ...........................
  • Page 10 (2) Detaching and refitting the heater lamp, heat roller, fuser thermistor, thermal cutout, and press roller............................1-5-10 (3) Detaching and refitting the engine/high voltage PWB and power source PWB ......1-5-14 (4) Detaching and refitting the laser scanner unit .................1-5-17 (5) Detaching and refitting the eraser lamp (PWB)................1-5-19 (6) Detaching and refitting the drive unit....................1-5-20 (7) Detaching and refitting the main motor ...................1-5-21 1-5-6 Scanner unit............................1-5-22...

  • Page 11: Specifications

    1-1 Specifications 1-1-1 Specifications Main body Printing system ....... Electro-photographic Originals.......... Sheets of paper, books and 3-dimensional objects Copy sizes ........Paper cassette: A4, B5 (JIS), A5, folio, legal, letter, oficio II Manual feed tray: A4, B5 (JIS), A5, folio, legal, letter, oficio II, statement, executive, A6, B6, B5 (ISO), envelope #10, envelope #9, envelope monarch, envelope #6, enve- lope C5, envelope DL, 16K Paper types........
  • Page 12 Scanning functions Scanning Speed......Monochrome: 5 scan/min. Full color or grayscale: 5 scan/min. (TWAIN) 4 scan/min. (QLINIK) 1:1, Letter/A4, 300 dpi × Resolution........600 300 dpi Color mode ........Full color: 24 bit/dot (each color) Grayscale: 8 bit/dot Monochrome: 1 bit/dot File format........
  • Page 13 Document processor (DP) Original feed system ....... Automatic feeding Originals.......... Sheets of paper Original size ........Maximum: Legal Minimum: Statement and A5R Original paper weight ...... 60 to 105 g/m Maximum number of originals..50 sheets Environmental specifications Duplex copying ....... Manual Paper feed ........

  • Page 14: Parts Names

    1-1-2 Parts names (1) Main body Figure 1-1-1 Scanner unit 15. USB Interface connector Front cover 16. 5 V DC output (for print server) Paper cassette 17. Rear cover Manual feed tray 18. Power switch Toner container 19. AC inlet Developer unit 20.
  • Page 15 (2) Operation panel d-Copia163MF Figure 1-1-2a Copy mode key and indicator 11. Exposure adjustment key/Exposure display Collate key and indicator 12. Zoom key Combine key and indicator 13. Memory overflow indicator SCAN key 14. Toner indicator COPY key and indicator 15.

  • Page 16: Machine Cross Section

    1-1-3 Machine cross section Paper path Figure 1-1-3 Machine cross section Paper cassette Transfer section Manual feed tray 10. Fuser unit Paper feeding/conveying 11. Paper exit section section 12. Output tray Toner container 13. Operation unit Developer unit 14. Scanner unit Main charger unit 15.

  • Page 17: Installation Environment

    1-2 Installation 1-2-1 Installation environment ° ° Temperature: 10 to 32.5 C/50 to 90.5 Humidity: 15 - 80%RH Power supply: 120 V AC, 8.2 A 220 - 240 V AC, 3.9 A ± ± Power source frequency: 50 Hz 0.3%/60 Hz 0.3% Installation location Avoid direct sunlight or bright lighting.

  • Page 18: Unpacking And Installation

    1-2-2 Unpacking and installation (1) Installation procedure start Removing the tapes. Unpacking. Unlocking the shipping lock. Installing the toner container. Loading the paper. Installing the original table and ejection extension. Attaching the language sheet label sheets. Connecting the cables. Connecting the machine to the telephone line. (d-Coppia164MF only) Initializing the machine and printing a report page for test.
  • Page 19 Unpacking. Figure 1-2-3a Unpacking Machine (main body) 10. Pad tray Machine cover 11. Plastic bag Outer carton 12. Operation guide, CD-ROM(s), Language label sheet and etc. Bottom pad L 13. Installation guide Bottom pad R 14. Power cord Top pad L 15.
  • Page 20 Unlocking the shipping lock. 1. Open the document processor (DP). 2. Unlock the shipping lock. 3. Close the document processor (DP). Document processor (DP) Shipping lock Figure 1-2-4 Installing the toner container. 1. Open the scanner unit. 2. Open the front cover. Scanner unit Front cover Figure 1-2-5...
  • Page 21 3. Shake the container horizontally to distribute the toner evenly. 4. Remove the seal from the toner container. Toner container Figure 1-2-6 5. Remove the seal from the toner container. Seal Figure 1-2-7 Y107330-8 Service Manual 1-2-5...
  • Page 22 6. Turn the toner container release lever to the [UNLOCK] position. 7. Install the toner container in the printer. Toner container Toner container release lever Figure 1-2-8 8. Push firmly on the top of the container at the positions marked [PUSH HERE] until you hear a click.
  • Page 23 Loading the paper. 1. Pull the paper cassette completely out of the machine. 2. Press the release button and adjust the paper length guide to the paper size required. 3. Adjust the position of the width guides located on the left and right sides of the paper cassette.
  • Page 24 Attaching the language label sheets. 1. Remove the language label sheet. 2. Attach the language label sheet on the oper- ation panel. Language label sheet Language label sheet Operation panel Figure 1-2-12 1-2-8 Service Manual Y107330-8...
  • Page 25 Connecting the cables. 1. Connect the printer cable to the USB inter- USB interface connector face connector. 2. Connect the other end of the printer cable to the PC’s USB interface connector. 3. Connect the power cord to the printer AC inlet.
  • Page 26 Initializing the machine and printing a report page for test. 1. Turn the power switch on. The machine will begin to warm up after which the basic screen is displayed. 2. Press the Menu key. 3. Press the key to select [3. Report.] 4.
  • Page 27 8. The Installation Wizard starts. Click Next. Figure 1-2-19 9. For the simple, default installation, select Express Mode and click Next. Note: If you selected Custom Mode, select Universal Serial Bus (USB) to select the connection method, and follow the on- screen instructions.
  • Page 28 Note: When installing software for Windows XP, if a software installation warning for an unsigned device driver is displayed, click Continue Anyway to bypass the warning and install the driver. All device drivers have been fully tested. 12. When the installation is complete, the Instal- Figure 1-2-23 lation Completed Successfully window is displayed.

  • Page 29: Service Mode

    1-3 Service Mode 1-3-1 Service mode (1) Printing the system configuration page Description Lists information on the settings and environments of use for this machine. Purpose To acquire the current printing environmental parameters and cumulative information. Procedure Press the Menu key. Press the key to select [3.

  • Page 30: Executing A Service Setting Item (D-Copia164Mf Only)

    (2) Executing a service setting item (d-Copia164MF only) Start Press the Menu key. Press * key. Press # key. Press key to select the item. Executing the service setting. 1-3-2 Service Manual Y107330-8...

  • Page 31: Contents Of Service Setting Items (D-Copia164Mf Only)

    (3) Contents of service setting items (d-copia164MF only) The machine is equipped with a service setting for fax function which can be used to maintain and service the machine. Service items Description Selecting the country destination 1.Country Select Description To set the fax destination code. Purpose Basically, the setting need not be changed.
  • Page 32 Service items Description Setting the dial tone detection 5.DialTone Det Description Sets PSTN dial tone detection. Purpose Selects if the dial tone is detected to check the telephone is off the hook when a fax is con- nected to a public switched telephone network. Setting 1.
  • Page 33 Service items Description Adjusting the ratio of make-to-break of dial pulses 8.Pulse type Description Adjusts the ratio of make-to-break (ratio of make in pulse cycles) of dial pulses. Purpose Change the setting if dial pulse transmission problems occur. Setting 1. Change the value using the key.

  • Page 34: System Settings

    1-3-2 System Settings The machine is equipped with a system settings which can be operated by users (mainly by the machine administrator). In this machine system settings, default settings can be changed. (1) Executing a system setting item Start Press the Menu key. Press key to select the Select [1.Common Setup].

  • Page 35: Fax Setting (D-Copia164Mf Only)

    (3) FAX setting (d-Copia164MF only) (2) Common setting Message Language Setting the Current Date and Time Select the language of the message display. Set the date and time of the built-in clock. 1. Press the key to select the language to be 1.
  • Page 36 Speaker Volume Setting Rx Speed Selects the speaker volume when the On-Hook key is Selects the starting speed on FAX reception. pressed, or during communication. 1. Press the key to select [416.Fax Main.]. 1. Press the key to select [49.SPKR Volume]. 2.

  • Page 37: Edit Phone Book (D-Copia164Mf Only)

    (4) Edit Phone book (d-Copia164MF only) Registering One-touch Dial To register a FAX number to a one-touch key (1-12). 1. Press the key to select [51.1-Touch]. 2. Press a one-touch key to which a FAX number to be registered. 3. Enter a destination name using the numeric keys and press the OK key.
  • Page 38 This page is intentionally left blank. 1-3-10 Service Manual Y107330-8...

  • Page 39: Paper Misfeed Detection

    1-4 Troubleshooting 1-4-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the machine immediately stops printing and displays the paper misfeed message on the operation panel. To remove paper misfed in the machine, open the front cover or the rear cover or pull out the paper cas- sette.To remove original jammed in the DP, open the original cover.

  • Page 40: Self-Diagnosis

    1-4-2 Self-diagnosis (1) Self-diagnostic function This machine is equipped with a self-diagnostic function. When a problem is detected, the machine stops printing and an error message is displayed on the operation panel. [PRINTER ERROR] Service Call-#### Error code [SCANNER ERROR] Lamp error Error causes Figure 1-4-2 Error message display...

  • Page 41: Service Error Message

    (2) Service error message Remarks Service error message Contents Causes Check procedures/corrective measures “####” means self- Self-diagnostic error Turn the power switch off and then back on [PRINTER ERROR] diagnostic error code. occurred. again. If this message still remains, follow Service Call-#### the self-diagnostic error code instruction.
  • Page 42 Remarks Service error message Contents Causes Check procedures/corrective measures Scanner home posi- Defective scanner Replace the scanner home position sensor [SCANNER ERROR] tion sensor error for home position sen- (See P.1-5-37). Home sensor scanner. sor. Defective main PWB. Turn the power switch off and then back on again.

  • Page 43: Service Call Codes

    (3) Service call codes Remarks Code Contents Causes Check procedures/corrective measures 2000 Main motor error Defective harness Follow the flow chart. The main motor ready input is not given between engine/ for two seconds during the main motor is high voltage PWB driven.
  • Page 44 Remarks Code Contents Causes Check procedures/corrective measures 4000 Polygon motor (laser scanner unit) Defective harness Follow the flow chart. error between engine/ The polygon motor ready input is not high voltage PWB given for eight seconds during the poly- and laser scanner gon motor is driven.
  • Page 45 Remarks Code Contents Causes Check procedures/corrective measures 4200 PD (Pin photo diode) sensor (laser Defective main Follow the flow chart. scanner unit) error PWB. The first BD input is not given for 10 sec- Defective harness onds after power is turned on and the between main laser begins emitting.
  • Page 46 Remarks Code Contents Causes Check procedures/corrective measures 4200 Continued from Continued from cont. previous page. previous page. Replace laser scanner unit. Replace main PWB. See P.1-5-17. See P.1-5-29. Replace main PWB. See P.1-5-29. Turn power switch on. Turn power switch on. End.
  • Page 47 Remarks Code Contents Causes Check procedures/corrective measures 6000 Broken heater lamp error Defective fuser Follow the flow chart. ° thermistor. The temperature won’t rise by 1 C/33.8 ° F during warming up and the heater is Broken thermal turned on for 5 s. cutout or heater °...
  • Page 48 Remarks Code Contents Causes Check procedures/corrective measures 6010 Fuser low temperature Defective the fuser Follow the flow chart. After the fuser heater lamp is turned on, thermistor. the temperature at the upper fuser roller Defective the ° ° lower than 100 C/212 F continues for engine/high volt-...
  • Page 49 Remarks Code Contents Causes Check procedures/corrective measures 6050 Broken fuser thermistor Defective the fuser Follow the flow chart. The thermistor AD value is less than 1 thermistor. for 600 ms. Defective the engine/high volt- age PWB. Start Turn power switch off, and remove power cord.
  • Page 50 Remarks Code Contents Causes Check procedures/corrective measures 7980 Waste toner full (Total page count Defective drum Follow the flow chart. less than 100,000 pages of printing) unit. The toner-full sensor has detected that Defective waste the waste toner is full before the total toner full sensor.
  • Page 51 Remarks Code Contents Causes Check procedures/corrective measures 7990 Waste toner full (Total page count Defective drum Follow the flow chart. more than 100,000 pages of printing) unit. The toner-full sensor has detected that Defective waste the waste toner is full before the total toner full sensor.

  • Page 52: Error Codes

    (4) Error codes (d-Copia164MF only) (4-1) Error code Error codes are listed on the communication reports, activity report, etc. The codes consist of an error code indication a 6- digit number. The 6th digit indicates the transmission/reception error, 5th digit indicates codec system, 3rd and 4th digit indicate commu- nication speed, and then, the lower two indicate error description.

  • Page 53: Table Of Error Code

    (4-3) Table of error code Error code Description xxxx01 Transmission was interrupted. 1xxx11 Transmission was interrupted due to jam in the DP. 1xxx12 Transmission was interrupted because the left cover of the DP. 1xxx13 Transmission was interrupted due to shutting down of the facsimile. 2xxx14 Reception failed because the facsimile memory is full.

  • Page 54: Image Formation Problems

    1-4-3 Image formation problems (1) Completely (2) All-black print- (3) Dropouts. (4) Black dots. (5) Black horizon- blank printout. out. tal streaks. See P.1-4-17 See P.1-4-17 See P.1-4-18 See P.1-4-18 See P.1-4-18 (6) Black vertical (7) Unsharpness. (8) Gray back- (9) Dirt on the top (10) Undulated print- streaks.

  • Page 55: No Image Appears (Entirely Black)

    (1) Completely blank printout Copy example Causes Check procedures/corrective measures Defective drum unit or developer unit. Open the top cover and check that the drum unit and devel- oper unit is correctly seated. Check for poor contact of the main charger terminal between the main charger unit and the drum unit.

  • Page 56: Dropouts

    (3) Dropouts Copy example Causes Check procedures/corrective measures Defective developing roller (in the If the defects occur at regular intervals of 47.2 mm/1 ", the developer unit). problem may be the damaged developing roller (in the devel- oper unit). Replace the developer unit (See P.1-5-6). Defective drum unit.

  • Page 57: Black Vertical Streaks

    (6) Black vertical streaks Copy example Causes Check procedures/corrective measures Contaminated main charger wire. Contaminated main charger wire. Clean the main charger wire by sliding the green colored cleaning knob in and out several times. Defective drum surface. Defective drum surface. A streak of toner remaining on drum after printing means that the cleaning blade (in the drum unit) is not working properly.

  • Page 58: Gray Background

    (8) Gray background Copy example Causes Check procedures/corrective measures Print density setting. Print density setting. The print density may be set too high. Try adjusting the print density. For details refer to the opera- tion guide. Defective drum surface potential. Defective drum surface potential.

  • Page 59: Electric Problems

    1-4-4 Electric problems Problem Causes Check procedures/corrective measures (1)The machine does No electricity at the power Measure the input voltage. not operate when the outlet. power switch is The power cord is not Check the contact between the power plug and the outlet. turned on.
  • Page 60 Problem Causes Check procedures/corrective measures (6)The feed clutch Broken feed clutch coil. Check for continuity across the coil. If none, replace the feed does not operate. clutch. Poor contact in the feed Reinsert the connector. clutch connector terminals. Defective harness between Check for continuity across the harness.
  • Page 61 Problem Causes Check procedures/corrective measures (12)No transfer bias Poor contact of transfer (See P.1-5-14). is output. bias terminal and transfer bias terminal (J1, J2, J3) on the engine/high voltage PWB. Defective engine/high volt- age PWB. (13)The message Defective paper sensor on Replace the engine/high voltage PWB (See P.1-5-14).

  • Page 62: Mechanical Problems

    1-4-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the feed roller is dirty Clean with isopropyl alcohol. No primary paper feed. with paper powder. Check if the paper feed roller is deformed. Check visually and replace any deformed paper feed roller.

  • Page 63: Assembly And Disassembly

    1-5 Assembly and Disassembly 1-5-1 Precautions for assembly and disassembly (1) Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly. When the fax kit is installed, be sure to disconnect the modular code before starting disassembly. When handling PWBs (printed wiring boards), do not touch connectors with bare hands or damage the board.

  • Page 64: Outer Covers And Scanner Unit

    1-5-2 Outer covers and scanner unit (1) Detaching and refitting the right cover, left cover and top cover <Procedure> 1. Remove the paper cassette. 2. Open the scanner unit. 3. Open the front cover. 4. Unlatch the four latches and then remove the right cover.
  • Page 65 6. Remove the scanner unit (See P.1-5-22). 7. While opening the rear cover and then hook remove the two screws. Top cover hook 8. While unhooking the two hooks and then remove the top cover. Top cover Top cover Screw Screw Rear cover Figure 1-5-3...

  • Page 66: Paper Feeding/Conveying Section

    1-5-3 Paper feeding/conveying section (1) Detaching and refitting the paper feed roller <Procedure> 1. Remove the paper cassette. 2. Remove the paper feed roller. 3. Check or replace the paper feed roller and refit all the removed parts. Paper feed roller Figure 1-5-4 Removing the paper feed roller 1-5-4 Service Manual...

  • Page 67: Detaching And Refitting The Transfer Roller

    (2) Detaching and refitting the transfer roller <Procedure> 1. Remove the developer unit and drum unit (See P.1-5-6). Paper passing direction 2. Remove the transfer roller from bushes. 3. Check or replace the transfer roller and refit Short Long all the removed parts. Transfer roller Bush Paper passing...

  • Page 68: Process Section

    1-5-4 Process section (1) Detaching and refitting the developer unit and drum unit <Procedure> 1. Open the scanner unit. Front cover 2. Open the front cover. 3. Remove the developer unit (with toner con- tainer. Developer unit Figure 1-5-6 Removing the developer unit 4.

  • Page 69: Detaching And Refitting The Main Charger Unit

    (2) Detaching and refitting the main charger unit <Procedure> 1. Remove the drum unit (See P.1-5-6). 2. While pushing on the main charger terminal (1), slide the main charger unit (2). 3. Remove the main charger unit (3) by lifting 4.

  • Page 70: Fuser Unit

    1-5-5 Fuser unit (1) Detaching and refitting the fuser unit <Procedure> 1. Remove the outer covers (See P.1-5-2). 2. Remove the two connectors. 3. Remove the wire from two clamps. Clamp Connector Wire Clamp Connector Figure 1-5-9 4. Pull out the rear cover axes (with springs) from the axis holes.
  • Page 71 5. Remove the two screws and then remove the fuser unit. Screw Screw Fuser unit Figure 1-5-11 6. Remove the two screws and then separate the upper fuser frame and lower fuser frame. 7. Check or replace the fuser unit and refit all the removed parts.

  • Page 72: Detaching And Refitting The Heater Lamp, Heat Roller, Fuser Thermistor, Thermal Cutout, And Press Roller

    (2) Detaching and refitting the heater lamp, heat roller, fuser thermistor, thermal cutout, and press roller <Procedure> 1. Remove the fuser unit (See P.1-5-8). 2. Remove the two screws and terminal. Screw 3. Remove the heater lamp. Fuser gear * Seat the heater lamp aligning its wattage mark and welding mark faced with the cor- rect direction and side.
  • Page 73 4. Pull the heat R bush and heat L bush (with Gear heat roller) from the upper fuser guide. 5. Remove the heat R bush, heat L bush and Bush heat gear from the heat roller. Heat roller Heat roller Heat roller Bush Bush...
  • Page 74 7. Remove the two screws (nuts), plate cord, and terminal. 8. Remove the thermal cutout. Cord plate Screw Thermal cutout Screw Terminal Figure 1-5-16 1-5-12 Service Manual Y107330-8...
  • Page 75 9. Remove the press roller from the bushes. 10. Check or replace the heater lamp, heat roller, fuser thermistor, thermal cutout, or Press roller press roller and refit all the removed parts. Bush Bush Lower fuser frame Figure 1-5-17Removing the press roller Y107330-8 Service Manual 1-5-13...

  • Page 76: Detaching And Refitting The Engine/High Voltage Pwb And Power Source Pwb

    (3) Detaching and refitting the engine/high voltage PWB and power source PWB <Procedure> 1. Remove the developer unit and drum unit (See P.1-5-6). 2. Remove the paper cassette. 3. Remove the scanner unit (See P.1-5-22). 4. Remove the six connectors. * When seating the engine/high voltage PWB, ensure that the developer bias termi- nal spring is correctly in contact with the...
  • Page 77 5. Turn the printer bottom side up. Screws 6. Remove the five screws and then remove the bottom frame plate with PWBs (behind the plate). Screws Bottom frame plate (Transfer bias terminal) Figure 1-5-19 Y107330-8 Service Manual 1-5-15...
  • Page 78 7. Remove the one screw and terminal from the bottom frame plate. * When securing the grounding terminal, EEPROM Screw hook the grounding wire to the projection. Socket 8. Remove the two connectors from power Screw source PWB. 9. Remove the three screws from power source PWB and power source fan motor.

  • Page 79: Detaching And Refitting The Laser Scanner Unit

    (4) Detaching and refitting the laser scanner unit <Procedure> 1. Remove the outer covers (See P.1-5-2). 2. Remove the two screws and then remove Screw the LSU lid. LSU lid Screw Figure 1-5-21 Y107330-8 Service Manual 1-5-17...
  • Page 80 3. Remove the three screws. Connector 4. Remove the two connectors and then Screw remove the laser scanner unit. 5. Check or replace the laser scanner unit and Laser scanner unit refit all the removed parts. Screw Screw Figure 1-5-22 1-5-18 Service Manual Y107330-8...

  • Page 81: Detaching And Refitting The Eraser Lamp (Pwb)

    (5) Detaching and refitting the eraser lamp (PWB) <Procedure> 1. Remove the laser scanner unit (See P.1-5-17). 2. Remove the one connector. 3. Remove the wire from two clamps. Clumps Wire Connector Figure 1-5-23 4. Remove the wire form clamp. 5.

  • Page 82: Detaching And Refitting The Drive Unit

    (6) Detaching and refitting the drive unit <Procedure> 1. Remove the right cover (See P.1-5-2). Connectors 2. Remove the three connectors. 3. Remove the two screws and then remove the two grounding plates. 4. Remove the two stoppers and then remove the two clutches.

  • Page 83: Detaching And Refitting The Main Motor

    (7) Detaching and refitting the main motor <Procedure> 1. Remove the right cover (See P.1-5-24). 2. Remove the one connector from main motor. 3. Remove the four screws and then remove the main motor. 4. Check or replace the main motor and refit all the removed parts.

  • Page 84: Scanner Unit

    1-5-6 Scanner unit (1) Detaching and refitting the scanner unit <Procedure> 1. Remove the right cover and left cover (See P.1-5-2). 2. Open the scanner unit. Scanner unit 3. While pressing the locks and then remove (DP) the lift link L and lift link R. Lift link L Lift link R Locks...
  • Page 85 4. Remove the two screws and then remove Screw the two terminals. 5. Remove the five connectors. Terminal 6. Remove the ferrite core. Connector Connector Connector Connector Connector Screw Terminal Ferrite core Figure 1-5-29 7. Remove the two pivot pins. 8.

  • Page 86: Detaching And Refitting The Optical Module Unit

    (2) Detaching and refitting the optical module unit <Procedure> Original table 1. Remove the scanner unit (See P.1-5-22). 2. Unlatch the two latches and then remove the original table. 3. Remove the ejection extension. Ejection extension Latches Figure 1-5-31 4. Turn over the scanner unit. Screw 5.
  • Page 87 6. Remove the screw and then remove the ter- minal. 7. Remove the connector. Main PWB 8. Cut the band. Screw 9. Split and remove the ferrite core. Terminal Ferrite core Connector Band Figure 1-5-33 10. Remove the two screws and then remove Document processor (DP) the DP signal cable.
  • Page 88 12. Remove the three screws. Screw Screw Operation unit Screw Figure 1-5-35 13. Remove the FFC form FFC connector. 14. Remove the connector (d-copia164MF only). 15. Remove the operation unit. Operation unit Connector FFC connector Operation unit Figure 1-5-36 1-5-26 Service Manual Y107330-8...
  • Page 89 16. Remove the four screws and then remove Screw the scanner upper housing. Scanner upper Screw housing Screw Screw Screw Figure 1-5-37 17. Remove the sliding rod. Scanner bottom housing Sliding rod Optical module unit Sliding rod Figure 1-5-38 Y107330-8 Service Manual 1-5-27...
  • Page 90 18. Remove the two FFCs. FFC connector 19. Remove the optical module unit from the FFC connector Optical module unit scanner belt. 20. Check or replace the optical module unit and refit all the removed parts. Scanner belt Bottom view Scanner belt Optical module unit...

  • Page 91: Detaching And Refitting The Main Pwb

    (3) Detaching and refitting the main PWB <Procedure> 1. Remove the scanner unit (See P.1-5-22). 2. Remove the original table and ejection Screw extension (See P.1-5-24). 3. Turn over the scanner unit. 4. Remove the six screws and then open the Screw main PWB cover.
  • Page 92 10. Remove the two screws (A) and then Screw (B) Screw (A) remove the three terminals. 11. Remove the four screws (B) and then Main PWB Terminal remove the Main PWB. Screw (B) Screw (B) 12. Remove the lug terminal. Terminal Screw (B) terminal...

  • Page 93: Detaching And Refitting The Fax Control Pwb (D-Copia164Mf Only)

    (4) Detaching and refitting the fax control PWB (d-Copia 164MF only) <Procedure> 1. Remove the right cover (See P.1-5-2). 2. Remove the five connectors. Connector 3. Remove the screw and then remove the ter- Connector minal. Connector Connector Connector Screw Terminal Figure 1-5-44 4.
  • Page 94 6. Remove the relay cable. 7. Check or replace the fax control PWB and refit all the removed parts. Fax control PWB Relay cable Figure 1-5-46 1-5-32 Service Manual Y107330-8...

  • Page 95: Detaching And Refitting The Exposure Lamp

    (5) Detaching and refitting the exposure lamp <Procedure> 1. Remove the optical module unit Hook (See P.1-5-24). 2. Remove the CCD cover. CCD cover Optical module unit Stopper Figure 1-5-47 3. Remove the one connector. Hook 4. Remove the adhesive tape. 5.
  • Page 96 6. Remove the wires from the exposure lamp Wire holder. 7. Remove the exposure lamp. 8. Check or replace the exposure lamp and refit all the removed parts. Exposure lamp Wire Exposure lamp holder Figure 1-5-49 1-5-34 Service Manual Y107330-8...

  • Page 97: Detaching And Refitting The Inverter Pwb

    (6) Detaching and refitting the inverter PWB <Procedure> 1. Remove the optical module unit (See P.1-5-24). 2. Cut the band. Optical module unit Band Figure 1-5-50 3. Remove the CCD cover. Hook CCD cover Optical module unit Stopper Figure 1-5-51 Y107330-8 Service Manual 1-5-35...
  • Page 98 4. Remove the two connectors. Connector 5. Remove the one screw and then remove the inverter PWB. 6. Check or replace the inverter PWB and refit Screw all the removed parts. Inverter PWB Connector Figure 1-5-52 1-5-36 Service Manual Y107330-8...

  • Page 99: Detaching And Refitting The Scanner Home Position Sensor

    (7) Detaching and refitting the scanner home position sensor <Procedure> 1. Remove the optical module unit (See P.1-5-24). Hook 2. Remove the CCD cover. CCD cover Optical module unit Stopper Figure 1-5-53 3. Remove the one connector. 4. Remove the one screw and then remove the Screw scanner home position sensor.

  • Page 100: Detaching And Refitting The Scanner Motor

    (8) Detaching and refitting the scanner motor <Procedure> 1. Remove the optical module unit Hook (See P.1-5-24). 2. Remove the one connector. 3. Remove the scanner motor wire. Connector CCD cover Scanner motor wire Stopper Optical module unit Figure 1-5-55 4.

  • Page 101: Document Processor (Dp)

    1-5-7 Document processor (DP) (1) Detaching and refitting the document processor (DP) <Procedure> 1. Remove the scanner unit (See P.1-5-22). Screw 2. Remove the original table (See P.1-5-24). 3. Turn over the scanner unit. 4. Remove the six screws and then open the Screw main PWB cover.
  • Page 102 9. Remove the two screws and then remove Document processor (DP) the DP signal cable. Screws 10. While unlocking the both hinge locks and then remove the document processor (DP). 11. Check or replace the document processor (DP) and refit all the removed parts. DP signal cable Hinge lock...

  • Page 103: Detaching And Refitting The Pad Assembly

    (2) Detaching and refitting the pad assembly <Procedure> 1. Open the DP cover. Pad assembly 2. Press both arms of the pad assembly inwardly with your fingers and then pull out the pad assembly. 3. Check or replace the pad assembly and refit all the removed parts.

  • Page 104: Detaching And Refitting The Original Feed Roller

    (3) Detaching and refitting the original feed roller <Procedure> 1. Open the DP front cover. 2. Open the shaft holder. 3. Remove the original feed roller. 4. Check or replace the original feed roller and refit all the removed parts. Shaft holder DP front cover...

  • Page 105: Firmware

    1-6 Firmware 1-6-1 Updating the firmware Follow the procedure below to upgrade the firmware on the main PWB and fax control PWB. Procedure Note: Ensure the machine is plugged in and connected to the PC’s USB port, install the updating firmware folder (files) before firm- ware updating.
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  • Page 107: Paper Feeding/Conveying Section

    2-1 Mechanical construction 2-1-1 Paper feeding/conveying section The paper feeding/conveying system picks up paper from the paper cassette, manual feed tray, feeds it in the machine and delivers in the output tray. Paper is feed at the precise timing in synchronization with data processing. (1) Paper feed section The figure below shows the components in the paper feeding/conveying section and the paths through which the paper travels.
  • Page 108 Engine/high voltage PWB Connect PWB +24V3 YC403-1 YC401-8 YC3-13 Feed clutch FEDSOLON FEDDOLON YC403-2 YC3-8 YC401-3 REGSOLON YC3-7 +24V3 YC401-2 Registration YC402-1 +24V3 REGDR YC3-6 YC401-1 clutch YC402-2 Registration sensor +24V3 CN1-1 YC5-1 Paper sensor YC5-2 CN1-2 MMOTRDY YC5-3 CN1-3 MOTCLK YC5-4 CN1-4...

  • Page 109: Drum Section

    2-1-2 Drum section (1) Drum unit The durable layer of organic photoconductor (OPC) is coated over the aluminum cylinder base. The OPC tend to reduce its own electrical conductance when exposed to light. After a cyclic process of charging, exposure, and development, the electrostatic image is constituted over the OPC layer.

  • Page 110: Main Charger Unit

    (2) Main charger unit As the drum rotates in a “clean (neutral)” state, its photoconductive layer is given a uniform, positive (+) corona charge dis- persed by the main charger wire. Due to high-voltage scorotron charging, the charging wire can get contaminated by oxi- dization after a long run.

  • Page 111: Expose Section

    2-1-3 Expose section (1) Laser scanner unit The charged surface of the drum is then scanned by the laser beam from the laser scanner unit. The laser beam (780 nm wavelength) beam is dispersed as the polygon motor revolves (27959 rpm) to reflect the laser beam over the drum.
  • Page 112 Figure 2-1-7 Laser scanner unit Laser diode ..........Emits diffused, visible laser. Cylindrical lens..........Compensates the vertical angle at which the laser beam hits a polygon mirror segment. Polygon mirror (motor) ........ Has six mirror segments around its hexagonal circumference; each mir- ror corresponding to one scanned line width on the drum when laser beam scans on it.

  • Page 113: Developing Section

    2-1-4 Developing section (1) Developer unit The latent image constituted on the drum is developed into a visible image. The developing roller contains a 3-pole (S-N- S) magnet core and an aluminum cylinder rotating around the magnet core. Toner attracts to the developing roller since it is powdery ink made of black resin bound to iron particles.
  • Page 114 Engine/high voltage PWB Developing bias output 350 + 5 V DC + AC Developing roller Figure 2-1-9 Developing section block diagram 2-1-8 Service Manual Y107330-8...

  • Page 115: Transfer Section

    2-1-5 Transfer section The image developed by toner on the drum is transferred onto the paper because of the electrical attraction between the toner itself and the transfer roller. The transfer roller is negatively biased so that the positively charged toner is attracted onto the paper while it is pinched by the drum and the transfer roller.

  • Page 116: Cleaning Section

    2-1-6 Cleaning section After the transferring process, the drum needs to be physically cleaned of toner which is residual after the development process. The cleaning blade is constantly pressed against the drum and scrapes the residual toner off to the sweep roller. The waste toner is collected at the output end of the sweep roller and sent back to the toner container, into the waste toner reservoir.

  • Page 117: Fuser Section

    2-1-7 Fuser section (1) Fuser unit The toner on the paper is molten and pressed into the paper as it passes between the heat roller and the press roller in the fuser unit. The heat roller has a heater lamp (750 W) inside which continuously turns on and off by the fuser thermistor to maintain the constant temperature onto the heat roller surface.
  • Page 118 Fuser unit Power source PWB Engine/high voltage PWB Thermal cutout HEATN HEATERLIVE YC2-6 YC1-6 CN1-1 SLEEP YC2-7 YC1-7 NEUTRAL ZCROSS CN1-3 YC2-9 YC1-9 Fuser heater lamp Fuser thermistor YC7-2 THERM YC7-1 Figure 2-1-15 Fuser section block diagram 2-1-12 Service Manual Y107330-8...

  • Page 119: Paper Exit Section

    2-1-8 Paper exit section (1) Paper exit section The paper exit section transports the paper which passed the fuser unit towards the output tray. The paper which passed through the fuser unit turns on the exit sensor which is driven by the fuser actuator in the fuser unit, and is led by the guide comprised of the rear cover and the frame, finally reaching the FD roller.
  • Page 120 Fuser unit Engine/high voltage PWB EXITN YC2-8 YC1-8 Exit sensor Power source PWB Figure 2-1-17 Paper exit section block diagram 2-1-14 Service Manual Y107330-8...

  • Page 121: Scanner Section

    2-1-9 Scanner section (1) Scanner unit Figure 2-1-18 Scanner section Scanner upper housing Exposure lamp Scanner bottom housing Mirror Platen (10) Mirror Size indicator (11) Mirror Optical module unit housing (12) Lens Lamp housing (13) CCD PWB CCD cover Original Platen Optical module unit Main PWB...
  • Page 122 (2) Optical module unit The optical module unit consists of an exposure lamp, three mirrors, a lens, a CCD PWB, and so on. Also an inverter PWB for driving the exposure lamp and a scanner home position sensor for detecting the home position of the optical module unit are incorporated.

  • Page 123: Document Processor (Dp) Section

    2-1-10 Document processor (DP) section (1) Document processor (DP) Figure 2-1-21 Document processor (DP) section Original feed roller DP bottom housing Pad assembly DP frame Original conveying roller DP contact plate Original conveying pulley (10) Original exit roller DP upper housing (11) Original exit pulley DP cover (12) Original table...
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  • Page 125: Electrical Parts Layout

    2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) Electrical parts layout Fuser unit Drum unit Laser scanner unit Developer unit Figure 2-2-1 Main frame Engine/high voltage PWB ......Controls the input/output of electrical parts and generates the high volt- age.
  • Page 126 Optical module unit Scanner unit Figure 2-2-2 Scanner unit and document processor (DP) Main PWB ............ Controls the software such as the print data processing and provides the interface with computer. Operation panel PWB ........Indicates the LED indicators and controls key inputs. Motor driver PWB.........

  • Page 127: Power Source Pwb

    2-3 Operation of the PWBs 2-3-1 Power source PWB Power source PWB +24V +24V1 AC input/Noise filter circuit Power switch 24 V DC on/off +24V4 LIVE Switching control circuit regulator circuit input SLEEPN NEUTRAL 24VGND 5VGND Zero-cross signal output ZCROSS circuit +24V2 Thermal...
  • Page 128 Figure 2-3-2 Power source PWB silk-screen diagram Connector Pin No. Signal Voltage Description LIVE 220 - 240 V AC AC power input Connected 120 V AC to the AC NEUTRAL 220 - 240 V AC AC power input inlet 120 V AC HEATERLIVE 220 - 240 V AC Power supply for heater lamp (On/Off)

  • Page 129: Engine/High Voltage Pwb

    2-3-2 Engine/high voltage PWB Engine/high voltage PWB Connect EECLK EEPROM EEDIO (U2) BUZZ RESETN Reset IC (U3) Buzzer Registration REGSOLON clutch FANH Cooling FEDSOLON Feed clutch FANL fan motor MMOTON TONER Toner empty MOTCLK Main motor sensor MMOTRDY Registration (U1) sensor TNFULL Waste toner...
  • Page 130 YC10 YC11 Figure 2-3-4 Engine/high voltage PWB silk-screen diagram 2-3-4 Service Manual Y107330-8...
  • Page 131 Connector Pin No. Signal Voltage Description 5 V DC 5 V DC power input Connected 5 V DC 5 V DC power input to the power Ground source PWB Ground +24V 24 V DC 24 V DC power output (via interlock switch) HEATN 0/24 V DC Heater lamp: On/Off...
  • Page 132 Connector Pin No. Signal Voltage Description +24V1 24 V DC 24 V DC power output Connected 0/12/24 V DC Cooling fan motor: Full speed/Half speed/Off to the cool- ing fan motor YC10 5 V DC 5 V DC power output Connected TONER 0/5 V DC...

  • Page 133: Main Pwbs

    2-3-3 Main PWBs Main PWB CCD PWB SDRAM 64 MB image sensor VD [0:7] Real time Stepping Scanner clock motor CCD control motor driver IC Video I/F ASIC Motor control (CPU) Logic IC Motor driver PWB Serial communication I/F Stepping Original USB 2.0 Glue...
  • Page 134 Main PWB CCD PWB SDRAM NVRAM 32 MB 2 kbytes image sensor VD [0:7] Real time Stepping Scanner clock motor CCD control motor driver IC Video I/F ASIC Motor control (CPU) Logic IC Motor driver PWB Serial communication I/F Original Stepping USB 2.0 Glue...
  • Page 135 Figure 2-3-7 Main PWB silk-screen diagram Y107330-8 Service Manual 2-3-9...

  • Page 136: Fax Control Pwb (D-Copia164Mf Only)

    2-3-4 Fax control PWB (d-Copia164MF only) Fax control PWB SYSDATA0 - 7 ID setup ID_CS3 circuit Crystal Main SYSADR0 - 3 SYS_RD modem module SYS_WR FAX_CS2 FAXINT RINGD /RESET Telephone /TALK line FAX_RING_DET Network interface Active circuit filter +12 V DC (NCU) circuit 5 V DC...

  • Page 137: Wiring Diagram

    2-4 Appendixes (1) Wiring diagram d-Copia 164MF Y107330-8 Service Manual 2-4-1...
  • Page 138 2-4 Appendixes d-Copia 163MF 2-4-2 Service Manual Y107330-8...

  • Page 139: Repetitive Defects Gauge

    (2) Repetitive defects gauge First occurrence of defect 24 mm ( ") [Upper registration roller] 15/16 38 mm (1 ") [Lower registration roller] 47.2 mm (1 ") [Developing roller] 48 mm (1 ") [Transfer roller] 63 mm (2 ") [Heat roller or press roller] 94 mm (3 ") [Drum] 11/16...
  • Page 140 UPDATING STATUS DATE UPDATED PAGES PAGES CODE 01/2007 EDITION Y107330-8...

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