Page 1 Di450/Di550 SERVICE MANUAL GENERAL...
Page 2 INDEX (GENERAL) GENERAL MECHANICAL/ELECTRICAL...
Page 3 GENERAL 11563...
Page 4: Table Of Contents
CONTENTS 1. SAFETY INFORMATION ................. G-1 2. SPECIFICATION ..................... G-6 3. PRECAUTIONS FOR INSTALLATION ............G-9 3-1. Installation 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.
Page 5: Safety Information
CAUTION: The use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. Because of this, Minolta strongly recommends that you operate your copy machine only as described in this documentation.
Page 6 The label shown on page G-3 indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States. CAUTION: Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. This is a semiconductor laser.
Page 7 A laser safety label is attached to the outside of the copy machine as shown below. Laser safety label For Europe CLASS 1 LASER PRODUCT LASER KLASSE 1 PRODUKT For United States 1166O252BA MINOLTA CO., LTD 2, Higashiakatsuchi, Yawata-cho, Toyokawa-shi Aichi-ken 442-8585, Japan MANUFACTURED: THIS PRODUCT COMPLIES WITH 21 CFR CHAPTER I, SUBCHAPTER J. 0946-7101-14...
Page 8 Label inside copy machine The following laser safety label will be attached inside the copy machine as shown below. Please read the following for your own protection. Caution Opening the cover indicated by the Caution label may expose you to harmful laser radiation which could cause damage or loss of eyesight.
Page 9 ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany only VORSICHT! Explosinsgefahr bei unsachgemäßen austausch der batterie. Ersatz nur durch denselben oder einen vom hersteller empfohlenen ähnlichen typ.
Page 10: Specification
SPECIFICATION TYPE Console ORIGINAL SCANNING SYSTEM Lens Reduction Type CCD Line Sensor PHOTOCONDUCTOR Organic Photoconductor COPYING SYSTEM Electrostatic Dry Powdered Image Transfer to Plain Paper RESOLUTION 600 dpi × 600 dpi PAPER FEEDING SYSTEM 4-Way system Multi Bypass Table : 50 sheets of paper 1st Drawer (Universal) : 500 sheets of paper 2nd Drawer (Universal) : 500 sheets of paper 3rd Drawer...
Page 11 MULTIPLE COPIES 1 to 999 WARMING-UP TIME 4 minute with room temperature of 20 °C and rated power voltage FIRST COPY TIME A4C: 4.0 second or less (in Full size Mode using 1st Drawer) CONTINUOUS COPY SPEED (copies/minute) Fed from 1st Drawer/Memory Mode: 45 Piece Copy Machine ×1.000 ×1.000...
Page 12 POWER/CURRENT CONSUMPTION (copier only) Exposure Lamp Fusing Heater Lamp Max. Power Consumption Voltage In Standby (Rating) (Rating) (Full System) 120 V 115 V Upper: 850 W 1430 W ± 10 % 1230 W ± 10 % 120 V Lower: 200 W 24 V 20 W 230 V...
Page 13: Precautions For Installation
PRECAUTIONS FOR INSTALLATION 3-1. Installation Site To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: • Where it will be subjected to extremely high or low temperature or humidity. • Where it will be subjected to sudden fluctuations in either temperature or humidity. •...
Page 14: Precautions For Use
PRECAUTIONS FOR USE 4-1. To ensure that the copier is used in an optimum condition • Never place a heavy object on the copier or subject the copier to shocks. • Insert the power plug all the way into the outlet. •...
Page 15: Handling Of Consumables
HANDLING OF CONSUMABLES Before using any consumables, always read the label on its container carefully. • Paper can be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded in the drawer, in a sealed plastic bag in a cool, dark place.
Page 16: System Options
SYSTEM OPTIONS 4002G508AA 1145M035AA 4002G507AA 4002G506AA 4002G502AA 4002G501AA 4002G504AA 4002G511AA 3, 4 4002G503AA 4002G509AA 4002G505AA 1. Copier 8. Original Cover OC-1 2. 2 Way Paper Feed Cabinet PF-208 9. Large Capacity Cassette C-306 3. Large Capacity Cassette PF-115 10. Large Capacity Cassette C-306L 4.
Page 17 MECHANICAL/ ELECTRICAL 11563...
Page 18 CONTENTS 1. CROSS SECTIONAL VIEW ................M-1 2. COPY PROCESS .................... M-2 3. DRIVE SYSTEM ....................M-4 4. SEQUENTIAL EXPLANATION ................ M-5 5. IMAGE STABILIZATION SYSTEM ..............M-6 5-1. AIDC Sensor .................... M-7 5-2. Image Stabilization System Control ............M-8 6.
Page 19 12-13.Sub Hopper Toner Empty Detecting Mechanism ........M-44 13. PAPER TAKE UP/FEED SECTION ..............M-45 13-1.Drawer In Position Detection ..............M-46 13-2.Paper Empty Detection Mechanism ............M-47 13-3.Drawer Paper Lifting/Lowering Mechanism ..........M-48 13-4.Paper Level Detection Mechanism ............M-50 13-5.Universal Tray Paper Size Detection Mechanism ........M-51 13-6.Paper Take Up Mechanism ..............
Page 20 22-2.Turnover Control ..................M-80 22-3.Turnover Roller Separation Control ............M-81 22-4.Turnover/Exit Mechanism ................ M-82 (1) Selection of Turnover or Exit Path ........... M-82 (2) Path for Accommodating Paper Longer Than A4L ......M-82 23. OTHER MECHANISM ..................M-83 23-1.Memory Backup ..................M-83 23-2.Flash Memory ..................
Page 21: Cross Sectional View
CROSS SECTIONAL VIEW 4002M501AA 1. Fusing Section 4. Developing Section 2. IR Section 5. Paper Tray 3. PH Section 6. Exit/Turnover Section...
Page 22: Copy Process
COPY PROCESS 4. IR Image- 3. Photoelectric 6. PH Image- 5. Memory Processing Conversion Processing 7. Laser 2. Drum Exposure Charging 14. Main Erase 13. Cleaning 1. PC Drum 8. Developing 11. Image 10. Bypass 17. Exit/Turnover 12. Paper 16. Fusing 15.
Page 23 10. Bypass Paper Feeding • Paper is fed from the Bypass Table. 11. Image Transfer • A DC positive corona emission is applied to the back side of the paper, thereby attracting toner onto the surface of the paper. 12. Paper Separation •...
Page 24: Drive System
DRIVE SYSTEM connect 4002M503AA 1. Fusing Motor (M2) 8. 1st Drawer Lift-Up Motor (M11) 2. PC Drum Drive Motor (M21) 9. 2nd Drawer Lift-Up Motor (M12) 3. Scanner Motor (M51) 10. 2nd Drawer Paper Take-Up Motor (M5) 4. Developing Unit Drive Motor (M1) 11.
Page 25: Sequential Explanation
SEQUENTIAL EXPLANATION Power Switch ON Start Key ON Full-speed Half-speed rotation rotation Power Supply Unit Cooling Fan Motor 1 (M16) Power Supply Unit Cooling Fan Motor 2 (M15) Suction Fan Motor (M17) IR Cooling Fan Motor (M52) Fusing Unit Cooling Fan Motor (M23) PH Cooling Fan Motor 2 (M19) PH Cooling Fan Motor 1 (M22) Fusing Temperature...
Page 26: Image Stabilization System
IMAGE STABILIZATION SYSTEM The following image stabilization controls are provided to ensure stabilized copy image. Item Purpose Method Initial Setup First correct for AIDC sensor disparity and Set initial values for grid voltage (Vg) and contamination. Then use ∆V control to set developer bias (Vb).
Page 27: Aidc Sensor
5-1. AIDC Sensor The AIDC Sensor is used to detect the toner density and background level on the PC Drum. 1. An LED projects infrared light onto the surface of the PC Drum. 2. A phototransistor detects the intensity of infrared light reflected off the surface of the PC Drum.
Page 28: Image Stabilization System Control
5-2. Image Stabilization System Control 1. AIDC Sensor Coarse Adjustment • The following adjustment is made to prevent the AIDC Sensor output voltage from deviat- ing from the specified range due to part-to-part variations in the AIDC Sensor (installa- tion, circuit, deterioration, etc.). •...
Page 29: Pc Drum Section
PC DRUM SECTION The PC Drum consists of layers of semiconductive materials placed on an aluminum alloy base, on which an electrostatic latent image is formed. Charge Holding Layer PC Drum Carrier Generation Layer 1139M007AA 4002M508AA Aluminum Bass 6-1. PC Drum Drive Mechanism •...
Page 30: Grounding Of The Pc Drum
6-2. Grounding of the PC Drum The potential on the surface of the PC Drum exposed to the light is grounded to the frame. Drive Gear PC Drum Ground Point Front Rear 4002M510AA Ground Plate Drum Holding Shaft M-10...
Page 31: Pc Drum Charging Section
PC DRUM CHARGING SECTION • The PC Drum Charge Corona has a scorotron grid to deposit a charge evenly across the surface of the PC Drum. • The corona unit has a comb electrode that discharges only toward the grid mesh, thus minimizing the amount of ozone produced.
Page 32: Image Reading Section
IMAGE READING SECTION Light is projected onto the surface of the original and the light reflected off the original is converted to a corresponding electrical signal. Rear Front 4002M512AA 1. Scanner 7. CCD Board (PWB-IA) 2. Exposure Lamp (FL51) 8. Lens 3.
Page 33: Exposure Components Section
8-1. Exposure Components Section 4002M513AA 1. Auxiliary Reflector: Reflects light onto the areas that the Exposure Lamp cannot illuminate when an original does not lie flat on the Original Glass (such as a book). It reduces shadows that would otherwise be transferred to the copy. 2.
Page 34: Exposure Lamp Control
8-2. Exposure Lamp Control Control to turn ON and OFF the Exposure Lamp is provided by an Exposure Lamp Remote signal output from PWB-B Operation when Power Switch is switched ON 1. The Scanner moves to, and stops at, the shading position. 2.
Page 35 Operation when the Start key is pressed (EDH scanning) 1. The Exposure Lamp turns ON 2. The Scanner starts moving to the shading position. 3. A gain adjustment and a shading correction are made at the shading position. 4. The Scanner moves to the original scanning position and starts reading the original. 5.
Page 36: Image Processing Process
8-3. Image Processing Process The IR image processing system is composed of the following blocks. These blocks imple- ment various types of corrective processing. 1. Photoelectric Conversion (CCD Sensor): PWB-IA 2. Analog Processing: PWB-B 3. ODD/EVEN Synthesis: PWB-B 4. Shading Correction: PWB-B 5.
Page 37 1. Photoelectric Conversion (CCD Sensor): PWB-IA Light from the Exposure Lamp reflects off the original, passes through mirrors and one lens, and reaches the CCD sensor. The CCD sensor converts the optical data into analog electrical signals. 2. Analog Processing: PWB-B This block eliminates noise from the (ODD and EVEN) analog signals output by the CCD sensor, then converts the result into (ODD and EVEN) 8-bit digital image signals (A/D conversion).
Page 38: Image Density Control
8-4. Image Density Control Auto Exposure Control • Auto Exposure Control varies the background removal threshold in accordance with the original type (newspaper, photograph, etc.). This helps ensure that only the fogging com- ponent in the low-density areas is removed, while retaining the image density of the char- acters and other high-density areas of the image.
Page 39 1. Scanning Original fed through EDH Realtime Scanning • Realtime scanning is a method in which the image data is sampled during a copy cycle. • The sampled image data is accumulated in the form of a reflectivity histogram. This histo- gram is used to determine the type of the original and the background removal threshold is calculated as may be necessary.
Page 40 Given below is the control flow when the Auto Exposure mode is selected. Start Key ON Scanning original fed through EDH Scanning original placed on glass Document <Scanning during prescan motion> <Realtime scanning> The Scanner starts reading the origi- The Scanner starts reading the nal as it starts moving to the original original.
Page 41: Manual Exposure Control
Manual Exposure Control • Manual Exposure Control selects an exposure level variable in nine steps according to the setting made on the control panel by the user when the copier is in the Manual Expo- sure mode. • According to the manual exposure setting made on the control panel, the CPU of PWB-B transmits a background removal threshold to the IR Density Correction block for density correction.
Page 42 Before page The threshold value is transmitted from the IRC to the IR Density Correction block. This block then corrects the image density of incoming data in accordance with the relation shown below. Output X=aχ-b X: Image density value after density correction a: 1 χ: Image density value before density correction -b: Threshold (intercept)
Page 43: Scanner And Mirrors Carriage Movement Mechanism
8-5. Scanner and Mirrors Carriage Movement Mechanism Scanner Movement Mechanism • The Scanner is driven by the Scanner Motor at a speed appropriate to the set zoom ratio with reference to the speed in the full size mode. • The Scanner is detected at its home position by the Scanner Reference Position Sensor. 2nd/3rd Mirrors Carriage Movement Mechanism The 2nd/3rd Mirrors Carriage moves at a speed half that of the Scanner, thereby keeping constant the optical path length between the original and the CCD Sensor.
Page 44: Scanner Motor Drive Control
8-6. Scanner Motor Drive Control • The speed at which the Scanner is moved is controlled by varying the period of the motor drive pulse that is timed with the reference clock. High Speed Low Speed Period • The distance over which the Scanner travels is controlled by the number of motor drive pulses that correspond to each paper size and zoom ratio.
Page 45: Memory Section
MEMORY SECTION The Memory section stores the image density data output from the IR section to effectively carry out data transmission to the Printer section. 9-1. Image Processing Process The binary image data transmitted from the Image Processing Board of the IR section undergoes the following processes before being transmitted to the PH section.
Page 46: Original Size Detecting Section
10. Original Size Detecting Section The original size detecting sensors fixed in the optical section are used to determine the size of the original in the Auto Paper or Auto Size mode. Rear Front 4002M521AA 1. Original Cover Detecting Sensor 5.
Page 47: 10-2.Original Size Detecting Sensors Locations
10-2. Original Size Detecting Sensors Locations • The original size detecting sensors are located in the following positions to enable them to detect different sizes of the original. • Adding optional original size detecting sensors increases the number of original sizes that can be detected by the system.
Page 48: 10-3.Original Size Detection
10-3. Original Size Detection The Original Size Detecting Board determines the correct original size based on the combi- nation of statuses of the original, either present or absent, as detected by the original size detecting sensors. Metric Area Need Original (Optional) (Optional) Optional...
Page 49 10-4. Original Size Detection Timing Takes size When the Original Cover is raised to an angle of 15° or more (Original readings Cover Detecting Sensor is deactivated). Affirms size When the Original Cover is lowered to an angle of 15° or less (Original readings Cover Detecting Sensor is just activated) and the Size Reset Switch is actuated.
Page 50: Ph Section
11. 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. Rear Front 4002M525AA 1. Lenses 6.
Page 51: 11-1.Image Processing Process
11-1. Image Processing Process The PH image processing system is composed of the following blocks. These blocks imple- ment a variety of types of corrective processing, as described below. Memory: PWB-B 1. Erasure of Outside Area : PWB-B Bit Expansion : PWB-B 6.
Page 52 1. Erasure of Outside Area: PWB-B Erases the area outside of the image area, so as to prevent firing of the laser over non-image areas. 2. Bit Expansion: PWB-B If image quality is set to photo mode, this block expands binary data values into 8-bit data values.
Page 53: 11-2.Laser Emission Timing (Sos Signal
11-2. Laser Emission Timing (SOS Signal) The laser diode is forced to turn ON to project the laser beam onto the SOS Sensor Board, which generates an SOS signal. Rear Front 4002M526AA 1. Lens 5. Beam Interval Correction Motor (M20) 2.
Page 54 Relation between laser emission timing and SOS signal The light path of the laser beam changes as the Polygon Mirror turns. The SOS signal syn- chronizes the rotation of the Polygon Mirror with the laser emission timing. A. LD force-ON The laser diode is forced ON to output an SOS signal.
Page 55: Developing Unit Section
12. DEVELOPING UNIT SECTION The Developing Unit agitates and triboelectrically charges toner so that it sticks to the elec- trostatic latent image formed on the surface of the PC Drum, then changing the image to a visible, developed one. 4002M527AA 1.
Page 56 12-1. Developing Unit Drive Mechanism The rollers and screws are driven through a gear train from the motor. Front Rear 4002M528AA 1. Coupling Gear 5. Sleeve/Magnet Roller 2. Sub Hopper Toner Agitating Lever 6. Toner Conveying Coil 3. Developer Conveying/Agitating Screw 7.
Page 57 12-2. Sleeve/Magnet Roller • The Sleeve/Magnet Roller, which consists of an outer sleeve roller and an inner magnet roller, conveys developer to the point of development. • The magnetic force of the magnet roller at the point of development is the strongest so that the developer brush stands straight up to deliver the greatest amount of toner to the point of development.
Page 58: 12-4.Developing Bias
12-4. Developing Bias • A developing bias voltage (Vb) is applied to the sleeve roller to prevent a foggy back- ground on the copy. • 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).
Page 59: Atdc Sensor Automatic Adjustment
12-5. ATDC Sensor The ATDC Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Developer Mixing Chamber. Developer Conveying/Agitating Screw ATDC Sensor UN2 4002M530AA REFERENCE STANDARD WIRING CONTROL SIGNAL T/C RATO OUTPUT VOLTAGE DIAGRAM PWB-A PJ7A-10B 5.0 % 2.27 V 4 - E ATDC Sensor Automatic Adjustment...
Page 60: 12-6.Toner Replenishing Control
12-6. Toner Replenishing Control Toner Replenishing Control by ATDC Sensor The ATDC Sensor samples T/C for each scan motion and the copier compares the reading with the reference T/C to determine the appropriate amount of toner to be replenished. Toner Replenishing Conditions Amount Replenished The sensor reading is lower than the refer-...
Page 61: 12-8.Toner Bottle Home Position Detection Mechanism
12-8. Toner Bottle Home Position Detection Mechanism The Toner Bottle is detected at its home position by a home position detection sensor. When the Toner Bottle is at the home position (stationary), its toner supply port should face Toner Supply Port Toner Bottle Home Position Sensor PC21 Home Position Detecting Plate...
Page 62: 12-10.Main Hopper Toner Replenishing Mechanism
12-10. Main Hopper Toner Replenishing Mechanism • The Main Hopper Toner Replenishing Motor supplies toner from the Toner Bottle to Sub Hopper. • Toner is replenished each time the toner-empty detection switch of the Sub Hopper is turned ON and OFF. Toner Supply Port Toner Supply Hole Main Hopper Toner Replenishing Motor...
Page 63: 12-12.Sub Hopper Toner Replenishing Mechanism
12-12. Sub Hopper Toner Replenishing Mechanism • The Sub Hopper Toner Replenishing Motor replenishes toner from the Sub Hopper to the Developer Mixing Chamber. • The toner replenishing time is calculated based on the T/C reading and paper size. Sub Hopper Toner Agitating Lever Sub Hopper Sub Hopper Toner Replenishing Motor Sub Hopper Toner Replenishing Roller...
Page 64: 12-13.Sub Hopper Toner Empty Detecting Mechanism
12-13. Sub Hopper Toner Empty Detecting Mechanism • A magnet and a toner-empty detecting switch detect a toner-empty condition in the Sub Hopper. • As toner in the Sub Hopper is consumed, the magnet turns ON the Sub Hopper Toner Empty Switch.
Page 65: Paper Take Up/Feed Section
13. PAPER TAKE UP/FEED SECTION 4002M541AA 1. Synchronizing Roller 13. 2nd Drawer Paper Take-Up Sensor 2. Synchronizing Roller Sensor 14. 2nd Drawer Feed Roll 3. Transport Rollers 15. 2nd Drawer Separator Roll 4. Transport Roller Sensor 16. 2nd Drawer Paper Take-Up Roll 17.
Page 66: 13-1.Drawer In Position Detection
13-1. Drawer In Position Detection When the drawer is slid into the copier, the light blocking plate blocks the Set Sensor. The copier then knows that the drawer has been slid in position. Drawer is slid in 1st Drawer Set Sensor PC10 2nd Drawer Set Sensor PC11...
Page 67: 13-2.Paper Empty Detection Mechanism
13-2. Paper Empty Detection Mechanism The Paper Empty Sensor detects a paper-empty condition in the drawer. Paper Empty Lever 4002M544AA Paper Empty Sensor 1st Drawer: PC16 2nd Drawer: PC17 Paper Lifting Plate Paper Present Paper not Present PC16, 17 Blocked PC16, 17 Unblocked 4002M543AA CONTROL SIGNAL...
Page 68: 13-3.Drawer Paper Lifting/Lowering Mechanism
13-3. Drawer Paper Lifting/Lowering Mechanism The paper lifting mechanism employs the Lift-Up Motor that causes the paper stack loaded in the drawer to be pressed up against the Paper Take-Up Roll with a given pressure, thereby ensuring positive paper take-up. Paper Take-Up Roll/Feed Roll Assy.
Page 69 During a copy cycle Paper is consumed. The Paper Take-Up Roll lowers. The Lift-Up Sensor is unblocked. The Lift-Up Motor is energized. The Paper Lifting Arm goes up. The Lift-Up Sensor is blocked. The Lift-Up Motor is deenergized. 4002M547AA CONTROL SIGNAL Blocked Unblocked WIRING DIAGRAM PC14 (1st Drawer)
Page 70: 13-4.Paper Level Detection Mechanism
13-4. Paper Level Detection Mechanism The amount of paper still available for use, or the paper level, of the drawer is detected by the Lift-Up Motor Pulse Sensor and a pulse disk. They function to detect the speed of the Lift-Up Motor.
Page 71 13-5. Universal Tray Paper Size Detection Mechanism • Both the width (in the crosswise direction) and length (in the feeding direction) of the paper are detected and the copier CPU determines the paper size based on the combi- nation of the two readings. Paper Size Detection Board 1st Drawer: PWB-I1 2nd Drawer: PWB-I2...
Page 72 Paper Size Detecting Switches × Width Paper Size Inch FD (PWB-I1, I2) Length Name Equivalent (mm) PC23, 25 PC24, 26 × × G LETTER C 10.5 × × QUART L × Korea FLS *1 × × EXE L *2 7.25 10.5 ×...
Page 73: 13-6.Paper Take Up Mechanism
13-6. Paper Take Up Mechanism Drive for the paper take-up sequence comes from a motor. 1st Drawer Paper Take-Up Motor Feed Roll Paper Take-Up Roll Rear Separator Roll 2nd Drawer Paper Take-Up Motor Front Torque Limiter 4640M003AA Paper Separating Mechanism The difference in friction coefficient between the Feed Roll and Separator Roll is used to stop the rotation of the Separator Roll for the prevention of double feed.
Page 74: Paper Pressure Release Mechanism
Paper Pressure Release Mechanism When the drawer is pulled out of the copier, the Pressure Release Rail presses down the Separator Roll Assy, which results in the Separator Roll being disengaged from the Feed Roll. Feed Roll Approx. Separator Roll Assy. 2 mm Drawer 4444M004AA...
Page 75: 13-7.Paper Take Up Control
13-7. Paper Take Up Control Paper Take Up Motor Control The Paper Take-Up Motor is controlled by the signal output from the Master Board. 1st sheet of paper Tak-Up start *Multi Copy cycle 2nd sheet of paper Tak-Up start 1st Drawer Paper Take-Up Motor 1st Drawer Paper Take-Up Sensor Upper Vertical Transport / Manual Feed Motor M6...
Page 76: Paper Take Up Interval Control
Paper Take Up Interval Control To minimize the occurrence of a paper misfeed due to improper paper separation, the paper take-up sequence is temporarily halted if the paper fails to reach the Paper Take-Up Detecting Sensor within a given period of time after the sequence has been started. After another given period of time, the paper take-up sequence is performed a second time, thereby ensuring a good interval between two paper take-up sequences.
Page 77 13-8. Vertical Transport Drive Mechanism A motor drives the Vertical Transport Rollers. Rear Upper Vertical Transport/Manual Feed Motor Paper Leading Edge Sensor SW1 Upper Vertical Transport Roller Front Lower Vertical Transport Motor Paper Leading Edge Sensor SW2 Lower Vertical Transport Roller 4002M551AA For details of the 1st Drawer control, see 13-7.
Page 78: Manual Feed Table Section
14. MANUAL FEED TABLE SECTION Rear Front 4002M552AA 1. Manual Feed Paper Empty Sensor 5. Upper Vertical Transport/Manual Feed PC18 Motor M6 2. Manual Bypass Feed Roll 6. Paper Stopper 3. Manual Bypass Separator Roll 7. Manual Bypass Take-Up Roll 4.
Page 79: 14-1.Manual Take Up Roll Pressure Mechanism
14-1. Manual Take Up Roll Pressure Mechanism The Multi/Manual Bypass Take-Up Roll is raised and lowered by energizing and deenergiz- ing the solenoid. Solenoid Take-Up Roll Position Paper Stoppers At take-up Deenergized Down Free At timings other Energized Locked than take-up Lock Lever Manual Feed Paper Pick-Up Solenoid Lever...
Page 80: 14-3.Manual Feed Paper Empty Detection Mechanism
14-3. Manual Feed Paper Empty Detection Mechanism The Multi/Manual Bypass Paper Empty Sensor detects a sheet of paper on the Multi/Man- ual Bypass Table. Manual Feed Paper Empty Sensor PC18 1154M064AA 1154M065AA When Paper is Placed When No Paper is Placed CONTROL SIGNAL Blocked Unblocked WIRING DIAGRAM...
Page 81: Transport/Synchronizing Rollers Section
15. TRANSPORT/SYNCHRONIZING ROLLERS SECTION The Synchronizing Rollers are turned in time with the optical section (Scanner) and trans- port section (paper). 4002M554AA 1. Upper Synchronizing Roller 5. Lower Transport Roller 2. Paper Dust Remover 6. Paper Leading Edge Sensor 3. Upper Transport Roller 4.
Page 82: 15-2.Transport Roller Drive Mechanism
15-2. Transport Roller Drive Mechanism The Transport Roller is driven by a motor. Upper Transport Roller Rear Transport Roller Motor Front 4002M557AA Lower Transport Roller CONTROL SIGNAL WIRING DIAGRAM PWB-A PJ5A-4B~6B Pulse Output 7 - C 15-3. Synchronizing Roller Drive Mechanism The Synchronizing Roller is driven by a motor.
Page 83: Image Transfer And Paper Separation Section
16. IMAGE TRANSFER AND PAPER SEPARATION SEC- TION • The DC corona emission applied by the Image Transfer Corona attracts the toner image formed on the surface of the PC Drum onto the surface of the paper, forming a visible, developed image of the original.
Page 84: 16-1.Pc Drum Paper Separator Fingers Section
16-1. PC Drum Paper Separator Fingers Section Finger Pressing Detection Mechanism • The PC Drum Paper Separator Fingers are pressed against the surface of the PC Drum to properly separate paper from the surface of the PC Drum. • This motion is done by the Separator Finger Solenoid. Swash Plate Cam Separator Solenoid PC Drum Paper Separator Finger Shaft...
Page 85: Pc Drum Cleaning Section
17. PC DRUM CLEANING SECTION • The Cleaning Blade scrapes off any toner remaining on the surface of the PC Drum. • The PC Drum Paper Separator Fingers physically separate paper from the surface of the PC Drum. Cleaning Blade Blade Tension Spring PC Drum Toner Conveying Coil...
Page 86: 17-2.Toner Conveying/Collecting Mechanism
17-2. Toner Conveying/Collecting Mechanism • The toner, which has been scraped off the surface of the PC Drum by the Cleaning Blade, is conveyed by the Toner Conveying Coil and dropped into the Toner Collecting Bottle. • The Toner Conveying Coil is driven by a motor. Cleaning Blade Residual Toner PC Drum...
Page 87: Main Erase Section
18. MAIN ERASE SECTION The light from the Main Erase Lamp neutralizes any surface potential remaining on the sur- face of the PC Drum after cleaning. Main Erase Lamp Board Main Erase Lamp Filter PC Drum 4002M565AA CONTROL SIGNAL WIRING DIAGRAM PWB-A PJ9A-7A 4 - E M-67...
Page 88: Transport Section
19. TRANSPORT SECTION • Rotation of the Suction Fan Motor results in the paper separated from the PC Drum being drawn onto the turning Suction Belts. • The Suction Belts are driven by a motor. Speed Front Door Plugged In* Wait Copy Trouble...
Page 89: Fusing Unit Section
20. FUSING UNIT SECTION The Fusing Unit fixes permanently the developed image to the paper by applying heat and pressure to the toner and paper. 4002M567AA 1. Web Take-Up Roller 8. Lower Fusing Roller Thermistor 2. Oil Supply/Web Feeding Roller 3.
Page 90: 20-1.Fusing Unit Drive Mechanism
20-1. Fusing Unit Drive Mechanism The Fusing Unit is driven by a motor. Front Connect Rear 4002M568AA 1. Clutch Spring 4. Upper Fusing Roller Drive Gear 2. Upper Fusing Roller 5. Fusing Motor M2 3. Lower Fusing Roller CONTROL SIGNAL WIRING DIAGRAM PWB-A PJ7A-1A 1 - C...
Page 91: 20-2.Fusing Rollers Pressure Mechanism
20-2. Fusing Rollers Pressure Mechanism To ensure that there is a certain width of area of contact between the Upper and Lower Fusing Rollers, a pressure spring is used to press the Lower Fusing Roller up against the Upper Fusing Roller. Rear Front 4002M569AA...
Page 92: 20-3.Fusing Roller Cleaning Mechanism
20-3. Fusing Roller Cleaning Mechanism Cleaning Web Take Up Mechanism • The Cleaning Web wound around the Web Roller is taken up by the Web Take-Up Roller which is driven by the Cleaning Web Take-Up Motor. • The Cleaning Web Take-Up Motor turns one turn in every 7 to 14 copies made to take up the Cleaning Web.
Page 93: 20-4.Fusing Temperature Control
20-4. Fusing Temperature Control • The Fusing Roller Heater Lamp is turned ON and OFF to keep a set temperature on the surface of the Fusing Roller. • The Fusing Roller surface temperature is detected by using a thermistor that translates the temperature to a corresponding electrical signal.
Page 94: 20-5.Mechanism And Control Of Fusing Roller Small-Amount Turning
CONTROL SIGNAL WIRING DIAGRAM PWB-A PJ7A-8A 1 - A PWB-A PJ7A-11A 1 - B PWB-A PJ7A-9A Analog Input 1 - B PWB-A PJ7A-12A Analog Input 1 - B 20-5. Mechanism and Control of Fusing Roller Small-Amount Turning • If the Fusing Rollers remain stationary for more than 60 minute with the temperature con- trol kept active, the areas of the two rollers in contact with each other are dented by heat and pressure.
Page 95: 20-6.Cpm Control
20-6. CPM Control The CPM (copies/minute) control is provided to keep good fusing performance even in multi-copy cycles and with the system power sourced from a single power outlet. 1. Overview The Fusing Roller surface temperature goes down in a multi-copy cycle, resulting in degraded fusing performance.
Page 96: Exit/Duplex Switching Section
21. EXIT/DUPLEX SWITCHING SECTION The Exit/Duplex Switching Unit switches the paper path to feed the copy out onto the Exit Tray or into the Turnover Unit. 4002M573AA 1. Exit Roll 8. Exit/Duplex Switching Solenoid 2. Paper Exit Sensor 9. Turnover Feed Entry Sensor 3.
Page 97: 21-1.Exit/Duplex Switching Mechanism
21-1. Exit/Duplex Switching Mechanism The paper path to the Exit Tray or to the Turnover Unit is selected by operating the Exit/ Turnover Switching Solenoid. Paper Exit Sensor PC9 Switching lever Rear Transport Roller Connect Lever Front 4002M574AA Exit Roller Exit/Duplex Switching Solenoid SL3 Sheet is ejected to Exit Tray Sheet is ejected to Turnover Section...
Page 98: Turnover Section
22. TURNOVER SECTION The turnover unit reverses the copy fed from the Exit/Turnover Switching Unit and feeds it into the Duplex Unit. Exit/Duplex Switching Section 4002M576AA 1. Exit Switching Lever 8. Turnover Roll 2. Exit/Duplex Switching Solenoid 9. Turnover Roller Switching Lever 10.
Page 99 22-1. Turnover Drive Mechanism The Turnover Unit is driven by a motor. Arrow is forward rotation Front Rear 4002M577AA 1. Turnover Motor 5. Turnover Roller 6. Turnover Transport Roller 2 2. Turnover Feed Jam Sensor 7. Turnover Roll 8. Turnover/Exit Sensor 3.
Page 100 22-2. Turnover Control • The paper transport direction is selected by turning the motor forward or backward. • A sensor on the paper path is used to determine the timing at which the direction of motor rotation is switched from backward to forward, or vice versa. Not Roller Separation Synchronizing Roller Motor ON Synchronizing Roller sensor OFF...
Page 101: 22-3.Turnover Roller Separation Control
22-3. Turnover Roller Separation Control • The Turnover Drive Roller is temporarily separated from the Turnover Driven Roller in the event that, during a multi-copy cycle using large-sized paper, the leading edge of the sub- sequent paper reaches the Turnover Drive/Driven Rollers before the trailing edge of the preceding paper moves past them.
Page 102: 22-4.Turnover/Exit Mechanism
22-4. Turnover/Exit Mechanism Selection of Turnover or Exit Path A flapper is used to select the paper exit path when the paper is to be turned over and fed out of the copier. At Entry to Turnover For Transport to Exit The flapper retracts as The flapper presses against soon as the leading...
Page 103: Other Mechanism
23. OTHER MECHANISM 23-1. Memory Backup Image Processing Board Backup RAM • NVRAM (backup RAM) mounted on the Image Processing Board (PWB-B) stores the Touch Panel-related adjustment values, and User’s Choice and other settings as well as counter values. • NVRAM has a built-in battery that ensures that the contents of the memory are not lost even when power to the copier and PWB-B is shut down, or when NVRAM is demounted from the PWB-B.
Page 104: 23-2.Flash Memory
23-2. Flash Memory • Flash memory is used for updating data when upgrading software. • Insert a memory card, in which data has previously been written, into the socket on the Memory Board and perform the updating procedure. This rewrites the data. Applicable Boards: PWB-A, PWB-B For details, refer to DIS/REASSEMBLY, ADJUSTMENT.
Page 105: 23-3.Dehumidifying Mechanism
23-3. Dehumidifying Mechanism PC Drum Dehumidifying A heater is used to prevent condensation from forming on the surface of the PC Drum due to changes in temperature and humidity. Drum Dehumidifying Power Cord Power Switch Switch Heater ON conditions Rear PC Drum Transport Lower Synchronizing Roller...
Page 106: Ir Section Cooling Mechanism
23-4. Cooling Mechanism IR Section Cooling Mechanism A fan motor draws air from the outside into the inside of the copier to cool the IR (especially the Exposure lamp, and CCD Sensor), PH and PWB-B. Speed Control Plugged in* Stand-by Copy Cycle PH Cooling Fan Motor 1 Stop...
Page 107: Fusing Section Cooling Mechanism
Fusing Section Cooling Mechanism A fan motor draws air from the area around the Fusing Unit to the outside to prevent the copier interior temperature from running high. Speed Front Door Plugged In* Wait Copy Trouble pre-Heat Control open stop Half Full Half...
Page 108: Copier Interior Cooling Mechanism
Copier Interior Cooling Mechanism A fan motor draws air from the inside of the copier to prevent the copier interior temperature from running high. The Ozone Filter absorbs ozone produced inside the copier. Speed Front Door Plugged In* Wait Copy Trouble pre-Heat Control...
Page 109: Power Supply Section Cooling Mechanism
Power Supply Section Cooling Mechanism A fan motor draws air from the area around the Power Supply Unit to the outside to prevent the Power Supply Unit temperature from running high. Speed Front Door Plugged In* Wait Copy Trouble pre-Heat Control open stop...
Page 110 Di450/Di550 SERVICE MANUAL GENERAL Copyright 2000 MINOLTA Co., Ltd. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA Co., Ltd. 4002-7990-11 00091200 11563...
Page 111 Di450/Di550 SERVICE MANUAL FIELD SERVICE 4002-7991-11...
Page 112 INDEX (FIELD SERVICE) INSTALLATION DIS/REASSEMBLY, ADJUSTMENT SWITCHES ON PWBs, TECH. REP. SETTINGS TROUBLESHOOTING PARTS MANUAL...
Page 113 Safety Precautions for Inspection and Service When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. Depending on the model, some of the precautions given in the following do not apply. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Page 114 4. Handle the power cord with care and never use a multiple outlet. • Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock.
Page 115 CAUTION 1. Precautions for Service Jobs • A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire. • When reassembling parts, make sure that the correct screws (size, type) are used in the correct places.
Page 116 5. Precautions for the Laser Beam (Only for Products Employing a Laser) • 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.
Page 117 Other Precautions • To reassemble the product, reverse the order of disassembly unless otherwise specified. • While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses. • The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.
Page 118 Used Batteries Precautions ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ.
Page 119 PRECAUTIONS FOR SERVICE When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply. Precautions Before Service •...
Page 120 Precautions for Dis/Reassembly • Be sure to unplug the copier from the outlet before attempting to service the copier. • The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears.
Page 121 Handling of PWBs 1. During Transportation/Storage: • During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem- perature.
Page 122 Handling of the PC Drum Only for Products Not Employing an Imaging Cartridge. 1. During Transportation/Storage: • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. •...
Page 123 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 PC Drum in one con- tinuous movement from its rear edge to its front edge and off its surface one to two times.
Page 124 INSTALLATION Rev. 1.0/10.00 Di450/550...
Page 125 1.2.3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-26 1.2.4 Installation of the Document Guide - - - - - - - - - - - - - - - - - I-28 Di450/550 Rev. 1.0/10.00...
Page 126 1.6.8 Checking the Hole Positions for Hole Punch (FN-105 only) I-54 1.6.9 Adjusting the Hole Positions for Hole Punch (FN-105 only) I-55 C-306 / C-306L Installation- - - - - - - - - - - - - - - - - - I-56 Rev. 1.0/10.00 Di450/550...
Page 127 1.10.2 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-81 Di450/550 Rev. 1.0/10.00...
Page 128 1.11.13.1Setting Telephone No. - - - - - - - - - - - - - - - - - - - - - - I-97 1.11.14Initial Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-98 Rev. 1.0/10.00 Di450/550...
Page 129 Di450/550 Rev. 1.0/10.00...
Page 130: Installation
5. Power Cord (For Particular area only) 6. Operator’s Manual Holder 7. Warranty Card (U.S.A. and Canada only) 8. Power Cord Instructions (For Particular area only) 1.1.2 Setting-up 1. Remove all the tape from the machine. Rev. 1.1/10.00 Di450 / Di550...
Page 131 5. Pull the Transport Unit Release Lever down. 6. First press the Image Transfer/Paper Separator Coronas Unit down and then pull it out of the machine. 7. Remove the fixing materials from both ends of the Unit. Di450 / Di550 Rev. 1.1/10.00...
Page 132 13. Screw in the two Screws (front and rear) alternately until they are completely tightened. NOTE Ensure that the Upper and Lower Fusing Rollers are pressed together evenly at the front and rear ends. Rev. 1.1/10.00 Di450 / Di550...
Page 133: Loading The Starter
3. Remove three screws and unplug connector. Take the Sub Hopper off of the Developing Unit. 4. Pour one packet of Starter evenly into the Bucket Roller side of the Developer Chamber. NOTE Shake the Starter well before pouring. Di450 / Di550 Rev. 1.1/10.00...
Page 134 Toner. 3. Holding the Toner Bottle with your left hand, gently peel off the seal from the Bottle. 4. Insert a brush into the Toner Bottle to dip it into the toner. Rev. 1.1/10.00 Di450 / Di550...
Page 135 7. Using the rear edge of the PC Drum, turn it one turn in the direction shown by the arrow. 8. Slide the Developing Unit all the way into the machine and tighten the screws. 9. Lift the Transport Unit Release Lever up. Di450 / Di550 Rev. 1.1/10.00...
Page 136 Turn ON the Power Switch. 2. Access the initial Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.) 3. Touch “Function” on the screen. 4. Touch “Printer.” 5. Touch “F8 ATDC Sensor.” Rev. 1.1/10.00 Di450 / Di550...
Page 137: Atdc Level Adjustment
Control onto the Label attached inside the Upper Front Door. Insert the toner bottle 11. With the side marked UP facing up, insert the Toner Bottle into the Bottle Holder. NOTE Insert the toner bottle after runnig the ATDC level adjust! Di450 / Di550 Rev. 1.1/10.00...
Page 138: Aidc Level Adjustment
12. Check that the Marker on the Bottle is aligned with the Marker on the Holder. 13. Close the Front Door. 1.1.6 AIDC Level Adjustment 1. Touch “Menu.” 2. Touch “Function.” 3. Touch “Printer.” Rev. 1.1/10.00 Di450 / Di550...
Page 139 4. Touch “F5 AIDC Sensor.” 5. Press the Start key. The machine automatically performs the AIDC Level Adjustment. 6. After completion of the AIDC Level Adjustment, touch “END.” 7. Press the Panel Reset key. 8. Touch “Exit.” Di450 / Di550 I-10 Rev. 1.1/10.00...
Page 140: Paper Loading
2. Slide the Edge Guide and the Trailing Edge Stop up against the paper. 3. Load the paper into the Drawer. NOTE The paper should be loaded no higher than the Max. Level Indication on the Edge Guide. 4. Close the Drawer. Rev. 1.1/10.00 I-11 Di450 / Di550...
Page 141: Way Paper Feed Cabinet
NOTE The paper should be loaded no higher than the Max. Level Indication on the Edge Guide. 3. Close the Drawer. 1.1.7.3 Large Capacity Cabinet 1. Press the Descent Button and open the Drawer. Di450 / Di550 I-12 Rev. 1.1/10.00...
Page 142 3. Load the paper into the Sub-Tray, pressing it up against the left side. NOTE The paper should be loaded no higher than the Max. Level Indication on the Edge Guide. 4. Close the Drawer. Rev. 1.1/10.00 I-13 Di450 / Di550...
Page 143: Drawer Size Change
Input the Paper Size 1.1.9.1 2 way Paper Feed Cabinet 1. Access the initial Tech, Rep. Mode screen. (Refer to the Service Manual for the procedure.) 2. Touch “System Input.” 3. Touch “Paper Size Input.” Di450 / Di550 I-14 Rev. 1.1/10.00...
Page 144 5. Touch the key of the desired size to highlight 6. Touch “OK” to input the paper size. Another Drawer can be selected after “OK” is touched on the screen. 7. Press the Panel Reset key. 8. Touch “Exit.” Rev. 1.1/10.00 I-15 Di450 / Di550...
Page 145: Adjusting The Support Feet
Installing the Manual Holder 1. Mount the Operator’s Manual Holder as shown. NOTE The mounting location differs according to whether the copier is with or without a Finisher. Be sure to mount it in the correct location. Di450 / Di550 I-16 Rev. 1.1/10.00...
Page 146: Checking For Registration
1. Access the initial Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.) 2. Press the “Stop” key and then press the “Start” key immediately. 3. Touch “Printer.” 4. Touch “Registration (CD).” Rev. 1.1/10.00 I-17 Di450 / Di550...
Page 147: Way Paper Feed Cabinet
Check that the margins reproduced on the copy meet the following specifications. Margin Registration Specifications : A : 5±0.5mm If the margins reproduced on the copy fall outside the specified range, make the “Registration Adjustment.” Di450 / Di550 I-18 Rev. 1.1/10.00...
Page 148 4. Make a test print again and check for correct registration. 1.1.13.2 Large Capacity Cabinet 1. Press the Paper Descent Button of the 3rd Drawer. This releases the 3rd Drawer allowing you to slide it out of the machine. Rev. 1.1/10.00 I-19 Di450 / Di550...
Page 149 If distance “A” is more than 5.5mm, turn screw B clockwise. If distance “A” is less than 4.5mm, turn screw B counterclockwise. 3. Tighten the screw. 4. Make a test print again and check for correct registration. Di450 / Di550 I-20 Rev. 1.1/10.00...
Page 150: Checking For Registration
4. Check that the margin B reproduced on the front surface (double-sided surface) of the copy meets the specifications. Margin Registration Specifications: B : 5±0.5mm If the margins reproduced on the copy fall outside the specified range, make the “Registration Adjustment.” Rev. 1.1/10.00 I-21 Di450 / Di550...
Page 151: Duplex Unit
1.1.15 Registration Adjustment 1.1.15.1 Duplex Unit 1. Pull out the Duplex Unit. 2. Remove the Cover (four screws). 3. Loosen the four screws as shown. Di450 / Di550 I-22 Rev. 1.1/10.00...
Page 152 Assy. toward right as needed. 5. Loosen the screw as shown and then re- tighten it. 6. Make a test print again and check for correct registration. 7. Remount the Cover and close the Duplex Unit. Rev. 1.1/10.00 I-23 Di450 / Di550...
Page 153: Affixing The Labels
1.1.16 Affixing the Labels Affix the Labels enclosed with the optional Paper Feed Cabinet. Di450 / Di550 I-24 Rev. 1.1/10.00...
Page 154: Installing Edh 3
1. Shoulder Head Screw 2. Chart (Save this Chart for use in future adjustment.) 3. Document Guide 4. Flat Spring (for particular areas only) 1.2.2 Removal of Tape and Cushions Remove pieces of tape and cushions Rev. 1.1/10.00 I-25 Di450 / Di550...
Page 155: Installation
Handler drop as it is insecure yet. 4. Secure both Hinges of the Electronic Document Handler with Shoulder Head Screws (two). NOTE Use care not to let the Electronic Document Handler drop as it is insecure yet. Di450 / Di550 I-26 Rev. 1.1/10.00...
Page 156 Plate: Use the upper two screw holes. Hinge: Use the upper two screw holes. Note Check that the Electronic Document Handler does not open more than 60 degrees. Rev. 1.1/10.00 I-27 Di450 / Di550...
Page 157: Installation Of The Document Guide
Document Guide should be fitted. 3. Pressing the lock lever, lower the Document Handling Tray into the original position. Note Be careful not to let the tray pinch your fingers Di450 / Di550 I-28 Rev. 1.1/10.00...
Page 158: Checking For Skew Feed
1.2.6 Adjusting Skew Feed 1. Raise the Document Handling Tray until it is locked into position. Then, after loosening the screw indicated by the arrow, remove the two remaining screws and the Rear Cover. Rev. 1.1/10.00 I-29 Di450 / Di550...
Page 159 4. Tighten the three screws shown. 5. Reinstall the Rear Cover (three screws). Note Note that the right screw, looking the machine from the front side, is of a different kind. Di450 / Di550 I-30 Rev. 1.1/10.00...
Page 160: Displaying The I.r. & Edh Check Screen
Displaying the I.R. & EDH Check Screen 1. Show the Tech. Rep. mode screen. For the detailed procedure, refer to the Service Manual.) 2. Touch “I.R. & EDH Check.” 3. Touch “Function (EDH).” The I.R. & EDH Check screen appears. Rev. 1.1/10.00 I-31 Di450 / Di550...
Page 161: Adjustment Of Fd Reading Position And Zoom Ratio
Document Handling Tray and press the Start key. Note Place the Chart crosswise on the Document Handling Tray. 3. Touch “SAVE.” 4. Touch “END.” If the “SAVE” key is not shown on the screen, repeat the above steps. Di450 / Di550 I-32 Rev. 1.1/10.00...
Page 162: Adjustment Of Cd Reading Position
Document Handling Tray and press the Start key. Note Place the Chart crosswise on the Document Handling Tray. 3. Touch “SAVE.” 4. Touch “END.” If the “SAVE” key is not shown on the screen, repeat the above steps. Rev. 1.1/10.00 I-33 Di450 / Di550...
Page 163: Adjustment Of Single Feed Cd Reading Position
Note Press the Chart up against the Rear Edge Guide and insert it crosswise. 3. Touch “SAVE.” 4. Touch “END.” If the “SAVE” key is not shown on the screen, repeat the above steps. Di450 / Di550 I-34 Rev. 1.1/10.00...
Page 164: Adjustment Of Single Feed Fd Reading Position
Press the Chart up against the Rear Edge Guide and insert it crosswise. 3. Touch “SAVE.” 4. Touch “END.” If the “SAVE” key is not shown on the screen, repeat the above steps. 5. Close the Single Feed Tray. Rev. 1.1/10.00 I-35 Di450 / Di550...
Page 165: Adjustment Of Original Detection
3. Touch “Orig. Size Adjust.” 4. Press the Start key. 5. Touch “SAVE.” If the “SAVE” key is not shown on the screen, repeat the above steps. 6. Touch “END.” 7. Press the Panel Reset key. Di450 / Di550 I-36 Rev. 1.1/10.00...
Page 166: Entering The Adjust/Edh Adjustment Values
4. Each time the adjustment value is displayed, enter it on the Label affixed to the inside of the Front Door. Note Refer to the Table given below and make sure that each value is entered at the correct column. Rev. 1.1/10.00 I-37 Di450 / Di550...
Page 167: Example Of Data Entry
2. Enter the value shown in the corresponding column in the table. Note The adjustment values differ from one machine to another. Adjustment value 3. After the adjustment values have been checked, touch “END.” Di450 / Di550 I-38 Rev. 1.1/10.00...
Page 168: Installation
1. Take the Bag of Accessories and Cabinet out of the Carton. Check to see that the following item in the bag: Label ......1 2. Peel off all the tapes from the cabinet. Tapes Tapes Rev. 1.1/10.00 I-39 Di450 / Di550...
Page 169: Fitting The Copier To The Cabinet
Positioning Pins are securely located in the holes in the base frame of the copier. 3. Using the four screws shipped with the copier, secure the Paper Feed Cabinet to the copier. Screw (shipped with the copier) -4x8mm (4) Di450 / Di550 I-40 Rev. 1.1/10.00...
Page 170 Screw (shipped with the copier) -4x10mm (1) 6. Affix the Cassette Label furnished with the unit to the location shown in the illustration. For checking the Side-to-Side Image Registration (PF-115), refer to the Di450/Di550 Unpacking/Setting-Up Instructions. Rev. 1.1/10.00 I-41 Di450 / Di550...
Page 171: Installation
Positioning Pins are securely located in the holes in the base frame of the copier. 3. Using the four screws shipped with the copier, secure the Paper Feed Cabinet to the copier. Screw (shipped with the copier) -4x8mm (4) Di450 / Di550 I-42 Rev. 1.1/10.00...
Page 172 Screw (shipped with the copier) -4x10mm (1) 6. Affix the Cassette Label furnished with the unit to the location shown in the illustration. For checking the Side-to-Side Image Registration (PF-208), refer to the Di450/Di550 Unpacking/Setting-Up Instructions. Rev. 1.1/10.00 I-43 Di450 / Di550...
Page 173: Fitting The Copier To The Cabinet
1. Take the Copier out of the carton. 2. While holding the Carrying Handles, lift the copier up and onto the cabinet ensuring that the Positioning Pins are securely located in the holes in the base frame of the copier. Di450 / Di550 I-44 Rev. 1.1/10.00...
Page 174 5. Install the Harness Cover shipped with the copier. Screw (shipped with the copier) -4x10mm (1) For checking the Side-to-Side Image Registration (Duplex Unit), refer to the Di450/ Di550 Unpacking/Setting-Up Instructions. Rev. 1.1/10.00 I-45 Di450 / Di550...
Page 175: Fn-106 Installation
3. Positioning Pin ........1 4. Fixing Bracket A ........ 2 5. Fixing Bracket B ........ 2 6. Tray ........... 1 7. Wire Form .......... 1 8. Label..........2 9. Screw..........8 10. Unpacking/Setting-up Instructions ..1 Di450 / Di550 I-46 Rev. 1.1/10.00...
Page 176: Remove Tape And Packing Materials
1.6.2 Remove tape and packing materials For FN-105 : Tape Cushion Note Do not remove this part! Cushion Rev. 1.1/10.00 I-47 Di450 / Di550...
Page 177 After the Finisher has been relocated, attach the Pipe back again by following the steps given in “Attaching the Pipe.” When moving the Finisher, press the side opposite to the Tray to prevent the Finisher from toppling over. Di450 / Di550 I-48 Rev. 1.1/10.00...
Page 178: Attaching The Positioning Pin, Fixing Brackets, And Pip
4. Lower the Lower Left Door of the machine and fit one end of the Pipe into the Feeder Attachment. Note Face the grooved end of the Pipe down and fit the Pipe positively into position. Rev. 1.1/10.00 I-49 Di450 / Di550...
Page 179: Adjusting The Position Of The Finisher
Finisher (height) (at the front) Note If the parts are not properly aligned with each other, perform these steps to make an adjustment. 2. Remove the Lower Front Cover (two screws) of the Finisher. Di450 / Di550 I-50 Rev. 1.1/10.00...
Page 180 6. After the check has been made, tighten the upper locking bolts of the casters (at four Locking bolt places), while holding the lower adjusting Adjusting bolt bolts in position 7. Reinstall the parts which have been removed. Rev. 1.1/10.00 I-51 Di450 / Di550...
Page 181: Connecting The Hookup Cord
Connecting the Hookup Cord Remove the knockout from the machine and connect the Hookup Cord. 1.6.6 Installing the Tray and Wire Form Install the Tray and Wire Form that come with the Finisher at the locations shown. Di450 / Di550 I-52 Rev. 1.1/10.00...
Page 182: Affixing The Labels
Label (for the electronic document handler) : FN-105 : FN-106 (For FN-105 and the copier) (For FN-105 and the electronic document handler) (For FN-106 and the electronic document handler) (For FN-106 and the copier) Rev. 1.1/10.00 I-53 Di450 / Di550...
Page 183: Checking The Hole Positions For Hole Punch (Fn-105 Only
3. Touch “Finishing.” 4. Touch “Hole-Punch” to highlight it 5. Touch “Select Position.” 6. Select the position for the holes to be made in Hole Punch. 7. Press the Start key. Di450 / Di550 I-54 Rev. 1.1/10.00...
Page 184: Adjusting The Hole Positions For Hole Punch (Fn-105 Only
2. Tighten the screw which has been loosened in step 1. Note Make a copy again and check for correct hole positions. If the specifications are not still met, readjust. 3. After the adjustment has been completed, close the Top Cover. Rev. 1.1/10.00 I-55 Di450 / Di550...
Page 185: C-306L Installation
4. Check the contents of the accessories box. Elevator Table ............2 Paper Transport Guide Plate ........1 Pan Head Tapping Scre .......... 7 Cap Head Screw............. 2 External Toothed Lock Washer....... 1 Support Stand............1 Di450 / Di550 I-56 Rev. 1.1/10.00...
Page 186: Unpacking C-306L
4. Open the Cassette Door and remove the tape and packing materials. Tapes Packing material 5. Check for the following items: Paper Transport Guide Plate ........1 Cover Plate ..............2 Pan Head Tapping Screw ..........7 Shoulder Head Screw..........2 External Toothed Lock Washer........1 Support Stand .............1 Rev. 1.1/10.00 I-57 Di450 / Di550...
Page 187: Installing The Paper Transport Guide
2. Remove the screws provided on the copier. 3. Insert part A of the Support Stand into position A’ underneath the copier. Then, insert part B of the Support Stand into position B’ at the bottom of the copier. A’ B’ Di450 / Di550 I-58 Rev. 1.1/10.00...
Page 188 Stand so that they can securely support the weight of the Large Capacity Cassette. Only C-306L 7. Turn the Feet about a half turn counterclockwise so that the gap between the Feet and the Floor is 0-0.5mm. 0 - 0,5mm Rev. 1.1/10.00 I-59 Di450 / Di550...
Page 189 Shoulder Head Screw x 2 Toothed Lock Washer x 1 1.7.4 CONNECTING THE HOOKUP CORD (C-306 / C-306L) 1. Remove the Connector Cover from the copier. 2. Plug in the Connector of the Hookup Cord Di450 / Di550 I-60 Rev. 1.1/10.00...
Page 190: Changing Paper Size
2. Lifting up the Top Cover a little, unplug the Connector and remove the Top Cover. 3. Remove the two Screws of the Paper Edge Guides. 4. Slide out the Paper Edge Guides. Rev. 1.1/10.00 I-61 Di450 / Di550...
Page 191 Position Outer slot Inner slot LetterC Center slot Letter C 6. Peel off the backing from two Elevator Tables contained in the accessories box. 7. Install the Elevator Tables. Letter C Letter C A4C Di450 / Di550 I-62 Rev. 1.1/10.00...
Page 192: C-306L
Paper Table is in the lowered position at this time. 3. Remove the Cassette Door. 4. Remove the right two Screws, loosen the left two screws, lift the Top cover a little, unplug the connector, and remove the Top Cover. Rev. 1.1/10.00 I-63 Di450 / Di550...
Page 193 8. Unplug the connector, take out four screws and remove the Motor in order to free the Paper Table. Note To avoid dropping the Paper Table, be sure to lower the Paper Table before removing the Motor. Di450 / Di550 I-64 Rev. 1.1/10.00...
Page 194 (Refer to the following diagram.) A : A4(L), Letter(L), Legal(L) B : Letter(C) C : A4(C) 12. Peel off the backing from two Cover Plates contained in the accessories box. Rev. 1.1/10.00 I-65 Di450 / Di550...
Page 195 A : A4(L), B5(C), Letter(L), Legal(L) B : Letter(C) C : A4(C) 15. While the Paper Table is in the lowered position, plug in the connector and reinstall the Motor. 16. Remount the Rear Cover. Di450 / Di550 I-66 Rev. 1.1/10.00...
Page 196 Cassette Door according to the paper size as indicated below. A4(C), B5(C), Legal(L) A4(L), Letter(L) 19. Mount the Cassette Door and close it. 20. Set the Large Capacity Cassette onto the Slide Rails and slide it firmly against the copier. Rev. 1.1/10.00 I-67 Di450 / Di550...
Page 197: Input The Paper Size For C-306 / C306L
3. Touch “Paper Size Input.” 4. Touch “L” which represents the Large Capacity Cassette on the screen. 5. Touch the desired paper size key to highlight 6. Touch “OK” to input the paper size. Di450 / Di550 I-68 Rev. 1.1/10.00...
Page 198: Loading Paper
7. Press the Panel Reset key to terminate the Paper Size Input Mode and return to the Tech. Rep. Mode screen. 8. Touch the “Exit” key to return to the initial screen. 1.7.6 LOADING PAPER 1. Open the Cassette Door. (C-306) (C-306L) Rev. 1.1/10.00 I-69 Di450 / Di550...
Page 199: Checking The Large Capacity Cassette Installation (C-306 / C-306L
Carry out “Installing the Large Capacity Casette” on page 2 again. 1.7.8 CHECKING THE SIDE-TO-SIDE IMAGE REGISTRATION 1. Access the Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.) Di450 / Di550 I-70 Rev. 1.1/10.00...
Page 200 3. Touch “Printer.” 4. Touch “Registration (CD).” 5. Touch “LCT.” 6. Press the Start key and input the same value of the 1st cassette. Pressing the ID Key can change the “+” or “-” sign. Rev. 1.1/10.00 I-71 Di450 / Di550...
Page 201 9. If the amount of deviation is out of the tolerance range, remove the Large Capacity Cassette from the rails. 10. Loosen two screws securing the Support Stand and move the Support Stand toward the front or rear of the copier as necessary. Di450 / Di550 I-72 Rev. 1.1/10.00...
Page 202: 32Mb Memory (M32-2) Installation
2. Move the Original Glass as shown by the arrows to remove it from the machine 3. Holding the Scanner as illustrated, move it in the direction of the arrow. Note Be sure to move the Scanner slowly. Rev. 1.1/10.00 I-73 Di450 / Di550...
Page 203 4. Remove the cover (four screws). 5. Insert the memory board as illustrated and push it until it is clicked into position. 6. Reinstall the parts which have been removed. Di450 / Di550 I-74 Rev. 1.1/10.00...
Page 204: Hard Disk Drive Kit (Hdd-1) Installation
Harness A................1 Harness B................1 Edge Cover................2 Wiring Saddle ................. 2 Flat Spring ................1 10. Gasket ..................2 11. Screw, silver ................4 12. Screw 3x6mm................. 4 13. Screw 4x8mm................. 3 Rev. 1.1/10.00 I-75 Di450 / Di550...
Page 205: Installation
5. Fit Edge Covers and Wiring Saddles at the locations shown in the illustration, connect Harness A to the PWB-R (PJ2R) and the HDD (PJ75), and secure Harness A with the Edge Covers and Wiring Saddles. Di450 / Di550 I-76 Rev. 1.1/10.00...
Page 206 8. Connect Harness B as illustrated and secure it in position using cord clamps (at seven places). 9. After Harness B has been connected to the PWB-R as illustrated, connect the cable of the kit to the connector on the machine. Rev. 1.1/10.00 I-77 Di450 / Di550...
Page 207: Setting
13. Reinstall the parts which have been removed 1.9.2.1 Setting 1. Turn ON the Power Switch. 2. Show the initial screen of the Tech. Rep. mode. (For the detailed procedures, see Service Manual.) 3. Touch “System Input.” Di450 / Di550 I-78 Rev. 1.1/10.00...
Page 208: Formatting
8. Turn OFF the Power Switch. 9. Turn ON the Power Switch again to complete the procedures. 1.9.2.2 Formatting 1. Show the initial screen of the Tech. Rep. mode. (For the detailed procedures, see Service Manual.) 2. Touch “Function.” Rev. 1.1/10.00 I-79 Di450 / Di550...
Page 209 3. Touch “Image Memory.” 4. Touch “Hard Disk Format.” 5. Press the Start key. 6. After the formatting has been completed, touch “End.” 7. Press the Panel Reset key. 8. Touch “Exit.” Di450 / Di550 I-80 Rev. 1.1/10.00...
Page 210: If Kit Installation
Main Board of the machine and secure the Board Assy with screws (four). Screws 4x8 m Note Tighten the screws marked with in the illustration first, then tighten the other screws. Rev. 1.1/10.00 I-81 Di450 / Di550...
Page 211 4x8 mm (5) 3x6 mm (8) 5. Install the Flat Springs (two) as illustrated. Screws 4x6 mm, silver (2) 6. Cut out the knockout from the Left Cover. 7. Reinstall the parts which have been removed. Di450 / Di550 I-82 Rev. 1.1/10.00...
Page 212 2. AC Adapter ..............1 3. Telephone Cord ............1 4. Backup Battery ............. 1 5. Cord Bushing..............1 6. Cord Holder ..............1 7. Velcro ................6 8. Screw ................2 9. Unpacking/Setting-up Instructions........ 1 Rev. 1.1/10.00 I-83 Di450 / Di550...
Page 213: Installing
1.11.3 Installing the Backup Battery 1. Remove the Cover. 2. Plug the connector of the Backup Battery into CN2. Note Leave the Cover opened. Di450 / Di550 I-84 Rev. 1.1/10.00...
Page 214: Initialization
4. Flip key no. 3 of DIP SW to the OFF position. 5. Reinstall the Cover. 1 2 3 4 1.11.4.1 Connecting the Hookup Cord 1. Remove the ornament cover (one screw) and unplug the connectors (two) Rev. 1.1/10.00 I-85 Di450 / Di550...
Page 215 The lower right screw is of a kind different from the rest. 6. Remove the metal bracket (four screws) shown. Note The upper (one) screw comes with a washer, while the lower (three) screws do not. Di450 / Di550 I-86 Rev. 1.1/10.00...
Page 216 Make sure of the correct orientation of the Cord Bushing and Cord Holder. Study the illustration. Cord bushing 9. Pass the Hookup Cord as illustrated. 10. Connect the Hookup Cord to the PJ311 connector on PWB-B. Rev. 1.1/10.00 I-87 Di450 / Di550...
Page 217 (three) and edge cover (one) as illustrated. 13. Reinstall the metal bracket. 14. Secure the Cord Holder at the location shown (one screw that comes with the DT-105). 15. Reinstall the parts which have been removed. Di450 / Di550 I-88 Rev. 1.1/10.00...
Page 218: Attaching The
D-103 from being installed. If a D-103 has been installed Make sure that the DT-105 is attached so that the connector of the AC Adapter does not contact the mounting bracket of the D-103. Rev. 1.1/10.00 I-89 Di450 / Di550...
Page 219: Connecting The Telephon Cord
Only used for DT-105 Commonly used for DT-105 and the telephone Commonly used for DT-105 and the Fax Unit Note Connecting the line to the Fax Unit is explained in the Operator’s Manual of your Fax Unit. Di450 / Di550 I-90 Rev. 1.1/10.00...
Page 220: Precautions For Connecting A Telephone To The
ON the Power Switch of the machine. 2. Access the Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.) 3. Touch “SMART.” 4. Touch “Modem.” 5. Touch “End.” Rev. 1.1/10.00 I-91 Di450 / Di550...
Page 221: Setting Common Dt
3. Change the dial mode according to the type of office system as shown below. For pulse dial: Pulse For tone: Tone 4. Touch “END. 5. Touch “Auto Receive.” 6. Touch “NO.” 7. Touch “END” twice. Di450 / Di550 I-92 Rev. 1.1/10.00...
Page 222: 10Setting Date/Time
The following procedures are concerned with setting of Maintenance Center. Setting of Billing Center may also be performed as may be necessary, to which the same procedures apply. Following the setting of Maintenance Center, set Billing Center as necessary. Rev. 1.1/10.00 I-93 Di450 / Di550...
Page 223: 12Maintenance Ram Clear
3. Enter the ID code (7 digits) from the 10-Key Pad. Note Enter the ID code of the Tech. Rep. 4. Touch “ID Code” again to show it normally. 5. Touch “Mainte. RAM Clear.” Di450 / Di550 I-94 Rev. 1.1/10.00...
Page 224 1. Touch “ID Code” to show it in reverse video. 2. Enter the ID code (7 digits) from the 10-Key Pad. Note Enter the ID code of the Tech. Rep. 3. Touch “ID Code” again to show it normally. 4. Touch “DT Setting.” Rev. 1.1/10.00 I-95 Di450 / Di550...
Page 225 9. Enter the Data Terminal ID (6 digits) from the 10-Key Pad. Note If the number of digits is less than 6, add “0” in the beginning. 10. Touch “DT-ID” again to show it normally. Di450 / Di550 I-96 Rev. 1.1/10.00...
Page 226: 1Setting Telephone No
Pause Energy Saver key Wait Pulse Tone Extension key (sharp) Extension key (asterisk) 4. After the telephone number has been input, call the Center to inform them of the details of the telephone number. Rev. 1.1/10.00 I-97 Di450 / Di550...
Page 227: 14Initial Transmission
Display. Condition Line is busy Not answering. Max. trial number reached. The other line is busy. Connection failed. DT modem error. Connected. Dialing. End of normal data DT Connection failed. transmission. Di450 / Di550 I-98 Rev. 1.1/10.00...
Page 228 3. Press the Panel Reset key. 4. Touch “Exit.” Note This completes the setting of Maintenance Center. Perform the same procedures to set Billing Center as may be necessary. Rev. 1.1/10.00 I-99 Di450 / Di550...
Page 229 Di450 / Di550 I-100 Rev. 1.1/10.00...
Page 230 SWITCHES ON PWBs, TECH. REP. SETTINGS...
Page 231 CONTENTS 1. CONTROL PANEL KEYS AND TOUCH PANEL ..........S-1 1-1. Control Panel Keys .................. S-1 1-2. Explanation of the Touch Panel ............... S-3 Basis Screen ................... S-3 Warning Screens ................S-4 2. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs ......S-5 2-1.
Page 232: Control Panel Keys And Touch Panel
CONTROL PANEL KEYS AND TOUCH PANEL 2-1. Control Panel Keys 1 2 3 4 4002O279EA...
Page 233 1. HDD Lamp 11. Original Key • Lights up to indicate that the Hard Disk • Press to select the Mixed Orig. Detec- Drive Kit (option) is being accessed. tion and other document-related func- 2. Access Key tions setting screen. •...
Page 234: Explanation Of The Touch Panel
2-2. Explanation of the Touch Panel Basis Screen The Basic screen is the initial screen that appears when the copier is turned ON. 4003P137CA 1. Supplementary Function Keys • The auxiliary, Density, Orig. Copy, and Basics keys are displayed. 2. Message Display •...
Page 235: Warning Screens
Warning Screens The Warning screen may be a malfunction display, error display, warning display, or a cau- tion display. <Malfunction Display> Given when a malfunction occurs. E.g.: Malfunctions that can be identified with a specific code. 4003P200CA 4003P201CA <Error Display> <Warning Display>...
Page 236: Function Of Switches And Other Parts On Pwbs
FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs 3-1. PWB Location PWB-S 4002S001AB 3-2. PWB-S (Tech. Rep. Setting Switches Board) 4002S002AB Symbol Name Description Trouble Reset Switch Resets the malfunction display. Tech. Rep. Switch Display the Tech. Rep. mode screen. Initialize Switch Resets a misfeed, malfunction, and erratic display.
Page 237: Clearing Procedures
Clearing Procedures <Initialize> 1. Turn OFF the Power Switch. 2. With the circuit across pins of PJ2 closed, turn ON the Power Switch. 3. Open the circuit in about 5 seconds. 4. Check that the message “Initialize Completed” is displayed on the Touch Panel and then touch the “OK”...
Page 238: Utility Mode
UTILITY MODE • Utility Mode is used to make various settings according to the user’s need. 4-1. Utility Mode selection Screen • Press the Utility key on the control panel. 4003P605CA 4-2. Utility Mode Function Tree Job Memory Input Job/Image Men. Input Image Memory Input Meter Count User’s Choice 1/6...
Page 239: Settings In The Utility Mode
4-3. Settings in the Utility Mode Touch Panel Setting Display Job/Image Permits programming of various functions, including copying jobs. Men. Input Meter Count Displays the counts of various counters. User’s Choice User’s Choice is used to make various settings according to the user’s need.
Page 240 2. User’s Choice Function Tree Original Copy Default Language selected User’s Choice 1/6 Mixed Original Detect Memory Recall Auto Paper/Auto Size Tray Priority 2in1, 4in1, Booklet, copy Zoom Density Priority User’s Choice 2/6 Default Level Output Priority Intelligent Sorting Criss Cross Mode “Small”...
Page 241 3. Settings in the User’s Choice Mode Touch Panel Setting (The default is Highlighted Display Original Copy Select the priority type of Original Copy setting selected automati- Default cally when the Power Switch is turned ON or Panel Reset key pressed.
Page 242 Touch Panel Setting (The default is Highlighted Display Density Priority Specify the priority exposure mode that is selected automatically when the Power Switch is turned ON or the Panel Reset key pressed. <Density> Manual Auto Exposure <Original Image Type> Text/Photo Photo Text Default Level...
Page 243 Touch Panel Setting (The default is Highlighted Display “Smaller” Originals Select whether to enable or disable a copy cycle when it is initiated with an original of a small size that is not detectable by the system placed on the Original Glass. Default: Metric areas OFF/Inch Areas ON.
Page 244 Touch Panel Setting (The default is Highlighted Display Universal Tray Set the paper size for the Universal Tray. Size Input Auto Detect Special Paper Define the type of paper used for each paper source, or designate a particular paper source for special paper. Cover/Insert Normal Recycled...
Page 245 Touch Panel Setting (The default is Highlighted Display Auto Shut-Off Select the time it takes the Auto Shut Off function, which shuts down Mode the copier when the set period of time elapses after a copy cycle has been completed or the last key operated, to be activated. When a Printer NOTE: Controller is not...
Page 246: Administrator Mode
Administrator Mode • The entry of the “Administrator #” set using the Tech. Rep. mode permits the settings of the following functions. 1. Administrator Mode Function Setting Procedure <Procedure> 1. Press the Utility key. 2. Touch the “Administrator Mode” key. 3.
Page 247 Touch Panel Setting (The default is Highlighted Display 100 Accounts The copy track data of the selected page is displayed. “No.”: Enter the set account number from the 10-Key Pad. “Total Count”: Displays the count of the Total Counter. “Size Count”: Displays the count of the Size Counter. “Copy Limit”: Enter the maximum number of copies that can be made from the 10-Key Pad.
Page 248: Tech. Rep. Mode
TECH. REP. MODE • This mode is used by the Tech. Rep. to check, set, adjust, and/or program various ser- vice functions. 5-1. Tech. Rep. Mode Menu Screen 4003P602CA 5-2. Tech. Rep. Mode Function Setting Procedure <Procedure> 1. Press the Utility key. 2.
Page 249: Tech. Rep. Mode Menu Function Tree
5-3. Tech. Rep. Mode Menu Function Tree F1: Paper Passage F2: HV Output Printer F5: AIDC Sensor F8: ATDC Sensor F12: Test Pattern Function Opt. Men. Check Memory Check Comp./Expansion Image I.R. Men. Prn. Memory Hard Disk Format Hard Disk Check ECC Check Date/Time Check FLS Paper...
Page 250: I/O Check
I/O Check Focus Check Zoom (CD) Function Zoom (FD)/Scale (IR) Scale (CD) Scanning Check Orig. Size Adjust Position/Zoom (FD) Position (CD) Function S-ADF Mode (CD) (EDH) S-ADF Mode (FD) Skew Check I/O Check Tech. Rep. Mode I.R. & EDH Check (IR) I/O Check (EDH)
Page 251: Finisher
Tech. Rep. Mode Punch Loop Adjust Finisher Sensors I/O Check Port Signals S-20...
Page 252 5-4. Setting in the Tech. Rep. Mode Function • This function allows the Tech. Rep. to make the various function tests and adjustments. <Functions> Printer: Used for making the various function tests and adjustments for the printer. Image Memory: Used for making the various function tests and adjustments for image memory.
Page 253 Touch Panel Operation Display Memory Check Writes data in the image memory and reads it out to check for exact correspondence. The Touch Panel shows the percentage of processing completed of each diagnostic sequence and the number of diagnostic sequences carried out.
Page 254 Touch Panel Operation Display Hard Disk Format Formats the Hard Disk. The Touch Panel shows the percentage of processing completed. If formatting has been normally completed, the panel gives the mes- sage of “OK”; if it has been abnormally terminated, the panel gives the message of “NG”...
Page 255 Tech. Rep. Choice • This function allows the Tech. Rep. to make various settings and adjustments. <Functions> System Set: Choice functions relating to the printer. Printer: Choice functions relating to image memory. Controller Set: Choice functions relating to the Printer Controller. Touch Panel Setting (The default is Highlighted...
Page 256 Touch Panel Setting (The default is Highlighted Display Toner Empty Stop Select whether or not to inhibit copying when a toner-empty condition is detected. Disable Enable T/C Abnormal Select whether to enable or disable copying when an abnormal T/C is detected.
Page 257 Touch Panel Setting (The default is Highlighted Display Peripheral Mode Select the type of external I/F operation. Mode 1 External I/F operation mode 1 External I/F operation mode 2 Mode 2 Mode 3 External I/F operation mode 3 After the setting has been made, touch “END” and turn OFF and ON the Power Switch.
Page 258 Counter • Shows the number of copies made on each paper size or type. <Clearing a Count> 1. Open the counter menu screen. 2. Select the counter to be cleared. 3. Press the Clear key. 4. Touch “END”. Press the Interrupt key to undo the clearing operation, restoring the original count. <Clearing All Counts of a Counter Type at Once>...
Page 259 Touch Panel Setting Display Counts the number of misfeeds that have occurred at different loca- tions in the copier. Display Description MCBJ System Total Counter divided by the sum of all misfeed- counters (including misfeeds in the Finisher) MCBJ Machine Total Counter divided by the sum of machine mis- Only feed counter (excluding misfeeds in the Finisher)
Page 260 Touch Panel Setting Display Display Description Fold No. of misfeeds that occurred at the Folding Unit Staple No. of misfeeds that occurred at the Stapling Unit Finisher No. of misfeeds that occurred in the Finisher, other than above Needle No. of staple misfeeds that occurred. Duplex Entrance No.
Page 261 Touch Panel Setting Display Display Description Staple 1 No. of stapling sequences performed Staple 2 No. of stapling sequences performed (FN-105) Punch No. of holes made (FN-105) Sort/Group No. of copies fed out in the Sort/Group mode Trans./Sepa. pass No. of times a sheet of paper is fed through Ozone Filter No.
Page 262 Touch Panel Setting Display Trouble Malfunction Malfunction Description Description Code Code C004E/F Cooling Fan C0210 Transfer Corona C0042 Fusing Unit Fan C04X0 Exposure Lamp C0070/2 Toner Hopper Motor C05X0 Fusing Unit C0090 Dev. Unit Drive Motor C0602 Scanner Drive Malfunction Malfunction Description Description...
Page 263 Touch Panel Setting Display Trouble Malfunction Malfunction Description Description Code Code C1430 H. sysnc Trouble C1461/2 Serial GA Trouble C143E EDH Trouble C1499 IR Cooling Fan C1440 Gain Adjust Trouble C14XX IR Sequence Trouble C1441 CCD Trouble C1802 SPC Error Malfunction Code Description C1803...
Page 264 Touch Panel Setting Display Scanning Check Check the operations from image scanning to image processing. Normal: OK: Abnormal: NG See the following for details of “NG” display Display Action Optical Analog Check the optical system, change PWB-IA or B. Digital Change PWB-B.
Page 265 RD Mode • Make the initial settings of the copier for the Data Terminal. 1. RD Mode Menu Function Tree e-mail System Set Modem CT-ID DT-ID TEL. No. DT Setting (Setting Modem) Initial Mail Address Billing Center Transmission (Setting e-mail) (Setting Modem) Billing RAM Clear...
Page 266 2. Setting in the RD Mode Touch Panel Setting Display System Set Set the control system. e-mail Modem Billing Center Displays the various setting screens. DT Setting Displays the setting screens for CT-ID, DT-ID, and telephone number. The mail address is also displayed if “e-mail” is set for System Set. CT-ID Enter the ID number of the Center PC from the 10-Key Pad.
Page 267 Touch Panel Setting Display Date/Time Set Set the date and time-of-day for Date Printing. Common DT Displays the screens for communications settings. Dial Mode Sets the type of telephone line of the user. Tone Pulse Auto Receive Sets the auto reception function. Level History •...
Page 268 (10) Admin. Mode • Makes the various settings. Touch Panel Setting Display Copy Track See User’s Choice. Copy Track Data See User’s Choice. Max. Copy Sets See User’s Choice. Administrator # Set an ID number for opening the “Administrator Mode” screen of Util- Input ity Mode from the 10-Key Pad.
Page 269: Security Mode
SECURITY MODE • Allows the Tech. Rep. to set the various counters. 6-1. Security Mode Menu Screen 4003P603CA 6-2. Security Mode Setting Procedure <Procedure> 1. Show the Tech. Rep. mode menu screen. 2. Press the following keys in this order: Stop 3.
Page 270: Settings In The Security Mode
6-3. Settings in the Security Mode Touch Panel Setting (The default is Highlighted Display Key Counter Set to “ON” if a Key Counter is plugged in. NOTE: • If “OFF” is set, copies can be made without having to plugging the Key Counter into the socket.
Page 271 Touch Panel Setting (The default is Highlighted Display Vender Mode Set the initial screen according to the type of vender mounted on the copier. Coin Card Admin. Unit Select the model of the Data Controller mounted on the copier. D102 D103 S-40...
Page 272: Adjust Mode
ADJUST MODE • Used at the factory for making adjustments. NOTE: • Use only when the RAM Board has been replaced. If any of the adjustment values has been changed, be sure to enter the value in the label affixed to the copier. 7-1.
Page 273: Adjust Mode Function Tree
7-3. Adjust Mode Function Tree Registration (CD) Registration (CD) PHC beam Adjust Image Density ATDC Control Printer Separator Charge LD Bias Leading Edge Erase Trailing Edge Erase Loop Adjustment Vg adjust Zoom (CD) Zoom (FD)/Manual Adjust Mode Image Reader Scale (FD) Scale (CD) Zoom (FD)/EDH Feed (2)
Page 274: Settings In The Adjust Mode
7-4. Settings in the Adjust Mode <Function> Printer: Adjust functions relating to the printer. I.R.: Adjust functions relating to the I.R. EDH: Adjust functions relating to the EDH. Touch Panel Setting (The default is Highlighted Display Registration (CD) Adjust registration in the CD direction on the engine side. Setting -8.2 ........
Page 275 Touch Panel Setting (The default is Highlighted Display Leading Edge Select whether to enable or disable the leading edge erase. Erase 0 to 5 ( 3 mm Trailing Edge Select whether to enable or disable the trailing edge erase. Erase 3 mm 0 to 5 ( Loop Adjustment...
Page 276 Touch Panel Setting (The default is Highlighted Display Feed (FD) Set the correction value for the original scanning position in the FD direction when the EDH is used. -4.0 to +4.0 ( 0.0 mm Feed (CD) Set the correction value for the original scanning position in the CD direction when the EDH is used.
Page 277 DIS/REASSEMBLY, ADJUSTMENT...
Page 278 CONTENTS 1. SERVICE INSTRUCTIONS ................D-1 1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS ....D-1 1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ....D-1 1-3. PARTS WHICH MUST NOT BE TOUCHED ........... D-2 Red painted Screws ................ D-2 Variable Resistors on Board ............D-2 Other Screws ...................
Page 279 (19) Cleaning of the Multi Bypass Paper Separator Roll Assy....D-37 2-6. OPTICAL SECTION ................D-38 Cleaning of the Original Glass and EDH Glass ....... D-38 Cleaning of the Mirrors ..............D-38 Cleaning of the Lens ................ D-38 Cleaning of the Scanner Rails/bushings .......... D-39 Cleaning of the PH Glass ..............
Page 280 Cleaning of the Lower Fusing Paper Separator Fingers ....D-67 Cleaning of the Entrance Guide Plate ..........D-67 Removal of the Upper Fusing Roller Thermistor ......D-68 Cleaning of the Upper Fusing Roller Thermistor ......D-68 Removal of the Lower Fusing Roller Thermistor ......D-68 Cleaning of the Lower Fusing Roller Thermistor ......
Page 281 (13) Scale (CD) ..................D-105 (14) Scale (FD) ..................D-107 3-8. OTHER ADJUSTMENTS ................. D-109 Adjustment of the Reference Position of Each Drawer ....D-109 Adjustment of the Reference Position of the Multi Bypass Tray ..D-111 Adjustment of the Upper Right Door (Multi Bypass Unit) ....D-112 Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage ...................
Page 282: Service Instructions
SERVICE INSTRUCTIONS 1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS Inverter Board DC Power Supply Main INV 250 V 2 A (F1) PU1 <100 V Areas> 125 V 15 A (F1) Power Supply Board 125 V 4 A (F2) PWB-C 250 V 4 A (6 pce.) 125 V 15 A (F3) 125 V 6.3 A (F4)
Page 283: Parts Which Must Not Be Touched
NOTES • The Organic Photoconductor Drum is softer than CdS and Selenium Drums and is there- fore susceptible to scratches. • Even when the PC Drum is only locally dirtied, wipe the entire surface. • Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination.
Page 284: Disassembly/Reassembly
DISASSEMBLY/REASSEMBLY 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES 4002D025AC 4002D026AC...
Page 285 Part Name Removal Procedure Original Glass Remove No.3. EDH Glass Remove No.3. EDH Glass Holder Raise No.13. Remove four EDH Glass Holder mounting screws. Control Panel Raise No.13. Swing down No.5. Remove No.18. Remove No.11. Remove five Control Panel mounting screws. Unplug two connectors.
Page 286: Removal Of Circuit Boards And Other Electrical Components
2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS • When removing a circuit board or other electrical component, refer to “Handling of PWBs” and follow the corresponding removal procedures. • The removal procedures given in the following omit the removal of connectors and screws securing the circuit board support or circuit board.
Page 287 Symbol Part Name Removal Procedure Inverter Board Remove the Scanner. Unplug two connectors and remove two screws and the Inverter Board Mounting Bracket Assy. PWB-A Master Board Remove the Right Cover. Remove the Rear Cover. Remove three screws and the Cover. Remove four screws and the Cover.
Page 288 Removal of the Image Processing Board 1. Remove the Rear Cover and Right Cover. 2. Remove the Original Glass and EDH Glass. 3. Remove eight screws and the CCD Unit Cover. 4002D043AB 4. Remove four screws and the cover on the left. 5.
Page 289 10. Unplug two connectors, one flat cable. 4002D034AC 11. Unplug five connectors, two flat cables. 12. Remove the harness from the edge cover. 4002D258AB 13. Unplug four connectors. 14. Remove five screws and the Imaging Processing Board Mounting Bracket Assy. 4002D515AA 15.
Page 290: Maintenance Schedule
2-3. MAINTENANCE SCHEDULE • To ensure that the copier produces good copies and to extend its service life, it is recom- mended that the maintenance jobs described in this schedule be carried out as instructed. 45-cpm copier Maintenance Reference Cycle (K) PM Parts Parts No.
Page 291 Maintenance Reference Cycle (K) PM Parts Parts No. Page Clean Replace PC Drum 1, PC Drum – (*4) – – D-47 2, 3 Developer Cleaning Blade – 1136-5534-02 D-50 1, 2 Developer 1 Toner Antispill Seal 1013-5524-01 D-53 Cleaning 1 Main Erase Lamp Filter –...
Page 292 Maintenance Reference Cycle (K) PM Parts Parts No. Page Clean Replace Fusing Upper Fusing Roller – 4002-5701-01 D-62 Roller Upper Fusing Roller Bearings – 4002-5705-01 D-62 Fusing Unit Upper Fusing Roller Bushings – 4002-5704-01 D-62 Fusing Roller Lower Fusing Roller –...
Page 293: 55-Cpm Copier
55-cpm copier Maintenance Reference Cycle (K) PM Parts Parts No. Page Clean Replace Paper Take-Up Roll 4002-3216-01 D-24 1st Drawer Paper Feed Roll (*1) 4002-3216-01 D-24 2nd Drawer Paper Separator Roll Assy. (*1) 1136-0162-01 D-24 Upper Transport Roller – – –...
Page 294 Maintenance Reference Cycle (K) PM Parts Parts No. Page Clean Replace PC Drum Charge Corona Grid – – – D-57 Mash Cleaning 1 PC Drum Charge Corona – – – D-56 Housing Developer PC Drum Charge Corona 4002-4001-01 D-58 1, 2 Comb Electrode Cleaning 1 Image Transfer/Paper Separa-...
Page 295 Maintenance Reference Cycle (K) PM Parts Parts No. Page Clean Replace Turnover Roller – – – D-71 Cleaning 1 Transport Roller – – – D-71 Perform the maintenance jobs based on the PM Counter count. *1: Replace the Paper Feed Roll and Paper Separator Roll Assy at the same time. *2: Perform cleaning when a malfunction occurs.
Page 296: Removal Of The Unit
2-4. Removal of the Unit Removal of the Multi Bypass Unit 1. Open the Upper Right Door. 2. Remove two connectors and the cover. 3. Unplug two connectors. 4002D027AD 4. Remove two screws and the Upper Right Cover. NOTE When reinstalling the Upper Right Cover, Adjustment of the Upper Right Door (Multi Bypass Unit).
Page 297: Removal Of The Main Hopper Unit
8. Swing down the Transport Section Release Lever. 9. Holding up the Suction Unit, remove the compres- sion coil. 4002D031AD 10. Remove the Suction Unit by sliding it to the right. 1136D101AA NOTE When reinstalling the Suction Unit, make sure that two positioning pins on the copier fit into the positioning holes in the Suction Unit.
Page 298: Removal Of The Ir Unit
Removal of the IR Unit 1. Swing down the Front Door and slide out the Developer Unit. 2. Remove the Right Door, Left Door, Rear Upper Cover, Rear Cover and Control Panel. 3. Slide out the Fusing Unit. 4. Remove four screws and the Cover. NOTE Do not remove the belt mounting screw on the cover.
Page 299 11. Unplug two connectors, one flat cable from the Imaging Processing Board. 4002D034AC 12. Unplug four connectors at the front. 4002D035AD 13. Remove five screws and the Cover. Cover 4002D238AC 14. Remove five screws and the Master Board Moun- tain Bracket Assy. 4002D069AC 15.
Page 300 17. Remove two screws and the relay connector. 4002D037AB 18. Remove four screws and the right mounting bracket. 4002D038AC 19. Remove four screws and the left mounting bracket. 4002D039AC 20. Remove five screws that secure the IR Unit on the front side.
Page 301: Removal Of The Ph Unit
22. Remove the IR Unit. 4002D042AB Removal of the PH Unit NOTES • Do not place the PH Unit upside down, tilt it excessively, or subject it to excessive shock. • Replace the PH Unit as one unit. • NEVER attempt to disassemble or adjust the PH Unit. •...
Page 302 7. Remove three screws and the PH Cooling Fan Motor mounting bracket Assy. 8. Remove six screws and the mounting bracket. 4002D046AB 9. Remove the harness from two cord clamps and one edge cover. 4002D047AC 10. Unplug two relay connectors and remove the har- ness from the cord clamp.
Page 303: Removal Of The Developing Unit
Removal of the Developing Unit 1. Swing down the Front Door. 2. Swing down the Transport Section Release Lever. 4002D051AB 3. Loosen two screws and remove the Developing Unit. 4002U072AB Removal of the Sub Hopper Unit 1. Swing down the Front Door and slide out the Developing Unit.
Page 304: Removal Of The Upper Left Door (Exit/Duplex Switching Unit
Removal of the Upper Left Door (Exit/Duplex Switching Unit) 1. Swing down the Front Cover and slide out the Fus- ing Unit. 2. Remove the cable from the spring. 4002D261AA 3. Remove the Rear Cover. 4. Open the Upper Left Door. 5.
Page 305: Paper Take-Up/Transport Section
2-5. PAPER TAKE-UP/TRANSPORT SECTION Removal of the Paper Take-Up Roll, Paper Feed Roll and Paper Separator Roll Assy. 1. Remove the Right Door. 2. Remove one screw and the Paper Guide Plate from each drawer. 4002D057AB 3. Remove the Paper Separator Roll/Paper Guide Plate Assy.
Page 306: Cleaning Of The Paper Take-Up Roll And Paper Feed Roll
6. Unbending one tab of the holder, remove the holder. 4002D061AB 7. Remove the Paper Take-Up Roll and Paper Feed Roll. 4002D062AB Cleaning of the Paper Take-Up Roll and Paper Feed Roll 1. Remove the Paper Separator Roll Mounting Bracket Assy. 2.
Page 307: Removal Of The Drawer Lift-Up Motor
Removal of the Drawer Lift-Up Motor 1. Remove the Right Door. 2. Slide out the drawer and remove one screw and the right stopper. 4002D065AB 3. Pushing the tab on the left rail, pull out the drawer. 4002D066AC 4. Remove three screws and the Drawer Set Sensor Mounting Bracket Assy.
Page 308: Removal Of The Upper And Lower Transport Rollers
8. Disassemble the Drawer Lift-Up Unit. 1156D022AA Removal of the Upper and Lower Transport Rollers 1. Swing down the Front Door and slide out the Cover Developing Unit. 2. Slide out the 1st Drawer. 3. Remove the Rear Cover. 4. Remove the Right Cover. 5.
Page 309 8. Remove three screws and the Power Supply Board Mounting Bracket Assy. 4002D070AB 9. Remove three screws and the Flywheel. 4002D071AB 10. Remove three screws and the Transport/Synchro- nizing Rollers Drive Assy. 4002D073AB 11. Snap off the E-ring and remove the gear. 12.
Page 310: Cleaning Of The Upper Transport Roller
15. Unhook one spring and snap off two E-rings. Then remove the bushings from the front end of the Upper and Lower Transport Roller. 4002D240AB 16. Remove the Upper Transport Roller. 17. Remove the Lower Transport Roller. 4002D241AA Cleaning of the Upper Transport Roller 1.
Page 311: Cleaning Of The Vertical Transport Rollers
Cleaning of the Vertical Transport Rollers 1. Open the Upper Right Door. 2. Using a soft cloth dampened with alcohol, wipe each roller clean of dirt. 4002D244AA Removal of the Synchronizing Roller 1. Swing down the Front Door and slide out the Cover Developing Unit.
Page 312 8. Remove three screws and the Flywheel. 4002D071AB 9. Unplug two connectors and remove five screws and the Developing Unit Drive Assy. 4002D072AB 10. Unplug two connectors and remove three screws and the Transport/Synchronizing Rollers Drive Assy. 4002D073AB 11. Snap off the E-ring and remove the gear. 12.
Page 313: Cleaning Of The Upper Synchronizing Roller
14. Snap off the E-ring and remove the bushing from the front end of the Upper Synchronizing Roller. 15. Remove the Upper Synchronizing Roller. 4002D076AB (10) Cleaning of the Upper Synchronizing Roller 1. Swing down the Front Door and slide out the Developing Unit.
Page 314: Cleaning Of The Lower Synchronizing Roller
(12) Cleaning of the Lower Synchronizing Roller 1. Swing down the Transport Section Release Lever. 2. Using a brush or a vacuum cleaner, clean the Lower Synchronizing Roller. 4002D081AB (13) Removal of the Synchronizing Paper Dust Remover 1. Swing down the Front Door and slide out the Developing Unit.
Page 315: Cleaning Of The Paper Dust Remover
NOTE When only the Paper Dust Remover is to be replaced, affix the new one along the reference line as shown on the left. 1 mm 4002D517AA (15) Cleaning of the Paper Dust Remover 1. Remove the Synchronizing Paper Dust Remover Assy.
Page 316: Disassembly Of The Multi Bypass Unit
5. Remove four Suction Belts. 4002D085AB 6. Remove the Suction Roller as shown on the left. 4002D086AB (17) Disassembly of the Multi Bypass Unit 1. Remove the Right Door. 2. Remove four screws and the Separator Guide Plate Assy. 4002D087AB 3.
Page 317 5. Snap off the C-clip and remove the Separator Roll Assy. 1136D109AA 6. Remove five screws and the Solenoid Mounting Bracket Assy. NOTE Whenever a solenoid has been replaced or a solenoid mounting screw removed, be sure to adjust the posi- tion of the solenoid.
Page 318: Cleaning Of The Multi Bypass Paper Take-Up Roll/Paper Feed Roll
11. Snap off the E-ring and remove the Paper Take-Up Roll. 4002D094AB (18) Cleaning of the Multi Bypass Paper Take-Up Roll/Paper Feed Roll 1. Using a soft cloth dampened with alcohol, clean the Paper Take-Up Roll/Paper Feed Roll. 4002D095AB (19) Cleaning of the Multi Bypass Paper Separator Roll Assy. 1.
Page 319: Optical Section
2-6. OPTICAL SECTION Cleaning of the Original Glass and EDH Glass 1. Wipe clean the Original Glass and EDH Glass with a soft cloth. 4002O262AB Cleaning of the Mirrors 1. Remove the Original Glass. 2. Wipe the surface of each mirror clean of dirt using a soft cloth.
Page 320: Cleaning Of The Scanner Rails/Bushings
Cleaning of the Scanner Rails/bushings 1. Remove the Original Glass. 2. Wipe clean the Scanner Rails/bushings with a soft cloth. NOTE Apply lubricant to the Scanner Rails/Bushings after they have been cleaned. 4002D100AA Cleaning of the PH Glass 1. Swing down the Front Door and slide out the Developing Unit.
Page 321: Removal Of The Exposure Lamp
Scanner mounting screws NOTE Do not remove the Scanner positioning screws. Scanner positioning screws 4002D264AB 4. Swing the Scanner counterclockwise and take it out of the copier. NOTE At this point, the Scanner is kept connected to a flat cable and cannot be taken off. 4002D102AB 5.
Page 322: Removal Of The Edh Glass
Removal of the EDH Glass 1. Remove four screws and the EDH Glass Holder. 2. Remove the EDH Glass. 4002D245AB Removal of the Scanner Drive Cable 1. Remove the Original Glass and EDH Glass. 2. Remove the Left Cover, Right Cover, Rear Upper Cover and Control Panel. 3.
Page 323: Winding Of The Scanner Drive Cable
9. Remove one screw and the slide the rear pulley and bushing toward the front. 4002D113AA 10. Remove the Scanner Drive Gear, pulleys and bushings at the front and rear, and the shaft. 4002D114AD (10) Winding of the Scanner Drive Cable Pulley F Pulley E Pulley D...
Page 324 2. Wind the fixed bead end of the cable around the pulley five turns clockwise, from the rear toward the front side. 4002D003AA 3. Wind the hook end of the cable around the pulley five turns counterclockwise, from the front toward the rear side.
Page 325 7. Wind the hook end of the cable around the pulley five turns counterclockwise, from the rear toward the front side. NOTE Make sure that no part of the cable rides on the other. 4002D007AA 8. Slip the Cable Holding Jig onto the pulley to secure the cable in position.
Page 326 13. Slide the rear pulley and bushing to the rear and secure install one mounting screw. 4002D118AD Front Pulley C 14. Wind the bead end of the cable around pulley C and pulley B, then hook the bead onto the Adjust- able Anchor.
Page 327 18. Wind the hook end of the cable around pulley D and pulley E. Pulley E Pulley D 4002D011AA 19. Fit the hook end of the cable into the groove in the Cable Guide and hook the spring. Cable Guide 4002D120AB 20.
Page 328: Developing Unit
2-7. DEVELOPING UNIT Remove of the Developing Unit 1. Swing down the Front Door and slide out the Developing Unit. 2. Move the PC Drum Charge Corona to the rear, raise it, and take it off. 4002U015AA 3. Loosen the two screws of the PC Drum stopper and remove the PC Drum stopper.
Page 329 6. Remove two screws and the Stopper and Devel- oper Scattering Prevention Plate. 4002D125AB 7. Remove two screws and the Cleaning Blade. 4002D127AB NOTE When reinstalling the Cleaning Blade, press the blade tightly up against the mounting bracket. 1136D173AA 8. Remove two screws, unplug one connector, and remove the ATDC Sensor.
Page 330 Coupling Holder NOTE When reinstalling the PC Drum Paper Separator Fin- ger Holder Assy., fit the collar of the assy onto the cou- pling holder in the rear. Collar 1134D047AA 11. Remove the PC Drum Paper Fingers and AIDC Sensor Board as shown below. Assy AIDC Sensor Board 4002D128AB...
Page 331: Cleaning Of The Developer Scattering Prevention Plate
Cleaning of the Developer Scattering Prevention Plate 1. Using a brush, whisk dust off the Developer Scat- tering Prevention Plate. 4002D129AA Cleaning of the DS Positioning Collars 1. Using a brush or a soft cloth dampened with alco- hol, clean the DS Positioning Collars. 1136D177AA Cleaning of the Toner Antisocial Trap 1.
Page 332 2. Remove the Toner Bottle from Main Hopper. Insert a brush through the toner port and into the toner. 4002U022AA 3. Apply toner to the entire surface of the new Clean- ing Blade. 4002D132AA 4. Using the brush, apply lubricant shipped with the Cleaning Blade to the two side seals shown.
Page 333: Replacement Of The Developer
7. Apply a thin coat of toner to the surface of the PC Drum. 4002U023AB 8. Holding onto the both sides of the PC Drum with hands, turn the PC Drum a half turn in the direction of the arrow. 4002U024AC 9.
Page 334: Cleaning Of The Aidc Sensor Board
3. Turning the Bucket Roller, pour fresh developer evenly into the chamber. NOTES • Shake the packet of developer well before opening • When the developer has been replaced, clear the counts of “Developer 1” and “Developer 2” of “PM” of 1134D051AA “Counter”...
Page 335: Cleaning Of The Toner Antispill Seal
NOTE When reinstalling the Toner Antispill Plate and Toner Antispill Seal, press them in the direction of the arrows. 4002D139AB (10) Cleaning of the Toner Antispill Seal 1. Remove the Toner Antispill Seal. 2. Using a brush, clean the Toner Antispill Seal. 4002D140AA (11) Removal of the Main Erase Lamp 1.
Page 336: Removal Of The Ozone Filter (Pc Drum Charge Corona
3. Using a soft cloth dampened with alcohol, wipe clean the Main Erase Lamp Filter. 1136D187AA (13) Removal of the Ozone Filter (PC Drum Charge Corona) 1. Swing down the Front Door. 2. Swing out the Main Hopper. 3. Slide out the Ozone Filter. 4002D143AB (14) Removal of the Ozone Filter (Image Transfer/Paper Separator Coronas) 1.
Page 337: Pc Drum Charge Corona And Image Transfer/Paper Separator Coronas
2-8. PC DRUM CHARGE CORONA AND IMAGE TRANSFER/ PAPER SEPARATOR CORONAS Removal of the PC Drum Charge Corona 1. Swing down the Front Door and slide out the Developing Unit. 2. Move the PC Drum Charge Corona to the rear, raise it, and take it off.
Page 338: Cleaning Of The Pc Drum Charge Corona Grid Mesh
NOTE When handling the Comb Electrode, be sure to hold it onto its both ends. 10 mm 17 mm 4002D147AB 6. Wipe clean the Housing with a soft cloth. 1139D177AA Cleaning of the PC Drum Charge Corona Grid Mesh 1. Blow all foreign matter off the Grid Mesh with a blower brush.
Page 339: Cleaning Of The Comb Electrode
Cleaning of the Comb Electrode 1. Clean Comb Electrode using the PC Drum Charge Corona Cleaning Lever. 1156D072AA Removal of the Image Transfer/Paper Separator Coronas 1. Swing down the Front Door. 2. Pull out the Transfer/Paper Separator Coronas. 1134D062AA Cleaning of the Image Transfer Corona Wire 1.
Page 340: Removal Of The Image Transfer Corona Wire
Removal of the Image Transfer Corona Wire 1. Remove the End Caps from the front and rear ends of the Unit. 4002D149AA 2. Remove the corona wire, first at the spring end. 4002D150AA Cleaning of the Paper Separator Corona Wire 1.
Page 341: Removal Of The Paper Separator Corona Wire
Removal of the Paper Separator Corona Wire 1. Remove the End Caps from the front and rear ends of the Unit. 4002D149AA 2. Remove the four Paper Guides. 4002D151AA 3. Remove the corona wire, first at the spring end. 4002D150AA (10) Cleaning of the Image Transfer/Paper Separator Coronas Housing 1.
Page 342: Cleaning Of The Pre-Image Transfer Guide Plate
(11) Cleaning of the Pre-Image Transfer Guide Plate 1. Using a soft cloth dampened with alcohol, wipe clean the Pre-Image Transfer Guide Plate. 4002D152AA D-61...
Page 343: Fusing Unit
2-9. FUSING UNIT Disassembly of the Fusing Unit 1. Slide out the Fusing Unit. 2. Remove two screws and the Fusing Unit Front Cover. 4002D153AB NOTE When reinstalling the Front Cover, hook the tab into position. 4002D266AA 3. Remove four harness holders. 4.
Page 344 9. Remove four harness holders. 10. Remove the Upper Fusing Roller Heater Lamp har- ness from one wiring saddle. 11. Unplug two connectors of the Heater Lamp on the rear. 12. Remove the Upper and Lower Fusing Roller Heater Lamp harnesses from three edge covers. 4002D157AB 13.
Page 345 19. Remove two screws and the Web Roller Assy. 4002D162AD 20. Remove two springs. 21. Remove one shoulder screw and the Lower Exit Guide Assy. 4002D165AA NOTE When reinstalling the Upper Fusing Guide Plate Assy, press both ends of the guide plate up against the frame.
Page 346 NOTE When tightening the roller pressure screws with the springs installed, tighten the front and rear ones alter- nately until there is no clearance in the mounting bracket. 4002D167AB 24. Remove two screws and the rear holder. 4002D168AA 25. Remove two screws and the front holder. 4002D169AA 26.
Page 347 27. Remove one shoulder screw and the Pre-Fusing Guide Plate. 28. Remove two springs. 4002D172AA NOTE When reinstalling the Pre-Fusing Guide Plate, make sure that the rear harness is on the inside of the shoul- der screw. 4002D173AA 29. Remove one E-ring, two shoulder screws, and two gears.
Page 348: Removal Of The Upper Fusing Paper Separator Fingers
Removal of the Upper Fusing Paper Separator Fingers 1. Remove the Upper Fusing Guide Plate Assy. 2. Remove five springs. 3. Slide out the shaft to remove five Upper Fusing Paper Separator Fingers. 4002D177AA Cleaning of the Upper Fusing Paper Separator Fingers 1.
Page 349: Removal Of The Upper Fusing Roller Thermistor
Removal of the Upper Fusing Roller Thermistor 1. Slide out the Fusing Unit. 2. Unplug one connector. 3. Remove one screw and the Upper Fusing Roller Thermistor Assy. 4002D159AD 4. Remove one screw and the Upper Fusing Roller Thermistor. 4002D182AB Cleaning of the Upper Fusing Roller Thermistor 1.
Page 350: Cleaning Of The Lower Fusing Roller Thermistor
5. Remove the rubber stopper, and slide out the shaft. 6. Remove the Lower Fusing Roller Thermistor. 4002D185AB Cleaning of the Lower Fusing Roller Thermistor 1. Remove the Lower Fusing Roller Thermistor Assy. 2. Using a soft cloth dampened with oil, wipe the Lower Fusing Roller Thermistor clean of dirt.
Page 351: Removal Of The Web Roller
(12) Removal of the Web Roller 1. Remove the Web Roller Assy. 2. Remove two screws and the Web Roller bushing and Web Take-Up Roller bushing. NOTE When reinstalling the Web Roller bushing and Web Take-Up Roller bushing, ensure that they are in correct position without being tilt or out of correct position.
Page 352: Removal Of The Misfeed Removal Knob Bushing
(14) Removal of the Misfeed Removal Knob Bushing 1. Slide out the Fusing Unit. 2. Remove one E-ring and the gear and bearing. 4002D193AC 3. Remove the Misfeed Removal Knob Assy. and bushing. 4002D194AB (15) Removal of the Fusing Unit Drive Coupling Gear 1.
Page 353: Adjustment
ADJUSTMENT 3-1. ADJUSTMENT JIGS AND TOOLS USED 1. Front Door Interlock Switch 2. Predrive Inhibit Switch Actuating Jig Actuating Jig 1136D001AA 1136D005AA 3. Scanner Positioning Jig 4. Scanner Positioning Jig (Front) (Rear) 4002D505AA 4002D504AA 5. Sleeve/Magnet Roller 6. D.B. Adjusting Jigs Positioning Jig 1136D003AA 1074D129AA...
Page 354: Adjustment Requirements List
3-2. ADJUSTMENT REQUIREMENTS LIST Adjustment Item Requirements Ref. Page Touch Panel Adj. Automatically adjusted D-85 Orig. Size Adjust D-86 F8 ATDC Sensor D-87 F5 AIDC Sensor D-88 Registration (CD) 5.0 ± 0.5 mm D-89 Registration (FD) D-91 Lead Edge Erase 3.0 ±...
Page 355: Adjustment Of Switches
3-3. ADJUSTMENT OF SWITCHES Microswitches The following microswitches are used in various parts of this copier. Blue (NC) Yellow (NO) Red (COM) Red (COM) 1136D007AA 1136D008AA Wiring for the NO Type Wiring for the NC Type NC (Normally-Closed) : Current flows between NC and COM when the actuator is open.
Page 356: Adjustment Of Front Door Interlock Switch
Adjustment of Front Door Interlock Switch 1. Swing down the Front Door. 2. Remove the Left Cover. 3. Slide out the Fusing Unit. 4. Remove four screws and the Cover. NOTE Do not remove the belt mounting screw on the cover. 4002D196AC 5.
Page 357: Adjustment Of Belt Tension
3-4. ADJUSTMENT OF BELT TENSION Checks after Adjustment • Turn the Timing Belt and check that all the Pulleys and grooves of the Belt fit securely. • Each Belt should flex a little when the Belt is lightly pressed with a finger. Reference Since a given tension is applied by a tension spring to the Tension Lever that maintains the tension of each timing belt, adjustment is completed by re-tightening the mounting screw...
Page 358: Adjustment Of The Scanner Motor Timing Belt
7. Loosen two screws by which the Tension Lever 2 is Tension Lever 2 mounted as shown on the left and then re-tighten 4002D202AC Adjustment of the Scanner Motor Timing Belt 1. Remove the Rear Upper Cover. 2. Loosen three screws on the Scanner Motor mount- ing bracket and then re-tighten them.
Page 359: Solenoid Position Adjustment
3-5. SOLENOID POSITION ADJUSTMENT Adjustment of Manual Feed Paper Pick-Up Solenoid Requirement The Paper Stoppers should be fixed perpendicularly when the Pick-Up Solenoid is ON. Adjustment Procedure 1. Remove the Right Cover. 2. Remove five screws and the Manual Feed Paper Pick-Up Solenoid mounting bracket Assy.
Page 360 5. Move the Pick-Up Solenoid in the direction of arrow , then slowly move it in the direc- tion of arrow 6. Move the Pick-Up Solenoid up to the position where the Lock Lever of the Paper Stop- per becomes perpendicular (the position where the Paper Stopper is locked). NOTES •...
Page 361: Adjustment Of Turnover Roller Retraction Solenoid
Adjustment of Turnover Roller Retraction Solenoid Requirement The gap between the E-ring of the plunger and the Retraction Solenoid should be 3 ± 0.2 mm when the Retraction Solenoid OFF. Adjustment Procedure 1. Slide out the Fusing Unit. 2. Loosen two screws by which the Retraction Sole- noid is mounted.
Page 362: Adjustment Of Exit/Duplex Switching Solenoid
Adjustment of Exit/Duplex Switching Solenoid Requirement The gap between the E-ring of the plunger and the Switching Solenoid should be 3 ± 0.2 mm when the Switching Solenoid OFF. Adjustment Procedure 1. Remove the Left Cover. 2. Slide out the Fusing Unit. 3.
Page 363: Positioning Of The Pc Drum Paper Separator Fingers (Separator Finger Solenoid
Positioning of the PC Drum Paper Separator Fingers (Separator Finger Solenoid) Requirement The gap between the three PC Drum Paper Separator Fingers and the PC Drum should be 0.3 to 1.0 mm when the Separator Finger Solenoid OFF. NOTE Use care not to deform the Separator Fingers during the adjustment procedure. Adjustment Procedure 1.
Page 364: Adjustment Of Turnover Route Switching Solenoid
Adjustment of Turnover Route Switching Solenoid Requirement The gap between the E-ring of the plunger and the Switching Solenoid should be 3 ± 0.2 mm when the Switching Solenoid OFF. Adjustment Procedure 1. Remove the Left Cover. 2. Loosen two screws by which the Switching Sole- noid is mounted.
Page 365: Accessing The Tech. Rep. Mode And Adjust Mode
3-6. ACCESSING THE TECH. REP. MODE AND ADJUST MODE Accessing the Tech. Rep. Mode 1. Press the Utility key. 2. Touch [Meter Count]. 3. Press the following keys in this order: Stop Stop Accessing the Adjust Mode 1. Enter the Tech. Rep. mode. 2.
Page 366: Electrical/Image Adjustment
3-7. ELECTRICAL/IMAGE ADJUSTMENT Touch Panel Adj. Make this adjustment after either of the following procedures have been performed: • Memory Clear • Control Panel replacement Adjustment Procedure 1. Call the Tech. Rep. mode to the screen. 2. Touch [Tech. Rep. Choice] and [System Set], in that order. 3.
Page 367: Orig. Size Adjust
Orig. Size Adjust Make this adjustment after any of the following procedures have been performed: • Memory Clear • The original size is incorrectly detected • Replacement of the CCD Unit and Scanner parts • An Original Size Detecting Sensor has been replaced or added Adjustment Procedure 1.
Page 368: F8 Atdc Sensor
F8 ATDC Sensor Make this adjustment after any of the following procedures have been performed: • Developer replacement • ATDC replacement • Memory Clear NOTE Make this adjustment before running an F5 AIDC Sensor operation. Adjustment Procedure 1. Load the Developing Unit with fresh developer. 2.
Page 369: F5 Aidc Sensor
F5 AIDC Sensor Make this adjustment after any of the following procedures have been performed: • Developer replacement • ATDC replacement • Memory Clear NOTE This adjustment must be made after F8 ATDC Sensor. Adjustment Procedure 1. Turn the Power Switch ON. 2.
Page 370: Registration (Cd
Registration (CD) Requirement Width A on the test pattern output should fall within the following range. 1155D154AB Specification Adjust Mode Setting Range 5.0 ± 0.5 mm Registration (CD) -8.2 to +8.2 This adjustment must be made after the PH Unit has been replaced. Adjustment Procedure 1.
Page 371 7. Press the Clear key to clear the current Use to clear the setting value. setting value. Use to enter the setting value. Use to change the + or - sign. 4002D510CB 8. Use the 10-key pad to change the setting value.
Page 372: Registration (Fd
Registration (FD) Requirement Width A on the test pattern output should fall within the following range. 1155D155AB Specification Adjust Mode Setting Range 5.0 ± 0.5 mm Registration (FD) -8.2 to +8.2 This adjustment must be made after the PH Unit has been replaced. Adjustment Procedure 1.
Page 373 6. Press the Clear key to clear the current Use to clear the setting value. setting value. Use to enter the setting value. Use to change the + or - sign. 4002D510CB 7. Use the 10-key pad to change the setting value.
Page 374: Lead Edge Erase
Lead Edge Erase Requirement Width A on the test pattern output should fall within the following range. NOTE The measurement shall be taken at the center on the leading edge of the paper. 1155D156AB Specification Adjust Mode Setting Range 3.0 ± 1.0 mm Lead Edge Erase 0 to 5 This adjustment must be made after the PH Unit has been replaced and following Registra-...
Page 375 6. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 4002D519AA 7. Use the 10-key pad to change the setting value. Setting Value 4002D512CB Setting Instructions If width A is longer than the specifications, make the setting value smaller than the current one.
Page 376: Trail Edge Erase
Trail Edge Erase Requirement Width A on the test pattern output should fall within the following range. NOTE The measurement shall be taken at the center on the trailing edge of the paper. 1155D157AB Specification Adjust Mode Setting Range 3.0 ± 1.0 mm Trail Edge Erase 0 to 5 This adjustment must be made after the PH Unit has been replaced and following Registra-...
Page 377 6. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 4002D519AA 7. Use the 10-key pad to change the setting value. Setting Value 4002D513CB Setting Instructions If width A is longer than the specifications, make the setting value smaller than the current one.
Page 378: Loop Adjustment
Loop Adjustment Requirement Adjust so that a correct loop is formed at part A when paper is fed through. Specification Adjust Mode Setting Range Approx. 4.0 mm (visual) Loop Adjustment -3 to +3 This adjustment is to be made when any of the following symptoms occurs: variation in the amount of print leading edge void, paper skew, folded edge, and misfeed.
Page 379 If the loop length falls outside the specified range, perform the following adjustment steps. 4. Call the Adjust mode to the screen. 5. Touch [Printer]. 6. Touch [Loop Adjustment]. 7. Touch [Drawer]. 8. Press the Clear key to clear the current Use to clear the setting value.
Page 380: Erasure Width
(10) Erasure Width Requirement Adjust so that no shade of the Original Scale is produced on the sample copy. Adjust Mode Setting Range Erasure Width 0 to 5 This adjustment must be made when a shadow is produced from the Original Scale. Adjustment Procedure 1.
Page 381 11. Place a sheet of A3 or 11 × 17 paper on the Origi- nal Glass and lower the Original Cover. 12. Make a copy in the full size (× 1.000) mode. 13. Check to see if a shadow of the Original Scale is produced on the sample copy.
Page 382: Zoom (Cd
(11) Zoom (CD) Requirement Adjust to eliminate any difference in width between the original test pattern and a test pat- tern copy. Adjust Mode Setting Range Zoom (CD) 0.990 to 1.010 This adjustment must be made when the CCD Unit has been replaced. Adjustment Procedure 1.
Page 383 12. Call the Adjust mode to the screen. 13. Touch [IR]. 14. Touch [Zoom (CD)]. 15. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 4002D519AA 16. Use the 10-key pad to change the setting value.
Page 384: Zoom (Fd
(12) Zoom (FD) Requirement Adjust to eliminate any difference in width between the original test pattern and a test pat- tern copy. Adjust Mode Setting Range Zoom (FD) 0.990 to 1.010 This adjustment must be made when the Scanner Drive Cable has been replaced. Adjustment Procedure 1.
Page 385 12. Call the Adjust mode to the screen. 13. Touch [IR]. 14. Touch [Zoom (FD)]. 15. Press the Clear key to clear the current setting value. Use to clear the setting value. Use to enter the setting value. 4002D519AA 16. Use the 10-key pad to change the setting value.
Page 386: Scale (Cd
(13) Scale (CD) Requirement Adjust so that the leading edge of the image of the scale on the copy sample meets the requirements. Adjust Mode Setting Range Scale (CD) -10.0 to +10.0 This adjustment must be made when the CCD Unit or Original Glass has been replaced. Adjustment Procedure 1.
Page 387 10. Call the Adjust mode to the screen. 11. Touch [IR]. 12. Touch [Scale (CD)]. 13. Press the Clear key to clear the current Use to clear the setting value. setting value. Use to enter the setting value. Use to change the + or - sign.
Page 388 (14) Scale (FD) Requirement Adjust so that the leading edge of the image of the scale on the copy sample meets the requirements. Adjust Mode Setting Range Scale (FD) -7.0 to +7.0 This adjustment must be made when the Scanner has been removed the Scanner Drive Cable or Original Glass has been replaced.
Page 389 10. Call the Adjust mode to the screen. 11. Touch [IR]. 12. Touch [Scale (FD)]. 13. Press the Clear key to clear the current Use to clear the setting value. setting value. Use to enter the setting value. Use to change the + or - sign.
Page 390: Other Adjustments
3-8. OTHER ADJUSTMENTS Adjustment of the Reference Position of Each Drawer Requirement Width A on the test pattern output should fall within the following range. Specification 5 ± 0.5 mm 1155D154AB The adjustment should be made after Registration (CD/FD). Adjustment Procedure 1.
Page 391 7. Slide out the drawer used as the paper source for the test pattern and then loosen the seven screws shown on the left. 4002D250AA 8. Watching the scale on the adjustment plate in the drawer, move the Edge Guide. 4002D251AA Setting Instructions If width A on the test pattern is greater than the specifications, move the Edge Guide to the...
Page 392: Adjustment Of The Reference Position Of The Multi Bypass Tray
Adjustment of the Reference Position of the Multi Bypass Tray Requirement Width A on the test pattern output should fall within the following range. Specification 5 ± 0.5 mm 1155D154AB The adjustment should be made after Registration (CD/FD). Adjustment Procedure 1.
Page 393: Adjustment Of The Upper Right Door (Multi Bypass Unit
Adjustment of the Upper Right Door (Multi Bypass Unit) If the Right Door has been removed and reinstalled, the position of the actuator of Upper Right Door Set Sensor may deviate from the correct position. Hence, the necessity of the following adjustment.
Page 394: Adjustment Of The Position Of The Scanner And 2Nd/3Rd Mirrors Carriage
Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage Requirement With the Scanner fixed to the Scanner Drive Cables, there should be no gap between the Scanner/Mirrors Carriage Positioning Jig and the Scanner and also between the Scanner/ Mirrors Carriage Positioning Jig and the 2nd/3rd Mirror Carriage.
Page 395: Adjustment Of The 2Nd/3Rd Mirrors Carriage Assy For Parallel Alignment
5. Press the Scanner and the 2nd/3rd Mirrors Car- riage Assy tightly up against the Scanner Position- ing Jigs. 6. Check that there is no clearance between the Scanner and the Scanner Positioning Jig, and between the 2nd/3rd Mirrors Carriage Assy and the Scanner Positioning Jig.
Page 396: Adjustment Of The Gap Between The Doctor Blade And Sleeve Roller (D.b. Adjustment
Adjustment of the Gap Between the Doctor Blade and Sleeve Roller (D.B. Adjustment) Requirement The gap between the Doctor Blade and Sleeve Roller should be 0.6 + 0.03 - 0.05 mm. Adjustment Procedure 1. Slide out the Developer Unit and remove the PC Drum Charge Corona and PC Drum.
Page 397: Miscellaneous
MISCELLANEOUS 4-1. INSTALLATION OF THE KEY COUNTER SOCKET (OPTION) 1. Remove the Right Cover. 2. Remove the Counter Cover. 4002D227AA 3. Swing down the Front Door and slide out the Developer Unit. 4. Remove three screws and the cover. NOTE Do not remove the belt mounting screw on the cover.
Page 398: Mounting The Original Size Detecting Sensors (Option
4-2. MOUNTING THE ORIGINAL SIZE DETECTING SENSORS (OPTION) NOTE When an Original Size Detecting Sensor has been added, turn “ON” “Original Size Detect- ing Option” of “System Input” under the Tech. Rep. mode and make the “Orig. Size Adjust- ment.” D-86 1.
Page 399: Flash Memory
4-3. FLASH MEMORY Software has conventionally been upgraded by replacing ROM on each board. This copier employs flash memory for the system control IC mounted on the Master Board and Image Processing Board. Its contents are reprogrammed easily by performing the following steps using the IC card (memory card), into which data has been previously downloaded.
Page 400: Rewriting The Image Processing Board Data
10. Turn OFF the Power Switch. 11. Plug the power cord into the power outlet. 12. Turn ON the Power Switch. 13. Call the Tech. Rep. Mode to the screen. 14. Touch [ROM Version]. 15. Check to see if the printer version shown on the screen matches the version marked on the flash memory.
Page 401 Check Items • “Downloading Completed.” is shown. • The number shown to the left of “Language” matches that entered from the 10-Key Pad when the Power Switch is turned ON. • The Check Sum value matches the value given on the memory card.
Page 402: Rewriting The Ecc Board Data (Option
Rewriting the ECC Board Data (option) 1. Unplug the power cord from the power outlet with the Power Switch OFF. 2. Remove the Rear Cover. 3. Insert the memory card into the ECC Board. 4002D538AB 4. Plug the power cord into the power outlet. 5.
Page 403: Rewriting The Master Board, Image Processing Board, And Ecc Board (Option) Simultaneously
Rewriting the Master Board, Image Processing Board, and ECC Board (Option) Simultaneously NOTE Steps 4 and 9 are to be performed only when the ECC Board (option) is mounted. 1. With the Power Switch in the OFF position, unplug the power cord from the power out- let.
Page 404: Remounting Eeprom
4-4. REMOUNTING EEPROM NOTE If the PW Board has replaced, be sure to remount EEPROM from the old to new PW Board. If the PW Board has been replaced and EEPROM has not been remounted, be sure to replace the PC Drum with a new one. EEPROM contains no data in this case, so make entries again of numeric values given on the Adjust Label.
Page 405: Remounting Eeprom On The Image Processing Board
Remounting EEPROM on the Image Processing Board 1. Remove the Image Processing Board. 2. Remove EEPROM (IC400) from the new Image Processing Board. 3. Remove EEPROM (IC400) from old Image Processing Board and remount it onto the new Image Processing Board. 4002D254AB NOTE Note the alignment notch (A) on EEPROM (IC101)
Page 406 TROUBLESHOOTING 13430...
Page 407 CONTENTS 1. INTRODUCTION ..................... T-1 1-1. Reading the Text ..................T-1 2. I/O CHECK ...................... T-1 2-1. Controlled Parts Check Procedure ............T-1 2-2. I/O Check List ..................T-2 3. PAPER TRANSPORT FAILURE ..............T-8 3-1. Paper Misfeed ..................T-8 3-2.
Page 408 C0924: 1st Drawer Lift-Up Motor’s failure to turn ......T-53 (13) C0900: 3rd Drawer Paper Lift-Up Sensor malfunction C0904: 3rd Drawer Paper Lift-Up Motor’s failure to turn C0950: 4th Drawer Paper Lift-Up Sensor malfunction C0954: 4th Drawer Paper Lift-Up Motor’s failure to turn ....T-55 (14) C0990: Main Tray lifting motion failure C0994: Main Tray Elevator Motor’s failure to turn ......
Page 409: Introduction
INTRODUCTION 1-1. Reading the Text 1. The paper transport failure troubleshooting procedures are given according to the symptom. First identify the location where the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward.
Page 410: I/O Check List
2-2. I/O Check List <I/O Check Screens> • The following screen is only typical and the port data shown does not necessarily repre- sent the actual one. [IR] 4002T003CA <I/O Check List> [IR] Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name...
Page 411 <I/O Check Screens> • The following screens are only typical and the port data shown does not necessarily rep- resent the actual one. [Printer] Previous Screen Next Screen 4002T004CA 4002T005CB Next Previous Screen Screen 4002T006CA 4002T009CA Previous Next Next Previous Screen Screen Screen...
Page 412 <I/O Check List> [Printer] Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board PC10 In position Out of Master PJ3A-9A Drawer Set Sen- position Board Drawer (PWB-A) Take-up 1 Paper Paper not PJ3A-6A Drawer Paper present present Take-Up Sensor PC14...
Page 413 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board PC124 Lift-up Blocked Unblocked Control PJ5A-5A Drawer Lift-Up Pulse Board Drawer Motor Pulse Sensor (PWB-A) (PF- 208) PC135 Cabinet Toner Toner Collecting Out of In position PJ13A-2 Box Set Bottle Set Sensor position...
Page 414 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board PC113 LCC2 Leading Paper Leading Paper Paper not Control PJ9A-5 (PF- Edge Edge Sensor 3 present present Board 115) (PWB-A) PC142 Elev. Mtr Elevator Motor Blocked Unblocked PJ7A-5A Pulse Pulse Sensor...
Page 415 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board PC23 Univer- Paper Size Detect- Blocked Unblocked Master PJ12A-3A sal Tray ing Sensor CDA1 Board (PWB-A) PC24 Paper Size Detect- Blocked Unblocked PJ12A-6A ing Sensor CDB1 Paper Timing Synchronizing Paper...
Page 416: Paper Transport Failure
PAPER TRANSPORT FAILURE 3-1. Paper Misfeed When a paper misfeed occurs, the Touch Panel shows the corresponding message, mis- feed location, and paper location. Blinking Misfeed location Paper location 4002T011CA Display Misfeed/Paper Location Ref. Page EDH take-up EDH reverse, EDH exit See the relevant EDH transport option service...
Page 417: Misfeed Detection Sensor Layout
3-2. Misfeed Detection Sensor Layout • When PF-115 is Mounted Synchronizing Roller Paper Exit Sensor Sensor (PC1) (PC9) Transport Roller Sensor (PC2) Paper Leading Edge Sensor SW1 (PC5) Turnover Feed Entry Drawer Paper Take-Up Sensor (PC7) Sensor (PC3) Turnover Feed Jam Paper Leading Edge Sensor (PC8) Sensor SW2 (PC6)
Page 418: Types Of Misfeed Detection And Detection Timings
3-3. Types of Misfeed Detection and Detection Timings • The following lists the types of misfeed detection and detection timings for different mis- feed locations. • The symbol “L” (for the leading edge) and “T” (for the trailing edge) given in ( ) indicate the particular edge of the paper detected by the sensor.
Page 419: Duplex Paper Take-Up Misfeed
<Duplex Paper Take-Up Misfeed> Type Detection Start Detection Leading edge detection by Paper Turnover Feed Entry Sen- Paper Exit Sensor (L) Exit Sensor during turnover exit sor (T) Trailing edge detection by Paper Paper Exit Sensor (L) Paper Exit Sensor (T) Exit Sensor during turnover exit Leading edge detection by Turn- Turnover Feed Entry Sen-...
Page 420 3-4. Misfeed Troubleshooting Procedures Copier Paper Take-Up Misfeed Relevant Electrical Parts Drawer Paper Take-Up Sensor (PC3) Drawer Paper Take-Up Motor (M4) Drawer Paper Take-Up Sensor (PC4) Drawer Paper Take-Up Motor (M5) Paper Leading Edge Sensor SW1 (PC5) Upper Vertical Transport/Manual Feed Paper Leading Edge Sensor SW2 (PC6) Motor (M6) Lower Vertical Transport Motor (M7)
Page 421 Copier Paper Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage. Edge Guide and Trailing Edge Stop are at cor- Set.
Page 422 • Paper is at a stop in the Vertical Transport Section. Step Check Result Action Vertical Transport Rollers are dirty with paper Change paper. dust, deformed, or worn. Paper take-up guide plate or vertical transport Clean or change. guide plate is dirty or deformed. Change Master Board.
Page 423 Multi Bypass Misfeed Relevant Electrical Parts Transport Roller Sensor (PC2) Manual Feed Paper Pick-Up Solenoid (SL5) Manual Feed Paper Empty Sensor (PC18) Master Board (PWB-A) Upper Vertical Transport/Manual Feed Motor (M6) PWB-A CN29 PJ18 PJ2A-1(DC5V) PJ2A-2(GND) PC18 PJ2A-3(PC18 ON) CN205 PJ2A-4(DC24V) PJ2A-5(SL5 ON) PJ2A-6(SL5 OFF)
Page 424 Multi Bypass Misfeed Troubleshooting Procedures • Paper is not detected. Step Check Result Action I/O check for Manual Feed Paper Empty Sen- Change Master Board. sor operation: the voltage across PJ2A-3 on Correct actuator. Master Board and GND is DC0V when the sen- Change sensor.
Page 425 Transport/Separator Misfeed Relevant Electrical Parts Transport Roller Sensor (PC2) Suction Fan Motor (M17) Synchronizing Roller Sensor (PC1) Separator Finger Solenoid (SL4) Transport Roller Motor (M8) Master Board (PWB-A) Synchronizing Roller Motor (M9) PWB-A CN19 PJ4A-11A(DC5V) PJ4A-12A(GND) PJ4A-13A(PC2 ON) CN20 PJ4A-1B(DC5V) PJ4A-2B(GND) PJ4A-3B(PC1 ON) PJ108...
Page 426 Transport/Separator Misfeed Troubleshooting Procedures • Paper is at a stop at the Synchronizing Rollers. Step Check Result Action Synchronizing Rollers are dirty with paper Clean or change. dust, deformed, or worn. The length of the loop formed before the Syn- Adjust loop length.
Page 427 • Paper is at a stop at the Transport Rollers. Step Check Result Action Transport Rollers are dirty with paper dust, Clean or change. deformed, or worn. Transport Roller Motor turns when the Start Correct drive coupling. key is pressed. Change motor or Master Board.
Page 428 Fusing/Exit Misfeed Relevant Electrical Parts Paper Exit Sensor (PC9) Exit/Duplex Switching Solenoid (SL3) Fusing Motor (M2) Master Board (PWB-A) PWB-A PJ109 PJ7A-2A(M2 ON) PJ7A-1A(M2 LOCK) CN30 PJ9A-1A(DC5V) PJ9A-2A(GND) PJ9A-3A(PC9 ON) CN203 CN22 PJ9A-1B(DC24V) PJ9A-2B(SL3 ON) 4002C04TAA Fusing/Exit Misfeed Troubleshooting Procedures •...
Page 429 PF-208 Paper Take-Up Misfeed Relevant Electrical Parts Drawer Paper Take-Up Sensor (PC117) Drawer Paper Take-Up Motor (M122) Drawer Paper Take-Up Sensor (PC125) Drawer Paper Take-Up Motor (M123) Paper Leading Edge Sensor 3 (PC113) Vertical Transport Motor (M121) Paper Leading Edge Sensor 4 (PC118) Control Board (PWB-A): PF-208 Master Board (PWB-A) PWB-A(PF-208)
Page 430 PF-208 Paper Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage. Edge Guide and Trailing Edge Stop are at cor- Set.
Page 431 • Paper is at a stop at the Vertical Transport Rollers. Step Check Result Action Vertical Transport Rollers are dirty with paper Clean or change. dust, deformed, or worn. Paper take-up guide plate or vertical transport Clean, correct, or change. guide plate is dirty or deformed.
Page 432 PF-115 Paper Take-Up Misfeed Relevant Electrical Parts Drawer Paper Take-Up Sensor (PC117) Drawer Paper Take-Up Motor (M122) Paper Leading Edge Sensor 3 (PC113) Vertical Transport Motor (M121) Paper Leading Edge Sensor 4 (PC118) Control Board (PWB-A): PF-115 Master Board (PWB-A) PWB-A(PF-115) PJ101 PJ3A-3(W)
Page 433 PF-115 Paper Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage. Paper Lifting Plate is dirty or deformed. Clean or change.
Page 434 Duplex Paper Take-Up Misfeed Relevant Electrical Parts Turnover Feed Entry Sensor (PC7) Turnover Motor (M10) Turnover Feed Jam Sensor (PC8) Vertical Transport Motor (M121) Turnover/Exit Sensor (PC27) Duplex Unit Turnover Motor (M130) Duplex Unit Turnover Entry Sensor (PC112) Horizontal Transport Motor (M131) Turnover Feed Jam Sensor (PC131) Turnover Roller Retraction Solenoid (SL1) Horizontal Transport Entry Sensor (PC132)
Page 435 Duplex Paper Take-Up Misfeed Troubleshooting Procedures • Paper is at a stop at the turnover section. Step Check Result Action Rollers at the turnover section are dirty, Clean or change. deformed, or worn. Guide plate at the turnover section is dirty or Clean, correct, or change.
Page 436 • Paper is at a stop at the horizontal transport section. Step Check Result Action Horizontal Transport Rollers are dirty with Clean or change. paper dust, deformed, or worn. Horizontal transport guide plate is dirty or Clean, correct, or change. deformed.
Page 437: Malfunctions
MALFUNCTIONS The copier’s CPU is equipped with a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. Resetting a Malfunction • Press the Trouble Reset Switch on the Tech. Rep. Setting Switches Board to reset fusing- and Exposure Lamp-related malfunctions.
Page 438: C004E: Power Supply Unit Cooling Fan Motor 1'S Failure To Turn C004F: Power Supply Unit Cooling Fan Motor 2'S Failure To Turn
Code Description Detection Timing C004C Ventilation Fan Motor’s • The Lock signal remains HIGH for a continuous failure to turn period of 1.5 sec. or more after the lapse of 10 sec. after the motor has started turning. • The Lock signal remains LOW for a continuous period of 1.5 sec.
Page 439: C0510 Abnormally Low Fusing Temperature
Code Description Detection Timing C0500 Warming-up failure The surface temperature of the Upper Fusing Roller does not reach a specified level even after the lapse of a predetermined period of time during warming-up as detailed below: • From room temperature to 90°C: Within 180 sec. •...
Page 440: C0914: 2Nd Drawer Lift-Up Motor's Failure To Turn
Code Description Detection Timing C0910 2 Drawer Paper Lift-Up • The 2 Drawer Paper Lift-Up Sensor is not blocked Sensor malfunction (LOW) even after the lapse of 5 sec. after the 2 Drawer Paper Lift-Up Motor has started turning. • The 2 Drawer Paper Lift-Up Sensor is not acti- vated even when the 2 Drawer Paper Lift-Up...
Page 441 Code Description Detection Timing C0B00 C0B02 Transport mechanism malfunction C0B03 C0B04 C0B20 Stapling Unit drive sys- C0B21 tem malfunction C0B24 C0B30 C0B31 C0B34 Paper Aligning Mecha- nism malfunction C0B35 C0B36 C0B38 C0B48 Neat copy stack trans- port mechanism mal- function C0B49 See the relevant option service manual.
Page 442: C0D50: Duplex Horizontal Transport Motor Malfunction
Code Description Detection Timing C0BC0 C0BC1 Paper folding mechanism malfunction C0BC2 C0BC3 See the relevant option service manual. C0BF0 Control system malfunc- tion C0D50 Duplex Horizontal Trans- port Motor malfunction C0E00 Main Erase Lamp’s fail- • The Main Erase Lamp Malfunction signal remains ure to turn ON LOW for a continuous 1-sec.
Page 443 Code Description Detection Timing C1334 Duplex take-up print • A Duplex take-up print command is not received for command error the paper to be taken up from the Duplex after the paper has moved past the horizontal transport, but before it reaches the Transport Roller. •...
Page 444 4-2. Troubleshooting Procedures by Malfunction Code C0000: Fusing Motor’s failure to turn C0010: PC Drum Drive Motor’s failure to turn Relevant Electrical Parts Fusing Motor (M2) Master Board (PWB-A) PC Drum Drive Motor (M21) PWB-A PJ121 PJ7A-5A(M21 FR) PJ7A-4A(M21 LOCK) PJ7A-3A(M21 START) PJ102 PJ7A-2A(M2 LOCK)
Page 445 C0040: Suction Fan Motor’s failure to turn C004C: Ventilation Fan Motor’s failure to turn Relevant Electrical Parts Suction Fan Motor (M17) Master Board (PWB-A) Ventilation Fan Motor (M18) CN22 PWB-A CN118 PJ9A-5B(M18 LD) PJ9A-6B(GND) PJ9A-7B(DC24V) CN117 DC24V PJ13A-1B(M17 LOCK) PJ13A-2B(M17 H/L) 4002C09TAA C0040 Step...
Page 446 C0042: Fusing Unit Cooling Fan Motor’s failure to turn Relevant Electrical Parts Fusing Unit Cooling Fan Motor (M23) Power Supply Board (PWB-C) CN30 PWB-C CN123 PJ13C-1 (DC24V) PJ13C-2 (GND) PJ13C-3 (M23 LD) 4002C24TAA C0042 Step Check Result Action Fusing Unit Cooling Fan Motor rotation: the Change Power Supply voltage across PJ13C-1 on Power Supply Board.
Page 447 C0045: IR Cooling Fan Motor malfunction C0046: PH Cooling Fan Motor 1 malfunction C0047: PH Cooling Fan Motor 2 malfunction Relevant Electrical Parts PH Cooling Fan Motor 2 (M19) IR Cooling Fan Motor (M52) PH Cooling Fan Motor 1 (M22) SCP Board (PWB-IC) PWB-IC CN122...
Page 448 C0045 Step Check Result Action IR Cooling Fan Motor rotation: the voltage Change SCP Board. across PJ4IC-4 on SCP Board and GND is DC24V (during high-speed rotation) and DC12V (during low-speed rotation) after the malfunction has been reset. IR Cooling Fan Motor rotation: the voltage Change SCP Board.
Page 449 C0049: Paper source option Vertical Transport Cooling Fan Motor malfunction Relevant Electrical Parts Vertical Transport Cooling Fan Motor (M132) Control Board (PWB-A) PWB-A CN18 (CABINET) PJ14A-1(DC24V) M132 PJ14A-2(GND) PJ14A-3(M132 LOCK) 4002C27TAA C0049 Step Check Result Action Vertical Transport Cooling Fan Motor rotation: Change Control Board.
Page 450 C004E: Power Supply Unit Cooling Fan Motor 1’s failure to turn C004F: Power Supply Unit Cooling Fan Motor 2’s failure to turn Relevant Electrical Parts Power Supply Unit Cooling Fan Motor 1 Master Board (PWB-A) (M16) Power Supply Board (PWB-C) Power Supply Unit Cooling Fan Motor 2 (M15) PWB-A...
Page 451 C004F Step Check Result Action Power Supply Unit Cooling Fan Motor 2 rota- Change Master Board. tion: the voltage across PJ6A-11 on Power Supply Board and GND is DC24V after the malfunction has been reset. Power Supply Unit Cooling Fan Motor 2 rota- Check motor for installa- tion: the voltage across PJ6A-13 on Power tion.
Page 452 C0072: Main Hopper Toner Replenishing Motor’s failure to turn C0090: Developing Unit Drive Motor’s failure to turn Relevant Electrical Parts Toner Bottle Home Position Sensor (PC21) Sub Hopper Toner Replenishing Motor Developing Unit Drive Motor (M1) (M14) Main Hopper Toner Replenishing Motor Master Board (PWB-A) (M13) PWB-A...
Page 453 C0072 Step Check Result Action Toner Bottle turns when the Toner Bottle is Correct drive coupling. turned a half turn and the Front Door is closed. I/O check for Toner Bottle Home Position Sen- Change Master Board. sor operation: the voltage across PJ11A-5 on Check sensor for installa- Master Board and GND is DC5V (Toner Bottle tion.
Page 454 C0210: Image Transfer/Paper Separator Corona charge leak detected Relevant Electrical Parts PC Drum Charge/Developing Bias HV Master Board (PWB-A) (HV1) PWB-A PJ2HV1 PJ12A-4B(SCD) PJ12A-5B(Sep BIAS) PJ12A-6B(Sep REM) PJ12A-7B(Tra REM) PJ12A-8B(Dev BIAS) PJ12A-9B(Dev REM) PJ12A-10B(GRID) PJ12A-11B(C.G.REM) PJ1HV1 DC24V 4002C12TAA C0210 Step Check Result Action...
Page 455 C0400: Exposure Lamp’s failure to turn ON C0420: Exposure Lamp turning ON at abnormal timing Relevant Electrical Parts Exposure Lamp (FL51) Image Processing Board (PWB-B) Inverter Board (UN51) Power Supply Board (PWB-C) Lamp Flat Cable (PWB-IF) SCP Board (PWB-IC) UN51 FL51 CN2UN51-1 PWB-B...
Page 456 (10) C0500: Warming-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature Relevant Electrical Parts Upper Fusing Roller Heater Lamp (H1) Upper Fusing Roller Thermostat (TS1) Lower Fusing Roller Heater Lamp (H2) DC Power Supply Main (PU1) Upper Fusing Roller Thermistor (TH1) Master Board (PWB-A) Lower Fusing Roller Thermistor (TH2) CN11...
Page 457 C0500, C0510 Step Check Result Action Upper Fusing Roller Heater Lamp turns ON Correct thermistor for when the Power Switch is turned ON. mounting position and/or clean. Lower Fusing Roller Heater Lamp turns ON Check step 7 and onward. when the malfunction is reset with the surface temperature of Lower Fusing Roller Heater Lamp is 140°C or less as indicated on “Level History”...
Page 458 C0520 Step Check Result Action Upper Fusing Roller Heater Lamp is ON even Change DC Power Supply after the copier has completed warming up. Or Main. Lower Fusing Roller Heater Lamp is ON when the surface temperature of Lower Fusing Roller Heater Lamp is 140°C or more as indicated on “Level History”...
Page 459 (11) C0602: Cable unwound C0650: SHOME signal error Relevant Electrical Parts Scanner Motor (M51) Image Processing Board (PWB-B) Scanner Reference Position Sensor (PC51) SCP Board (PWB-IC) PWB-B PJ51 PJ306B-10(GND) PJ306B-9(PC51 ON) PC51 PJ306B-11(DC5V) PWB-IC PJ151 PJ3IC-1 (U) PJ3IC-2 (V) PJ3IC-3 (W) 4002C14TAB T-51...
Page 460 C0602 Step Check Result Action Scanner moves as moved manually. Correct drive coupling. Rewind cables. Connector on SCP Board is connected prop- Connect. erly: PJ3IC on PWB-IC. Scanner Motor turns when the Start key is Correct drive coupling. pressed. Change motor or SCP Board.
Page 461 (12) C0910: 2 Drawer Paper Lift-Up Sensor malfunction C0914: 2 Drawer Lift-Up Motor’s failure to turn C0920: 1 Drawer Paper Lift-Up Sensor malfunction C0924: 1 Drawer Lift-Up Motor’s failure to turn Relevant Electrical Parts Drawer Set Sensor (PC11) Drawer Set Sensor (PC10) Drawer Lift-Up Motor Pulse Sensor Drawer Lift-Up Motor Pulse Sensor (PC13)
Page 462 C0910, C0914 Step Check Result Action Correct drive coupling. Lift-Up Motor turns when the 2 Drawer is slid out and then back in. Change motor. Drawer Lift-Up Motor rotation: the voltage across PJ3A-13B on Master Board and GND is Change Master Board. DC0V (motor deenergized) and DC24V (motor energized) after the 2 Drawer has been slid...
Page 463 (13) C0900: 3 Drawer Paper Lift-Up Sensor malfunction C0904: 3 Drawer Paper Lift-Up Motor’s failure to turn C0950: 4 Drawer Paper Lift-Up Sensor malfunction C0954: 4 Drawer Paper Lift-Up Motor’s failure to turn Relevant Electrical Parts Drawer Paper Lift-Up Sensor (PC115) Drawer Paper Lift-Up Sensor (PC119) Drawer Set Sensor (PC121) Drawer Set Sensor (PC122)
Page 464 C0900, C0904 Step Check Result Action Correct drive coupling. Lift-Up Motor turns when the 3 Drawer is slid out and then back in. Change motor. Drawer Paper Lift-Up Motor rotation: the voltage across PJ5A-3B on Control Board and Change Control Board. GND is DC0V (motor deenergized) and DC24V (motor energized) after the 3 Drawer has...
Page 465 (14) C0990: Main Tray lifting motion failure C0994: Main Tray Elevator Motor’s failure to turn Relevant Electrical Parts Elevator Motor Pulse Sensor (PC142) Drawer Paper Lift-Up Sensor (PC115) Elevator Motor (M126) Drawer Paper Empty Sensor (PC116) Cabinet Transport Board (PWB-H) Lower Position Overrun Detecting Sensor Control Board (PWB-A): PF-115 (PC137)
Page 466 C0990 Step Check Result Action Change Control Board. I/O check for 3 Drawer Paper Lift-Up Sensor operation: the voltage across PJ8A-2 on Con- Change sensor. trol Board and GND is DC5V (sensor unblocked) and DC0V (sensor blocked). I/O check for Lower Position Overrun Detecting Change Control Board.
Page 467 (15) C0996: Main Tray lock release failure C0997: Shift Gate malfunction Relevant Electrical Parts Shift Gate Position Sensor (PC136) Drawer Lock Solenoid (SL112) Drawer Set Sensor (PC144) Cabinet Transport Board (PWB-H) Shift Gate Motor (M128) Control Board (PWB-A): PF-115 DC5V PWB-H PJ35 PJ1H-11B...
Page 468 C0996 Step Check Result Action Change solenoid. Drawer Lock Solenoid operation: the volt- age across PJ10A-6 on Control Board and Change Control Board. GND is DC24V (solenoid deenergized) and DC0V (solenoid energized) when the Paper Descent key is pressed and the Main Tray com- pletes its descent motion.
Page 469 (16) C0998: Shifter return failure C099C: Shift Motor’s failure to turn Relevant Electrical Parts Shifter Home Position Sensor (PC140) Shift Motor (M127) Shifter Return Position Sensor (PC141) Cabinet Transport Board (PWB-H) Shift Motor Pulse Sensor (PC143) Control Board (PWB-A): PF-115 DC5V PWB-H PJ27...
Page 470 C0998 Step Check Result Action I/O check for Shifter Return Position Sensor Change Control Board. operation: the voltage across PJ7A-7A on Con- Change sensor or Cabinet trol Board and GND is DC5V (sensor Transport Board. unblocked) and DC0V (sensor blocked). Change flat cable.
Page 471 (17) C0D50: Duplex Horizontal Transport Motor malfunction Relevant Electrical Parts Horizontal Transport Motor (M131) Control Board (PWB-A) PWB-A PJ25 (Cabinet) PJ12A-13(GND) M131 PJ12A-12(DC5V) PJ12A-10(GND) PJ12A-9(DC24V) PJ12A-8(M131 CLK) PJ12A-7(M131 LOCK) PJ12A-5(M131 REM) PJ12A-1(GND) 4002C25TAA C0D50 Step Check Result Action Horizontal Transport Motor turns when the Correct drive coupling.
Page 472 (18) C0E00: Main Erase Lamp’s failure to turn ON Relevant Electrical Parts Main Erase Lamp (LA2) Master Board (PWB-A) CN30 PWB-A PJ74 PJ9A-7A (LA2 REM) DC24V 4002C20TAA C0E00 Step Check Result Action Main Erase Lamp ON: the voltage across Change Master Board. PJ9A-7A on Master Board and GND is DC24V (lamp OFF) and DC0V (lamp ON) when the Start key is pressed.
Page 473 (19) C0F24: AIDC Sensor contamination correction failure Relevant Electrical Parts AIDC Sensor Board (PWB-G) Master Board (PWB-A) CN10 CN41 PWB-A PJ7A-5B(AIDC LED) PWB-G PJ7A-6B(GND) AIDC PJ7A-7B(AIDC OUT) 4002C21TAA C0F24 Step Check Result Action PJ7A, CN10, and CN41 are plugged securely Plug them in securely.
Page 474 (20) C0F32: ATDC Sensor malfunction C0F33: Abnormally low T/C as detected by ATDC Sensor Relevant Electrical Parts ATDC Sensor (UN2) Master Board (PWB-A) CN10 PWB-A PJ7A-8B(CONTROL) PJ7A-9B(DC24V) ATDC PJ7A-10B(OUT) PJ7A-11B(GND) 4002C22TAA C0F32, C0F33 Step Check Result Action PJ7A on Master Board, CN10, and PJ7 on the Plug them in securely.
Page 475: C10Xx To C18Xx
(21) C10XX to C18XX • These malfunctions are concerned with faulty symptoms relating to software, hardware, and communications. Code Action C10XX 1. Reset the malfunction and turn OFF and ON the Power Switch. C11XX 2. If the same malfunction persists, check cables and connectors for proper C12XX connection.
Page 476 Code Action C1401 1. Reset the malfunction. C1402 2. If the same malfunction persists, change the Image Processing Board. C1410 C1426 C1428 C1429 C142A C1430 C143E See the option service manual. C1440 1. Reset the malfunction. 2. Check that the Original Glass is properly installed. 3.
Page 477: Copier Does Not Turn On
(22) Copier does not turn ON. Relevant Electrical Parts Power Switch (S1) DC Power Supply Main (PU1) Front Door Interlock Switch (S21) DC Power Supply Sub (PU2) Upper Left Door Interlock Switch (S22) Power Supply Board (PWB-C) Main Relay (RY1) Master Board (PWB-A) •...
Page 478 Step Check Result Action Power Supply Board operation: the voltage Change Power Supply across PJ5C-3 on Power Supply Board and Board. GND is AC10V when Power Switch is turned Check Main Relay. T-70...
Page 479: Image Failure
IMAGE FAILURE 5-1. Image Failure Troubleshooting • In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting proce- dures classified by image failures.” • If any image failure has occurred, first make the initial checks, then proceed to the corre- sponding image failure troubleshooting procedure.
Page 480: Troubleshooting Procedures Classified By Image Failure
5-3. Troubleshooting Procedures Classified by Image Failure • Image Failure Samples 1. Blank copy 2. Black copy 3. Low image density 4. Foggy background 5. Black streaks or bands 6. Black spots 7. Blank streaks or bands 8. Void areas 9.
Page 481: Blank Copy
Blank copy Section Step Check Result Action Developing Unit is installed in Install correctly. position. There is drive to the Develop- Correct or change drive cou- ing Unit. pling. Image Transfer Corona wire is Install properly. installed properly. Engine Wiring between HV and Image YES Change HV.
Page 482: Low Image Density
Low image density Section Step Check Result Action Image Transfer Corona is dirty. YES Clean or change. Wiring between HV and Image Connect. Transfer Corona is connected. Developing bias contact is YES Clean or change. dirty or deformed. Engine PH lens is dirty. YES Clean.
Page 483: Black Streaks Or Bands
Black streaks or bands Section Step Check Result Action PC Drum is dirty. YES Clean or change. Cleaning Blade has correct Correct lateral movement lateral movement. mechanism. Cleaning Blade is curled YES Change. upward or deteriorated. Engine Comb Electrode and grid YES Clean or change.
Page 484: Blank Streaks Or Bands
Blank streaks or bands Section Step Check Result Action PC Drum is scratchy and dirty. YES Clean or change. PC Drum Paper Separator YES Clean of change. Fingers are dirty or deformed. PC Drum is properly Clean or change PC Drum grounded.
Page 485: Smear On Back
(10) Smear on back Section Step Check Result Action Suction Belts are dirty. YES Clean. Image Transfer Corona is dirty. YES Clean. Image Transfer Guide Plate is Clean. dirty. Engine Pre-Fusing Guide Plate is YES Clean. dirty. Fusing Rollers are dirty. YES Clean or change.
Page 486: Rough Image
(13) Rough image Section Step Check Result Action Foreign matter and caked YES Remove foreign matter and toner inside Developing Unit caked toner. Change devel- and DB. oper. Image Transfer Corona wire is YES Clean or change. Engine dirty or deteriorated. Wiring between HV and Image YES Change HV.
Page 487: Resetting The Maintenance Code Display
RESETTING THE MAINTENANCE CODE DISPLAY 6-1. Details of Maintenance Codes Code Description The count of “Waste Toner” of the Consumables counter reaches a predeter- mined value before the setting value. The count of “Web” of the Consumables counter reaches the setting value. 6-2.
Page 500 CN No. LOCATION GRID CN No. LOCATION GRID 32-A 7-I~J CN206 CONNECTORS LAYOUT Suction Unit CN10 5-D~E CN210 10-J CN11 2~3-A~B CN211 10-J CN12 32-B CN212 13-L CN13 32-C CN215 26-A CN216 CN14 32-D CN216 13-B CN17 26-E CN217 11-I CN119 CN18 26-F...
Page 501 SYMBOL PART NAME LOCATION GRID SYMBOL PART NAME LOCATION GRID CNT1 Total Counter PC21 Toner Bottle Home Position Sensor 4~5-B 14-D ELECTRICAL PARTS LAYOUT Suction Unit CNT2 Key Counter (OPTION) — PC23 Paper Size Detecting Sensor CDA1 26-F~G FL51 Exposure Lamp 17-F 4~5-H PC24...

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Di550

Minolta Di450 Service Manual

General

Mechanical/ Electrical

I Nstallation

Switches on Pwbs, Tech. Rep. Settings

Dis/Reassembly, Adjustment

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Troubleshooting

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