Minolta Di152 Service Manual
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Minolta Di152 Service Manual

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Service Manual

[Field Service]
Di152/Di183

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Summary of Contents for Minolta Di152

  • Page 1: Service Manual

    Service Manual [Field Service] Di152/Di183...
  • Page 2 INDEX (FIELD SERVICE) SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE DIS/REASSEMBLY, ADJUSTMENT SWITCHES ON PWBs, TECH. REP . SETTINGS TROUBLESHOOTING...
  • Page 3 SAFETY PRECAUTIONS FOR INSPECTION AND SERVICE • When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. Depending on the model, some of the precautions given in the following do not apply. • Different markings are used to denote specific meanings as detailed below. Indicates a potentially hazardous situation which, if not avoided, WARNING could result in death or serious injury.
  • Page 4 3. Do not throw toner or the toner bottle into a fir. • Do not throw toner or the toner bottle (Imaging Cartridge) into a fire. Toner expelled from the fire may cause burns. 4. Use the specified parts. • For replacement parts, always use the genuine parts specified in the manufac- turer’s parts manual.
  • Page 5 11. Restore all parts and harnesses to their original positions. • To promote safety and prevent product damage, make sure the harnesses are returned to their original positions and properly secured in their clamps and sad- dles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed.

  • Page 6: Other Precautions

    3. Precautions for the Working Environment. • The product must be placed on a flat, level surface that is stable and secure. • Never place this product or its parts on an unsteady or tilting workbench when servicing. • Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time.
  • Page 7 1-4. 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 gleichwertigen Typ.
  • Page 8 1-5. 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. 1. Precautions Before Service •...
  • Page 9 4. 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 10 6. Handling of PWBs < 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 11 8. Handling of the PC Drum Only for Products Not Employing an Imaging Cartridge. < 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 12 C. 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 13 DIS/REASSEMBLY, ADJUSTMENT 10230...

  • Page 14: Table Of Contents

    CONTENTS 1. SAFETY INFORMATION ................. D-1 1-1. LASER SAFETY ..................D-1 1-2. INTERNAL LASER RADIATION .............. D-1 1-3. LASER SAFETY LABEL ................D-4 1-4. LASER CAUTION LABEL ................ D-4 1-5. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ....D-4 2. SERVICE INSTRUCTIONS ................D-5 2-1.
  • Page 15 (3) Application of Toner ................. D-34 (4) Replacement of the ATDC Sensor ..........D-35 3-8. IMAGE TRANSFER SECTION ..............D-36 (1) Removal of the Image Transfer Roller Assy ........D-36 (2) Cleaning of the Pre-Image Transfer Lower Guide Plate ....D-36 (3) Cleaning of the Charge Neutralizing Plate ........
  • Page 16 (1) Remounting the EEPROM (U29) ............. D-68 (2) Installation of the Plug-In Counter Socket (Option) ......D-69 (3) Installation of the Mechanical Counter (Option) ......D-70...

  • Page 17: Safety Information

    SAFETY INFORMATION 1-1. LASER SAFETY • This is a digital machine certified as a class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual. 1-2. INTERNAL LASER RADIATION Semiconductor laser Maximum average radiation power(*)
  • Page 18 the U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class I Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
  • Page 19 Finland, Sweden VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle. Puolijohdelaser Laserdiodin suurin teho 5 mW Aallonpituus 770-795 nm...

  • Page 20: Laser Safety Label

    1-3. LASER SAFETY LABEL • A laser safety labels is attached to the outside of the machine as shown below. Laser safety label For Europe CLASS 1 LASER PRODUCT LASER KLASSE 1 PRODUCT 1155O764AA For United States 4002O312CA 4022D038CA 1-4. LASER CAUTION LABEL •...

  • Page 21: Service Instructions

    SERVICE INSTRUCTIONS 2-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS Control Board (PWB-C) Thermoswitch 1 (TS1) 125 V 3 A 250 V 7.5 A/125 V 15 A DC Power Supply (PU1) 4022D028AA 100 V system 125 V 15 A (F2) 200 V system 250 V 6.3 A (F2)

  • Page 22: Parts Which Must Not Be Touched

    2-2. PARTS WHICH MUST NOT BE TOUCHED Red Painted Screws Purpose of Application of Red Paint Red painted screws show that the assembly or unit secured can only be adjusted or set at the factory and shall not be readjusted, set, or removed in the field. If it becomes unavoidably necessary to disassemble any of these assemblies and units, disassembly may be done provided that the conditions permitting reassembly are met.

  • Page 23: Disassembly/Reassembly

    DISASSEMBLY/REASSEMBLY 3-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES...
  • Page 24 Part Name Removal Procedure Original Cover Pull the Original Cover straight up. Remove no. 18. → Remove two holding brackets or no. 11 and Original Glass the Original Glass. Remove two control panel mounting screws. → Remove two ground wire mounting screws. → Remove one flat cable and Control Panel unplug one connector.

  • Page 25: Removal Of Circuit Boards And Other Electrical Components

    3-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPONENTS • When removing a circuit board or other electrical component, refer to “PRECAUTIONS FOR HANDLING THE 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 26: Removal Of The Master Board

    Symbol Part Name Removal Procedure PWB-A Master Board D-10 PWB-C Control Board D-11 Remove the Rear Cover. → Remove the PWB Assy. → Paper Size Detecting PWB-I Remove two screws and the PWB-I Assy. → PWB-I Board D-23 PWB-J CCD Board Remove the CCD Unit as a unit.

  • Page 27: Removal Of The Control Board

    3. Unplug all connectors (but PJ20) from the Master Board. 4. Remove four screws and the Master Board. Removal of the Control Board 1. Remove the Rear Cover. 2. Remove the PWB Cover Assy. 3. Unplug all connectors from the Control Board. 4.
  • Page 28 5. Unplug three connectors from the High Voltage Unit and remove the harness from one wiring saddle. 6. Remove the harness from one wiring saddle. 7. Remove ten screws and the PWB Assy. 8. Remove the harness from one wiring saddle of the High Voltage Unit cover.

  • Page 29: Removal Of The Dc Power Supply

    9. Remove nine screws and the High Voltage Unit cover. 10. Unplug two connectors from the High Voltage Unit. 11. Remove two screws and the High Voltage Unit. Removal of the DC Power Supply 1. Remove the control panel, Front Cover, Rear Cover, Left Cover, and Upper Cover. 2.
  • Page 30 6. Remove four screws and the Power Supply Left Cover. 7. Unplug one connector and remove the harness from one edge cover. 8. Unplug one connector and remove the harness from one wiring saddle. 9. Unplug one connector and remove the harness from one wiring saddle.
  • Page 31 11. Remove two screws. 12. Remove two screws. 13. Remove four screws and the DC Power Supply. D-15...

  • Page 32: Maintenance Schedule

    3-3. MAINTENANCE SCHEDULE D-16...
  • Page 33 D-17...

  • Page 34: Paper Take-Up/Transport Section

    3-4. PAPER TAKE-UP/TRANSPORT SECTION Removal of the Paper Separator Roll Assy and Paper Take-Up Roll 1. Slide out the 1st Tray. 2. Remove two screws and the Paper Separator Roll Assy. 3. Press down the Paper Lifting Plate. 4. Snap off one C-clip from the Paper Take-Up Roll Assy.

  • Page 35: Cleaning Of The Right And Left Synchronizing Rollers

    Cleaning of the Right and Left Synchronizing Rollers 1. Remove the Imaging Unit. 2. Using a soft cloth dampened with alcohol, wipe the Right and Left Synchronizing Rollers clean of dirt. Removal of the Paper Dust Remover Assy 1. Remove the Imaging Unit. 2.

  • Page 36: Cleaning Of The Paper Dust Remover

    Cleaning of the Paper Dust Remover 1. Remove the Paper Dust Remover Assy. 2. Using a brush, whisk dust and dirt off the Paper Dust Remover. Cleaning of the Bypass Transport Roller 1. Remove the Imaging Unit. 2. Remove two screws, unplug one connector, and remove the Bypass Transport Roller Assy.

  • Page 37: Optical Section

    3-5. OPTICAL SECTION Cleaning of the Original Glass and ADF Glass 1. Using a soft cloth dampened with alcohol, wipe the Original Glass and ADF Glass clean of dirt. Cleaning of Mirrors 1. Remove the Original Glass. 2. Using a soft cloth dampened with alcohol, wipe the mirrors clean of dirt.

  • Page 38: Cleaning Of The Ccd Sensor

    3. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt. Cleaning of the CCD Sensor 1. Remove the Original Glass. 2. Remove 15 screws and the CCD Unit cover. 3. Remove the Lens cover. 4. Using a soft cloth dampened with alcohol, wipe the CCD Sensor clean of dirt.

  • Page 39: Removal Of The Ccd Unit

    Removal of the CCD Unit 1. Remove the Original Glass. 2. Remove 15 screws and the CCD Unit cover. 3. Unplug one connector. 4. Remove three screws and the CCD Unit. NOTE • NEVER attempt to loosen or remove screws that are not specified when removing the CCD Unit.
  • Page 40 3. Remove two Scanner mounting screws (to which no red paint has been applied). 4. Remove one screw and the cable holder. 5. Remove the flat cable from the Inverter Board and then remove the Scanner. 6. Unplug one connector from the Inverter Board. 7.

  • Page 41: Removal Of The Scanner Drive Cables

    Removal of the Scanner Drive Cables 1. Remove the control panel, Front Cover, Rear Cover, Left Cover, Right Cover, Original Glass, and ADF Glass. 2. Remove the Scanner. NOTE • Remove the two red painted screws to remove the Scanner in this step. 3.
  • Page 42 7. Remove the rear cable from the cable pulley. 8. Snap off one C-ring from the front side of the pul- ley assy. 9. Snap off one C-ring from the rear side of the pul- ley assy. 10. Remove the belt and the pulley assy. 11.

  • Page 43: Winding Of The Scanner Drive Cables

    Winding of the Scanner Drive Cables Rear Front 4022D003AA 1. Wind the cable around the rear cable pulley of the pulley assy from side B toward side A and then secure the cable with tape. 2. Wind the cable around the front cable pulley of the pulley assy from side A toward side B and then secure the cable with tape.
  • Page 44 4. Mount the pulley assy using two C-rings. 4022D006AB 5. Wind the cable at the front. 6. Hook the spring onto the cable hook and hook the spring onto the frame. 4022D007AB 7. Wind the cable in the rear. 8. Secure the cables at the front and rear with a spring. 4022D008AB 9.

  • Page 45: Removal Of The Ph Unit

    3-6. Removal of the PH Unit 1. Remove the control panel, Front Cover, Rear Cover, Left Cover, and Upper Cover. 2. Remove the PWB Cover Assy. 3. Remove one flexible harness and unplug one connector from the Master Board. 4. Remove the harness from one edge cover and one wiring saddle.

  • Page 46: Imaging Unit (Iu

    3-7. Imaging Unit (IU) NOTE • When loading developer as part of the IU replacement procedure or when changing the developer, remove the Toner Bottle and run “ATDC Sensor Automatic Adjustment” (F8) twice to allow toner in the Spent Toner Recycling Duct and Toner Conveying Duct into the Developer Mixing Chamber before removing the IU.
  • Page 47 3. Remove two screws at the front of the IU. 4. Widen flaps on both ends (marked with A in the illustration on the left) of the Cleaning Assy in the direction of arrow and turn to take off the Clean- ing Assy.
  • Page 48 9. Remove the Ozone Filter. <Removal of the PC Drum Charge Corona Assy> 10. Turn the holder in the rear in the direction of the arrow to remove it from the side bracket. 11. Slide out the PC Drum Charge Corona in the direction of the arrow.
  • Page 49 <Cleaning of the Ds Collars> 14. Using a soft cloth dampened with alcohol, wipe the Ds Collars clean of dirt. <Cleaning of the Developer Scattering Prevention Plate> 15. Remove three screws and the Developer Scatter- ing Prevention Plate. 16. Using a brush, whisk dust and dirt off the surface of the Developer Scattering Prevention Plate.

  • Page 50: Application Of Toner

    18. Pour one packet of developer. NOTE • Shake the packet of developer well before pouring. • When the developer has been replaced, run “ATDC Sensor Automatic Adjustment.” D-61 <Cleaning of the Pre-Image Transfer Guide Plate> 19. Using a soft cloth dampened with alcohol, wipe the Pre-Image Transfer Guide Plate clean of dirt.

  • Page 51: Replacement Of The Atdc Sensor

    <<Area to which toner is to be applied>> 10 - 15 mm 20 - 25 mm PC Drum 4021U057AA 3. Hold both ends of the PC Drum with your both hands and turn the PC Drum a half turn in the direction of the arrow.

  • Page 52: Image Transfer Section

    3-8. IMAGE TRANSFER SECTION Removal of the Image Transfer Roller Assy 1. Open the Right Door. 2. Loosen one fixing bracket mounting screw. 3. Turn to remove the Pre-Image Transfer Upper Guide Plate. NOTE • When reinstalling the fixing bracket, make sure that the hook of the fixing bracket fits into the slot in the Pre-Image Transfer Upper Guide Plate.

  • Page 53: Fusing Section

    3-9. FUSING SECTION Removal of the Fusing Unit 1. Remove the control panel. NOTE • In this step, free the control panel without removing one flat cable and two ground wires and unplugging one connector. 2. Remove the Front Cover, Rear Cover, and Rear Right Cover. 3.
  • Page 54 <Removal of the Right Fusing Roller> 2. Unhook the pressure springs at the front and rear. 3. Remove two shoulder screws, two washers, and the Right Roller Assy. 4. Remove the Right Roller. <Removal of the Fusing Heater Lamp> 5. Remove the Pressure Lever Assemblies at the front and rear.
  • Page 55 7. Remove the harness in the rear of the Heater Lamp from the cover. 8. Remove the thermistor harness from the cover. 9. Remove one mounting screw from the front of the Heater Lamp. 10. Remove one screw and the cover. NOTE •...
  • Page 56 <Left Fusing Roller> 13. Snap off one retaining ring. 14. Unhook the spring in the rear of the Guide Assy. 15. Unhook the spring at the front of the Guide Assy. 16. Remove the Guide Assy. NOTE • When removing and reinstalling the Guide Assy, use care not to allow the sensor lever spring to be unhooked.
  • Page 57 20. Snap off the retaining ring at the front of the Left Fusing Roller and remove the washer and bush- ing. 21. Snap off the retaining ring in the rear of the Left Fusing Roller and remove the gear. 22. Remove the collar. 23.

  • Page 58: 3-10.Multiple Bypass (Mb-5): Option

    3-10. MULTIPLE BYPASS (MB-5): OPTION Removal of the Separator Roll Assy 1. Open the Right Door. 2. Remove two screws and the Separator Roll Assy. Removal of the Paper Take-Up Roll 1. Remove two screws and the cover. 2. Remove the harness from one cord clamp. 3.
  • Page 59 4. Unplug two connectors. 5. Remove four screws and the Multiple Bypass. <<Multiple Bypass Installation Procedure>> Temporarily secure the Multiple Bypass using four screws. Install the positioning pin at the location shown in the illustration. (Use the positioning pin furnished as an acces- sory with the Multiple Bypass.) Close the Right Door and correctly position the Multiple Bypass using the positioning pin.
  • Page 60 6. Remove four screws and the Paper Take-Up Assy. 7. Snap off one C-ring and remove the gear. 8. Snap off one C-ring. 9. Snap off one C-ring and remove the Paper Take- Up Roll Assy. 10. Snap off one C-ring and remove the roll. D-44...

  • Page 61: Cleaning Of The Separator Roll/Paper Take-Up Roll

    11. Snap off one C-ring and one C-clip and remove the paper Take-Up Roll. Cleaning of the Separator Roll/Paper Take-Up Roll 1. Open the Right Door. 2. Remove two screws and the Separator Roll Assy. NOTE • When attempting to reinstall the Separator Roll Assy, try to move the assy in the direction of the arrow.

  • Page 62: 3-11.Job Tray (Js-202): Option

    3-11. JOB TRAY (JS-202): OPTION Removal of the Main Board 1. Remove the control panel, Front Cover, Rear Cover, Right Cover, and Right Inside Cover. 2. Remove two screws and the fan cover. 3. Remove one screw and the Mechanical Counter (if the copier is so equipped).
  • Page 63 8. Unplug one connector and remove the harness from one edge cover. 9. Remove two screws and the PWB Assy. 10. Unplug four connectors. 11. Remove two screws, two PWB Supports, and the Main Board. D-47...

  • Page 64: Paper Detecting Board

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

  • Page 65: 3-12.Shifting Unit (Ot-103): Option

    3-12. SHIFTING UNIT (OT-103): OPTION Removal of the Main Board 1. Remove the control panel, Front Cover, Rear Cover, Right Cover, and Right Inside Cover. 2. Remove two screws and the fan cover. 3. Remove one screw and the Mechanical Counter (if the copier is so equipped).
  • Page 66 8. Remove two screws and the Main Board Assy. 9. Unplug two connectors. 10. Remove two screws, two PWB Supports, and the Main Board. D-50...

  • Page 67: Adjustment

    ADJUSTMENT 4-1. ADJUSTMENT JIGS AND TOOLS USED <Scanner/Mirrors Carriage Positioning Jigs> <Ds Collar Positioning Jigs> 4022D010AA 4022D011AA <Db Gap Adjusting Jigs> <PC Positioning Jig> 4022D012AA 4022D030AA 4-2. TIMING BELT TENSION ADJUSTMENT <Scanner Motor Timing Belt Adjustment> 1. Loosen three screws and move the Scanner Motor Assy to the right or left to give tension to the spring.

  • Page 68: Accessing The Function, Tech. Rep. Choice, And Adjust Mode

    4-3. ACCESSING THE FUNCTION, TECH. REP. CHOICE, AND ADJUST MODE Function Mode 1. Press the Meter Count key. 2. Press the following keys in this order: Stop → 0 → 0 → Stop → 0 → 1. 3. Enter the code number “1” from the 10-Key Pad. 4.

  • Page 69: Electrical/Image Adjustment

    4-4. ELECTRICAL/IMAGE ADJUSTMENT Edge Erase Adjustment (Leading, Trailing, and Top/Bottom Edges) Requirement • Adjust the erase width on the leading edge (width A), trailing edge (width B), and the top/bottom edge (width C). Default Setting: 4 mm 4022D503AA Mode Code No. Setting Range 5 (leading edge) Tech.

  • Page 70: Loop Length Adjustment (1St And 2Nd Trays, Bypass Tray

    Loop Length Adjustment (1st and 2nd Trays, Bypass Tray) Requirement • Adjust so that a loop of an adequate length is formed in the paper before the Synchroniz- ing Roller as the paper is being fed through the copier. Mode Code No.

  • Page 71: Printer Cd Registration Adjustment

    Printer CD Registration Adjustment Requirement • Adjust so that width A on the test print produced falls within the specified range. 4686D504AA Specifications Mode Code No. Setting Range A4C: 20 ± 2.0 mm; 60 to 140, Adjust 8-1/2 × 11C: 11.2 ± 2.0 mm 1 step: 0.1 mm NOTES •...

  • Page 72: Printer Fd Registration Adjustment

    Printer FD Registration Adjustment Requirement • Adjust so that width B on the test print produced falls within the specified range. 4022D502AA Specifications Mode Code No. Setting Range 67 to 133, 1 step: 10 ± 1.5 mm Adjust Approx. 0.19 mm NOTES •...

  • Page 73: Scanner Cd Registration Adjustment

    Scanner CD Registration Adjustment Requirement • Adjust so that the deviation between width A on the test print and that on the copy falls within the spec- ified range. 4686D504AA Specifications Mode Code No. Setting Range 20 to 180, 0 ± 2.0 mm Adjust 1 step: 0.1 mm NOTES...

  • Page 74: Scanner Fd Registration Adjustment

    Scanner FD Registration Adjustment Requirement • Adjust so that the deviation between width B on the test print and that on the copy falls within the spec- ified range. 4022D502AA Specifications Mode Code No. Setting Range 60 to 140, 0 ± 1.5 mm Adjust 1 step: 0.1 mm NOTES...

  • Page 75: Scanner Cd Zoom Adjustment

    Scanner CD Zoom Adjustment Requirement • Adjust so that the amount of error falls within ±1.0 % of the length to be measured. • Adjust so that the following specifications are met when the length of the scale is 200 Zoom Ratio Specifications Mode...

  • Page 76: Scanner Fd Zoom Adjustment

    Scanner FD Zoom Adjustment Requirement • Adjust so that the amount of error falls within ±1.0 % of the length to be measured. • Adjust so that the following specifications are met when the length of the scale is 300 Zoom Ratio Specifications Mode...

  • Page 77: Atdc Sensor Automatic Adjustment (F8

    ATDC Sensor Automatic Adjustment (F8) NOTES • This adjustment is made when the developer has been replaced. • Make this adjustment with the Toner Bottle removed from the copier. <Adjustment Procedure> 1. Enter the Function mode. 2. With “F-” shown on the Display, enter the code number “8” from the 10-Key Pad to set the copier into the “ATDC Sensor Automatic Adjustment”...

  • Page 78: (10) Manual Bypass Registration Adjustment

    (10) Manual Bypass Registration Adjustment Requirement • Adjust so that the deviation between width A on the test print and that on the copy falls within the spec- ified range. Specifications: 0 ± 2.0 mm 4686D504AA NOTES • This adjustment is made when the PH Unit has been replaced and after “Printer Regis- tration Adjustments (CD and FD)”...

  • Page 79: (11) Multiple Bypass Registration Adjustment (Mb-5): Option

    (11) Multiple Bypass Registration Adjustment (MB-5): Option Requirement • Adjust so that the deviation between width A on the test print and that on the copy falls within the spec- ified range. Specifications: 0 ± 2.0 mm 4686D504AA NOTES • This adjustment is made when the Multiple Bypass has been removed. •...

  • Page 80: Other Adjustments

    4-5. OTHER ADJUSTMENTS Adjustment of the Position of the Scanner and 2nd/3rd Mirrors Carriage 1. Fit the Scanner/Mirrors Carriage Positioning Jigs in the space between the Scanner and the 2nd/ Rear 3rd Mirrors Carriage. 4022D013AA 2. Press the 2nd/3rd Mirrors Carriage tightly up 2nd/3rd Mirrors Carriage against the jigs.

  • Page 81: Ccd Unit Position Adjustment

    CCD Unit Position Adjustment NOTE • This adjustment is made when the CCD Unit has been replaced. <Adjustment Procedure> 1. Place a scale on the Original Glass in parallel with the Original Width Scale and make a copy. 2. Measure the length of the scale on the copy. Requirement •...

  • Page 82: Adjustment Of The Gap Between The Doctor Blade And Sleeve Roller (Db Adjustment

    Adjustment of the Gap between the Doctor Blade and Sleeve Roller (Db Adjust- ment) Requirement • The gap between the Doctor Blade and the Sleeve Roller should be 0.39 ± 0.04 mm (as set using the jigs). <Adjustment Procedure> 1. Remove the IU. 2.
  • Page 83 10. Install the Db Gap Adjusting Jigs in a space between the Sleeve Roller and Doctor Blade. 4022D021AB 11. Put the Developing Assy and Cleaning Assy together. 12. Press the Doctor Blade tightly up against the Db Gap Adjusting Jigs and, keeping that position, tighten the screws in the order of at the front, at the center, and...

  • Page 84: Miscellaneous

    4-6. MISCELLANEOUS Remounting the EEPROM (U29) NOTE • When the Control Board (PWB-C) is replaced with a new one, EEPROM (U29) must be demounted from the old PWB-C and remounted on the new PWB-C. Remove the EEPROM (U29) from the new Control Board and mount the EEPROM (U29) of the old Control Board to the new Control Board.
  • Page 85 Installation of the Plug-In Counter Socket (Option) 1. Cut out the knockout from the Right Cover. 4022D023AA 2. Using two screws, secure the counter mounting bracket. 4022D024AA 3. Connect the Plug-In Counter Socket connector. 4. Using two screws, secure the counter socket. 4022D025AA 5.
  • Page 86 Installation of the Mechanical Counter (Option) 1. Remove the control panel, Front Cover, Rear Cover, and Right Cover. 2. Cut out the knockout from the Right Cover. 4021D001AA 3. Using one screw, secure the Mechanical Counter to its mounting bracket. 4021D002AA 4.
  • Page 87 SWITCHES ON PWBs, TECH. REP. SETTINGS 17196...
  • Page 88 CONTENTS 1. CONTROL PANEL KEYS AND TOUCH PANEL ..........S-1 1-1. Control Panel Keys .................. S-1 2. UTILITY MODE ....................S-4 2-1. Settings in the Utility Mode ..............S-4 2-2. Utility Mode Setting Procedure ..............S-4 (1) User’s Choice Mode (Display: U-1) ..........S-4 (2) Drum Dehumidify Mode (Display: U-2) ..........

  • Page 89: Control Panel Keys And Touch Panel

    CONTROL PANEL KEYS AND TOUCH PANEL 1-1. Control Panel Keys 4021S002CA Metric area 12 13 14 15 16 4021S003CA Inch area 4021S001CA...
  • Page 90 Name Description Printer Lamp Lit while data received from personal computer is being printed Job Input key Press to select the Job Input mode. Two different jobs can be programmed. Meter Counter key Press to display the Total Counter or Size Counter value. Neg.↔...
  • Page 91 Name Description 24 Clear key Press to reset the number of copies to “1”. 25 Stop key • Press to stop a print cycle. • Press to stop a scanning sequence. 26 Start key • Press to start a scanning sequence. •...

  • Page 92: Utility Mode

    UTILITY MODE • Utility Mode is used to make various settings according to the user’s need. 2-1. Settings in the Utility Mode Code No. Description User’s Choice Mode Drum Dehumidify Mode Toner Replenisher Mode Custom Size Input Mode Administrator Mode 2-2.
  • Page 93 2. User’s Choice Mode Setting Procedure <Procedure> 1. Hold down the Panel Reset key for 3 seconds. 2. Enter “1” from the 10-Key Pad. (Display: U-1) 3. Press the Start key. 4. Enter the corresponding code number from the 10-Key Pad. 5.
  • Page 94 Code No. Setting (The default is Highlighted <Density Priority> Select the priority exposure mode selected when the Power Switch is turned ON or Panel Reset key pressed. Setting Description Auto Manual Photo Manual <Density Level (Auto)> Select the priority exposure level in the Auto Exposure mode. Setting Description Lighter...
  • Page 95 Code No. Setting (The default is Highlighted <Margin Setting> Adjust the margin width for the File Margin copy. Setting 0 ............20 Description (mm) 0 <Erase Setting (Left)> Adjust the erase width for the Left Erase copy. Setting 5 ............
  • Page 96 Code No. Setting (The default is Highlighted <Density ADF> Adjust the copy image density level when the ADF is being used. Setting Description When the standard original (text, etc.) is used. To give better reproduction of faint original. <Priority Density> Set the image density level for printing Setting Description Lighter.
  • Page 97 Code No. Setting (The default is Highlighted <Special Paper Setting> Allow Paper of same type to be fed from another tray when paper from one source is empty. Setting Description Enables Auto Paper (selection). Enables Auto Tray C28 to 33 Switching.
  • Page 98 Administrator Mode (Display: U-5) • The entry on the “Administrator No. Input” set using the Tech. Rep. Mode permits the set- tings of the following functions. 1. Administrator Mode Function Setting Procedure <Procedure> 1. Hold down the Panel Reset key for 3 seconds. 2.
  • Page 99 3. Setting in the Administrator Mode Code No. Setting (The default is Highlighted <Administrator Mode> Allows for setting two functions, “Copy Track” and “Disable Auto Shut OFF.” <Copy Track> Allows for making the six different subfunctions. <Disable Auto Shut OFF> Select whether to allow the option “0”...
  • Page 100 Code No. Setting (The default is Highlighted <Delete Account> Delete an account (access number) which has previously been stored. <Procedure> 1. Enter “3” from the 10-Key Pad. (Display: A-3) 2. Press the Start key. This will blank out the Display. If no accounts are yet to be programmed, the contents of the Dis- play alternate between “A-3”...

  • Page 101: Tech.rep.mode

    TECH.REP.MODE • This mode allows the Tech. Rep. to set adjust, and/program various service functions. 3-1. Tech.Rep.Mode Menu Function Tree ---0: Control Panel LED Check F-1 : Paper Passage Test F-2 : HV Output ---1: Function “F- ” F-8 : ATDC Sensor Automatic Adjustment F12: Test Pattern Output c-1 : Maintenance Counter Count c-2 : IU Life Stop...

  • Page 102: Tech.rep.mode Function Setting Procedure

    ---8: Change Fixed Zoom ---9: Marketing Area Setting -10: Memory Clear “CLr” ---: Tech.Rep.Mode -11: Total Clear “tCL” -12: ADF Document Passage Test “doc” -13: ADF Original Glass Check “AdF” -14: Scanner Drive Check “ccd” -20: Serial No. Display “Sn” 3-2.

  • Page 103: Setting In The Tech.rep.mode

    3-3. Setting in the Tech.Rep.Mode Control Panel LED Check • The LEDs on the control panel are made to blink to check for any LED that has burned out. Any LED that is not blinking is considered to be out. Function •...

  • Page 104: Tech.rep.choice

    Tech.Rep.Choice • This function allows the Tech. Rep. to make various settings and adjustments. <Procedure> 1. Enter the code number corresponding to the function to be used from the 10-Key Pad. 2. Press the Start key to display the current setting value. 3.
  • Page 105 Code No. Setting (The default is Highlighted <Leading Edge Erase Adjustment> Select whether to enable or disable the leading edge erase. Setting Description (mm) <Trailing Edge Erase Adjustment> Select whether to enable or disable the trailing edge erase. Setting Description (mm) <Top/Bottom Edge Erase Adjustment>...

  • Page 106: Counter Mode

    Counter Mode • Shows the number of copies made on each paper size or type. <Procedure> 1. Enter the code number corresponding to the function to be used from the 10-Key Pad. 2. Press the Start key to show the count. If the count consists of 4 or more digits, it is displayed in two groups alternately as fol- lows.

  • Page 107: Setting

    Code No. Setting <IU Life Counter> Show the count of the IU Life Counter. The count is based on a countdown system and, if counting continues after “0,” a minus sign (-) is appended to the value shown on the Dis- play.

  • Page 108: Description (Mm)

    Code No. Setting <Trouble Counter> Counts the number of malfunctions that have occurred at different parts of the copier. If all malfunction counters are “0,” “ALL” and “0” alternate. Display Description Main Motor malfunction Fusing Cooling Fan Motor malfunction Power Supply Cooling Fan Motor malfunction Toner Replenishing Motor malfunction Faulty image transfer voltage Warm-up failure...

  • Page 109: Atdc Sensor Output

    ATDC Sensor Output • This function displays a T/C ratio representing the current ATDC Sensor output value. • It is used for checking the T/C when image density is not good. It is not possible to change or reset the sensor output data. <Exiting the Mode>...

  • Page 110: Administrator No. Input

    Administrator No. Input • Set an ID number for opening the “Administrator Mode” screen of Utility Mode from the 10-Key Pad. <Procedure> 1. Press the Start key to alternately display the current administrator number. 2. Press the Clear key to clear the current administrator number. 3.

  • Page 111: (11) Memory Clear

    (11) Memory Clear • This function is used to clear all data except that of the various electronic counters. <Procedure> 1. Press the Start key to display “CLr” on the Display. 2. Press the Start key to blank out the Display. Then, “CLr”...

  • Page 112: (14) Adf Original Glass Check

    (14) ADF Original Glass Check • The original scanning area of the ADF is scanned to check for possible dirt or scratches on the glass. The scanned area is produced as a copy. <Procedure> • Press the Start key to start the sequence. For details, see the relevant option service manual.

  • Page 113: Security Mode

    SECURITY MODE • Allows the Tech. Rep. to set the various counters. 4-1. Settings in the Security Mode Code No. Description Total Counter Count Mode Size Counter Count Mode Key Counter Total Counter 4-2. Security Mode Setting Procedure <Procedure> 1. Set the machine into the Tech. Rep. Mode. 2.

  • Page 114: Setting In The Security Mode

    4-3. Setting in the Security Mode Code No. Setting (The default is Highlighted <Total Counter Count Mode> Select the condition by which the Counter count is increased. Setting Description 1 Copy per 1 copy cycle. Multiple count-up according to the paper size and copying mode.

  • Page 115: Adjust Mode

    ADJUST MODE • Used at the factory for making adjustments. 5-1. Settings in the Adjust Mode Code No. Description Printer CD Registration adjustment Printer FD Registration adjustment Scanner CD Zoom adjustment Scanner FD Zoom adjustment Scanner CD Registration adjustment Scanner FD Registration adjustment ADF FD Zoom adjustment ADF CD Registration adjustment ADF FD Registration adjustment...

  • Page 116: Setting In The Adjust Mode

    5-3. Setting in the Adjust Mode Code No. Setting (The default is Highlighted <Printer CD Registration adjustment> Adjust registration in the CD direction on the printer (engine) side. It is used when the PH Unit has been replaced. Setting 60 ............

  • Page 117: Setting 0

    Code No. Setting (The default is Highlighted <ADF FD Zoom adjustment> Adjust the zoom ratio in the FD direction on the ADF side. It is used when the machine is set up, the PH Unit or Scanner Drive Cables have been replaced, or the Scanner has been removed. Setting 87......

  • Page 118: Troubleshooting

    TROUBLESHOOTING 14390...
  • Page 119 CONTENTS 1. INTRODUCTION ..................... T-1 1-1. Reading the Text ..................T-1 2. PAPER TRANSPORT FAILURE ..............T-2 2-1. Paper Misfeed Detection ................. T-2 (1) Outline ..................... T-2 2-2. Paper Misfeed ..................T-2 2-3. Misfeed Detection Sensor Layout ............T-4 2-4. Types of Misfeed Detection and Detection Timings ........ T-6 3.
  • Page 120 (3) Low image density ................T-47 (4) Foggy background or rough image ..........T-49 (5) Black streaks or bands ..............T-51 (6) Black spots ..................T-52 (7) Blank streaks or bands ..............T-53 (8) Void areas ..................T-54 (9) Smear on back ................T-55 (10) Uneven image density ..............

  • Page 121: 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 122: Paper Transport Failure

    PAPER TRANSPORT FAILURE 2-1. Paper Misfeed Detection Outline • A paper misfeed is detected by detecting different states of signals (H, L) of several sen- sors located near the paper take-up section and the Exit Paper Sensor. • The timings of the rising and falling edges of the paper take-up-related sensors and the Exit Paper Sensor are monitored to detect a misfeed of paper being fed through the copier.
  • Page 123 LED No. Code Misfeed/Paper Location Action Ref. Page Misfeed on paper transport path between PC1 T-11 and PC12 (3rd Tray) Misfeed on paper transport path between PC12 T-11 (3rd Tray) and PC12 (4th Tray) Misfeed on paper transport path between PC12 T-11 (4th Tray) and PC12 (5th Tray) Misfeed at the PC Drum...

  • Page 124: Misfeed Detection Sensor Layout

    2-3. Misfeed Detection Sensor Layout PC4* PC3* PC5* PC12* PC12* PC12* PC12* Paper Path 4022T504AA Copier Symbol Name Synchronizing Roller Sensor Manual Feed Paper Sensor Exit Paper Sensor Paper Feed Cabinet (option) Symbol Name PC12* 2nd Tray Paper Take-Up Sensor PC12* 3rd Tray Paper Take-Up Sensor PC12*...
  • Page 125 <Resetting the Misfeed Display> Misfeed Location Resetting Procedure Misfeed in Misfeed at 1st Tray J01, Open the Right Door or slide out the copier misfeed at Multiple Bypass Tray J06, the 1st Tray, remove all sheets of misfeed at Manual Bypass Tray J06, paper misfeed and left inside, and misfeed at PC Drum J2, close the Right Door.

  • Page 126: Types Of Misfeed Detection And Detection Timings

    2-4. Types of Misfeed Detection and Detection Timings • The following list 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 127: Misfeed Troubleshooting Procedures

    MISFEED TROUBLESHOOTING PROCEDURES 3-1. Misfeed at Copier Paper Take-Up J01 and Misfeed at Bypass Tray J06 Relevant Electrical Parts Synchronizing Roller Sensor (PC1) Manual Bypass Solenoid (SL2) Manual Feed Paper Sensor (PC2) Multiple Bypass Solenoid (SL21) Paper Take-Up Solenoid (SL1) Master Board (PWB-A) PWB-A Master Board...
  • Page 128 Step Check Result Action Paper Take-Up Roll (1st Tray) is dirty, YES • Clean or change. scratchy, deformed, or worn. Paper Separator Roll (1st Tray) is YES • Clean or change. dirty, scratchy, deformed, or worn. Paper Take-Up Roll drive shaft turns •...
  • Page 129 Step Check Result Action Manual Bypass Solenoid (SL2) is • Change Manual Bypass Solenoid operational when the Start key is (SL2). pressed. <Check Procedure> Check voltage across a Master Board (copier: PWB-A) pin and GND. • Voltage across PJ4A-2 and GND In standby: DC24 V When pressed: DC0 V Manual Feed Paper Sensor (PC2) is...
  • Page 130 Step Check Result Action Multiple Bypass Solenoid (SL21) is • Change Multiple Bypass Solenoid operational when the Start key is (SL21). pressed. <Check Procedure> Check voltage across a Master Board (copier: PWB-A) pin and GND. • Voltage across PJ4A-2 and GND In standby: DC24 V When pressed: DC0 V Paper Take-Up Roll (Multiple Bypass...

  • Page 131: Misfeed At Paper Feed Cabinet Paper Take-Up And Transport Section J02, J03, J04, J05, J1

    3-2. Misfeed at Paper Feed Cabinet Paper Take-Up and Transport Section J02, J03, J04, J05, J1 (PF-120) Relevant Electrical Parts Paper Take-Up Solenoid (SL11) Master Board (PWB-A) Synchronizing Roller Sensor (PC1) Control Board (PWB-A): PF-120 Paper Take-Up Sensor (PC12) PJ6A-1(PC1 ANODE) Synchronizing PJ6A-2(GND) Roller Sensor...
  • Page 132 Misfeed at Paper Feed Cabinet Paper Take-Up and Transport Section J02, J03, J04, J05, J1 (PF-120) 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. YES •...

  • Page 133: Misfeed At Pc Drum J2

    3-3. Misfeed at PC Drum J2 Relevant Electrical Parts Synchronizing Roller Sensor (PC1) Synchronizing Roller Clutch (CL1) Fusing Cooling Fan Motor (M3) Master Board (PWB-A) PWB-A Master Board TRANSPORT SECTION Synchronizing Roller Clutch Synchronizing Roller Senser PC1 ANODE FUSING SECTION Fusing Cooling Fan Motor 4022T523AA...
  • Page 134 Step Check Result Action Synchronizing Roller Sensor (PC1) is • Change Synchronizing Roller Sen- operational. sor (PC1). <Check Procedure> Check voltage across a Master Board (copier: PWB-A) pin and GND when the sensor is blocked. • Voltage across PJ6A-3 and GND When blocked: DC5 V When unblocked: DC0 V The following voltage is supplied to...
  • Page 135 • Paper is at a stop at the transport section. Step Check Result Action Transport guide plate is dirty, YES • Clean or change. scratchy, deformed, worn, or dam- aged. The following voltage is supplied to YES • Change Fusing Cooling Fan Motor the Fusing Cooling Fan Motor (M3).

  • Page 136: Misfeed At Fusing Unit J3

    3-4. Misfeed at Fusing Unit J3 Relevant Electrical Parts Exit Paper Sensor (PC3) Master Board (PWB-A) Fusing Cooling Fan Motor (M3) FUSING SECTION Fusing Cooling Fan Motor PC3 ANODE PWB-A PAPER EXIT SECTION Master Board Exit Paper Sensor 4022T511AA Misfeed at Fusing Unit J3 Troubleshooting Procedures •...
  • Page 137 Step Check Result Action Exit Paper Sensor (PC3) is opera- • Change Exit Paper Sensor (PC3). tional. YES • Change Master Board (copier: <Check Procedure> PWB-A). Check voltage across a Master Board (copier: PWB-A) pin and GND when the sensor is blocked. •...

  • Page 138: Malfunction

    MALFUNCTION The copier’s CPU is equipped with a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Display. 4-1. Detection Timing by Malfunction Code Code Description Detection Timing C0000 Main Motor malfunc- • The Main Motor (M1) Lock signal remains HIGH for a tion continuous 1-sec.
  • Page 139 Code Description Detection Timing C0650 Faulty Scanner Home • The Scanner Home Position Sensor (PC6) does not Position Sensor go from HIGH to LOW when the Scanner Motor (M5) is energized for a given number of steps after the sequence to bring the Scanner back to its home posi- tion has been started at the end of a scan motion and during re-shading.
  • Page 140 Code Description Detection Timing C0B60 Bin Switching Motor If both the Upper Home Position Sensor and the Lower malfunction Home Position Sensor are HIGH during an initial opera- tion: • If the Lower Home Position Sensor (PC33) does not go LOW at a time 2.5 sec. after the Bin Switching Motor (M1) has started turning forward, the Bin Switching Motor is kept deenergized for a given period of time and then energized again to turn back-...
  • Page 141 Code Description Detection Timing C1200 Faulty ASIC/memory ASIC/memory (for image and control) fault • A write or read error occurs with SRAM on the Control Board (PWB-C). C1300 Polygon Motor mal- Startup failure function • A LOW Polygon Motor (M2) Lock signal is not detected within a given period of time that begins 1 sec.

  • Page 142: Resetting Procedure By Malfunction Code

    4-2. Resetting Procedure by Malfunction Code Code Description Resetting Procedure C0000 Main Motor malfunction • Turn OFF and ON the Power Switch. C0045 Fusing Cooling Fan Motor mal- function C004E Power Supply Cooling Fan Motor malfunction C0070 Toner Replenishing Motor mal- function C0210 Abnormal image transfer voltage C03FF Improperly set Adjust Mode 11...

  • Page 143: Troubleshooting Procedures By Malfunction Code

    4-3. Troubleshooting Procedures by Malfunction Code C0000: Main Motor malfunction Relevant Electrical Parts Main Motor (M1) Master Board (copier: PWB-A) PWB-A Master Board PJ7A Main Motor 4022T525AA Step Check Result Action Main Motor (M1) turns when the Start • Check for overload. key is pressed.

  • Page 144: C0045: Fusing Cooling Fan Motor Malfunction

    C0045: Fusing Cooling Fan Motor malfunction Relevant Electrical Parts Fusing Cooling Fan Motor (M3) Master Board (copier: PWB-A) PWB-A Master Board FUSING SECTION Fusing Cooling Fan Motor 4022T526AA Step Check Result Action Fusing Cooling Fan Motor (M3) turns • Check for overload. when the Power Switch is turned ON.

  • Page 145: C004E: Power Supply Cooling Fan Motor Malfunction

    C004E: Power Supply Cooling Fan Motor malfunction Relevant Electrical Parts Power Supply Cooling Fan Motor (M4) Master Board (copier: PWB-A) PWB-A Master Board POWER SUPPLY SECTION Power Supply Cooling Fan Motor 4022T527AA Step Check Result Action Power Supply Cooling Fan Motor •...

  • Page 146: C0070: Toner Replenishing Motor Malfunction

    C0070: Toner Replenishing Motor malfunction Relevant Electrical Parts Toner Replenishing Motor (M6) Master Board (copier: PWB-A) Toner Bottle Home Position Sensor (PC7) PWB-A Master Board DEVELOPING SECTION Toner Replenishing Motor Toner Bottle Home PC7 ANODE Position Sensor 4022T528AA Step Check Result Action The coupling of the Toner Hopper...

  • Page 147: C0210: Abnormal Image Transfer Voltage

    C0210: Abnormal image transfer voltage Relevant Electrical Parts High Voltage Unit (HV1) Master Board (copier: PWB-A) DEVELOPING SECTION PWB-A Master Board High Voltage Unit Developing Bias P.C/I.T._REM Not Use I.T.Control Image Transfer I.T.Voltage Monitor P.C/I.T._REM VG Voltage I.T.Control I.T.Voltage Monitor Charge Neutralizing Cloth Photo Conductor 4022T529AA...

  • Page 148: C0500: Warm-Up Failure C0510: Abnormally Low Fusing Temperature C0520: Abnormally High Fusing Temperature

    C0500: Warm-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature Relevant Electrical Parts Fusing Heater Lamp (H1) Fusing Unit Interlock Switch (S2) Thermistor (TH1) DC Power Supply (PU1) Thermoswitch 1 (TS1) Master Board (copier: PWB-A) PWB-A Master Board Not Use Thermistor FUSING SECTION...
  • Page 149 Step Check Result Action Fusing Unit Interlock Switch (S2) is • Change Fusing Unit Interlock operational. Switch (S2). <Check Procedure> YES • Change DC Power Supply (PU1). Check continuity across terminals when the Fusing Unit Interlock Switch (S2) is turned ON. •...

  • Page 150: C0650: Faulty Scanner Home Position Sensor

    C0650: Faulty Scanner Home Position Sensor Relevant Electrical Parts Scanner Motor (M5) Control Board (copier: PWB-C) Scanner Home Position Sensor (PC6) PWB-C IR SECTION Contorol Board PWB-A Scanner Master Moter Board Scanner Home Position Sensor 4022T531AA Step Check Result Action Scanner Motor (M5) turns when the •...

  • Page 151: C0B60: Bin Switching Motor Malfunction

    C0B60: Bin Switching Motor malfunction Relevant Electrical Parts Bin Switching Motor (JS-202: M1) Main Board (JS-202: PWB-A) Upper Home Position Sensor (JS-202: PC32) Master Board (copier: PWB-A) Lower Home Position Sensor (JS-202: PC33) JS-202 PWB-A PWB-A Master Main Board Board Bin Switching Motor Upper Home...
  • Page 152 Step Check Result Action Lower Home Position Sensor (JS- • Change Lower Home Position Sen- 202: PC33) is operational. sor (PC33). <Check Procedure> YES • Change Master Board (copier: Check voltage across a Main Board PWB-A). (JS-202: PWB-A) pin and GND when the sensor is blocked.

  • Page 153: C0B80 Shift Motor Malfunction

    C0B80 Shift Motor malfunction Relevant Electrical Parts Shift Motor (OT-103: M1) Main Board (OT-103: PWB-A) Home Sensor (OT-103: S31) Master Board (copier: PWB-A) OT-103 PWB-A PWB-A Master Main Board Board CN55 Shift Motor PJ3A PJ58 S31 ANODE Home Sensor S31 ON Not Use 4022T536AA Step...

  • Page 154: C0F33: Improperly Adjusted Atdc Sensor

    (10) C0F32: Faulty ATDC Sensor C0F33: Improperly adjusted ATDC Sensor Relevant Electrical Parts ATDC Sensor (UN1) Master Board (copier: PWB-A) PWB-A Master Board DEVELOPING SECTION ATDC Sensor 4022T533AA Step Check Result Action Developer is not even in the Devel- YES • Gently swing the IU in the horizon- oper Mixing Chamber.

  • Page 155: (11) C1038: Engine Connection Failure

    (11) C1038: Engine connection failure Relevant Electrical Parts Master Board (copier: PWB-A) Control Board (copier: PWB-C) Step Check Result Action C1038 reappears when the copier is YES • Go to step 2. turned OFF and ON again. <Check Procedure> Turn OFF and ON the Power Switch to check to see if C1038 reappears.

  • Page 156: C13F0: Faulty Hsync

    (13) C1300: Polygon Motor malfunction (startup failure, Lock signal failure, faulty Lock signal) C13F0: Faulty HSYNC Relevant Electrical Parts Polygon Motor (M2) Master Board (copier: PWB-A) PWB-A Master Board IR/PH SECTION Polygon Motor 4022T534AA Step Check Result Action C1300/C13F0 reappears when the YES •...

  • Page 157: (14) C1468: Faulty Eeprom

    (14) C1468: Faulty EEPROM Relevant Electrical Parts Control Board (copier: PWB-C) Step Check Result Action C1468 reappears when the copier is YES • Go to step 2. turned OFF and ON again. <Check Procedure> Turn OFF and ON the Power Switch to check to see if C1468 reappears.

  • Page 158: (15) C14A3: Ir Fluorescent Lamp Fault

    (15) C14A3: IR fluorescent lamp fault Relevant Electrical Parts Exposure Lamp (LA2) Control Board (copier: PWB-C) Inverter Board (copier: PU2) IR SECTION PWB-C PWB-J Control Board Not Use Not Use Inverter Board Exposure Lamp Not Use Not Use 4022T535AA T-38...
  • Page 159 Step Check Result Action Exposure Lamp turns ON when the • Go to step 3. Power Switch is turned ON. Exposure Lamp is abnormally lit • Go to step 4. (flickers or abnormally dark) when the Power Switch is turned ON. Inverter Board (copier: PU2) connec- YES •...

  • Page 160: (16) The Copier Does Not Turn On

    (16) The copier does not turn ON. Relevant Electrical Parts Power Switch (S1) Control Board (copier: PWB-C) DC Power Supply (PU1) Master Board (copier: PWB-A) Control Panel (UN2) PWB-C Control Boad JP2UN2 JP4C Control Panel Main Switch PJ11C Fusing Heater Lamp Thermoswitch 1 Fusing Unit Interlock Switch DC Power Supply...
  • Page 161 Step Check Result Action Power supply voltage check • Check wall outlet for volt- <Check Procedure> age. Check voltage across pins of DC Power Sup- • Check power cord for con- ply (PU1) when the Power Switch is turned tinuity. •...

  • Page 162: 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 163 • Determine if the failure is attributable to an input system (IR) or output system (engine). Check Result Action Copy made at a reduced Full-size copy Reduced copy ratio. Input system Original 1177T04YA Full-size copy Reduced copy 1177T03YA Output system 1177T05YA T-43...

  • Page 164: Image Failure Samples

    5-3. Image Failure Samples 1. Blank copy 2. Black copy 3. Low image density 4. Foggy background or rough 5. Black streaks or bands 6. Black spots image 7. Blank streaks or bands 8. Void areas 9. Smear on back 12.

  • Page 165: Troubleshooting Procedures By Image Failure

    5-4. Troubleshooting Procedures by Image Failure Blank copy Section Step Check Result Action Output system Imaging Unit is installed correctly. • Reinstall. Connector between the Imaging YES • Clean. Unit and copier is dirty. PH Shutter (located along the YES • Correct or reinstall. laser path between the PH Unit and PC Drum) is not in correct position or malfunctions.

  • Page 166: Black Copy

    Black copy Section Step Check Result Action Output PC Drum Charge Corona grid mesh and YES • Reinstall. system Comb Electrode are loose. PC Drum Charge Corona contact is dirty, YES • Correct or change. scratchy, folded, bent, or damaged. Grid bias contact is dirty, folded, or bent.

  • Page 167: Low Image Density

    Low image density Section Step Check Result Action Output Image density changes after “Toner YES • Replenish the supply of system Replenisher” has been run. toner using “Toner • “Toner Replenisher” of Utility Replenisher.” Image density changes after “ID Adjust- YES •...
  • Page 168 Section Step Check Result Action Input Shading sheet reading portion (the por- YES • Clean. system tion on the backside of the Original Glass to which Original Width Scale is affixed) is dirty. CCD Board (copier: PWB-J) connector YES • Reconnect. is loose.

  • Page 169: Foggy Background Or Rough Image

    Foggy background or rough image Section Step Check Result Action Output Image condition changes after “ID YES • Readjust. system Adjustment” and “VG Adjustment” have For more details, see been made. SWITCHES ON PWBs/ TECH. REP. SET- TINGS. PC Drum surface and the areas in con- YES •...
  • Page 170 Section Step Check Result Action Input Exposure Lamp is abnormally lit (flickers • Go to step 7. system or abnormally dark) when the Start key is pressed. Inverter Board (copier: PU2) connector YES • Reconnect. CN1PU2 is loose. • Change Exposure Lamp (LA2).

  • Page 171: Black Streaks Or Bands

    Black streaks or bands Section Step Check Result Action Output PC Drum is dirty or scratchy. YES • Clean or change. system Foreign matter (such as paper dust) YES • Remove foreign mat- sticks to the Cleaning Blade of IU or the ter, correct, or change.

  • Page 172: Black Spots

    Black spots Section Step Check Result Action Output Toner is present along the paper path. YES • Clean. system PC Drum is dirty or scratchy. YES • Clean or change. Tip of the PC Drum Paper Separator YES • Clean or change. Finger is dirty, scratchy, deformed, worn, or damaged.

  • Page 173: Blank Streaks Or Bands

    Blank streaks or bands Section Step Check Result Action Output PC Drum ground terminal is dirty, YES • Clean, correct, or system scratchy, deformed, or damaged. change. DB of IU is plugged with foreign matter YES • Remove foreign matter. (such as paper dust).

  • Page 174: Void Areas

    Void areas Section Step Check Result Action Output Foreign matter is present along the YES • Remove foreign matter. system paper path. Paper dust plugs up the Paper Dust YES • Clean or change. Remover. PC Drum Charge Corona, grid mesh, YES •...

  • Page 175: Smear On Back

    Smear on back Section Step Check Result Action Output Toner is spilled over area inside copier. YES • Clean interior. system Toner is present along the paper path. YES • Clean. Right Fusing Roller is dirty, scratchy, or YES • Clean or change. damaged.

  • Page 176: (10) Uneven Image Density

    (10) Uneven image density Section Step Check Result Action Output PC Drum ground plate is dirty, scratchy, YES • Clean, correct, or system deformed, worn, or damaged. change. PC Drum Charge Corona grid mesh and YES • Clean, correct, or Comb Electrode are dirty, scratchy, change.
  • Page 177 Section Step Check Result Action Input Control Board (copier: PWB-C) connec- YES • Reconnect. system tor PJ1A is loose. • Change CCD Unit. • Change Control Board (copier: PWB-C). T-57...

  • Page 178: (11) Gradation Reproduction Failure

    (11) Gradation reproduction failure Section Step Check Result Action Output PC Drum is dirty. YES • Clean. system Image Transfer Roller is dirty, scratchy, YES • Clean or change. deformed, worn, or damaged. PH Unit connectors PJ12A and PJ13A are YES •...

  • Page 179: (12) Periodically Uneven Image

    (12) Periodically uneven image Section Step Check Result Action Output IU is securely fastened using the dedi- • Secure in position. system cated fixing screws. PH Unit is securely fastened using the • Secure in position. dedicated fixing screws. IU drive mechanism is dirty or damaged. YES •...

  • Page 180: Other Error Codes

    OTHER ERROR CODES • When an error that does not fall into the category of paper transport failure or malfunc- tion, a corresponding error code is displayed in the Display. 4022T503AA 4022T505AA Code Description Resetting Procedure Toner empty stop • Change Toner Bottle. Paper size is physically changed of •...
  • Page 181 Code Description Resetting Procedure Plug-In Counter not plugged in • Plug in the Plug-In Counter. • Change setting in Security mode. For details, see SWITCHES ON PWBs/TECH. REP. SETTINGS. A numeral outside the specified set- • Automatically reset 1 sec. after the ting range is entered.
  • Page 182 Copyright 2001 MINOLTA CO., LTD. Printed in Japan Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA Co.,Ltd. 4021-7991-11 01100500...

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