Konica Minolta bizhub C250 Service Manual
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Konica Minolta bizhub C250 Service Manual

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Table of Contents

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Download this manual See also: Service Manual, Function Manual

SERVICE MANUAL

FIELD SERVICE
2005.07
2005.07
Ver. 1.0
Ver. 1.0

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Summary of Contents for Konica Minolta bizhub C250

  • Page 1: Service Manual

    SERVICE MANUAL FIELD SERVICE 2005.07 2005.07 Ver. 1.0 Ver. 1.0...

  • Page 2: Table Of Contents

    WARNING INDICATIONS ON THE MACHINE ............S-18 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-20 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 bizhub C250 Main Unit General ........................... 1 Maintenance ........................9 Adjustment/Setting...................... 141 Troubleshooting......................
  • Page 3 AD-503 General ........................... 1 Maintenance ........................3 Adjustment/Setting ......................7 Troubleshooting ......................11 FS-501 General ........................... 1 Maintenance ........................5 Adjustment/Setting ......................9 Troubleshooting ......................19 FS-603 General ........................... 1 Maintenance ........................5 Adjustment/Setting ....................... 23 Troubleshooting ......................51...

  • Page 4: Safety And Important Warning Items

    IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.

  • Page 5: Safety Warnings

    [1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
  • Page 6 SAFETY AND IMPORTANT WARNING ITEMS [2] POWER PLUG SELECTION In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.

  • Page 7: Connection To Power Supply

    SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
  • Page 8 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • When using the power cord set (inlet type) that came with this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly.
  • Page 9 SAFETY AND IMPORTANT WARNING ITEMS Wiring WARNING • Never use multi-plug adapters to plug multiple power cords in the same outlet. If used, the risk of fire exists. • When an extension cord is required, use a specified one. Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire.
  • Page 10 SAFETY AND IMPORTANT WARNING ITEMS Ventilation CAUTION • The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
  • Page 11 SAFETY AND IMPORTANT WARNING ITEMS Work Performed with the Product Powered On WARNING • Take every care when making adjustments or performing an operation check with the product powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.
  • Page 12 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Check electrode units such as a charging corona unit for deterioration and sign of leakage. Current can leak, leading to a risk of trouble or fire. • Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected.

  • Page 13: Handling Of Consumables

    SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Make sure that all screws, components, wiring, connec- tors, etc. that were removed for safety check and mainte- nance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of product trouble, electric shock, and fire exists.
  • Page 14 SAFETY AND IMPORTANT WARNING ITEMS Handling of Service Materials CAUTION • Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off. A risk of fire exists. •...
  • Page 15 SAFETY AND IMPORTANT WARNING ITEMS [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.

  • Page 16: Internal Laser Radiation

    SAFETY AND IMPORTANT WARNING ITEMS [5] FUSE CAUTION Double pole / neutral fusing ATTENTION Double pôle / fusible sur le neutre. [6] 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.
  • Page 17 SAFETY AND IMPORTANT WARNING ITEMS U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class 1 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 18 SAFETY AND IMPORTANT WARNING ITEMS Finland, Sweden LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! • Laitteen käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saat- taa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle laser- säteilylle. puolijohdelaser Laserdiodin suurin teho 10 mW aallonpituus 775-800 nm VARNING!

  • Page 19: Laser Safety Label

    SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety label is attached to the inside of the machine as shown below. * Only for the U.S.A. 4038P0E505DA Laser Caution Label • A laser caution label is attached to the outside of the machine as shown below. 4038P0C503DA S-16...

  • Page 20: Precautions For Handling The Laser Equipment

    SAFETY AND IMPORTANT WARNING ITEMS PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT • When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. • When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the printer OFF.

  • Page 21: Warning Indications On The Machine

    SAFETY AND IMPORTANT WARNING ITEMS WARNING INDICATIONS ON THE MACHINE Caution labels shown are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. High voltage •...
  • Page 22 SAFETY AND IMPORTANT WARNING ITEMS WARNING WARNING • Do not position the used Waste • Do not burn used Toner Cartridges. Toner Box so that it is standing Toner expelled from the fire is dan- on end or tilted, otherwise toner gerous.

  • Page 23: Measures To Take In Case Of An Accident

    MEASURES TO TAKE IN CASE OF AN ACCIDENT MEASURES TO TAKE IN CASE OF AN ACCIDENT 1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.

  • Page 24: Composition Of The Service Manual

    Composition of the service manual This service manual consists of Theory of Operation section and Field Service section to explain the main machine and its corresponding options. Theory of Operation section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.

  • Page 25: Notation Of The Service Manual

    Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) PWB-MFP: MFP Control Board (2) bizhub C250: Main Unit (3) Microsoft Windows 95: Windows 95 Microsoft Windows 98: Windows 98...

  • Page 26: Main Unit

    SERVICE MANUAL FIELD SERVICE Main Unit 2005.07 Ver. 1.0...

  • Page 27: Revision History

    Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 28 Field Service Ver. 1.0 Jul. 2005 CONTENTS bizhub C250 Main Unit General System configuration....................1 Product specifications ..................... 3 Type ........................3 Functions ......................4 Types of Paper ...................... 5 Maintenance ......................5 Machine Specifications ..................6 Operating Environment..................6 Print Functions......................

  • Page 29: Maintenance

    Field Service Ver. 1.0 Jul. 2005 3.5.9 Replacing the Waste Toner Box..............27 3.5.10 Cleaning of the Area around the Waste Toner Collecting Port ....28 3.5.11 Replacing the Ozone Filter ................. 28 3.5.12 Replacing the Deodorant Filter ..............29 3.5.13 Replacing the Dust Filter/Vertical Conveyance...........
  • Page 30 Field Service Ver. 1.0 Jul. 2005 6.3.4 Exit Tray/Upper Rear Cover/Lower Rear Cover/Rear Left Cover ....57 6.3.5 Multi Bypass Tray Left Cover/Multi Bypass Tray Right Cover/Multi Bypass Tray Upper Cover ..................58 6.3.6 Front Door ....................59 6.3.7 Rear Right Cover ..................59 6.3.8 Control Panel (UN201)................

  • Page 31: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 6.3.41 Toner Supply Motor Y/M (M6)..............116 6.3.42 Main Motor (M1) ..................117 6.3.43 Fusing Drive Motor (M4) ................119 6.3.44 Tray 2 Lift-Up Motor (M3-PC)..............121 6.3.45 Tray 2 Paper Feed Motor (M1-PC)............121 6.3.46 Tray 2 Vertical Transport Motor (M2-PC) ..........
  • Page 32 Field Service Ver. 1.0 Jul. 2005 8.4.3 User Box ....................160 User Setting ...................... 161 8.5.1 System Setting..................161 8.5.2 Display Setting ..................163 8.5.3 Initial Setting ..................... 166 8.5.4 Copier Setting ................... 166 8.5.5 Scanner Setting ..................168 8.5.6 Printer Setting ...................
  • Page 33 Field Service Ver. 1.0 Jul. 2005 10.6.1 Gradation Adjust ..................244 10.6.2 D Max Density ..................245 10.6.3 Background Voltage Margin..............246 10.6.4 Transfer Output Fine Adjustment .............. 246 10.6.5 Stabilizer ....................247 10.6.6 Thick Paper Density Adjustment............... 248 10.6.7 TCR Toner Supply ..................
  • Page 34 Field Service Ver. 1.0 Jul. 2005 10.9.9 Line Mag Setting ..................270 10.9.10 Data Capture..................... 271 10.10 Counter ......................274 10.10.1 Procedure ....................274 10.10.2 Life ......................274 10.10.3 Jam ......................275 10.10.4 Service Call Counter ................. 275 10.10.5 Warning..................... 275 10.10.6 Maintenance .....................
  • Page 35 Field Service Ver. 1.0 Jul. 2005 10.13.4 Lattice Pattern................... 292 10.13.5 Solid Pattern ..................... 293 10.13.6 Color Sample .................... 293 10.13.7 8 Color Solid Pattern................. 294 10.13.8 Running Mode ..................294 10.13.9 Fax Test ....................294 10.14 ADF ........................294 10.15 FAX........................
  • Page 36 Field Service Ver. 1.0 Jul. 2005 14.4 PH Unit Mechanical Adjustment ............... 309 14.4.1 Skew Adjustment ..................309 Troubleshooting Jam Display......................313 15.1 Misfeed Display....................313 15.1.1 Misfeed Display Resetting Procedure ............314 15.2 Sensor layout ....................315 15.3 Solution......................317 15.3.1 Initial Check Items..................
  • Page 37 Field Service Ver. 1.0 Jul. 2005 16.2.14 P-31: Black PC Drum Sensor malfunction..........333 16.3 Trouble code ..................... 334 16.3.1 Trouble code list ..................334 16.4 How to reset ..................... 355 16.5 Solution ......................356 16.5.1 C0204: Tray 2 Elevator failure ..............356 16.5.2 C0211: Manual Tray Rise Descent Error ..........
  • Page 38 Field Service Ver. 1.0 Jul. 2005 16.5.34 C3452: Press. Heater Trouble..............365 16.5.35 C3751: Abnormal High Temp. (Heater)............. 365 16.5.36 C3752: Abnormal High Temp. (Press) ............365 16.5.37 C3851: Abnormal Low Temp. (Heater)............365 16.5.38 C3852: Abnormal Low Temp. (Press) ............365 16.5.39 C3461: Fusing Unit New Article Release..........
  • Page 39 Field Service Ver. 1.0 Jul. 2005 16.5.71 C6704: Image Input Time Out ..............372 16.5.72 C6751: CCD clamp/gain adjustment failure..........372 16.5.73 C9401: Exposure Lamp’s failure to turn ON ..........373 16.5.74 C9402: Exposure Lamp turning ON at abnormal timing......373 16.5.75 CA051: Standard Controller configuration failure ........
  • Page 40 Field Service Ver. 1.0 Jul. 2005 16.5.108 CEEE1: MSC undefined malfunction occurring ........377 16.5.109 CEEE2: Scanner Section undefined malfunction........377 16.5.110 CEEE3: Engine Section undefined malfunction........378 Power supply trouble ................... 379 17.1 Machine is not Energized at All (PU1 Operation Check) ........379 17.2 Control panel indicators do not light.
  • Page 41 Field Service Ver. 1.0 Jul. 2005 18.3.15 Printer Monocolor: white lines in Main Scan Direction, white bands in Main Scan Direction, colored lines in Main Scan Direction, colored bands in Main Scan Direction ..................401 18.3.16 Printer Monocolor: uneven density in sub scan direction ......402 18.3.17 Printer Monocolor: uneven density in main scan direction .......
  • Page 42 Field Service Ver. 1.0 Jul. 2005 19.3 PC103/PC203 (Option)..................435 19.4 PC-403 (Option)....................436 19.5 AD-503 (Option)....................437 19.6 FS-501 (Option) ....................438 19.7 JS-601 (Option) ....................440 19.8 FS-603 (Option) ....................441 19.9 PK-501 (Option)....................443 19.10 Horizontal Transport Unit .................. 444 Connector layout drawing..................
  • Page 43 Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 44: General

    Field Service Ver. 1.0 Jul. 2005 1. System configuration General System configuration 1/2 System Front View [13] [12] [11] [10] 4038T1E101AA Machine Paper Feed Cabinet PC-403 Reverse Automatic Document Feeder Desk DK-502 DF-601 Original cover OC-501 [10] Finisher FS-501 Working Table WT-501 [11] Job Separator JS-601 Auto Duplex Unit AD-503 [12] Finisher FS-603...
  • Page 45 1. System configuration Field Service Ver. 1.0 Jul. 2005 2/2 System Rear View PC-103 DK-502 PC-203 PC-403 4038T1E102AA Machine Mount Kit MK-704 Vender Kit VK-501 Local Interface Kit EK-702 * Only for Europe, North America, and Latin America (only 120V area) Mount Kit MK-706 Fax Kit FK-502 * Only for Europe, North America, Latin...

  • Page 46: Product Specifications

    Field Service Ver. 1.0 Jul. 2005 2. Product specifications Product specifications Type Type Desktop-type printer integrated with scanner Copying System Electrostatic dry-powdered image transfer to plain paper Printing Process Tandem-type indirect electrostatic recording system PC Drum Type OPC (organic photo conductor) Scanning Density Equivalent to 600 dpi Exposure Lamp...

  • Page 47: Functions

    2. Product specifications Field Service Ver. 1.0 Jul. 2005 Functions Types of Original Sheets, books, and three-dimensional objects A3 or 11 × 17 (Ledger) Max. Original Size Max. Original Weight Max. 2 kg Multiple Copies 1 to 999 110 sec. or less Warm-up Time (at ambient temperature of 23°...

  • Page 48: Types Of Paper

    Field Service Ver. 1.0 Jul. 2005 2. Product specifications Types of Paper Paper Source Type Tray1 Tray2 Multiple Bypass Plain paper ❍ ❍ ❍ (60 to 90 g/m Translucent paper – – – OHP transparencies (crosswise – feeding only) Thick paper 1 –...

  • Page 49: Machine Specifications

    2. Product specifications Field Service Ver. 1.0 Jul. 2005 Machine Specifications Power Requirements Voltage: AC 110 V, 120 V, 127 V, 220-240 V Frequency: 50/60 Hz ± 3.0 Hz Max Power Consumption Less than 1500 W (120 V, 12 A / 220 - 240 V, 8 A) 653 *2 (W) ×...

  • Page 50: Scan Functions

    Field Service Ver. 1.0 Jul. 2005 2. Product specifications Scan Functions Driver KONICA MINOLTA Scanner Driver Compatible Operating Windows 98/98SE/Me, Windows NT 4.0 (SP6 or later), Windows 2000, Systems Windows XP Scan Speed 25 pages/min. for both monochrome and full color (600 dpi, A4) Scannable Range Same as the copier (Max.
  • Page 51 2. Product specifications Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 52: Maintenance

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check Maintenance Periodical check Service schedule Guarantee period (5-year or 600,000 prints) × 10,000-print Per cycle Number × print number of times Upon each call ● ● ● ● ● ● ● ●...

  • Page 53: Maintenance Call (Per 60,000-Print)

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 3.2.2 Maintenance call (per 60,000-print) Number of Lubrica- Descrip- Class Parts to be replaced Check Clean Replace personnel tion tions Paper feed and image ● conditions Overall ● ● Appearance Conveyance ●...

  • Page 54: Periodical Parts Replacement 2 (Per 200,000-Print)

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3.2.4 Periodical parts replacement 2 (per 200,000-print) Number of Lubrica- Descrip- Class Parts to be replaced Check Clean Replace personnel tion tions Paper feed and image ● conditions Overall ● ● Appearance ●...

  • Page 55: Maintenance Parts

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 Maintenance parts • To ensure that the machine produces good copies and to extend its service life, it is rec- ommended that the maintenance jobs described in this schedule be carried out as instructed.

  • Page 56: Cleaning Parts

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check B. Option Actual Ref.Page Descrip- No. Classification Parts name durable Parts No. in this ntity tions cycle *1 manual Pick-up Roller 200 K 4582 3022 xx Replace those three Feed Roller 200 K 4582 3014 xx DF-601...

  • Page 57: Concept Of Parts Life

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 Concept of parts life Life value Max. number of Description (Specification printed pages value) A waste toner full condition is detected when about Waste Toner 2,500 printed pages have been produced after a –...
  • Page 58 Field Service Ver. 1.0 Jul. 2005 3. Periodical check A. Conditions for Life Specifications Values • The life specification values represent the number of copies made or figures equivalent to it when given conditions (see the Table given below) are met. They can be more or less depending on the machine operating conditions of each individual user.

  • Page 59: Maintenance Procedure (Periodical Check Parts)

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol. 3.5.1 Replacing the Tray 1 Feed Roller 1. Slide out the Tray 1. 2.

  • Page 60: Replacing The Bypass Tray Feed Roller

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3. Take off the rubber stopper [3], shaft [4], spring [5], and guide plate [6] to remove the Paper Separation Roller fixing bracket Assy [7]. 4038F2C003DB 4. Snap off the E-ring [8] and the Tray 1 Paper Separation Roller Assy [9].
  • Page 61 3. Periodical check Field Service Ver. 1.0 Jul. 2005 3. Remove the Gear [3]. 4038F2C005DA 4. Snap off the E-ring [4] and remove the Bearing [5]. 4038F2C006DB 5. Snap off two C-ring [6], and remove the Bearing [7]. 4038F2C007DB...

  • Page 62: Replacing The Bypass Tray Separation Roller Assy

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 6. Remove the Bypass Tray Feed Roller [8]. 7. To reinstall, reverse the order of removal. 8. Select [Service Mode] → [Counter] → [Life] and clear the count of [Manual Tray]. NOTE •...

  • Page 63: Replacing The Tray 2 Separation Roller

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 4. Snap off the C-clip [5], and remove the spring [6] and the guide plate [7]. Remove the Bypass Paper Separa- tion Roller Assy [8]. 5. To reinstall, reverse the order of removal.
  • Page 64 Field Service Ver. 1.0 Jul. 2005 3. Periodical check 5. Remove two Screws [5] and the Tray 2 Separation Roller installation plate Assy [6]. 4038F2C013DA 6. Remove two C-rings [7] and the Shaft [8], and remove the Separation Roller fixing plate Assy [9]. NOTE •...

  • Page 65: Replacing The Tray 2 Feed Roller

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 3.5.6 Replacing the Tray 2 Feed Roller 1. Remove the Tray 2 Separation Roller installation plate Assy. ☞ See the procedures 1 to 5 in page 20 “Tray 2 Separation Roller.” 2.
  • Page 66 Field Service Ver. 1.0 Jul. 2005 3. Periodical check 6. Remove two Screws [6] and the Installation flame [7] of the Tray 2 Separation Roller installation plate Assy. 4037F2C005DB 7. Remove two Screws [8] and Tray 2 Feed Roller cover [9]. 4037F2C006DB 8.
  • Page 67 3. Periodical check Field Service Ver. 1.0 Jul. 2005 9. Remove the C-ring [13] and Gear [14] while sliding out the Shaft Assy [12] in the direction indicated in left [12] figure. [14] [13] 4038F2C511DA 10. Remove the C-ring [15] and Bushing [16], and remove the Shaft Assy [17].

  • Page 68: Replacing The Tray 2 Pick-Up Roller

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 12. Remove the C-ring [21] and Tray 2 [21] Feed Roller [22]. 13. Select [Service Mode] → [Counter] → [Life] and clear the count of [2nd.]. [22] 4036fs2596c0 3.5.7 Replacing the Tray 2 Pick-up Roller 1.
  • Page 69 3. Periodical check Field Service Ver. 1.0 Jul. 2005 6. Remove two Screws [6], and remove the Tray 2 Separation Roller installa- tion plate Assy [7] together with Frame. 4037F2C005DB 7. Remove two Screws [8] and Tray 2 Feed Roller cover [9]. 4037F2C006DB 8.

  • Page 70: Cleaning Of The Registration Roller

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3.5.8 Cleaning of the Registration Roller 1. Open the Right Door. 2. Using a soft cloth dampened with alcohol, wipe the Registration Roll- ers [1] clean of dirt. 4038F2C017DA 3.5.9 Replacing the Waste Toner Box 1.

  • Page 71: Cleaning Of The Area Around The Waste Toner Collecting Port

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 4. Clean the surface around the waste toner collecting port. ☞ 28 5. Remove the Waste Toner Box from its box, and remove the packing material. 6. Set the Waste Toner Box [3] in place. 7.

  • Page 72: Replacing The Deodorant Filter

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3.5.12 Replacing the Deodorant Filter 1. Holding onto the hook, take out the Deodorant Filter [1]. NOTE • The Deodorant Filter is supplied with the Toner Cartridge (Black). Replace it when replacing the Toner Cartridge (Black).

  • Page 73: Replacing The Unit

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 Replacing the unit 3.6.1 Replacing the 2nd Image Transfer Roller Unit A. Removal Procedure 1. Open the Front Door and turn OFF the Main Power Switch. 2. Open the Right Door. 3.

  • Page 74: Replacing The Image Transfer Belt Unit

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3.6.2 Replacing the Image Transfer Belt Unit A. Removal Procedure 1. Open the Front Door and turn OFF the Main Power Switch. 2. Remove the Waste toner Box ☞ 27 3. Slide out the Imaging Unit (C/M/Y/K). ☞...
  • Page 75 3. Periodical check Field Service Ver. 1.0 Jul. 2005 7. Hold the position [4] as shown in the left and remove the Image Transfer Belt Unit [5]. NOTE • Do not touch the surface of the Image Transfer Belt Unit. •...

  • Page 76: Replacing The Toner Cartridge (C, M, Y, K)

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3.6.3 Replacing the Toner Cartridge (C, M, Y, K) A. Removal Procedure 1. Open the Front Door. 2. Pressing the Toner Cartridge Lock Claw [1], pull it toward. 4038F2C560DA 3. Pull the Toner Cartridge [2] toward to remove it.

  • Page 77: Cleaning Of The Comb Electrode

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 2. Insert the Toner Cartridge [2] by fit- ting it to the groove on the main unit. NOTE • Make sure the colors are matched between the Toner Cartridge and label on the machine. •...

  • Page 78: Replacing The Imaging Unit (C, M, Y, K)

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3.6.5 Replacing the Imaging Unit (C, M, Y, K) A. Removal Procedure 1. Open the Front Door and turn OFF the Main Power Switch. 2. Unplug the power cord. 3. Press the unlocking knob [1] of Imaging Unit.
  • Page 79 3. Periodical check Field Service Ver. 1.0 Jul. 2005 3. Tilt the Imaging Unit [3] to the left and shake it a small stroke in the tilt direction twice. Then, tilt it to the right and shake it a small stroke in the tilt direction twice.
  • Page 80 Field Service Ver. 1.0 Jul. 2005 3. Periodical check 6. Pull out the PC Drum protective sheet [6] while pressing the Imaging Unit. 7. Insert the Imaging Unit all the way. NOTE • Make sure that the Imaging Unit is inserted all the way.

  • Page 81: Replacing The Fusing Unit

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 3.6.6 Replacing the Fusing Unit CAUTION • Before replacing the Fusing Unit, ensure that it has had time to cool down. 1. Open the Front Door. 2. Turn OFF the Main Power Switch and unplug the power cord from the power outlet, then wait for about 20 minutes.
  • Page 82 Field Service Ver. 1.0 Jul. 2005 3. Periodical check 7. Disconnect two Connectors [6]. 4038F2C031DA 8. Open the Right Cover. 9. Open the Fusing Unit Cover. 10. Remove two Screws [7], and remove the Fusing unit [8]. 4038F2C032DA...

  • Page 83: Service Tool

    4. Service tool Field Service Ver. 1.0 Jul. 2005 Service tool CE Tool list Tool name Shape Personnel Parts No. Remarks Scanner Drive Cable 4581 7901 xx Holding Jig 4036fs2001c0 PH Window Cleaning Jig 4038 2083 xx 4038F2C557DA PH Window Cleaning Jig 4038 2084 xx 4038F2C558DA ⎯...

  • Page 84: Copy Materials

    Field Service Ver. 1.0 Jul. 2005 4. Service tool Copy materials 4.2.1 Imaging Unit Single Parts (IU) Also replace the Dust filter packed in the Imaging Unit Black at the same time. Parts name Replacing period IU Black 70,000 copies IU Yellow 45,000 copies IU Magenta...

  • Page 85: Firmware Upgrade

    5. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 Firmware upgrade Preparations for Firmware rewriting 5.1.1 Service environment • OS: Windows 2000 • Drive which enables writing/reading of Compact flash • Compact flash (with 128MB or more) 5.1.2 Application to be used •...
  • Page 86 Field Service Ver. 1.0 Jul. 2005 5. Firmware upgrade 4. Specify the folder for installation. Check to make sure that “Root Directory” is in default setting, [C:\cygwin]. NOTE • Make sure to check that “Root Directory” is in default setting, [C:\cygwin]. •...
  • Page 87 5. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 8. Click [Next (N)]. 4037F2E549DA 9. Click [Complete] to start installing. 4037F2E550DA 10. After installing, open the Property of “My Computer”, and click the “Environmental Vari- able” of “Advanced” tab. 11. Click the “New” in System Variable Setting. 4036fs2620e0...

  • Page 88: Writing Into The Compact Flash

    Field Service Ver. 1.0 Jul. 2005 5. Firmware upgrade 12. Set the following two values as the Windows Environmental Variable. Variable name Variable value CYGWIN ntsec HOME /home/username 4036fs2621e0 5.1.4 Writing into the Compact flash 1. Put the data of Firmware in the optional directory. (C:\C250 in the below figure) 4038F2E562DA NOTE •...
  • Page 89 5. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 2. Double-click the Firmware data, and specify the directory to be uncompressed, and then uncompress it. 4038F2E563DA NOTE • When old Firmware is still left in the specified directory to be uncompressed, delete it before uncompressing.
  • Page 90 Field Service Ver. 1.0 Jul. 2005 5. Firmware upgrade → → → 4. Click [Start] [Program] [Accessories] [Command Prompt] to open the Com- mand Prompt. 5. Use the Command prompt to move into the uncompressed directory. 6. Specify the Drive of Compact flash, which was recognized through the procedure 3, and execute the “mksf.bat.”...

  • Page 91: Firmware Rewriting

    5. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 Firmware rewriting • The F/W is updated using the Compact flash. 5.2.1 Updating method NOTE • NEVER remove or insert the Compact Flash card with the machine power turned 1. Open the Front Door, and turn OFF the Main Power Switch.
  • Page 92 Field Service Ver. 1.0 Jul. 2005 5. Firmware upgrade 4. Turn ON the Main Power Switch and the Sub Power Switch. 5. Control Panel shows up to four types of F/W to be updated. 6. Select the particular type of F/W to be updated. (Select [YES].) 4038F2C530DA F/W to be updated Appropriate board...

  • Page 93: Action When Data Transfer Fails

    5. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 5.2.2 Action When Data Transfer Fails • If “NG” appears on the Touch Panel, indicating that rewriting has been unsuccessful (in which case the Start key lights up red), take the following steps. 1.

  • Page 94: Other

    Field Service Ver. 1.0 Jul. 2005 6. Other Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 95: Disassembly/Assembly/Cleaning List (Other Parts)

    6. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly/Cleaning list (Other parts) 6.2.1 Disassembly/Assembly parts list Section Part name Ref.Page ☞ IR Upper Right Cover ☞ IR Right Cover ☞ IR Upper Rear Cover ☞ Left Cover ☞ Upper Front Cover ☞...

  • Page 96: Cleaning Parts List

    Field Service Ver. 1.0 Jul. 2005 6. Other Section Part name Ref.Page ☞ Board and etc. PH Interface Board ☞ Multi Bypass Unit ☞ PH Unit ☞ Unit Transport Drive Assy ☞ Hopper Drive Assy ☞ Right Door Assy ☞ Scanner Motor ☞...

  • Page 97: Disassembly/Assembly Procedure

    6. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly procedure 6.3.1 IR Upper Right Cover/IR Right Cover/IR Upper Rear Cover 4037F2C033DA 1. Remove three Screws [1], and remove the IR Upper Right Cover [2]. 2. Open the Fusing Unit Cover. 3.

  • Page 98: Left Cover/Upper Front Cover/Ir Left Cover/Ir Upper Front Cover

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.2 Left Cover/Upper Front Cover/IR Left Cover/IR Upper Front Cover [10] 4037F2C034DA 1. Open the Front Door [1]. 2. Remove three Screws [2], and remove the Left Tray [3]. 3. Remove the Screw [4], and remove the Upper Front Cover [5]. 4.

  • Page 99: Original Glass/Ir Front Cover

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.3 Original Glass/IR Front Cover 4037F2C035DA 1. Remove the IR Upper Right Cover. ☞ 54 2. Remove each Screw [1], and remove the Original Glass fixing bracket (near side/ inmost side) [2]. 3.

  • Page 100: Exit Tray/Upper Rear Cover/Lower Rear Cover/Rear Left Cover

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.4 Exit Tray/Upper Rear Cover/Lower Rear Cover/Rear Left Cover [10] 4037F2C036DA 1. Remove the Left Cover. ☞ 55 2. Remove the Sub Tray [1]. 3. Remove three Screws [2], and remove the Exit Tray [3]. 4.

  • Page 101: Multi Bypass Tray Left Cover/Multi Bypass Tray Right Cover/Multi Bypass Tray Upper Cover

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.5 Multi Bypass Tray Left Cover/Multi Bypass Tray Right Cover/Multi Bypass Tray Upper Cover 4037F2C037DA 1. Unhook the tab [1], and remove the Multi Bypass Tray Left Cover [2]. 2. Remove the Screws [3], and remove the Multi Bypass Tray Right Cover [4]. 3.

  • Page 102: Front Door

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.6 Front Door 1. Open the Front Door. 2. Remove the Screw [1] each to remove the Right and Left Stoppers [2]. 4038F2C038DB 3. Pull out the Right and Left Pins [3] to remove the Front Door [4].

  • Page 103: Control Panel (Un201)

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.8 Control Panel (UN201) 1. Remove four caps [1] at both ends of Control Panel. 4038F2C040DB 2. Remove four Screws [2]. 4038F2C041DB...

  • Page 104: Tray 1

    Field Service Ver. 1.0 Jul. 2005 6. Other 3. Remove the Flat Cable [3]. 4. Remove the Control Panel [4]. 4038F2C042DA 6.3.9 Tray 1 1. Slide out the Tray 1 [1]. 4038F2C043DB 2. Slide out the Tray 1 [3] while press- ing the Slide Locks [2] at both ends.

  • Page 105: Tray 2

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.10 Tray 2 1. Slide out the Tray 2 [1]. 4038F2C045DB 2. Remove the Screw [2], and remove the Stopper [3]. 3. Slide out the Tray 2 while pressing the Slide Locks [4]. 4038F2C046DB...

  • Page 106: Tray 2 Rear Right Cover/Tray 2 Rear Left Cover

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.11 Tray 2 Rear Right Cover/Tray 2 Rear Left Cover 1. Unhook two tabs [1], and remove the Wiring cover [2]. 4038F2C047DA 2. Remove four Screws [3], and remove the Tray 2 Rear Right Cover [4]. 4038F2C048DA 3.

  • Page 107: Tray 2 Right Rear Cover

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.12 Tray 2 Right Rear Cover 1. Remove two Screws [1], and remove the Tray 2 Right Rear Cover [2]. 4038F2C050DA 6.3.13 Front Cover 1. Remove the Front Door. ☞ 59 2. Remove the Left Cover, Upper Front Cover and Exit Tray. ☞...
  • Page 108 Field Service Ver. 1.0 Jul. 2005 6. Other 7. Disconnect two Connectors [3]. 4038F2C052DA 8. Disconnect two Connectors [4]. 4038F2C053DA 9. Remove four Screws [5]. 4038F2C054DA...

  • Page 109: Mechanical Control Board (Pwb-M)

    6. Other Field Service Ver. 1.0 Jul. 2005 10. Unhook six tabs [6], and remove the Front Cover [7]. 4038F2C055DA 6.3.14 Mechanical Control Board (PWB-M) NOTE • If a Finishing Option is installed, remove if from the main unit before trying to remove the Mechanical Control Board.
  • Page 110 Field Service Ver. 1.0 Jul. 2005 6. Other 5. Remove all the Connectors and Flat Cables on the Mechanical Control Board. 4037F2C058DB 6. Remove six Screws [5], and remove the Mechanical Control Board [6]. 4038F2C059DA...
  • Page 111 6. Other Field Service Ver. 1.0 Jul. 2005 NOTE • When Mechanical Control Board (PWB-M) is replaced, relocate the Parameter Chip (IC6). Mount the Parameter Chip (IC6) of old Mechanical Control Board onto the new Mechanical Control Board. 4037F2C061DB NOTE •...

  • Page 112: Dc Power Supply (Pu1)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.15 DC Power Supply (PU1) NOTE • If a Finishing Option is installed, remove if from the main unit before trying to remove the DC Power Supply. • When removing the Finishing Option, support the Horizontal Transport Unit with your hand to prevent if from dropping.
  • Page 113 6. Other Field Service Ver. 1.0 Jul. 2005 6. Disconnect the Connector [7], and remove the Harness [9] from the Wire saddles [8]. 4038F2C064DA 7. Remove two Screws [10], and remove the Power Supply Cooling Fan Motor/1 [11]. [11] [10] 4038F2C065DA 8.

  • Page 114: Scanner Motor Drive Board (Pwb-Ic)

    Field Service Ver. 1.0 Jul. 2005 6. Other 9. Remove four Screws [12], and [12] [13] remove the DC Power Supply [13]. [12] 4038F2C067DB 6.3.16 Scanner Motor Drive Board (PWB-IC) 1. Remove the IR Upper Rear Cover. ☞ 54 2. Disconnect three Connectors [1] and four Board Supports [2].
  • Page 115 6. Other Field Service Ver. 1.0 Jul. 2005 3. Remove four Screws [3] and Flat Cable [4], and remove the CCD Unit [5]. 4038F2C070DA B. Reinstallation Procedure 1. Align the CCD Unit with the center of the graduations as illustrated on the left and then tighten the four screws.

  • Page 116: Image Processing Board (Pwb-C)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.18 Image Processing Board (PWB-C) 1. Remove the Upper Rear Cover and IR Right Cover. ☞ 57, 54 2. Remove the CCD Unit Cover. ☞ Refer to the step1 to 2 on page 135. 3.
  • Page 117 6. Other Field Service Ver. 1.0 Jul. 2005 6. Disconnect two Connectors [7]. 4037F2C037DA 7. Remove all the Connectors and the Flat Cables on the Image Processing Board [8]. 4038F2C072DB 8. Remove six Screws [9] and two Bolts [10], and remove the Image Process- ing Board [11].

  • Page 118: Slide Interface Board (Pwb-Sif)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.19 Slide Interface Board (PWB-SIF) 1. Remove the Lower Rear Cover. ☞ 57 2. Remove all the Connectors and the Flat Cable on the Slide Interface Board. 4038F2C074DA 3. Remove five Screws [1]. 4038F2C075DA 4.

  • Page 119: Mfp Control Board (Pwb-Mfp)

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.20 MFP Control Board (PWB-MFP) 1. Remove the Upper Rear Cover, Lower Rear Cover and Rear Right Cover. ☞ 57, 59 2. Remove the Slide Interface Board. ☞ 75 3. Remove thirteen Screws, and remove the Shield cover [1].
  • Page 120 Field Service Ver. 1.0 Jul. 2005 6. Other 6. Disconnect the Connector [4] and Flat Cable [5]. 4038F2C079DA 7. Remove four Bolts [6] and six Screws [7], and remove the Interface cover [8]. 4038F2C080DA 8. Remove thirteen Screws [9], and remove the MFP Control Board [10].

  • Page 121: Dimm0 (Work0), Dimm1 (Work1)

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.21 DIMM0 (Work0), DIMM1 (Work1) 1. Remove the Upper Rear Cover, Lower Rear Cover and Rear Right Cover. ☞ 57, 59 2. Remove thirteen Screws, and remove the Shield cover [1]. 4038F2C507DA 3.
  • Page 122 Field Service Ver. 1.0 Jul. 2005 6. Other 3. Disconnect the Connector [2]. 4038F2C083DA 4. Remove the four Screws [3], and remove the Hard Disk Drive Assy [4]. 4038F2C084DA 5. Remove four screws [5] and the Flat cable [6], and remove the Hard Disk Drive [7].

  • Page 123: High Voltage Unit (Hv1)

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.23 High Voltage Unit (HV1) 1. Remove the PWB Box. ☞ 112 2. Disconnect four Connectors [1]. 4038F2C085DA 3. Remove five Screws [2] and the tab [3], and remove the High Voltage Unit [4].

  • Page 124: Tray 1 Paper Size Board (Pwb-I)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.24 Tray 1 Paper Size Board (PWB-I) 1. Slide out the Tray 1. 2. Remove the PWB Box. ☞ 112 3. Remove two Screws [1] and Connec- tor [2], and remove the Tray 1 Paper Size Board Assy [3].
  • Page 125 6. Other Field Service Ver. 1.0 Jul. 2005 3. Remove the Screw [2], and remove the Metal blanking plate [3]. 4038F2C090DA 4. Remove the Harness [5] from the Wire saddle [4]. 4038F2C091DA 5. Remove all the Connectors on the Tray 2 Control Board. 4038F2C092DA...

  • Page 126: Tray 2 Paper Size Board (Pwb-I-Pc)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6. Remove four Screws [6], and remove the Tray 2 Control Board [7]. 4038F2C093DA 6.3.26 Tray 2 Paper Size Board (PWB-I-PC) 1. Slide out the Tray 2. 2. Remove the Tray 2 Rear Right Cover and Tray 2 Rear Left Cover.
  • Page 127 6. Other Field Service Ver. 1.0 Jul. 2005 5. Remove the Harness [5] from the Edge cover [4]. 4038F2C094DB 6. Remove three Screws [6], and remove the Tray 2 Control Board Assy [7]. 4038F2C095DA 7. Remove two Claws [8] and the Con- nector [9], and remove the Tray 2 Paper Size Board Assy [10].

  • Page 128: Inverter Board (Pu201)

    Field Service Ver. 1.0 Jul. 2005 6. Other 8. Remove the Lever [11], and remove [11] the Tray 2 Paper Size Board [12]. [12] 4038F2C517DA 6.3.27 Inverter Board (PU201) 1. Remove the Scanner Assy. ☞ 103 2. Remove four Screws [1], Flat Cable [2] and Connector [3], and remove the Inverter Board [4].
  • Page 129 6. Other Field Service Ver. 1.0 Jul. 2005 4. Remove seven Screws [3], and remove the Right Door Switch Assy [4]. 4038F2C098DA 5. Remove the Screw [5] each, and remove the Imaging Unit contact Assy [6] of each color. 4038F2C099DA 6.

  • Page 130: Multi Bypass Unit

    Field Service Ver. 1.0 Jul. 2005 6. Other 7. Remove all the Connectors and the Flat Cables on the PH Interface Board. 4038F2C101DA 8. Remove two Screws [9] and six tabs [10] [10], and remove the PH Interface Board [11]. [11] [10] 4038F2C102DB...
  • Page 131 6. Other Field Service Ver. 1.0 Jul. 2005 3. Remove four Screws [2], and remove the Multi Bypass Unit [3]. 4038F2C104DA NOTE • When installing the Multi Bypass Unit, fit the position of dowel shown in the left illustration. 4038F2C105DA...

  • Page 132: Ph Unit

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.30 PH Unit A. Removal Procedure 1. Remove the Front Cover. ☞ 64 2. Remove the Image Transfer Belt Unit. ☞ 31 3. Remove the Screw [1] and discon- nect the Connector [2] respectively, and remove three Imaging Unit Guide rails [3].
  • Page 133 6. Other Field Service Ver. 1.0 Jul. 2005 6. Remove the Stopper [8] of the PH Unit (Black). NOTE • When removing the Stopper, use care so that both ends of the Stop- per will not open but stay parallel as shown on the left.
  • Page 134 Field Service Ver. 1.0 Jul. 2005 6. Other Remove the PH Unit [14]. [14] 8. Follow the same procedures to remove all PH Units. 4037F2C112DB B. Reinstall Procedure 1. Fit the back of the PH Unit [1] into the plate spring [2] of installation plate.
  • Page 135 6. Other Field Service Ver. 1.0 Jul. 2005 4. Reinstall the Stopper [7]. NOTE • When reinstalling the Stopper, use care so that both ends of the Stop- per will not open but stay parallel as shown on the left. Keep using the Stopper after once stretched out may cause uneven pitch or other image troubles.

  • Page 136: Transport Drive Assy

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.31 Transport Drive Assy 1. Remove the PWB Box. ☞ 112 2. Remove the High Voltage Unit. ☞ 80 3. Remove the Color Developing Motor. ☞ 115 4. Remove the Color PC Drum Motor. ☞...
  • Page 137 6. Other Field Service Ver. 1.0 Jul. 2005 9. Remove five Screws [7] and the Connector [8], and remove the Rear Handle Assy [9]. 4038F2C121DA 10. Disconnect the Connector [10]. [12] 11. Remove the Harnesses [12] from [11] five Wire Saddles [11]. [12] [10] [11]...

  • Page 138: Hopper Drive Assy

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.32 Hopper Drive Assy 1. Remove the Transfer Drive Assy. ☞ 93 2. Disconnect seven Connectors [1]. 4038F2C124DB 3. Remove the Harness from four Wire Saddles [2]. 4038F2C125DA 4. Remove two Screws [3], and remove the Duct [4].

  • Page 139: Right Door Assy

    6. Other Field Service Ver. 1.0 Jul. 2005 5. Remove four Screws [5] and two Claws [6], and remove the Hopper Drive Assy [7]. 4038F2C127DA 6.3.33 Right Door Assy 1. Remove the PWB Box. ☞ 112 2. Remove the High Voltage Unit. ☞...
  • Page 140 Field Service Ver. 1.0 Jul. 2005 6. Other 6. Remove the Screw [3] fixing the IR cable. 4038F2C155DA 7. Remove six Screws [4], and remove the Motor cover [5]. 4038F2C156DA 8. Open the Right Door. 9. Remove three Screws [6], and remove the Reinforcement plate [7] of the right door and spring [8].
  • Page 141 6. Other Field Service Ver. 1.0 Jul. 2005 10. Remove the Shoulder Screw [9]. 4038F2C576DA 11. Remove two Screws [10], and remove the Metal blanking plate [11]. [10] [11] 4038F2C577DA 12. Remove five Screws [12] and the [12] [13] [12] Connector [13], and remove the Rear Handle Assy [14].
  • Page 142 Field Service Ver. 1.0 Jul. 2005 6. Other 13. Disconnect four Connectors [15]. [15] [15] [15] [15] 4038F2C579DA 14. Remove the Front Door. [17] [16] ☞ 59 15. Slide out the Tray 1. 16. Remove two Screws [16], and remove the Front Right Cover [17]. [16] 4038F2C580DA 17.

  • Page 143: Scanner Motor (M201)

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.34 Scanner Motor (M201) A. Removal Procedure 1. Remove the Upper Rear Cover and the IR Upper Rear Cover. ☞ 57, 54 2. Remove the Harness from two Wire Saddles [1] and the Edge Cover [2]. 4038F2C128DA 3.
  • Page 144 Field Service Ver. 1.0 Jul. 2005 6. Other 4. Remove 16 screws [5], and remove the IR reinforcement frame [6]. 4038F2C130DA 5. Remove the Tension spring [7] for the Scanner Motor belt. 4038F2C131DA 6. Disconnect the Connector [8]. 4038F2C132DB...
  • Page 145 6. Other Field Service Ver. 1.0 Jul. 2005 7. Remove three Screws [9], and remove the Scanner Motor Assy [10]. [10] 4038F2C133DB 8. Remove two Screws [11], Set screw [12], Damper [13], and remove the [14] Scanner Motor [14]. [12] [13] [11] 4037F2C134DB...

  • Page 146: Scanner Assy

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.35 Scanner Assy 1. Remove the Original Glass. ☞ 56 2. Move the Scanner Assy [1] to the notch position shown in the left illus- tration, and remove the mounting screws [2] at front and rear. 4038F2C135DB NOTE •...

  • Page 147: Scanner Drive Cables

    6. Other Field Service Ver. 1.0 Jul. 2005 4. Remove the Screw [5], and remove the Holder [6]. 5. Peel off the aluminum tape, and remove the flat cable [7]. 6. Remove the Scanner Assy [8]. 4038F2C136DA 6.3.36 Scanner Drive Cables A.
  • Page 148 Field Service Ver. 1.0 Jul. 2005 6. Other 4. Remove the IR Front Cover. ☞ 56 5. Remove the Screw [3], and remove the Ground cable from the Wire Sad- dle [4]. 6. Remove four screws [5], and remove the Control panel base [6]. 4038F2C139DA 7.
  • Page 149 6. Other Field Service Ver. 1.0 Jul. 2005 13. Remove the Screw [12], and remove [12] the Scanner drive gear [13]. [13] 4038F2C553DA 14. Snap off the C-clip [14], and remove the Bushing [15] (front). [15] [14] 4038F2C554DA 15. Slide the Shaft [16] toward the rear [16] [17] and lift it.
  • Page 150 Field Service Ver. 1.0 Jul. 2005 6. Other (2) Reinstallation Procedure <Front> 1. Position the round bead [1] of the Scanner Drive Cable in the pulley [2] as shown. NOTE • Make sure that the bead snugly rests in the slit in the pulley. 4036fs2554c0 2.
  • Page 151 6. Other Field Service Ver. 1.0 Jul. 2005 6. Wind the fixed bead end of the cable around the pulley five turns clock- wise, from the front toward the rear side. NOTE • Make sure that no part of the cable rides on the other.
  • Page 152 Field Service Ver. 1.0 Jul. 2005 6. Other 10. Mount the Scanner drive gear [11] [13] on the shaft [12] and secure it using the screw [13]. [12] NOTE • Allow a clearance of about 0.3 mm between the Scanner drive gear and bushing.
  • Page 153 6. Other Field Service Ver. 1.0 Jul. 2005 14. Wind the hook end of the cable [24] around pulley A [25] and pulley B [26]. [26] [24] [25] 4036fs2566c0 15. Fit the hook end of the cable [27] to the spring [28] and then hook the spring to the catch A in the frame.
  • Page 154 Field Service Ver. 1.0 Jul. 2005 6. Other 19. Fit the hook end of the cable [37] to the spring [38] and then hook the spring to the catch A in the frame. 20. Measure the Spring length, and check if its length is within the range of 63.0 mm ±...

  • Page 155: Pwb Box

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.37 PWB Box 1. Remove the Upper Rear Cover, Lower Rear Cover and Rear Right Cover. ☞ 57, 59 2. Remove thirteen Screws, and remove the Shield cover [1]. 4038F2C507DA 3. Disconnect the Flat Cable [2] on the MFP Control Board, and remove two Presser Bars [3] of Flat Cable.
  • Page 156 Field Service Ver. 1.0 Jul. 2005 6. Other 5. Disconnect three Connectors [6] on the Slide Interface Board. 4038F2C142DA 6. Disconnect the Connector [7], and remove the Harness from the Wire Saddle [8]. 7. Remove two tabs [9], and remove [10] the Cooling Fan Motor/2 [10].
  • Page 157 6. Other Field Service Ver. 1.0 Jul. 2005 9. Remove the Harness [13] from two [14] Edge Covers [14]. [14] [13] 4038F2C145DB 10. Disconnect the Connector [15], and remove the Harness from the Wire Saddle [16]. [16] [15] 4038F2C146DA 11. Remove the Screw [17] of the [17] Ground terminal.

  • Page 158: Color Developing Motor (M3)

    Field Service Ver. 1.0 Jul. 2005 6. Other 12. Remove eight Screws [18], and remove the PWB Box [19]. [18] [18] [18] [19] [18] 4038F2C148DB 6.3.38 Color Developing Motor (M3) 1. Remove the PWB Box. ☞ 112 2. Remove the Connector [1] and four Screws [2], and remove the Color Developing Motor [3].

  • Page 159: Color Pc Drum Motor (M2)

    6. Other Field Service Ver. 1.0 Jul. 2005 6.3.39 Color PC Drum Motor (M2) 1. Remove the PWB Box. ☞ 112 2. Remove the Connector [1] and four Screws [2], and remove the Color PC Drum Motor [3]. 4038F2C150DA 6.3.40 Toner Supply Motor C/K (M7) 1.

  • Page 160: Main Motor (M1)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.42 Main Motor (M1) 1. Remove the PWB Box. ☞ 112 2. Remove the IR Right Cover. ☞ 54 3. Remove the Harness from the Edge Cover [1]. 4038F2C153DA 4. Remove the Harness from the Wire Saddle [2].
  • Page 161 6. Other Field Service Ver. 1.0 Jul. 2005 6. Remove six Screws [4], and remove the Motor cover [5]. 4038F2C156DA 7. Remove the Connector [6] and four Screws [7], and remove the Main Motor [8]. 4038F2C157DA...

  • Page 162: Fusing Drive Motor (M4)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.43 Fusing Drive Motor (M4) 1. Remove the PWB Box. ☞ 112 2. Remove the IR Right Cover. ☞ 54 3. Remove the Harness from the Edge Cover [1]. 4038F2C153DA 4. Remove the Harness from the Wire Saddle [2].
  • Page 163 6. Other Field Service Ver. 1.0 Jul. 2005 6. Remove six Screws [4], and remove the Motor cover [5]. 4038F2C156DA 7. Remove the Connector [6] and two Screws [7], and remove the Fusing Drive Motor [8]. 4038F2C158DA...

  • Page 164: Tray 2 Lift-Up Motor (M3-Pc)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.44 Tray 2 Lift-Up Motor (M3-PC) 1. Pull out the Tray 2. 2. Remove the Tray 2 Rear Right Cover. ☞ 63 3. If the optional paper feed cabinet is mounted, remove it. 4.
  • Page 165 6. Other Field Service Ver. 1.0 Jul. 2005 4. Remove the Harness of the Motor Assy [4] from five Wire Saddles [3]. 5. Disconnect two Connectors [5]. 4038F2C167DA 6. Remove two Screws [6], and remove the Motor Assy [7]. 4038F2C168DA 7.

  • Page 166: Tray 2 Vertical Transport Motor (M2-Pc)

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.3.46 Tray 2 Vertical Transport Motor (M2-PC) 1. Pull out the Tray 2. 2. Remove the Tray 2 Rear Right Cover and the Tray 2 Rear Left Cover. ☞ 63 3. Remove two Screws [1], and remove the Reinforcement plate [2].

  • Page 167: Idc/Registration Sensor/1, Idc/Registration Sensor/2 (Se1/Se2)

    6. Other Field Service Ver. 1.0 Jul. 2005 7. Remove two Screws [8], and remove the Tray 2 Vertical Transport Motor [9]. 4038F2C520DA 6.3.47 IDC/Registration Sensor/1, IDC/Registration Sensor/2 (SE1/SE2) 1. Remove the Image Transfer Belt Unit. ☞ 31 2. Remove the Multi Bypass Unit. ☞...
  • Page 168 Field Service Ver. 1.0 Jul. 2005 6. Other 6. Remove the Claws [6] of both sides, and remove the Sensor cover [7]. NOTE • Use care not to miss the spring [8]. 4038F2C171DA 7. Remove two Screws [9] and Connec- tor [10], and remove the IDC/Regis- tration Sensor/1 [11].

  • Page 169: Cleaning Procedure

    6. Other Field Service Ver. 1.0 Jul. 2005 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 6.4.1 PH Window 1. Open the Front Door. 2. Remove the PH Window Cleaning Jig [1]. 4038F2C547DA 3.

  • Page 170: Image Transfer Belt Unit

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.4.2 Image Transfer Belt Unit 1. Remove the Image Transfer Belt Unit. ☞ 31 2. Using a dried soft cloth, wipe the Image Transfer Belt [1]. NOTE • If it is difficult to clean with dried soft cloth, dampen a soft cloth with a solvent.

  • Page 171: Bypass Tray Feed Roller

    6. Other Field Service Ver. 1.0 Jul. 2005 3. Using a soft cloth dampened with alcohol, wipe the Tray 1 Separation Roller [3] clean of dirt. 4038F2C176DA 6.4.5 Bypass Tray Feed Roller 1. Remove the Multi Bypass Unit. ☞ 87 2.

  • Page 172: Tray 2 Feed Roller/Tray 2 Pick-Up Roller

    Field Service Ver. 1.0 Jul. 2005 6. Other 3. Remove the Screw [3], and remove the Bypass Tray Separation Roller Assy [4]. 4038F2C010DA 4. Using the soft cloth dampened with alcohol, wipe the Bypass Paper Sep- aration Roller [5]. 4038F2C178DA 6.4.7 Tray 2 Feed Roller/Tray 2 Pick-up Roller 1.
  • Page 173 6. Other Field Service Ver. 1.0 Jul. 2005 4. Remove two Screws [3], and remove the Jam processing cover [4]. NOTE • Make sure the position of the Mylar when installing the Jam processing cover. 4038F2C012DB 5. Remove two Screws [5] and the Tray 2 Separation Roller installation plate Assy [6].

  • Page 174: Tray 2 Separation Roller

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.4.8 Tray 2 Separation Roller 1. Slide out the Tray 2. 2. Open the Vertical transport door. 3. Remove two Claws [1], and remove the Vertical transport door [2]. 4038F2C011DA 4. Remove two Screws [3], and remove the Jam processing cover [4].

  • Page 175: Tray 2 Transport Roller

    6. Other Field Service Ver. 1.0 Jul. 2005 6. Using a soft cloth dampened with alcohol, wipe the Tray 2 Separation Roller [7]. 4038F2C523DA 6.4.9 Tray 2 Transport Roller 1. Open the Vertical Transport Door. 2. Using a soft cloth dampened with alcohol, wipe the Tray 2 Transport Roller [1].

  • Page 176: Mirrors (1St/2Nd/3Rd)

    Field Service Ver. 1.0 Jul. 2005 6. Other 2. Remove two Screws [3] and two Original Glass fixing brackets [4] (at the front and rear). 3. Remove the Original Glass [5]. 4038F2C504DA 4. Using a soft cloth dampened with alcohol, wipe the Scanner Rails [6] clean of dirt.

  • Page 177: Lens

    6. Other Field Service Ver. 1.0 Jul. 2005 6.4.12 Lens 1. Remove the Original Glass. ☞ 56 2. Remove two Screws [1] and Lens cover [2]. 4038F2C181DA 3. Using a soft cloth dampened with alcohol, wipe the Lens [3] clean of dirt.

  • Page 178: Ccd Sensor

    Field Service Ver. 1.0 Jul. 2005 6. Other 6.4.14 CCD Sensor 1. Remove the Original Glass. ☞ 56 2. Remove seven Screws [1] and CCD Unit protective cover [2]. 4038F2C069DA 3. Remove two hooks [3] and the lens cover [4]. 4038F2C184DA 4.

  • Page 179: Mount The Original Size Detecting Sensor/2 (Pc204)

    6. Other Field Service Ver. 1.0 Jul. 2005 Mount the original size detecting sensor/2 (PC204) 1. Remove the Original glass. 2. Using the screw [2], mount the Origi- nal Size Detection Sensor/2 (PC204) [1] and fix it. 4037F2C113DB <How to set the Harness> PC203 PC204 4037F2C114DB...
  • Page 180 Field Service Ver. 1.0 Jul. 2005 6. Other 3. Select [Service Mode] → [System 1] → [Original Size Detection], and set the Original Glass to [Table2]. 4037F2E530DA 4. Select [Service Mode] → [Machine] → [Org. Size Detecting Sensor Adj]. ☞ 234 5.

  • Page 181: Option Counter

    6. Other Field Service Ver. 1.0 Jul. 2005 Option counter 6.6.1 Installation method for the Key Counter 1. cut out the Knockouts [1] of the Upper Rear Cover. 2. Remove the Upper Rear Cover. ☞ 57 4038F2C569DA 3. Pass the Key Counter Harness [2] through the hole.
  • Page 182 Field Service Ver. 1.0 Jul. 2005 6. Other 7. Using four screws [8], secure the Counter Mounting Bracket [7]. NOTE • Secure the Counter Mounting Bracket passing the connector into the bracket. • Use the four long screws (9646 0418 14: M4x18) in the Key Counter Kit to secure the Counter Mounting Bracket.
  • Page 183 6. Other Field Service Ver. 1.0 Jul. 2005 11. Fix the harness [15] with the cable [14] clamp [14] as shown in the left figure. 12. Select Service Mode → [Billing Set- ting] → [Management Function [15] Choice] → [Key Counter]. Press [Set], and set Color Mode and Mes- sage.

  • Page 184: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 7. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance Checks •...

  • Page 185: Utility Mode

    8. Utility Mode Field Service Ver. 1.0 Jul. 2005 Utility Mode Touch Panel Adjustment Functions • To adjust the position of the Touch Panel display • Make this adjustment if the Touch Panel is slow to respond to a pressing action. •...

  • Page 186: Utility Mode Function Tree

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Utility Mode function tree * The function tree is shown to comply with the format displayed on the screen. NOTE • Keys displayed on screens are different depending on the setting. •...
  • Page 187 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 System Paper Tray Auto Tray User Setting Setting Setting Switch ON/OFF ☞ ☞ No Matching Paper in Tray Setting Print Lists Reset System Auto Setting Reset Auto Reset When Job Reset Account is changed Auto Color...
  • Page 188 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Display Scan Basic Program User Setting Setting Screen Default Default ☞ ☞ Address Book Default Index Address Type Symbol Dis- play Fax Basic Screen Default Tab Default Setting Default Program Address Book Default Index Address Type Symbol Dis-...
  • Page 189 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 Auto Magnifi- Copier User Setting cation Selec- Setting tion (Platen)* ☞ ☞ Auto Magnifi- cation Selec- tion (ADF)* Specify Default Tray when APS Off* Select Tray for Insert Sheet* Print Jobs During Copy Operation** Scanner...
  • Page 190 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Printer Paper User Setting Staple Setting Setting ☞ ☞ Hole-Punch PCL Setting Typeface Symbol Set Font Size Line/Page CR/LF Mapping PS Setting PS Error Print Configuration Print Reports Page Demo Page PCL Font List PS Font List Administrator...
  • Page 191 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 Administrator System Weekly Weekly Timer ON/OFF Setting Setting Setting Timer Setting ☞ ☞ Time Setting Date Setting Select Time for Power Save Password for Non-Busi- ness Hours Restrict User Restrict Access to Access Saved Program Jobs Delete Saved...
  • Page 192 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Thick Paper Administrator System Expert Density Image Den- Setting Setting Adjustment Adjustment sity–Yellow ☞ ☞ Thick Paper Image Den- sity–Magenta Thick Paper Image Den- sity–Cyan Thick Paper Image Image Den- Stabilization sity–Black Black Image Density...
  • Page 193 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 Administrator System Expert ADF Adjust- Original Stop Setting Setting Adjustment ment *** Position*** ☞ ☞ Centering Auto Adjustment*** Auto Adj. of Stop Position*** Management Job Settings List/Counter List List Paper Size/ Type Counter Standard Original Glass...

  • Page 194: General

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Administrator One-Touch Public/Per- User Box Text *1 Setting Registration sonal User Box ☞ ☞ Bulletin Board User Box *1 One-Touch Address Book Registration List List Group List Program List E-Mail Sub- ject/Text List User Authenti- General...
  • Page 195 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 Administrator Network AppleTalk Setting Setting Setting ☞ ☞ LDAP Enabling Setting LDAP Setting Up LDAP E-Mail E-Mail TX Setting (SMTP) E-Mail RX (POP) Detail Device Setting Setting Time Adjust- ment Setting Notification Status Notifi- Address...
  • Page 196 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Print Jobs Administrator Copier During Copy Setting Setting Operation ☞ ☞ Printer Local I/F Setting Timeout ☞ Parallel I/F IEEE 1284/ Fax Setting Header Infor- mation *1 ☞ Header Header/Footer Position Position *1 Footer Position *1...
  • Page 197 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 Administrator Fax Setting TX/RX Incorrect User Box No. Entry Setting Setting *1 ☞ ☞ Tray Selection for RX Print Min. Reduction for RX Print Print Separate Fax Pages *1 File After Poll- ing TX *1 Function Function ON/...
  • Page 198 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Administrator Fax Setting Report Broadcast Result Report Setting Settings *1 ☞ ☞ Paper Tray for Reports *1 Job Settings TX Result Report Check List *1 System IS OpenAPI Access Connection Setting Setting ☞...
  • Page 199 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 Meter Count Details Copy Print Scan/Fax Other...

  • Page 200: Utility Mode Function Setting Procedure

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Utility Mode function setting procedure 8.3.1 Procedure 1. Press the Utility/Counter key. 2. The Utility mode screen will appear. 4037F3E522DA 8.3.2 Exiting • Touch the [Close] key. 8.3.3 Changing the setting value in Utility Mode functions •...

  • Page 201: One-Touch Registration

    8. Utility Mode Field Service Ver. 1.0 Jul. 2005 One-Touch Registration 8.4.1 Scan A. Address Book (1) E-Mail Functions • To register/change e-mail address to send scanned data. Setting/ • A new address can be registered by touching [New]. Procedure •...

  • Page 202: Fax

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode D. Subject/Text (for E-mail) (1) Subject Functions • To register the e-mail subject when transmitting the scanned data. Setting/ • A new address can be registered by touching [New]. Procedure • Select any displayed address to detail check, edit or delete the setting. •...
  • Page 203 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 B. Group Functions • To register/change a group of addresses to send Fax data simultaneously. Setting/ • A new group can be registered by touching [New]. Procedure • Select any displayed group to check, edit or delete the setting. •...

  • Page 204: User Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode User Setting 8.5.1 System Setting A. Language Selection Functions • To select the language on the LCD display. • To change the language on the control panel to another language. Setting/ •...
  • Page 205 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (4) Print Lists Functions • To set the Paper Feed Tray for output the list for the Meter count or the Unit check. Setting/ • The default setting is “Tray 1.” Procedure D.

  • Page 206: Display Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode <When NEXT JOB is selected: Staple Setting> Functions • To set whether to cancel the staple setting when the Staple setting job started and the next job setting has become available. Setting/ •...
  • Page 207 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 B. Scan Basic Screen Default Seeing (1) Default Tab Functions • To set the Basic Screen display in Scanner mode. • To change the Basic Screen display in Scanner mode. Setting/ •...
  • Page 208 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (3) Address Book Default Index Functions • To set the default display for abbreviation/address screen during Fax mode. • To keep the default display instead of abbreviations/address search string which fre- quently changes during Fax mode.

  • Page 209: Initial Setting

    8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (2) RX Display Functions • To set the screen display on the control panel when receiving Fax. • To display [Receiving] on the screen when receiving the Fax. Setting/ • The default setting is OFF. Procedure “OFF”...
  • Page 210 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode B. Auto Booklet ON when Fold & Staple Functions • To set whether to set the Auto Booklet when Fold & Staple is selected. • To cancel setting the Auto Booklet when Fold & Staple is selected. Setting/ •...

  • Page 211: Scanner Setting

    8. Utility Mode Field Service Ver. 1.0 Jul. 2005 H. Select Tray for Insert Sheet Functions • To select the default setting of the Tray for Cover sheet paper. Setting/ • The default setting is Tray 2. Procedure Print Jobs During Copy Operation Functions •...

  • Page 212: Printer Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode 8.5.6 Printer Setting A. Basic Setting (1) PDL Setting Functions • To set the PDL (Page Description Language) for PC printing. • To fix the PDL as necessary. It usually switches automatically. Setting/ •...
  • Page 213 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 B. Paper Setting (1) Paper Tray Functions • To set the Paper Feed Tray when not specified by the printer driver during PC print- ing. • To use when Paper Feed Tray cannot be specified by the printer driver when printing from Windows DOS, etc.
  • Page 214 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (6) Hole-Punch Functions • To select whether to make punch-holes or not when not specified by the printer driver during PC printing. • To use when the printer driver cannot specify punching during printing from Windows DOS, etc.
  • Page 215 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (5) CR/LF Mapping Functions • To set the mode for replacing data when printing the text data. • To change the mode for replacing data when printing the text data. Mode 1 : Replacing CR with CR-LF Mode 2 : Replacing LF with CR-LF Mode 3 : Replacing with CR-LF : Does not replace...

  • Page 216: Administrator Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Administrator Setting • The Administrator setting will be available by entering the administrator password (8 dig- its) set by the administrator setting or Service Mode. (The administrator password is initially set to “12345678.”) 8.6.1 System Setting A.
  • Page 217 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 B. Output Setting (1) Print/Fax Output Settings Functions • To set the timing for printing for the PC print job or Fax received. Batch Print : Starts printing when all data are received Page Print : Starts printing every time data for each page are received Setting/ <Printer>...
  • Page 218 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (2) Time Setting Functions • To set the time to turn ON/OFF the Weekly Timer for each day of the week. Setting/ 1. Touch the key of the day to be set. Procedure 2.
  • Page 219 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (2) Delete Saved Program Jobs Functions • To delete the registered Program Job. • To delete the registered Program Job. Setting/ 1. Touch the appropriate Program Job. Procedure 2. Touch [Delete]. 3.
  • Page 220 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (2) Printer Adjustment <Leading Edge Adjustment> Functions • To vary the print start position in the sub scan direction for each of different paper types in Tray 1. • The PH Unit has been replaced. •...
  • Page 221 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Centering> Functions • To vary the print start position in the main scan direction for each paper source. • The PH Unit has been replaced. • A paper feed unit has been added. •...
  • Page 222 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode <Centering (Duplex 2nd Side)> Functions • To vary the print start position in the main scan direction for each paper source in the 2-Sided mode. • To use when the optional Automatic Duplex Unit AD-503 is set up. •...
  • Page 223 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Media Adjustment> Functions • Adjust the 2nd image transfer output (ATVC) on the 1st page and the 2nd page for each paper type. • This function is provided to open [Transfer Output Fine Adjustment] → [2nd Transfer Adjust] of Service Mode up to Administrator and the fine-adjusted value is reflected in the Service Mode setting.
  • Page 224 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (4) Density Adjustment <Thick Paper Image Density-Yellow, Magenta, Cyan, Black> Functions • To fine-adjust density of printed images of each color for thick paper and OHP trans- parencies. • To change the density of the printed image for each color with thick paper and OHP transparencies Adjustment Lighter (5 steps), “Std”, Darker (5 steps)
  • Page 225 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Initialize+Image Stabilization> Functions • To carry out an image stabilization sequence after the historical data of image stabili- zation control has been initialized. • Use if an image problem persists even after Gradation Adjustment has been exe- cuted.
  • Page 226 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (6) Color Registration Adjust <Color Registration Adjust (Yellow, Magenta, Cyan)> Functions • To adjust color shift if there is any when comparing the original with copy of the plain or thick paper. •...
  • Page 227 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (7) Gradation Adjustment Functions • To make an automatic adjustment of gradation based on the test pattern produced and the readings taken by the Scanner • Color reproduction performance becomes poor. •...
  • Page 228 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (8) Scanner Adjustment • Use the following Color Chart for the adjustment of the Scanner Section. • If the Color Chart is not available, a scale may be used instead. • A: Centering COLOR CHART COLOR CHART •...
  • Page 229 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Centering> Functions • To adjust part-to-part variations in accuracy of IR parts and their mounting accuracy by varying the scan start position in the main scan direction. • When the CCD Unit is replaced. •...
  • Page 230 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode <Horizontal Adjustment> Functions • To adjust the zoom ratio in the main scan direction for the Scanner Section • The CCD Unit has been replaced. Adjustment •Measure C width on the color chart and on Specification the sample copy, and adjust the gap to be within the following specification.
  • Page 231 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Vertical Adjustment> Functions • To adjust the zoom ratio in the sub scan direction for the Scanner Section • The Scanner Assy has been replaced. • The Scanner Motor has been replaced. •...
  • Page 232 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode <Original Stop Position> Functions • To make a manual adjustment of the document stop position and scanning position in each of the ADF modes. • To use when the “Auto Adj. of Stop Position” cannot make adjustment completely. Setting/ 1.
  • Page 233 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Auto Adj. of Stop Position: Front> Functions • Adjust the document stop position for the first side. • Check for skew. • Upon setup of the ADF Setting/ 1. Call the Administrator Setting to the Procedure screen.

  • Page 234: Administrator/Machine Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (2) Paper Size/Type Counter Functions • To register the combination of the specific paper size and the paper type, and to set the count. Setting/ 1. Press a key out of 1 to 10 registration keys. Procedure 2.
  • Page 235 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <FTP> Functions • To register and change the FTP address for transmitting the scanned data by FTP. Setting/ • Touch [New] to register the new address. Procedure • Select any displayed address to check, edit, or delete the setting. <SMB>...
  • Page 236 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode <Text> Functions • To register the e-mail message for transmitting the scanned data by e-mail. Setting/ • Touch [New] to register the new message. Procedure • Select any displayed message to detail check or delete the setting. •...
  • Page 237 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (4) Subject/Text (for E-mail) <Subject> Functions • To register the e-mail Subject for transmitting the Fax original by e-mail. Setting/ • Touch [New] to register the new subject. Procedure • Select any displayed subject to detail check, edit, or delete the setting. •...

  • Page 238: User Authentication/Account Track

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (3) Program List Functions • To output the Program List. • To print out the list of the Program addresses which are registered. Setting/ 1. Select the Destination Type to be output. Procedure 2.
  • Page 239 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (4) Account Track Input Method Functions • To set the Authentication method for the Account Track. • To select whether to authenticate by password or by account name & password. Setting/ •...
  • Page 240 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode B. User Authentication Setting • The settings are available only when carrying out the User Authentication. (1) Administrative Setting <User Name List> Functions • To set whether to display or not the list key for User names on User Authentication screen.

  • Page 241: Network Setting

    8. Utility Mode Field Service Ver. 1.0 Jul. 2005 C. Account Track Setting • The settings are available only when carrying out the Account Track. (1) Account Track Registration Functions • To register and change the Account. • To register, change or delete the account for Account Track. Setting/ 1.
  • Page 242 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (2) IP Address Functions • To set the IP address of the device used in the network. • To enter the IP address of the machine. Setting/ • IP address Version 4 format Procedure [0 to 255] .
  • Page 243 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (8) IP Filtering Functions • To set the IP Filtering. • To set whether to receive IP address within the specified range of the value. Setting/ <Permit Access> Procedure 1. Select Enable or “Disable” on [Permit Access]. 2.
  • Page 244 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (2) Ethernet Frame Type Functions • To set the Ethernet Frame Type. • To specify the Frame type for transmission. Setting/ • The default setting is Auto Detect. Procedure “Auto Detect” 802.2 802.3 Ethernet II...
  • Page 245 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (8) File Server Name Functions • To set the File server name. • To set the Full server name for the print server to logon. Setting/ 1. Touch [File Server Name]. Procedure 2.
  • Page 246 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (2) Accept IPP job Functions • To set whether to allow or restrict the IPP job. • To restrict the IPP job Setting/ • The default setting is ON. Procedure “ON” (3) Support Operation Functions •...
  • Page 247 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (4) Connection Timeout Functions • To set the timeout period for connecting to FTP server. • To change the timeout period for connecting. Setting/ 1. Touch [Input]. Procedure 2. Press the Clear key. 3.
  • Page 248 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (4) Print Service Name Functions • To set the Print service name. • To set the Print service name. Setting/ 1. Touch [Print Service Name]. Procedure 2. Enter the Print Service name (up to 13 characters) on the on-screen keyboard, and touch [OK].
  • Page 249 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 G. LDAP Setting (1) Enabling LDAP <LDAP Function> Functions • To set whether to enable or disable the LDAP function. • To use LDAP function. Setting/ • The default setting is OFF. Procedure “OFF”...
  • Page 250 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode <Enable SSL> Functions • To set whether to use SSL (data encryption) for connecting to LDAP server. • To use SSL (data encryption) for connecting to LDAP server. Setting/ • The default setting is OFF. Procedure “OFF”...
  • Page 251 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Domain Name> Functions • To set the Domain Name for connecting to LDAP server. • To set the Domain Name for connecting to LDAP server. Setting/ 1. Touch [Domain Name]. Procedure 2.
  • Page 252 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode <Binary Division> Functions • To set whether to carry out Binary division for data to be transmitted • Not to carry out Binary division for data to be transmitted Setting/ • The default setting is ON. Procedure “ON”...
  • Page 253 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 <Detail Setting: POP Before SMTP Time> Functions • To set the time necessary for POP Before SMTP Authentication. • To change the time necessary for POP Before SMTP Authentication. Setting/ 1. Touch [Input]. Procedure 2.
  • Page 254 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode Detail Setting (1) Device Setting <MAC Address> Functions • To display the MAC address of the machine. • To check the MAC address of the machine. Setting/ • The address cannot be changed. Procedure <Network Speed>...
  • Page 255 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (3) Status Notification Setting <Notification Address Setting> Functions • To set the e-mail address for notifying the machine condition. • To set the e-mail address for notifying the machine condition. Setting/ 1.

  • Page 256: Copier Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (7) LPD Setting Functions • To set whether to use LPD during printing or not. • Not to use LPD during printing. Setting/ • The default setting is Enable. Procedure “Enable” Disable (8) SNMP Setting Functions...

  • Page 257: Printer Setting

    8. Utility Mode Field Service Ver. 1.0 Jul. 2005 B. Auto Zoom (ADF) Functions • To set whether to function the Auto Zoom when the Feed Tray is selected with docu- ment set on the ADF (excepting at Automatic Paper Selection mode.) •...

  • Page 258: Fax Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode C. IEEE 1284/USB Functions • To set the interface to be used when mounting the Local I/F kit. • To be used when using the Parallel interface. Setting/ • The default setting is USB. Procedure IEEE1284 “USB”...
  • Page 259 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (2) Receive Mode Functions • To set the Fax reception mode. • To change to manual reception when using the remote reception function, etc. when connected to the external telephone. Setting/ •...
  • Page 260 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode D. TX/RX Setting (1) Duplex Print (RX) Functions • To set whether to carry out the Duplex print for the received original when receiving Fax. • To carry out the Duplex print for the received original. Setting/ •...
  • Page 261 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (6) Tray Selection for RX Print Functions • To select the Paper Tray to be fixed when printing the received text. • To fix the Paper tray when printing the received text. Setting/ •...
  • Page 262 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (2) Memory RX Functions • To set whether to use the forced memory RX function. • To store the received text in the hard disk without printing, and print it out when ordered.
  • Page 263 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 (7) TSI User Box Setting Functions • To set whether to use TSI distribution or not. • To use TSI distribution. Setting/ • The default setting is OFF. Procedure “OFF” • When set to [ON], set the reception box to receive data F.
  • Page 264 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (5) Confidential RX Report Functions • To set whether to print out the Confidential RX Report. • To print out the Confidential RX Report. Setting/ • The default setting is ON. Procedure “ON”...

  • Page 265: System Connection

    8. Utility Mode Field Service Ver. 1.0 Jul. 2005 8.6.9 System Connection A. IS OpenAPI Setting (1) Access Setting Functions • To allow or restrict the access from other systems with IS OpenAPI when using Page Scope Data Administrator. • To restrict access from other systems with IS OpenAPI. Setting/ •...

  • Page 266: Security Setting

    Field Service Ver. 1.0 Jul. 2005 8. Utility Mode 8.6.10 Security Setting A. Administrator Password Functions • To set/change the Administrator Password. • To change the Administrator Password. Setting/ • Enter the Administrator password on the on-screen keyboard. Procedure Current Password : Enter the current Administrator password New Password : Enter the new Administrator password to be used Re-Input Password : Reenter the new Administrator password...
  • Page 267 8. Utility Mode Field Service Ver. 1.0 Jul. 2005 D. Security Details (1) Password Rules Functions • To set whether to apply the Password rules. • To apply the password rule to enhance security. • Passwords to be covered: Password for CE, Administrator, Box user authentication, Fax confidential print, Classified document, User authenti- cation, and Box transmission •...
  • Page 268 Field Service Ver. 1.0 Jul. 2005 8. Utility Mode (3) Delete Secure Documents Functions • To delete the whole classified documents in the hard disk. Setting/ 1. Touch [Delete Secure Documents]. Procedure 2. Touch [Yes] on the Check screen. (4) Overwrite All Data Functions •...

  • Page 269: Adjustment Item List

    9. Adjustment item list Field Service Ver. 1.0 Jul. 2005 Adjustment item list Replacement Part/Service Job Adjustment/Setting Items ❍ Print Positioning: Leading Edge Printer ❍ Print Positioning: Side Edge Area Dup Print Positioning: Side Image position: Leading Edge Machine Image position: Side Edge Scan Area Cross Direction Adjustment...
  • Page 270 Field Service Ver. 1.0 Jul. 2005 9. Adjustment item list ✽ This table shows the adjustment items that are required when a part of the machine has been replaced. Priority order, if applicable, during the adjustment procedures is indicated by the corresponding number in the parentheses. ❍...

  • Page 271: 10. Service Mode

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.1 Service Mode function setting procedure NOTE • Ensure appropriate security for Service mode function setting procedures. They should NEVER be shown to any unauthorized person not involved with service jobs.

  • Page 272: 10.2 Service Mode Function Tree

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.2 Service Mode function tree ✽ The function tree is shown to comply with the format displayed on the screen. *1: Settings are available only when the Optional FAX Kit (FK-502) is mounted. Service Mode Machine Fusing Temperature...

  • Page 273: Maintenance

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 System 1 Marketing Area ☞ Tel/Fax Number Serial Number No Sleep Foolscap Size Setting Original Size Detection Install Date Initialization System 2 ☞ Image Controller Setting Option Board Status Consumable Life Reminder Unit Change Software Switch Setting Scan Calibration...
  • Page 274 Field Service Ver. 1.0 Jul. 2005 10. Service Mode List Output ☞ State Confirmation Sensor Check ☞ Table Number Level History1 Level History2 Temp. & Humidity CCD Check Memory/HDD Adj. Memory/HDD State Color Regist IU Lot No. Adjustment Data List Test Mode Gradation Pattern ☞...

  • Page 275: 10.3 Date/Time Input Mode

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 FAX *1 Fax File Format *1 ☞ Communication *1 List Output *1 Function Parameter *1 Initialization *1 Finisher ☞ 10.3 Date/Time Input mode • This mode is used to set time-of-day and date. 10.3.1 Date &...

  • Page 276: 10.4 Machine

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.4 Machine 10.4.1 Fusing Temperature Functions • To adjust individually the temperature of the Heating Roller and the Fusing Pressure Roller for each type of paper, thereby coping with varying fusing performance under changing environmental conditions.

  • Page 277: Fusing Transport Speed

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.4.2 Fusing Transport Speed Functions • To adjust the speed of the Fusing Drive Motor so as to match the fusing speed with transport speed. • Brush effect or blurred image is evident as a result of changes in environmental con- ditions or degraded durability.

  • Page 278: Printer Area

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.4.4 Printer Area A. Print Positioning: Leading Edge Functions • To vary the print start position in the sub scan direction for each of different paper types in Tray 1. • The PH Unit has been replaced. •...
  • Page 279 10. Service Mode Field Service Ver. 1.0 Jul. 2005 B. Print Positioning: Side Edge Functions • To vary the print start position in the main scan direction for each paper source. • The PH Unit has been replaced. • A paper feed unit has been added. •...
  • Page 280 Field Service Ver. 1.0 Jul. 2005 10. Service Mode C. Dup Print Positioning: Side Edge Functions • To vary the print start position in the main scan direction for each paper source in the 2-Sided mode. • The image on the backside of the 2-sided copy deviates in the main scan direction. Adjustment Width A •Width A on the test pattern produced should...

  • Page 281: Scan Area

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.4.5 Scan Area • Use the following Color Chart for the adjustment of the Scanner Section. • If the Color Chart is not available, a scale may be used instead. • A: Image Position: Side Edge COLOR CHART COLOR CHART •...
  • Page 282 Field Service Ver. 1.0 Jul. 2005 10. Service Mode B. Image Position: Side Edge Functions • To adjust part-to-part variations in accuracy of IR parts and their mounting accuracy by varying the scan start position in the main scan direction. •...
  • Page 283 10. Service Mode Field Service Ver. 1.0 Jul. 2005 C. Cross Direction Adjustment Functions • To adjust the zoom ratio in the main scan direction for the Scanner Section • The CCD Unit has been replaced. Adjustment •Measure C width on the color chart and on Specification the sample copy, and adjust the gap to be within the following specification.

  • Page 284: Printer Resist Loop

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode D. Feed Direction Adjustment Functions • To adjust the zoom ratio in the sub scan direction for the Scanner Section • The Scanner Assy has been replaced. • The Scanner Motor has been replaced. •...

  • Page 285: Field Service Ver. 1.0 Jul

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.4.7 Color Registration Adjustment A. Cyan, Magenta, Yellow Functions • To adjust color shift if there is any when comparing the original with copy of the plain or thick paper. • To correct any color shift Adjustment “0”...

  • Page 286: Fusing Loop Size

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.4.8 Fusing Loop Size Functions • To vary the timing to start fusing loop processing and adjust the fusing loop size at Envelope printing. • To be used when paper wrinkle or transfer misalignment occur at Envelope printing. Adjustment in +: Delay the timing to start fusing loop processing Adjustment in -: Put ahead the timing to start fusing loop processing Setting/...

  • Page 287: Troubleshooting

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.6 Imaging Process Adjustment 10.6.1 Gradation Adjust Functions • To make an automatic adjustment of gradation based on the test pattern produced and the readings taken by the Scanner • Color reproduction performance becomes poor. •...

  • Page 288: D Max Density

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.6.2 D Max Density Functions • To adjust gradation, color, and image density to target reproduction levels by varying the maximum amount of toner sticking to paper through auxiliary manual fine-adjust- ment of gamma of each color after Gradation Adjust.

  • Page 289: Background Voltage Margin

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.6.3 Background Voltage Margin Functions • To adjust the highlight portion (fog level) to the target reproduction level by making an auxiliary manual fine-adjustment of γ of each color after Gradation Adjust. •...

  • Page 290: Stabilizer

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode B. 1st Transfer Adjust Functions • Adjust the output value for the 1st image transfer voltage. • To use when white spots appeared. Adjustment “0” (-5 to +5) Range Adjustment Adjust the output value for the 1st image transfer voltage by; Instructions Increasing it: Increase the setting value (white spots will decrease) Decreasing it: Decrease the setting value...

  • Page 291: Thick Paper Density Adjustment

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 B. Initialize+Image Stabilization Functions • To carry out an image stabilization sequence after the historical data of image stabili- zation control has been initialized. • Use if an image problem persists even after Gradation Adjustment has been exe- cuted.

  • Page 292: Monochrome Density Adjustment

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.6.8 Monochrome Density Adjustment Functions • To fine-adjust the density of the printed image for a black copy • To vary the density of the printed image of a black copy Adjustment Lighter (2 steps), “Std”, Darker (2 steps) Range...

  • Page 293: 10.7 Cs Remote Care

    RAM for CS Remote Care before resetting. ☞ For clearing the RAM, see page 259. • When using the telephone line for connection, use the recommended modem. (For recommended modem, contact responsible person of KONICA MINOLTA.) Step Procedure Register the device ID to the application at CS Remote Care Center.
  • Page 294 Field Service Ver. 1.0 Jul. 2005 10. Service Mode Step Procedure Setting the Device ID 1. Select [Service Mode] → [CS Remote Care], and touch [Detail Setting]. 2. Touch [Machine Setting] → [Device ID], and input Device ID (nine digits). ☞...

  • Page 295: Software Sw Setting For Cs Remote Care

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.7.3 Software SW setting for CS Remote Care NOTE • SW bits data are written into the NVRAM every time a change is made. In case you changed bit data by accident, be sure to restore the previous state. A.
  • Page 296 Field Service Ver. 1.0 Jul. 2005 10. Service Mode SW No. Functions Default SW 05 Modem redial interval 4 to 7 Reservation — — SW 06 Modem redial times Reservation — — SW 07 Redial for response time out Do not redial Redial 1 to 7 Reserved —...
  • Page 297 10. Service Mode Field Service Ver. 1.0 Jul. 2005 SW No. Functions Default SW 12 Timer 2 Dial request completed → CONNECT reception SW 13 0 to 7 Reservation — — SW 14 Timer 4 Line connection → Start request telegram delivery SW 15 Timer 5...
  • Page 298 Field Service Ver. 1.0 Jul. 2005 10. Service Mode *1: Baud rate Mode 01-7 01-6 01-5 01-4 9600 bps 19200 bps “38400 bps” *2: Modem redial interval Mode 05-3 05-2 05-1 05-0 1 minute 2 minutes “3 minutes” 4 minutes 5 minutes 6 minutes 7 minutes...
  • Page 299 10. Service Mode Field Service Ver. 1.0 Jul. 2005 *5: Retransmission times on E-Mail delivery error Mode 09-6 09-5 09-4 09-3 09-2 09-1 09-0 0 to 9 times 000 0000 to 000 1001 “10 times” 11 to 99 times 000 1011 to 110 0011 *6: Timer 1 (RING reception →...

  • Page 300: Setup Confirmation

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.7.4 Setup confirmation • Follow the steps below to make sure that CS Remote Care has been properly set 1. Call the Service Mode to the screen. 2. Touch [CS Remote Care]. 3.

  • Page 301: Calling The Center From The Administrator

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.7.6 Calling the Center from the Administrator • When the CS Remote Care setup is complete, the administrator can call the CS Remote Care center. 1. Select [Administrator Setting], and touch [System Connection]. 2.
  • Page 302 Field Service Ver. 1.0 Jul. 2005 10. Service Mode C. Detail Setting (1) Basic Setting Functions • Execute the primary setting. • Use to change the set contents. • Use to register the machine to the CS Remote Care Center. Setting/ 1.
  • Page 303 10. Service Mode Field Service Ver. 1.0 Jul. 2005 (4) Communication Log Print Functions • To print out the Communication Log. • Use to output and use the Communication Log. Setting/ 1. Call the Service Mode on the screen. Procedure 2.

  • Page 304: List Of The Cs Remote Care Error Code

    0004 Timeout of Incoming request response • Contact responsible person of (No response to incoming (starting) request KONICA MINOLTA. MSG) 0005 Timeout of CONNECT at receiving • Check if the power of the (No response to ATA) modem is ON.
  • Page 305 Solution 000F Transmitting RING Buffer Full • Contact responsible person of (When the Transmitting RING Buffer is full.) KONICA MINOLTA. 0010 RX FIF0 ERROR • Contact responsible person of (when Read / Write error occurs at RX FIF0) KONICA MINOLTA.
  • Page 306 0021 Telegram Size Over • Contact responsible person of (The machine receives the telegram whose size KONICA MINOLTA. exceeds the specification.) 0022 Transmitting Phase Response NG • Contact responsible person of (Transmitting phase response MSG is not appro- KONICA MINOLTA.

  • Page 307: Troubleshooting For Cs Remote Care

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.7.10 Troubleshooting for CS Remote Care If communication is not done properly during use of the modem, check the condition by fol- lowing the procedures shown below. 1. Shift the screen in the order of [Service Mode] → [CS Remote Care] → [Detail Setting]. At this time, in the cases of Initial transmitting / Administrator transmitting / Mainte- nance Start transmitting / Maintenance Finish transmitting, the communication result will be displayed at the top of the screen.

  • Page 308: System 1

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.8 System 1 10.8.1 Marketing Area Functions • To make the various settings (language, paper size, fixed zoom ratios, etc.) according to the applicable marketing area. • Upon setup. Setting/ <Marketing Area> Procedure •...

  • Page 309: No Sleep

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.8.4 No Sleep Functions • To display the option of “OFF” for the Sleep Mode Setting screen available from Administrator Setting. • To display the option of “OFF” for the Sleep Mode Setting. NOTE •...

  • Page 310: Initialization

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.8.7 Initialization A. Data Clear Functions • To initialize the setting data. • To clears the setting data. ☞ For details on items to be cleared, see page 302 “Contents to be cleared by Reset function.”...

  • Page 311: Image Controller Setting

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.9.2 Image Controller Setting Functions • To set the type of the controller. • [Peripheral Mode] appears when [Others] is selected. • When setting up the controller. Setting/ Image Controller Setting Procedure •...

  • Page 312: Unit Change

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.9.5 Unit Change Functions • To select who is to replace a unit. • When the unit life arrives, the warning display is intended for the specific person who is going to replace the unit. When “User”...

  • Page 313: Line Mag Setting

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.9.9 Line Mag Setting Functions • To set whether to use the offset value which has been set prior to the shipping. • To be used after replacing the CCD unit. After replacing the CCD unit, the default value needs to be set since the magnifica- tion offset value between the lines set for each unit changes to control the differences in reading performance on each scanner (CCD).

  • Page 314: Data Capture

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.9.10 Data Capture Functions • When an error occurs, it acquires the print job data in order to analyze the cause of the error. • When an error occurs, this will be used to analyze the cause of the error according to the print job data.
  • Page 315 10. Service Mode Field Service Ver. 1.0 Jul. 2005 Setting/ 6. Using the “ls” command, display the list of the file available for capture. Procedure 4037F3E540DA 7. Using the “binary” command, set the File transfer mode to the binary transfer. 4037F3E541DA...
  • Page 316 Field Service Ver. 1.0 Jul. 2005 10. Service Mode Setting/ 8. Using the “get” command, transfer the data for capture to PC. Procedure 4037F3E542DA 9. Finish the command prompt. NOTE • When the data capture is set to [ON], all print job data will be stored in the hard disk.

  • Page 317: 10.10 Counter

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.10 Counter • The Counter displays the counts of various counters to allow the Technical Representa- tive to check or set as necessary. 10.10.1 Procedure 1. Touch [Counter] to show the Counter menu. 2.

  • Page 318: Jam

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.10.3 Functions • To check the number of misfeeds that have occurred at different locations in the machine. • To clear the count of each counter. • To check the number of paper misfeeds that have occurred Setting/ •...

  • Page 319: Service Total

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.10.7 Service Total Functions • To display the count value for the service total counter. • Use to check the total No. of printed pages including the ones printed by the Ser- vice Mode.

  • Page 320: 10.11 List Output

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.11 List Output 10.11.1 Machine Management List Functions • To produce an output of a list of setting values, adjustment values, Total Counter val- ues, and others. • At the end of setup or when a malfunction occurs. Setting/ •...

  • Page 321: 10.12 State Confirmation

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.12 State Confirmation 10.12.1 Sensor Check Functions • To display the states of the input ports of sensors and switches when the machine remains stationary. • Used for troubleshooting when a malfunction or a misfeed occurs. Setting/ •...
  • Page 322 Field Service Ver. 1.0 Jul. 2005 10. Service Mode B. Sensor Check Screens • These are only typical screens which may be different from what are shown on each indi- vidual machine. 4038F3E511DA...
  • Page 323 10. Service Mode Field Service Ver. 1.0 Jul. 2005 C. Sensor Check List (1) Sensors 1 (Main Unit, PC-103, PC-203) Symbol Panel Display Part/Signal Name Operation Characteristics/ Panel Display PC12 Tray 1 Device Tray 1 Set Sensor In position Out of Detection position PC10...
  • Page 324 Field Service Ver. 1.0 Jul. 2005 10. Service Mode Symbol Panel Display Part/Signal Name Operation Characteristics/ Panel Display Paper Registration Registration Roller Sensor Paper Paper not Pas- Roller present present sage Exit Exit Sensor Paper Paper not present present OHP Detect OHP Sensor Not OHP Fusing Loop...
  • Page 325 10. Service Mode Field Service Ver. 1.0 Jul. 2005 D. Sensors 2 (Main Unit, PC-403) Symbol Panel Display Part/Signal Name Operation Characteristics/ Panel Display PC4-LCT Lift-Up Upper Lift-Up Upper Sensor At raised Not at raised position position PC13-LCT Lift-Up Lower Lift-Up Lower Sensor At lower limit Not at lower limit...
  • Page 326 Field Service Ver. 1.0 Jul. 2005 10. Service Mode E. Sensors 3 (FS-501, JS-601) Operation Characteris- tics/Panel Display Symbol Panel Display Part/Signal Name PC1-FN Multi Exit (Non-sort1) 1st Tray Exit Sensor Paper Paper not Staple present present Finisher PC19-FN Exit (Non-sort3) Job Tray Exit Sensor Paper Paper not...
  • Page 327 10. Service Mode Field Service Ver. 1.0 Jul. 2005 F. Sensors 4 (FS-603, PK-501) Operation Characteris- tics/Panel Display Symbol Panel Display Part/Signal Name PI1-FN Sad- Entrance Entrance Sensor Paper Paper not present present Stitch PI2-FN Paddle Home Paddle Home Position Sensor Fin- PI3-FN Bundle Roller...
  • Page 328 Field Service Ver. 1.0 Jul. 2005 10. Service Mode Operation Characteris- tics/Panel Display Symbol Panel Display Part/Signal Name MS1-FN Sad- Front Door SW Front Door Open Sensor Open — Remain in — Paper Stitch Reverse Section horiz. side Fin- MS2-FN Joint SW Joint Open Sensor Open...
  • Page 329 10. Service Mode Field Service Ver. 1.0 Jul. 2005 G. Sensors 5 (Main Unit) Symbol Operation Characteris- tics/Panel Display Panel Display Part/Signal Name PC201 Scan- Home Sensor Scanner Home Sensor At home Out of home S201 Org. Original Cover Size Reset Switch Lowered Raised Detecti...

  • Page 330: Level History1

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.12.3 Level History1 Functions • To display TCR (T/C ratio), IDC/Regist Sensor output values, and fusing temperature. • Used for troubleshooting of image problems. Setting/ • TCR-C/-M/-Y/-K: Shows the T/C output reading taken last. Procedure •...

  • Page 331: Memory/Hdd Adj

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.12.7 Memory/HDD Adj. A. Memory Check Functions • To check correspondence of data written to and that read from memory through write/read check. Rough Check • A check is made to see if the image data reading and writing are correctly made in a very limited area.
  • Page 332 Field Service Ver. 1.0 Jul. 2005 10. Service Mode D. Work Memory In/Out Check Functions • To check to see if input and output of image data of work memory are correctly per- formed. • If the print image is faulty. Adjustment 1.

  • Page 333: Memory/Hdd State

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.12.8 Memory/HDD State Functions • To display the condition and amount of the memory and Hard disk. • Use to check the condition and amount of the memory and Hard disk. Setting/ •...

  • Page 334: 10.13 Test Mode

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.13 Test Mode • To check the image on the printer side by letting the machine produce various types of test pattern. It also tests the printing operation in running mode, as well as the Fax trans- mission.

  • Page 335: Halftone Pattern

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.13.3 Halftone Pattern Functions • To produce a solid halftone pattern. • Used for checking uneven density and pitch noise. Pattern SINGLE HYPER Gradation Cyan Density: 255 4036fs3043c0 Setting/ • # of Print (“1” to 999) Procedure •...

  • Page 336: Solid Pattern

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.13.5 Solid Pattern Functions • To produce each of the C, M, Y, and K solid patterns. • Used for checking reproducibility of image density. Pattern SINGLE HYPER Gradation Density: 255 4036fs3045c0 Setting/ •...

  • Page 337: Color Solid Pattern

    10. Service Mode Field Service Ver. 1.0 Jul. 2005 10.13.7 8 Color Solid Pattern Functions • To produce an 8-color solid pattern. • Used for checking color reproducibility and uneven density of each color. Pattern SINGLE HYPER Gradation Density: 255 4036fs3047c0 Setting/ •...

  • Page 338: 10.16 Finisher

    Field Service Ver. 1.0 Jul. 2005 10. Service Mode 10.16 Finisher ☞ For details on adjustment, see the Service Manual for Option FS-603. Functions • To adjust the positions of center staple and folding for the Finisher. • Use when the center staple and folding positions deviate from the correct ones in the copies made using the Fold &...

  • Page 339: 11. Enhanced Security

    11. Enhanced Security Field Service Ver. 1.0 Jul. 2005 11. Enhanced Security 11.1 Enhanced Security Function Setting Procedure 11.1.1 Procedure 1. Call the Service Mode to the screen. 2. Press the following keys in this order. → → Stop Clear 3.

  • Page 340: 11.3 Settings In The Enhanced Security

    [Administrator Setting] → [Security Setting] • NEVER forget the CE password. When forgetting the CE password, call responsible person of KONICA MINOLTA. 11.3.2 Administrator Password Functions •...

  • Page 341: Administrator Feature Level

    11. Enhanced Security Field Service Ver. 1.0 Jul. 2005 11.3.3 Administrator Feature Level Functions • To set which Modes to be allowed for the Administrator to use in Service Mode. • Use when allowing the Administrator to use some Modes in Service Mode. •...

  • Page 342: 12. Billing Setting

    Field Service Ver. 1.0 Jul. 2005 12. Billing Setting 12. Billing Setting 12.1 Billing Setting Function Setting Procedure 12.1.1 Procedure 1. Call the Service Mode to the screen. 2. Press the following keys in this order. → Stop 3. Billing Setting menu will appear. 4037F3E510DA 12.1.2 Exiting...

  • Page 343: 12.3 Settings In The Billing Setting

    12. Billing Setting Field Service Ver. 1.0 Jul. 2005 12.3 Settings in the Billing Setting 12.3.1 Counter Setting Functions • To set the counting method for the Total Counter and Size Counter. • To set the size regarded as the Large size (2 counts.) •...

  • Page 344: Management Function Choice

    Field Service Ver. 1.0 Jul. 2005 12. Billing Setting 12.3.2 Management Function Choice Functions • To set whether or not the Key Counter and Management Device are installed. • Use to change the counting method for the administrative units. Setting/ Key Counter Procedure •...

  • Page 345: 13. Procedure For Resetting

    13. Procedure for Resetting Field Service Ver. 1.0 Jul. 2005 13. Procedure for Resetting 13.1 Trouble resetting Functions • If the trouble occurs and the status would not be cleared by turning Main Power Switch OFF and ON again, or opening and closing the front door, clear the status of the machine.

  • Page 346: 14. Mechanical Adjustment

    Field Service Ver. 1.0 Jul. 2005 14. Mechanical adjustment 14. Mechanical adjustment 14.1 Mechanical adjustment of the scanner section 14.1.1 Adjustment of the Scanner Motor Belt This adjustment must be made in the following case: • The Scanner Motor Assy has been removed. •...
  • Page 347 14. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 4. Remove 16 screws [5], and remove the Reinforcement frame [6]. 4038F2C130DA 5. Loosen the three screws that secure the Scanner Motor mounting bracket [7]. 4038F2C568DA 6. With the Scanner drive gear set [11] [10] screw [8] located on the right-hand...

  • Page 348: Focus Positioning Of The Scanner And Mirrors Unit

    Field Service Ver. 1.0 Jul. 2005 14. Mechanical adjustment 14.1.2 Focus Positioning of the Scanner and Mirrors Unit This adjustment must be made in the following case: • The Scanner Drive Cables have been rewound 1. Remove two Screws [1] and Lens cover [2].

  • Page 349: 14.2 Scanner Position Adjustment

    14. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 14.2 Scanner Position Adjustment This adjustment must be made in the following case: • The Scanner Drive Cables have been rewound. • Focus Positioning of the Scanner and Mirrors Unit must be completed. 1.

  • Page 350: 14.3 Mechanical Adjustment Of The Bypass Tray Section

    Field Service Ver. 1.0 Jul. 2005 14. Mechanical adjustment 14.3 Mechanical adjustment of the bypass tray section 14.3.1 Adjustment of the Bypass Paper Size Unit This adjustment must be made in the following case: • The Bypass Paper Size Unit has been removed. 1.
  • Page 351 14. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 3. When the Bypass Paper Size Unit base is mounted, align the lever position of the Bypass Paper Size Unit with the tab at the center in a straight line. 4038F3C512DA 4.

  • Page 352: 14.4 Ph Unit Mechanical Adjustment

    Field Service Ver. 1.0 Jul. 2005 14. Mechanical adjustment 14.4 PH Unit Mechanical Adjustment 14.4.1 Skew Adjustment This adjustment must be made in the following case: • When PH Unit is replaced. 1. Turn on the Main Power Switch. 2. Select [Service Mode] → [Test Mode] →...
  • Page 353 14. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 • If the value is out of the specification, follow the procedures shown below to adjust it to satisfy the specification. • If the value satisfies the specification, proceed to step 9. 6.
  • Page 354 Field Service Ver. 1.0 Jul. 2005 14. Mechanical adjustment • If either value is out of the specifica- tion, follow the procedures shown below to adjust it to satisfy the specifi- cation. • If the value of all color, C, M, Y, K, sat- isfy the specification, proceed to step 11.
  • Page 355 14. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 356: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display Troubleshooting 15. Jam Display 15.1 Misfeed Display • When a paper misfeed occurs, the misfeed message, misfeed location, and paper loca- tion are displayed on the Touch Panel of the machine. [12] [10] [10]...

  • Page 357: Misfeed Display Resetting Procedure

    15. Jam Display Field Service Ver. 1.0 Jul. 2005 Display Code *1 Misfeed Location misfeed processing location Action ☞ 1101 Tray 1 feed section Right Door ☞ 3001 2nd Image Transfer section Right Door ☞ 1201 Tray 2 feed section Tray 2 Right Door 2001 Tray 2 vertical transport section...

  • Page 358: 15.2 Sensor Layout

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display 15.2 Sensor layout • System Mounted with PC-203. [10] 4038F4C510DA Exit Sensor Tray 2 Paper Take-Up Sensor PC9-PC Duplex Unit Transport Sensor 1 PC1 DU Tray 3 Vertical Transport Sensor PC117-PC Duplex Unit Transport Sensor 2 PC2 DU Tray 3 Take-up Sensor PC116-PC...
  • Page 359 15. Jam Display Field Service Ver. 1.0 Jul. 2005 • System Mounted with PC-403. 4038F4C511DA Exit Sensor Tray 2 Vertical Transport Sensor PC8-PC Duplex Unit Transport Sensor 1 PC1 DU Tray 2 Paper Take-Up Sensor PC9-PC Duplex Unit Transport Sensor 2 PC2 DU Vertical Transport Sensor PC2-LCT [4]*1 Registration Roller Sensor...

  • Page 360: 15.3 Solution

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display 15.3 Solution 15.3.1 Initial Check Items • When a paper misfeed occurs, first make checks of the following initial check items Check Item Action Does paper meet product specifications? Change paper. Change paper.

  • Page 361: Misfeed At Tray 1 Feed Section

    15. Jam Display Field Service Ver. 1.0 Jul. 2005 15.3.2 Misfeed at Tray 1 feed section A. Detection Timing Type Description Detection of The leading edge of the paper does not block the Registration Roller Sensor misfeed at Tray 1 (PC1) even after the lapse of a given period of time after the Tray 1 Paper Feed feed section Clutch (CL2) has been energized.

  • Page 362: Misfeed At 2Nd Image Transfer Section

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display 15.3.3 Misfeed at 2nd Image Transfer section A. Detection Timing Type Description The leading edge of the paper does not block the Exit Sensor (PC2) even after the Detection of lapse of a given period of time after the Registration Roller Clutch (CL1) has been misfeed at 2nd energized.

  • Page 363: Misfeed At Tray 2 Feed, Tray 2 Vertical Transport Section

    15. Jam Display Field Service Ver. 1.0 Jul. 2005 15.3.4 Misfeed at Tray 2 feed, Tray 2 vertical transport section A. Detection Timing Type Description Detection of The leading edge of the paper does not block the Tray 2 Vertical Transport Sensor misfeed at Tray 2 (PC8-PC) even after the lapse of a given period of time after the Tray 2 Paper feed section...

  • Page 364: Misfeed At Manual Bypass Feed Section

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display 15.3.5 Misfeed at Manual Bypass feed section A. Detection Timing Type Description Detection of The leading edge of the paper does not block the Registration Roller Sensor misfeed at Manual (PC1) even after the lapse of a given period of time after the Bypass Paper Feed Bypass feed Clutch (CL5) has been energized.

  • Page 365: Misfeed At Lct Feed And Lct Vertical Transport Section (Pc-403)

    15. Jam Display Field Service Ver. 1.0 Jul. 2005 15.3.6 Misfeed at LCT feed and LCT vertical transport section (PC-403) A. Detection Timing Type Description Detection of The leading edge of the paper does not block the Paper Take-up Sensor (PC1- misfeed at LCT LCT) or Vertical Transport Sensor (PC2-LCT) even after the lapse of a given feed section...

  • Page 366: Misfeed At Tray 3 Feed And Tray 3 Vertical Transport Section

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display 15.3.7 Misfeed at Tray 3 Feed and Tray 3 vertical transport section (PC-103/PC203) A. Detection Timing Type Description The leading edge of the paper does not block the Tray 3 Vertical Transport Sensor (PC117-PC) even after the lapse of a given period of time after the Tray3 Take-up Motor (M122-PC) has been energized.

  • Page 367: Misfeed At Tray 4 Feed And Tray 4 Vertical Transport Section (Pc203)

    15. Jam Display Field Service Ver. 1.0 Jul. 2005 15.3.8 Misfeed at Tray 4 Feed and Tray 4 vertical transport section (PC203) A. Detection Timing Type Description Detection of The leading edge of the paper does not block the Tray 4 Vertical Transport Sensor misfeed at Tray 4 (PC126-PC) even after the lapse of a given period of time after the Tray4 Take-up feed or Vertical...

  • Page 368: Misfeed At Duplex Transport Section (Ad-503)

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display 15.3.9 Misfeed at Duplex transport section (AD-503) A. Detection Timing Type Description The Duplex Unit Transport Sensor 2 (PC2 DU) is not blocked even after the lapse of a given period of time after the paper has blocked the Duplex Unit Transport Sensor 1 (PC1 DU).

  • Page 369: Misfeed At Duplex Unit Pre-Registration Section (Ad-503)

    15. Jam Display Field Service Ver. 1.0 Jul. 2005 15.3.10 Misfeed at Duplex Unit pre-registration section (AD-503) A. Detection Timing Type Description Detection of The Registration Roller Sensor (PC1) is not blocked even after the lapse of a misfeed at Duplex given period of time after a Duplex paper feed sequence has been started.

  • Page 370: Misfeed At Fusing/Exit Section

    Field Service Ver. 1.0 Jul. 2005 15. Jam Display 15.3.11 Misfeed at Fusing/Exit section A. Detection Timing Type Description PC2 is not unblocked even after the lapse of a given period of time after the paper has blocked the Exit Sensor (PC2). Detection of misfeed at Fusing/ The Duplex Unit Transport Sensor 1 (PC1 DU) is not blocked even after the lapse...

  • Page 371: 16. Malfunction Code

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.1 Alert code • The machine’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel.

  • Page 372: Alert List

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.1.1 Alert list • If an image stabilization or Scanner fault occurs, the corresponding warning code appears. Code Item Description CCD clamp gain adjustment failure • It is detected that the CCD clamp gain adjustment value is faulty.

  • Page 373: 16.2 Solution

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.2 Solution 16.2.1 S-1: CCD clamp/gain adjustment failure Relevant Electrical Parts Scanner Assy CCD Sensor Board (PWB-A) Image Processing Board (PWB-C) Step Action Correct the harness connection between PWB-A and PWB-C if faulty. Check for possible extraneous light and correct as necessary.

  • Page 374: P-6: Cyan Imaging Unit Failure

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.2.4 P-6: Cyan Imaging Unit failure 16.2.5 P-7: Magenta Imaging Unit failure 16.2.6 P-8: Yellow Imaging Unit failure 16.2.7 P-9: Black Imaging Unit failure Relevant Electrical Parts Imaging Unit /C Image Transfer Belt Unit Imaging Unit /M High Voltage Unit (HV1) Imaging Unit /Y...

  • Page 375: P-26: 1St Image Transfer Atvc (Black) Failure

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.2.10 P-26: 1st image transfer ATVC (Black) failure 16.2.11 P-27: 2nd image transfer ATVC failure 16.2.12 P-29: 1st image transfer ATVC (Color) failure Relevant Electrical Parts High Voltage Unit (HV1) Image Transfer Belt Unit Mechanical Control Board (PWB-M) Step Action...

  • Page 376: P-31: Black Pc Drum Sensor Malfunction

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.2.14 P-31: Black PC Drum Sensor malfunction Relevant Electrical Parts Black PC Drive Main Sensor (PC15) Transport Drive Assy Black PC Drive Sub Sensor (PC16) Mechanical Control Board (PWB-M) Step Action Perform the faulty sensor check procedure *1.

  • Page 377: 16.3 Trouble Code

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.3 Trouble code • The machine’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel. 4038F4E513DA 16.3.1 Trouble code list * For the details of the malfunction codes of the options, see the Service Manual for the cor- responding option.
  • Page 378 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Description Rank C0301 Suction Fan Motor's failure to • The Fan Lock signal remains HIGH for a predeter- turn mined continuous period of time while the Motor remains stationary. ☞...
  • Page 379 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Description Rank C2151 2nd Image Transfer Roller • The 2nd Image Transfer Pressure Position Sensor Separation doesn’t turn ON (Retracting) even after the lapse of a given period of time after the 2nd Image Transfer Pressure/Retraction Motor has started rotating during the 2nd Image Transfer Roller is retracting.
  • Page 380 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Description Rank C2554 Abnormally high toner density • TC ratio in the developing machine, which is detected Magenta TCR Sensor determined by Toner replenishing amount control mechanism, is 12 % or more for a given number of times consecutively.
  • Page 381 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Description Rank C3451 Heat. Heater Trouble • The Heating Roller Thermistor/1 (TH1) and the Heating Roller Thermistor/2 (TH3) fails to raise a given degree of temperature even after the lapse of a given period of time after the Heating Roller Heater lamp/1 (H1) is turned ON.
  • Page 382 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Description Rank C3A01 Paper Stuck to Fuser Heater • The temperature of the Heating Roller Thermistor Roller /1 (TH1) goes down by a given level of degree compared to the temperature of a given period of time before when the paper passes on the Timing Roller and blocks the Exit Sensor (PC2).
  • Page 383 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Description Rank C5351 Power Supply Cooling Fan • The Fan Lock signal remains HIGH for a predeter- Motor/1's failure to turn mined continuous period of time while the Motor remains stationary.
  • Page 384 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Description Rank CA053 Controller start failure • A controller start failure is detected in the control- ler interface. ☞ CB001 FAX Board Error 1 See FK-502 Service Manual. CB002 FAX Board Error 2 CB003 FAX Board Error 3 CB051 FAX Board mount failure 1 CB052 FAX Board mount failure 2...
  • Page 385 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Description Rank ☞ CB130 MIF Driver Error: Driver Soft See FK-502 Service Manual. Error CB131 MIF Driver Error: Reception Frame Length Error from Main CB132 MIF Driver Error: Reception Frame Header Error from Main CB133 MIF Driver Error: 232C i/f Sequence Error...
  • Page 386 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Description Rank ☞ CB163 1 Destination Control: Message See FK-502 Service Manual. Que Control Error CB164 1 Destination Control: Sema- phore Acquisition Release Error CB165 1 Destination Control: Observer Registration Error CB166 1 Destination Control: Reception Resource Check Error...
  • Page 387 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Description Rank CC153 ROM contents error upon • A fault is detected in a sequence of ROM contents startup (PRT) check of the Mechanical Control Board (PWB-M) during starting. CC154 ROM contents error upon •...
  • Page 388 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Description Rank CEEE2 Scanner Section undefined • An undefined malfunction occurs in the Scanner malfunction Section. CEEE3 Engine Section undefined • An undefined malfunction occurs in the Engine malfunction Section (PWB-M, etc.).
  • Page 389 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CF121 Expand TIME OUT • MFP Control Board CF122 Expand Table OverFlow • MFP Control Board CF123 Expand ExpandLine Abnormal • MFP Control Board CF131 Print TIME OUT •...
  • Page 390 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CF550 Parity error + Overrun error • MFP Control Board CF560 Overrun error + Framing error • MFP Control Board CF570 Parity error + Overrun error + •...
  • Page 391 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CF912 SIO Receiving Port...Fiery • MFP Control Board CF915 SIO Receiving Port... • MFP Control Board PIC/PIC Terminal CF9ED SIO Receiving Port...EPNet •...
  • Page 392 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CFA33 Software rotating processing • MFP Control Board start CFA34 Other Sequence malfunction • MFP Control Board CFA35 Buffer Array malfunction • MFP Control Board CFA36 Thread Service malfunction •...
  • Page 393 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CFB6E Underrun at DMA_D 0 image • MFP Control Board output interface 1 CFB6F Underrun at DMA_D 1 image • MFP Control Board output interface 1 CFB70 Underrun at DMA_D 2 image •...
  • Page 394 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CFD01 ASIC10 Timeout Number of • MFP Control Board DMA under operation and trans- fer completion line=0: DMA_A1 CFD02 ASIC10 Timeout Number of •...
  • Page 395 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CFD11 ASIC10 Timeout Number of • MFP Control Board DMA under operation and trans- fer completion line=0: DMA 19 ASIC1 CFD12 ASIC10 Timeout Number of •...
  • Page 396 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CFE0C ASIC10 Timeout Number of • MFP Control Board DMA under operation and trans- fer completion line≠0: DMA_H1 CFE0D ASIC10 Timeout Number of •...
  • Page 397 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CFF07 ASIC10 Timeout Waiting state of • MFP Control Board DMA band preparation register setting:DMA_D CFF08 ASIC10 Timeout Waiting state of • MFP Control Board DMA band preparation register setting:DMA_E CFF09 ASIC10 Timeout Waiting state of...

  • Page 398: 16.4 How To Reset

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.4 How to reset • Different malfunction resetting procedures apply depending on the rank of the trouble code. * List of Malfunction Resetting Procedures Trouble Code Rank Resetting Procedures • Trouble Reset ☞...

  • Page 399: 16.5 Solution

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5 Solution 16.5.1 C0204: Tray 2 Elevator failure Relevant Electrical Parts Tray 2 Lift-Up Sensor (PC7-PC) Tray 2 Control Board (PWB-Z-PC) Tray 2 Lift-Up Motor (M3-PC) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the M3-PC connector for proper...

  • Page 400: C0301: Suction Fan Motor's Failure To Turn

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.3 C0301: Suction Fan Motor’s failure to turn Relevant Electrical Parts Mechanical Control Board (PWB-M) Right Door Assy WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the connector of motor for proper —...

  • Page 401: C2152: Transfer Belt Separation

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.5 C2152: Transfer Belt Separation Relevant Electrical Parts 1st Image Transfer Pressure/Retraction Position Main Motor (M1) Sensor (PC6) Mechanical Control Board (PWB-M) 1st Image Transfer Pressure/Retraction Clutch (CL3) WIRING DIAGRAM Step Action Location (Electri- Control Signal...

  • Page 402: C2255: Color Developing Motor's Failure To Turn

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.8 C2255: Color Developing Motor’s failure to turn Relevant Electrical Parts Color Developing Motor (M3) DC Power Supply (PU1) Mechanical Control Board (PWB-M) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the connector of motor for proper —...

  • Page 403: C2551: Abnormally Low Toner Density Detected Cyan Tcr Sensor

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.11 C2551: Abnormally low toner density detected Cyan TCR Sensor 16.5.12 C2553: Abnormally low toner density detected Magenta TCR Sensor 16.5.13 C2555: Abnormally low toner density detected Yellow TCR Sensor Relevant Electrical Parts Imaging Unit /C Mechanical Control Board (PWB-M) Imaging Unit /M...

  • Page 404: C2557: Abnormally Low Toner Density Detected Black Tcr Sensor

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.17 C2557: Abnormally low toner density detected Black TCR Sensor Relevant Electrical Parts Imaging Unit /K Mechanical Control Board (PWB-M) Toner Supply Motor C/K (M7) MFP Control Board (PWB-MFP) WIRING DIAGRAM Step Action Location (Electri-...

  • Page 405: C2559: Cyan Tcr Sensor Adjustment Failure

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.19 C2559: Cyan TCR Sensor adjustment failure 16.5.20 C255A: Magenta TCR Sensor adjustment failure 16.5.21 C255B: Yellow TCR Sensor adjustment failure Relevant Electrical Parts Imaging Unit /C Mechanical Control Board (PWB-M) Imaging Unit /M MFP Control Board (PWB-MFP) Imaging Unit /Y...

  • Page 406: C2651: Cyan Imaging Unit Eeprom Access Error

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.23 C2651: Cyan Imaging Unit EEPROM access error 16.5.24 C2652: Magenta Imaging Unit EEPROM access error 16.5.25 C2653: Yellow Imaging Unit EEPROM access error 16.5.26 C2654: Black Imaging Unit EEPROM access error Relevant Electrical Parts Imaging Unit /C Mechanical Control Board (PWB-M)

  • Page 407: C3301: Fusing Cooling Fan Motor /1'S Failure To Turn

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.31 C3301: Fusing Cooling Fan Motor /1’s failure to turn Relevant Electrical Parts Fusing Cooling Fan Motor/1 (M11) Mechanical Control Board (PWB-M) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the connector of motor for proper —...

  • Page 408: C3451: Heat. Heater Trouble

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.33 C3451: Heat. Heater Trouble 16.5.34 C3452: Press. Heater Trouble 16.5.35 C3751: Abnormal High Temp. (Heater) 16.5.36 C3752: Abnormal High Temp. (Press) 16.5.37 C3851: Abnormal Low Temp. (Heater) 16.5.38 C3852: Abnormal Low Temp. (Press) Relevant Electrical Parts Fusing Unit DC Power Supply (PU1)
  • Page 409 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.40 C3A01: Paper Stuck to Fuser Heater Roller 16.5.41 C3A02: Paper Stuck to Fuser Pressure Roller Relevant Electrical Parts Fusing Unit DC Power Supply (PU1) Exit Sensor (PC2) Mechanical Control Board (PWB-M) WIRING DIAGRAM Step Action...
  • Page 410 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.46 C4551: Laser malfunction (Cyan) 16.5.47 C4552: Laser malfunction (Magenta) 16.5.48 C4553: Laser malfunction (Yellow) 16.5.49 C4554: Laser malfunction (Black) Relevant Electrical Parts PH Unit PH Interface Board (PWB-D) Mechanical Control Board (PWB-M) WIRING DIAGRAM Step Action...
  • Page 411 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.51 C4761: Compression hardware timeout 16.5.52 C4765: Extraction hardware timeout 16.5.53 C4770: JBIG0 Error 16.5.54 C4771: JBIG1 Error 16.5.55 C4772: JBIG2 Error 16.5.56 C4773: JBIG3 Error 16.5.57 C4780: Compressor 0 command buffer stop failure 16.5.58 C4781: Compressor 1 command buffer stop failure 16.5.59...
  • Page 412 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.62 C5103: Main Motor Turning at abnormal timing Relevant Electrical Parts Main Motor (M1) Mechanical Control Board (PWB-M) DC Power Supply (PU1) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) M1 operation check PWB-M CNDM1-5 (REM) PWB-M CNDM1-8 (LOCK)
  • Page 413 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.65 C5354: Ozone Ventilation Fan Motor’s failure to turn Relevant Electrical Parts Ozone Ventilation Fan Motor (M14) Mechanical Control Board (PWB-M) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the connector of motor for proper —...
  • Page 414 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.68 C6102: Drive Home Sensor malfunction 16.5.69 C6103: Slider Over Run Relevant Electrical Parts Scanner Home Sensor (PC201) Scanner Motor Drive Board (PWB-IC) Scanner Motor (M201) Image Processing Board (PWB-C) WIRING DIAGRAM Step Action Location (Electri-...
  • Page 415 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.71 C6704: Image Input Time Out Relevant Electrical Parts MFP Control Board (PWB-MFP) Image Processing Board (PWB-C) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Select [Service Mode] → [State Confirma- tion] →...
  • Page 416 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.73 C9401: Exposure Lamp’s failure to turn ON 16.5.74 C9402: Exposure Lamp turning ON at abnormal timing Relevant Electrical Parts Scanner Assy Image Processing Board (PWB-C) Flat Cable WIRING DIAGRAM Step Action Location (Electri- Control Signal...
  • Page 417 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.78 CC001: Vendor connection failure Relevant Electrical Parts Mechanical Control Board (PWB-M) Coin Vendor (Japan) Coin Vendor Kit (North America, Europe) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the Vendor connector for proper —...
  • Page 418 Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.84 CD002: JOB RAM save error Relevant Electrical Parts MFP Control Board (PWB-MFP) Hard Disk WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the Hard Disk connector for proper —...
  • Page 419 16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.97 CD010: Hard disk unformat Relevant Electrical Parts MFP Control Board (PWB-MFP) Hard Disk WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Select [Service Mode] → [State Confirma- tion] → [Memory/HDD Adj.] → [HDD For- —...

  • Page 420: 16.5.108 Ceee1: Msc Undefined Malfunction Occurring

    Field Service Ver. 1.0 Jul. 2005 16. Malfunction code 16.5.101 CE001: Abnormal message queue 16.5.102 CE002: Message and Method parameter failure 16.5.103 CE003: Task error 16.5.104 CE004: Event error 16.5.105 CE005: Memory access error 16.5.106 CE006: Header access error 16.5.107 CE007: DIMM initialize error Relevant Electrical Parts MFP Control Board (PWB-MFP) WIRING DIAGRAM...

  • Page 421: 16.5.110 Ceee3: Engine Section Undefined Malfunction

    16. Malfunction code Field Service Ver. 1.0 Jul. 2005 16.5.110 CEEE3: Engine Section undefined malfunction Relevant Electrical Parts Mechanical Control Board (PWB-M) WIRING DIAGRAM Step Action Location (Electri- Control Signal cal Component) Check the PWB-M connector for proper — — connection and correct as necessary.

  • Page 422: 17. Power Supply Trouble

    Field Service Ver. 1.0 Jul. 2005 17. Power supply trouble 17. Power supply trouble 17.1 Machine is not Energized at All (PU1 Operation Check) Relevant Electrical Parts Main Power Switch (S1) DC Power Supply (PU1) Mechanical Control Board (PWB-M) WIRING Step Check Item DIAGRAM...

  • Page 423: 17.3 Fusing Heaters Do Not Operate

    17. Power supply trouble Field Service Ver. 1.0 Jul. 2005 17.3 Fusing Heaters do not Operate Relevant Electrical Parts Primary Interlock Switch (S2) DC Power Supply (PU1) Fusing Unit WIRING Step Check Item DIAGRAM Result Action (Location) Is the power source voltage applied across Check wiring from PJ2PU1-1 to 3 on PU1? power outlet to S2 to...

  • Page 424: Finisher

    Field Service Ver. 1.0 Jul. 2005 17. Power supply trouble 17.4.3 Power is not Supplied to Automatic Duplex Unit WIRING Step Check Item DIAGRAM Result Action (Location) Is DC24 V being output from CN19-2 on Malfunction in Duplex. K-22 Duplex? Check wiring from Is DC24 V being output from CNDUP-2 on J-22...

  • Page 425: Image Quality Problem

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.1 How to read Element date • As part of troubleshooting procedures, the numeric values set for “State Confirmation” available from “Service Mode” can be used to isolate the cause of the image problem. 4038F4E514DA 18.1.1 Table Number...

  • Page 426: Level History 1

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.1.2 Level History 1 4038F4E515DA TCR-C • Shows the T/C ratio (in 0.01 % increments). TCR-M • Standard value: 8 ± 2 % TCR-Y • Relevant Components: PH Unit, TCR Sensor K TCR-K IDC1 •...

  • Page 427: Level History 2

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.1.3 Level History 2 4038F4E516DA IDC Sensor Adjust 1 • Shows the IDC intensity adjustment value. IDC Sensor Adjust 2 • It should normally be around 40 and can range from 0 to 255. •...

  • Page 428: How To Identify Problematic Part

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.2 How to identify problematic part • This chapter is divided into two parts: “Initial Check Items” and “Troubleshooting Proce- dure by a Particular Image Quality Problem.” • When an image quality problem occurs, first go through the “Initial Check Items” and, if the cause is yet to be identified, go to “Troubleshooting Procedure by a Particular Image Quality Problem.”...

  • Page 429: Initial Check Items

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 C. Initial Check Items 3 • If the printer is responsible for the image problem, let the machine produce a test print and determine whether the image problem occurs in a specific single color or four colors 4 Colors Mono Color 4038F4C509DA...

  • Page 430: 18.3 Solution

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3 Solution 18.3.1 IR System: white lines in Sub Scan Direction, white bands in Sub Scan Direction, colored lines in Sub Scan Direction, and colored bands in Sub Scan Direction A.

  • Page 431: Scanner System: White Lines In Main Scan Direction, White Bands In Main

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.2 Scanner System: white lines in Main Scan Direction, white bands in Main Scan Direction, colored lines in Main Scan Direction, and colored bands in Main Scan Direction A. Typical Faulty Images White lines in Main White bands in Main Color lines in Main...

  • Page 432: Scanner System: Color Spots

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.3 Scanner System: color spots A. Typical Faulty Images 4036fs4029c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original is damaged or dirty. YES Change original. Original Cover Original Pad is dirty.

  • Page 433: Scanner System: Fog

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.4 Scanner System: fog A. Typical Faulty Images ABCD ABCD ABCD ABCD ABCD 4036fs4030c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original is damaged or dirty. YES Change original. Original Cover Original Pad is dirty.

  • Page 434: Scanner System: Blurred Image, Blotchy Image

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.5 Scanner System: blurred image, blotchy image A. Typical Faulty Images 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original does not lie flat. YES Change original. Original Cover Original Cover does not lie flat.

  • Page 435: Scanner System: Incorrect Color Image Registration, Sync Shift (Lines In Main Scan Direction)

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.6 Scanner System: incorrect color image registration, sync shift (lines in main scan direction) A. Typical Faulty Images 4036fs4032c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original does not lie flat. YES Change original.

  • Page 436: Scanner System: Moire

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.7 Scanner System: moire A. Typical Faulty Images 4036fs4033c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Moire distortions recur even after Change the original mode the orientation of original has been (select one other than that changed.

  • Page 437: Scanner System: Skewed Image

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.8 Scanner System: skewed image A. Typical Faulty Images 4036fs4034c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original is skew. YES Reposition original. Original Glass Original Glass is in positive contact Reinstall the glass.

  • Page 438: Scanner System: Distorted Image

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.9 Scanner System: distorted image A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4035c0 B. Troubleshooting Procedure Step Section Check Item Result Action Installation Machine is installed on a level sur- Reinstall.

  • Page 439: Scanner System: Low Image Density, Rough Image

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.10 Scanner System: low image density, rough image A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4036c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original sticks to Original Glass. YES Reposition original.

  • Page 440: Scanner System: Defective Acs

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.11 Scanner System: defective ACS A. Typical Faulty Images Colored Area of Original ABCDE ABCDE ABCDE Black-and-White Area of Original ABCDE ABCDE 4036fs4037c0 B. Troubleshooting Procedure Step Section Check Item Result Action Auto Color Level...

  • Page 441: Scanner System: Blank Copy, Black Copy

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.12 Scanner System: blank copy, black copy A. Typical Faulty Images Blank copy Black copy 4036fs4038c0 4036fs4039c0 B. Troubleshooting Procedure Step Section Check Item Result Action Cable connecting Connector is connected properly Reconnect.

  • Page 442: Scanner System: Abnormal Image

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.13 Scanner System: abnormal image A. Typical Faulty Images ABCDE ABCDE Data on previous page ABCDE ABCDE ABCDE ABCDE ABCDE Data on current page ABCDE 4036fs4040c0 4036fs4042c0 4036fs4041c0 B. Troubleshooting Procedure Step Section Check Item...

  • Page 443: Printer Monocolor: White Lines In Sub Scan Direction, White Bands In Sub

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.14 Printer Monocolor: white lines in Sub Scan Direction, white bands in Sub Scan Direction, colored lines colored bands in Sub Scan Direction A. Typical Faulty Images White lines in Sub White bands in Sub Colored lines in Sub Colored bands in Sub...

  • Page 444: Printer Monocolor: White Lines In Main Scan Direction, White Bands In Main

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.15 Printer Monocolor: white lines in Main Scan Direction, white bands in Main Scan Direction, colored lines in Main Scan Direction, colored bands in Main Scan Direction A. Typical Faulty Images Colored bands in Main White bands in Main Colored lines in Main...

  • Page 445: Printer Monocolor: Uneven Density In Sub Scan Direction

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.16 Printer Monocolor: uneven density in sub scan direction A. Typical Faulty Images 4036fs4043c0 4036fs4044c0 4036fs4045c0 B. Troubleshooting Procedure Step Section Check Item Result Action High image Uneven density in Sub Scan Direc- YES Feed 10 to 20 blank sheets of density original tion occurs at a pitch of 40 mm to...

  • Page 446: Printer Monocolor: Uneven Density In Main Scan Direction

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.17 Printer Monocolor: uneven density in main scan direction A. Typical Faulty Images 4036fs4046c0 4036fs4047c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit The surface of the PC Drum is YES Change Imaging Unit.

  • Page 447: Printer Monocolor: Low Image Density

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.18 Printer Monocolor: low image density A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4036c0 B. Troubleshooting Procedure Step Section Check Item Result Action State Confirm → Check data for Vg and Vdc. Go to next step.
  • Page 448 Field Service Ver. 1.0 Jul. 2005 18. Image quality problem Step Section Check Item Result Action Image Process “Conv. Value” falls within the speci- YES Go to step 19. Adjustment fied range as checked through Gra- →Gradation Adjust dation Adjust. (Service Mode) Max: 0 ±...

  • Page 449: Printer Monocolor: Gradation Reproduction Failure

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.19 Printer Monocolor: gradation reproduction failure A. Typical Faulty Images 4036fs4048c0 4036fs4049c0 B. Troubleshooting Procedure Step Section Check Item Result Action Photo/Density Original type and screen pattern are Change screen pattern. selected properly.

  • Page 450: Printer Monocolor: Foggy Background

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.20 Printer Monocolor: foggy background A. Typical Faulty Images ABCD ABCD ABCD ABCD ABCD 4036fs4030c0 B. Troubleshooting Procedure Step Section Check Item Result Action State Confirma- Check data for Vg and Vb. Go to next step.
  • Page 451 18. Image quality problem Field Service Ver. 1.0 Jul. 2005 Step Section Check Item Result Action Image Process After the Reset + Stabilizer Go to next step. Adjustment sequence has been completed, run → Stabilizer → Gradation Adjust. Reset + Stabilizer (Service Mode) The problem has been eliminated Change Imaging Unit.

  • Page 452: Printer Monocolor: Void Areas, White Spots

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.21 Printer Monocolor: void areas, white spots A. Typical Faulty Images Void areas White spots 4036fs4051c0 4036fs4050c0 B. Troubleshooting Procedure Step Section Check Item Result Action ☞ Image Check There are void areas at the front side or high density section.

  • Page 453: Printer Monocolor: Colored Spots

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.22 Printer Monocolor: colored spots A. Typical Faulty Images Colored spots 4036fs4052c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit Developing bias contact terminal Clean contact terminal and makes good connection.

  • Page 454: Printer Monocolor: Blurred Image

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.23 Printer Monocolor: blurred image A. Typical Faulty Images Blurred image 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action PH Unit The surface of the PH Window is YES Clean with cleaning jig.

  • Page 455: Printer Monocolor: Blank Copy, Black Copy

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.24 Printer Monocolor: blank copy, black copy A. Typical Faulty Images Blank copy Black copy 4036fs4038c0 4036fs4039c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image Check A blank copy occurs. YES Check PH Unit connector for proper connection.

  • Page 456: Printer Monocolor: Uneven Image

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.25 Printer Monocolor: uneven image A. Typical Faulty Images 4138fs4507c0 B. Troubleshooting Procedure Step Section Check Item Result Action Toner Cartridge The Toner Cartridge of every Re-install it. color is surely installed. PH Unit The PH Unit is surely installed.

  • Page 457: Maintenance

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.26 Printer 4-Color: white lines in sub scan direction, white bands in sub scan direction, colored lines in sub scan direction, and colored bands in sub scan direction A. Typical Faulty Images White lines in Sub White bands in Sub Colored lines in Sub...

  • Page 458: Printer 4-Color: White Lines In Main Scan Direction, White Bands In Main Scan Direction, Colored Lines In Main Scan Direction, And Colored Bands In Main Scan Direction

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.27 Printer 4-Color: white lines in main scan direction, white bands in main scan direction, colored lines in main scan direction, and colored bands in main scan direction A. Typical Faulty Images White lines in Main White bands in Colored lines in Main...

  • Page 459: Printer 4-Color: Uneven Density In Sub Scan Direction

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.28 Printer 4-Color: uneven density in sub scan direction A. Typical Faulty Images 4036fs4043c0 4036fs4044c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image Transfer Fingerprints, oil, or other foreign YES Clean with specified solvent.

  • Page 460: Printer 4-Color: Uneven Density In Main Scan Direction

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.29 Printer 4-Color: uneven density in main scan direction A. Typical Faulty Images 4036fs4046c0 4036fs4047c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image Transfer Fingerprints, oil, or other foreign YES Clean with specified solvent.

  • Page 461: Printer 4-Color: Low Image Density

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.30 Printer 4-Color: low image density A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4036c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper is damp. YES Change paper to one just unwrapped from its package.

  • Page 462: Printer 4-Color: Poor Color Reproduction

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.31 Printer 4-Color: poor color reproduction A. Typical Faulty Images 4036fs4058c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper is damp. YES Change paper to one just unwrapped from its package.

  • Page 463: Printer 4-Color: Incorrect Color Image Registration

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.32 Printer 4-Color: incorrect color image registration A. Typical Faulty Images 4036fs4032c0 B. Troubleshooting Procedure Step Section Check Item Result Action Warning display The maintenance call mark is dis- YES Take action according to the played on the panel.

  • Page 464: Printer 4-Color: Void Areas, White Spots

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.33 Printer 4-Color: void areas, white spots A. Typical Faulty Images Void areas White spots 4036fs4051c0 4036fs4050c0 B. Troubleshooting Procedure Step Section Check Item Result Action ☞ Image Check There are void areas at the front side or high density section.

  • Page 465: Printer 4-Color: Colored Spots

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.34 Printer 4-Color: colored spots A. Typical Faulty Images 4036fs4052c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit The surface of the PC Drum is YES Change Imaging Unit. scratched.

  • Page 466: Printer 4-Color: Poor Fusing Performance, Offset

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.35 Printer 4-Color: poor fusing performance, offset A. Typical Faulty Images Poor fusing performance Offset 4036fs4059c0 4036fs4060c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper type does not match. YES Change the setting.

  • Page 467: Printer 4-Color: Brush Effect, Blurred Image

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.36 Printer 4-Color: brush effect, blurred image A. Typical Faulty Images Brush effect Blurred image 4036fs4061c0 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper is damp. YES Change paper to one just unwrapped from its package.

  • Page 468: Printer 4-Color: Back Marking

    Field Service Ver. 1.0 Jul. 2005 18. Image quality problem 18.3.37 Printer 4-Color: back marking A. Typical Faulty Images 4036fs4062c0 4036fs4063c0 B. Troubleshooting Procedure Step Section Check Item Result Action 2nd Image Trans- Image Transfer Roller is scratched YES Change 2nd Image Transfer fer Roller Unit or dirty.

  • Page 469: Printer 4-Color: Uneven Image

    18. Image quality problem Field Service Ver. 1.0 Jul. 2005 18.3.38 Printer 4-Color: uneven image A. Typical Faulty Images 4138fs4507c0 B. Troubleshooting Procedure Step Section Check Item Result Action Toner Cartridge The Toner Cartridge of every Re-install it. color is surely installed. PH Unit The PH Unit is surely installed.

  • Page 470: Appendix

    Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing Appendix 19. Parts layout drawing 19.1 Main unit 19.1.1 IR section [12] [11] [10] 4038F5E513DA Original Size Detecting Sensor/2 (PC204) Scanner Home Sensor (PC201) Image Processing Board (PWB-C) Original Cover Angle Sensor (PC202) CCD Sensor Board (PWB-A) Original Size Detecting Sensor/1 (PC203) Size Reset Switch (S201)

  • Page 471: Engine Section

    19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 19.1.2 Engine section [12] [11] [10] 4038F5C506DA IDC/Registration Sensor/2 (SE2) Mechanical Control Board (PWB-M) Control Panel (UN201) Slide Interface Board (PWB-SIF) IDC/Registration Sensor/1 (SE1) DIMM/0 (WORK0) High Voltage Unit (HV1) [10] DIMM/1 (WORK1) PH Interface Board (PWB-D) [11] NVRAM Board (PWB-NVR)
  • Page 472 Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing [13] [12] [11] [10] 4038F5C507DB Fusing Drive Motor (M4) Cooling Fan Motor/1 (M12) Main Motor (M1) Toner Supply Motor Y/M (M6) Fusing Cooling Fan Motor/2 (M11) [10] Cooling Fan Motor/2 (M22) Power Supply Cooling Fan Motor/1 (M8) [11] Toner Supply Motor C/K (M7) Color Developing Motor (M3)
  • Page 473 19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 [12] [11] [10] 4038F5C509DA Right Door Switch (S5) Front Door Switch/2 (S4) Primary Interlock Switch (S2) Hard Disk Drive (HDD) PH Unit Main Erase Lamp/Y (LA4) Main Power Switch (S1) [10] Main Erase Lamp/M (LA3) Total Counter (CNT1) [11] Main Erase Lamp/C (LA2)
  • Page 474 Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing [13] [12] [11] [10] 4038F5C511DB Developing Clutch/K (CL4) Waste Toner Full Sensor (PC8) Exit Sensor (PC2) Color PC Drive Main Sensor (PC17) Temperature/Humidity Sensor (SE3) [10] Color PC Drive Sub Sensor (PC18) Registration Roller Sensor (PC1) [11] Black PC Drive Main Sensor (PC15) OHP Sensor (PC4)

  • Page 475: Tray 1

    19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 19.1.3 Tray 1 4038F5C508DA Tray 1 Paper Feed Clutch (CL2) Tray 1 Paper Size Board (PWB-I) Tray 1 Paper Empty Sensor (PC10) Tray 1 Paper Near-Empty Sensor (PC11) Tray 1 CD Paper Size Sensor (PC9) Tray 1 Device Detection Sensor (PC12)

  • Page 476: Tray 2/Multiple Bypass Tray

    Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing 19.1.4 Tray 2/Multiple bypass tray [19] [18] [17] [16] [15] [14] [13] [12] [11] [10] 4038F5C504DA Tray 2 Vertical Transport Motor (M2-PC) [11] Tray 2 Lift-Up Sensor (PC7-PC) Tray 2 Door Set Sensor (PC5-PC) [12] Tray 2 Paper Size Board (PWB-I-PC) Bypass Lift-Up Sensor (PC14) [13] Tray 2 Control Board (PWB-Z-PC)

  • Page 477: Df-601 (Option)

    19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 19.2 DF-601 (Option) [17] [16] [15] [14] [13] [12] [11] [10] 4038F5C501DA Exit Motor (M3-DF) [10] Empty Sensor (PC4-DF) Exit Cover Sensor (PC7-DF) [11] Pick-up Sensor (PC2-DF) Exit Sensor (PC6-DF) [12] Registration Sensor (PC1-DF) Turnover Sensor (PC5-DF) [13] Take-up Motor (M1-DF)

  • Page 478: Pc103/Pc203 (Option)

    Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing 19.3 PC103/PC203 (Option) [26] [25] [23] [24] [22] [21] [20] [19] [18] [17] [16] [15] [10] [13] [11] [14] [12] 4037F5C511DA Tray 3 Vertical Transport Motor (M120-PC) [14] Tray 4 Near Empty Sensor (PC122-PC) Tray 4 CD Paper Size Sensor/2 Tray 3 Door Set Sensor (PC111-PC) [15]...

  • Page 479: Pc-403 (Option)

    19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 19.4 PC-403 (Option) [24] [23] [22] [21] [20] [19] [10] [11] [18] [12] [13] [17] [14] [15] [16] 4037F5C512DA Vertical Transport Motor (M2-LCT) [13] Manual Button Down Board (NU1-LCT) Door Set Sensor (PC5-LCT) [14] Shift Tray Stop Sensor (PC11-LCT) Vertical Transport Sensor (PC2-LCT) [15] Lift-Up Lower Sensor (PC13-LCT)

  • Page 480: Ad-503 (Option)

    Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing 19.5 AD-503 (Option) 4038F5C512DA Duplex Unit Transport Sensor 2 Duplex Unit Switchback Motor (M1 DU) (in PWB-A DU) (PC2 DU) Duplex Unit Door Set Sensor (PCI DU) Duplex Control Board (PWB-A DU) Duplex Unit Transport Sensor 1 Duplex Unit Transport Motor (M2 DU) (in PWB-A DU) (PC1 DU)

  • Page 481: Fs-501 (Option)

    19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 19.6 FS-501 (Option) [22] [21] [20] [19] [18] [17] [10] [16] [11] [15] [14] [13] [12] 4038F5C502DA CD Aligning Home Position Sensor Upper Cover Sensor (PC18-FN) [12] (PC9-FN) 1st Tray Full Sensor (PC6-FN) [13] Shift Home Position Sensor (PC10-FN) 1st Tray Exit Sensor (PC1-FN) [14] Shift Motor Pulse Sensor (PC11-FN)
  • Page 482 Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing [16] [15] [14] [13] [12] [11] [10] 4038F5C503DA Upper Entrance Motor (M4-FN) Exit Motor (M3-FN) Storage Roller Home Position Sensor Entrance Motor (M1-FN) [10] (PC12-FN) Exit Roller/Rolls Spacing Motor [11] Upper Paddle Motor (M15-FN) (M13-FN) Upper/Lower Entrance Switching Solenoid [12] Upper Paddle Solenoid (SL3-FN)

  • Page 483: Js-601 (Option)

    19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 19.7 JS-601 (Option) 4037F5C513DA Job Tray Cover Sensor (PC21-FN) Job Tray Full Sensor (PC20-FN) Job Tray Exit Sensor (PC19-FN) 3rd Entrance Switching Solenoid (SL-4)

  • Page 484: Fs-603 (Option)

    Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing 19.8 FS-603 (Option) [17] [16] [15] [14] [13] [12] [11] [10] 4037F5C516DA Transport Motor (M1-FN) [10] Shift Motor (M6-FN) Entrance Motor (M9-FN) [11] Slide Motor (M8-FN) Saddle Clutch (CL1-FN) [12] Exit Motor (M3-FN) Joint Open Switch (MS2-FN) [13] Rear Aligning Motor (M5-FN) Front Door Open Switch (MS1-FN)
  • Page 485 19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 [19] [20] [18] [17] [16] [15] [14] [13] [12] [11] [10] 4037F5C521DA Entrance Sensor (PI1-FN) [11] Saddle Tray Sensor (PI13-FN) Folding Roller Home Position Sensor [12] Shift Motor Clock Sensor (PI17-FN) (PI12-FN) Folding Home Position Sensor (PI11-FN) [13] Stack Full Sensor (PI24-FN)

  • Page 486: Pk-501 (Option)

    Field Service Ver. 1.0 Jul. 2005 19. Parts layout drawing 19.9 PK-501 (Option) [10] 4037F5C517DA Punch Motor (M1P-PK) Side Registration Motor (M2P-PK) Side Registration Home Sensor (PI2P-PK) Punch Trash Full LED Board (PWB-F PK) Punch Trash Full Photo Sensor Board Punch Motor Clock Board (PI3P-PK) (PWB-E PK) Photo Sensor Board (PWB-C PK)

  • Page 487: Horizontal Transport Unit

    19. Parts layout drawing Field Service Ver. 1.0 Jul. 2005 19.10 Horizontal Transport Unit 4037F5C518DA Entrance Switching Solenoid (SL1-HO) Paper Sensor (PC1-HO) Turnover Empty Sensor (PC6-HO) Horizontal Unit Door Sensor (PC4-HO)

  • Page 488: Connector Layout Drawing

    Field Service Ver. 1.0 Jul. 2005 20. Connector layout drawing 20. Connector layout drawing Description ➀ Number of Pin Possible to confirm by removing external cover. Not possible to confirm by removing external cover. [16] [15] [14] [13] [12] [11] [10] 4038F5C515DA CN No.
  • Page 489 20. Connector layout drawing Field Service Ver. 1.0 Jul. 2005 [16] [15] [14] [13] [12] [11] [10] 4038F5C516DA CN No. Location CN No. Location CN41 CN44 K-23 to 24 CN45 [10] CN40 E-10 E-19 [11] CN18 E-11 CN13 K-21 to 22 [12] CN60 E-26 to 27...
  • Page 490 Field Service Ver. 1.0 Jul. 2005 20. Connector layout drawing [12] [11] [10] 4038F5C517DA CN No. Location CN No. Location CN39 E-20 CN28 CN81 K to L-3 CN27 E-7 to 8 CN29 E-3 to 4 [10] CN32 E-12 CN22 [11] CN58 U-16 [12]...

  • Page 491: Timing Chart

    21. Timing chart Field Service Ver. 1.0 Jul. 2005 21. Timing chart 21.1 Main unit Print request received Polygon Motor Main Motor (M1) Color PC Drum Motor (M2) Developing Bias DC (Y/M/C/K) Color Developing Motor (M3) Drum Charge Corona Bias (Y/M/C/K) 1st Image Transfer pressure/retraction...

  • Page 492: Automatic Document Feeder

    Field Service Ver. 1.0 Jul. 2005 21. Timing chart 21.2 Automatic Document Feeder 1-sided mode...
  • Page 493 21. Timing chart Field Service Ver. 1.0 Jul. 2005...
  • Page 494 Field Service Ver. 1.0 Jul. 2005 21. Timing chart...
  • Page 495 21. Timing chart Field Service Ver. 1.0 Jul. 2005...
  • Page 496 Field Service Ver. 1.0 Jul. 2005 21. Timing chart Mixed original detection mode...
  • Page 497 21. Timing chart Field Service Ver. 1.0 Jul. 2005...
  • Page 498 Field Service Ver. 1.0 Jul. 2005 21. Timing chart...
  • Page 499 21. Timing chart Field Service Ver. 1.0 Jul. 2005...
  • Page 500 Field Service Ver. 1.0 Jul. 2005 21. Timing chart...
  • Page 501 21. Timing chart Field Service Ver. 1.0 Jul. 2005...
  • Page 502 Field Service Ver. 1.0 Jul. 2005 21. Timing chart...
  • Page 503 21. Timing chart Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 504: Standard Controller

    SERVICE MANUAL FIELD SERVICE Standard Controller 2005.07 Ver. 1.0...
  • Page 505 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.

  • Page 506: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 CONTENTS Standard Controller General Controller specifications ..................1 Type ........................1 Supporting client specifications ................2 Maintenance Checking the controller firmware version ..............3 Firmware upgrade ....................3 Preparations for Firmware rewriting..............3 3.1.1 Service environment ..................
  • Page 507 Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 508: General

    Field Service Ver. 1.0 Jul. 2005 1. Controller specifications General Controller specifications Type Type Built-in type controller 25 ppm (Color/B&W, A4 or 8-1/2 x 11 paper, and simplex) Print Speed 23 ppm (Color/B&W, A4 or 8-1/2 x 11 paper, and duplex) PCL5e/c Emulation Printer Language PCL6 (XL 2.1) Emulation...

  • Page 509: Supporting Client Specifications

    1. Controller specifications Field Service Ver. 1.0 Jul. 2005 Supporting client specifications IBM PC and its compatible 64 MB or more (128MB or more for XP) Windows 98/98SE, Windows Me, Windows 2000, Windows XP, Windows NT 4.0, Windows Server 2003 Connection Ethernet 10Base-T/100Base-TX method...

  • Page 510: Maintenance

    Field Service Ver. 1.0 Jul. 2005 2. Checking the controller firmware version Maintenance Checking the controller firmware version • The version of the controller firmware can be checked on the Control Panel of the machine. 1. Call the Service Mode to the screen. 2.
  • Page 511 3. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 3. Select “Install from Local Directory”, and click [Next (N)]. 4037F2E546DA 4. Specify the folder for installation. Check to make sure that “Root Directory” is in default setting, [C:\cygwin]. NOTE • Make sure to check that “Root Directory” is in default setting, [C:\cygwin]. •...
  • Page 512 Field Service Ver. 1.0 Jul. 2005 3. Firmware upgrade 6. Specify the place of the data to be installed. For installing from CD-ROM, select the [cygwin] folder in CD-ROM drive. (Described below is the sample procedure when CD-ROM drive is E-drive.) 7.
  • Page 513 3. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 10. After installing, open the Property of “My Computer”, and click the “Environmental Vari- able” of “Advanced” tab. 11. Click the “New” in System Variable Setting. 4036fs2620e0 12. Set the following two values as the Windows Environmental Variable. Variable name Variable value CYGWIN...

  • Page 514: Writing Into The Compact Flash

    Field Service Ver. 1.0 Jul. 2005 3. Firmware upgrade 3.1.4 Writing into the Compact flash 1. Put the data of Firmware in the optional directory. (C:\C250 in the below figure) 4038F2E562DA NOTE • The file name of Firmware data consists of the “Release Date_Version_CHECKSUM-****.exe.”...
  • Page 515 3. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 3. Mount the Compact flash on the PC, and check the Drive name, which was recognized in the Windows. (F-drive in the following figure) 4036fs2623e0 → → → 4. Click [Start] [Program] [Accessories] [Command Prompt] to open the Com-...
  • Page 516 Field Service Ver. 1.0 Jul. 2005 3. Firmware upgrade 7. Once the “mkcf.bat” is executed, data writing into the Compact flash is started. 8. Upon completion of writing, CHECKSUM is executed. If CHECKSUM value is precisely matched, “VERIFY OK” appears. 4038F2E565DA 9.

  • Page 517: Firmware Rewriting

    3. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 Firmware rewriting • The F/W is updated using the Compact flash. 3.2.1 Updating method NOTE • NEVER remove or insert the Compact Flash card with the machine power turned 1. Open the Front Door, and turn OFF the Main Power Switch.

  • Page 518: Action When Data Transfer Fails

    Field Service Ver. 1.0 Jul. 2005 3. Firmware upgrade 4. Turn ON the Main Power Switch and Auxiliary Power Button. 5. Control Panel shows up to four types of F/W to be updated. 6. Select the particular type of F/W to be updated. (Select [YES].) 4038F2C530DA F/W to be updated Appropriate board...
  • Page 519 3. Firmware upgrade Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 520: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 4. Checking the Image Controller Setting Adjustment/Setting Checking the Image Controller Setting • Whenever the controller is mounted, it is necessary to select “Controller 0” in [Image Controller Setting]. 1. Call the Service Mode to the screen. 2.
  • Page 521 4. Checking the Image Controller Setting Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 522: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 5. Checking the system configuration Troubleshooting Checking the system configuration • When a malfunction occurs, let the printer print a Configuration Page to check for system configuration. 1. Press the Utility/Counter key. 2. Touch [User Setting] → [Printer Setting] → [Print Reports]. 3.
  • Page 523 7. Troubleshooting procedures Field Service Ver. 1.0 Jul. 2005 Check Possible Cause Action Remark The print destination Set the correct See “User’s Guide port setting is wrong. port. [Print Operations].” PC operates errati- Restart the PC. cally temporarily. Uninstall the printer Printer driver incor- driver through the See “User’s Guide...

  • Page 524: Unable To Transmit Data Through Scan To Ftp

    Field Service Ver. 1.0 Jul. 2005 7. Troubleshooting procedures Unable to transmit data through Scan to FTP. Check Possible Cause Action Remark The FTP server is not in Check with the network service. administrator. Check with the network IP address of the FTP administrator and enter server is wrong.

  • Page 525: Unable To Transmit Data Through Scan To E-Mail/Internet Fax

    7. Troubleshooting procedures Field Service Ver. 1.0 Jul. 2005 Unable to transmit data through Scan to E-Mail/Internet FAX. Check Possible Cause Action Remark The SMTP server is not in Check with the network service. administrator. Check with the network IP address of the SMTP administrator and enter the server is wrong.

  • Page 526: E-Mail Does Not Reach The Destination When Transmission Through Scan To E-Mail/Scan To Internet Fax Is Completed

    Field Service Ver. 1.0 Jul. 2005 7. Troubleshooting procedures E-mail does not reach the destination when transmission through Scan to E-Mail/Scan to Internet FAX is completed. Check Possible Cause Action Remark See “User’s Guide The destination mail Enter the correct mail [Network Scanner address is wrong.
  • Page 527 7. Troubleshooting procedures Field Service Ver. 1.0 Jul. 2005 Blank Page...
  • Page 528 SERVICE MANUAL FIELD SERVICE DF-601 2005.07 Ver. 1.0...
  • Page 529 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 530 Field Service Ver. 1.0 Jul. 2005 CONTENTS DF-601 General Product specifications ..................... 1 Mixed original feed ....................3 Mixed original feed chart..................3 Paper feed prohibited originals ................4 Paper feed not guaranteed originals..............4 Maintenance Periodical check ...................... 5 Maintenance procedure (Periodical check parts) ..........
  • Page 531 Field Service Ver. 1.0 Jul. 2005 Mechanical adjustment ..................18 Adjustment of the tray volume ................18 Adjustment of the document edge guide reference position ......19 Adjustment of the document skew..............20 Adjustment of the document stop position ............21 8.4.1 Auto adjust: Sub Scanning Direction 1-Sided Stop Position .......

  • Page 532: General

    Field Service Ver. 1.0 Jul. 2005 1. Product specifications General Product specifications A. Type Name Duplexing Document Feeder Paper Take-Up Paper Take-Up from top of stack Transport Endless Belt Transport Mode Type Turnover Loop Turnover Mode U-turn Turnover + Switchback U-Turn Turnover Paper Exit Mode (only in 1-Sided Mode) Installation...
  • Page 533 1. Product specifications Field Service Ver. 1.0 Jul. 2005 D. Machine specifications DC 24 V (supplied from the main unit) Power Requirements DC 5 V (generated within the DF-601) Max. Power 60 W or less Consumption 586 mm (W) × 519 mm (D) × 135 mm (H) Dimensions 23 inch (W) ×...

  • Page 534: Mixed Original Feed

    Field Service Ver. 1.0 Jul. 2005 2. Mixed original feed Mixed original feed Mixed original feed chart For Metric Max. Original 297 mm 257 mm 210 mm 182 mm 148 mm Size Mixed Original Size 297 mm 257 mm 210 mm 182 mm 148 mm For Inch...

  • Page 535: Paper Feed Prohibited Originals

    2. Mixed original feed Field Service Ver. 1.0 Jul. 2005 Paper feed prohibited originals • If fed, trouble occurrence will be highly possible. Type of Original Possible Trouble Take-up failure, damaged sheet, defective drive Sheets stapled or clipped together mechanism due to jammed staples or clips Sheets glued together Take-up failure, damaged sheet Take-up failure...

  • Page 536: Maintenance

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol. 3.1.1 Transport Belt A. Replacing procedure 1. Remove two C-clips [1]. 4582s2501c0 2.

  • Page 537: Pick-Up Roller / Paper Take-Up Roller

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 5. Remove the Transport Belt [7]. 4582fs2505c0 3.1.2 Pick-up Roller / Paper Take-up Roller A. Replacing procedure 1. Open the Paper Take-up Section Cover [1], press inward and unlock the locking claws [2] at both ends of the Paper Take-up Section Guide (the Inner Cover), and remove the Paper Take-up Section Guide [3].

  • Page 538: Separation Roller

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 5. Remove C-clip (black) of the Paper Take-up Roller, and remove the Paper Take-up Roller [12]. NOTE • Be careful not to lose the Pick-Up/ Take-Up Roller fixing pin. [12] 4582fs2509c0 3.1.3 Separation Roller A.

  • Page 539: Pick-Up Roller / Paper Take-Up Roller / Separation Roller

    3. Periodical check Field Service Ver. 1.0 Jul. 2005 3.1.4 Pick-up Roller / Paper Take-up Roller / Separation Roller A. Cleaning procedure 1. Open the Paper Take-up Section Cover [1]. 2. Wet a cloth with alcohol, and use it to wipe up the Pick-up Roller [2], Paper Take-up Roller [3] and Separation Roller [4].

  • Page 540: Exit Roller / Roll

    Field Service Ver. 1.0 Jul. 2005 3. Periodical check 3.1.6 Exit Roller / Roll A. Cleaning procedure 1. Open the Paper Exit Section Cover [1]. 2. Wet a cloth with alcohol, and use it to wipe up the Exit Roller [2]/Roll [3]. 4582fs2515c0 3.1.7 Turnover Roller...
  • Page 541 3. Periodical check Field Service Ver. 1.0 Jul. 2005 3. Remove the Registration Roller Cover. ☞ 8 4. Clean the Paper Empty Sensor [3] with a brush or the like. 4582fs2519c0 5. Open the Paper Exit Section Cover. 6. Clean the Paper Exit Sensor [4] with a brush or the like.

  • Page 542: Other

    Field Service Ver. 1.0 Jul. 2005 4. Other Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
  • Page 543 4. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Front Cover Exterior Parts ☞ Rear Cover Disassembly/Assembly procedure 4.3.1 Front Cover/Rear Cover 4582fs2521c0 1. Open the Paper Take-up Section Cover [1] and the Paper Exit Section Cover [2]. 2.

  • Page 544: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 5. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance Checks Before attempting to solve the customer problem, the following advance checks must be made.Check to see if:...

  • Page 545: Service / Test Mode

    6. Service / Test Mode Field Service Ver. 1.0 Jul. 2005 Service / Test Mode • The Service / Test Modes are set from the Service Mode screen of the main unit. Service Mode setting procedure 1. Press the [Utility/Counter] key. 2.

  • Page 546: Adf Paper Passage

    Field Service Ver. 1.0 Jul. 2005 6. Service / Test Mode ADF Paper Passage • The Paper Passage motion of the Automatic Document Feeder is checked. <Procedure> 1. Set the mode to the Service Mode. 2. Touch the [ADF] key. 3.

  • Page 547: Sensor Check

    7. Sensor Check Field Service Ver. 1.0 Jul. 2005 Sensor Check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
  • Page 548 Field Service Ver. 1.0 Jul. 2005 7. Sensor Check A. Sensor monitor Operation characteristics/ Panel display Symbol Panel display Part/Signal name PC4-DF Empty Empty Sensor Paper not Paper present present PC3-DF Original Take-Up Unit Take-up Cover Sensor OPEN CLOSE Interrock PC202 Transport Convey Original Cover Angle Sensor...

  • Page 549: Mechanical Adjustment

    8. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Mechanical adjustment Adjustment of the tray volume • Read out the value of maximum width and minimum width of the document width detec- tion volume interlocked with the Document Take-up Tray Edge Guide. <Procedure>...

  • Page 550: Adjustment Of The Document Edge Guide Reference Position

    Field Service Ver. 1.0 Jul. 2005 8. Mechanical adjustment Adjustment of the document edge guide reference position Adjustment standard: Displacement of the document edge should be within 4 ± 1 mm to the FD scale. A. Adjustment procedure 1. Place the chart furnished with the Document Feeder in the document feeding tray [1] (with the side having an arrow facing up).

  • Page 551: Adjustment Of The Document Skew

    8. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Adjustment of the document skew Adjustment standard: Skew should be ± 1.0 % or less with respect to the document length; within 3.0 mm for document of A4 size. 1. Place the chart furnished with the Document Feeder in the document feeding tray [1] (with the side having an arrow facing up).

  • Page 552: Adjustment Of The Document Stop Position

    Field Service Ver. 1.0 Jul. 2005 8. Mechanical adjustment Adjustment of the document stop position • Adjustment of the document stop position is made automatically and manually (by enter- ing numbers). The following adjustment is made in the Service Mode. 4582F3E513DA 8.4.1 Auto adjust: Sub Scanning Direction 1-Sided Stop Position...

  • Page 553: Auto Adjust: Sub Scanning Direction 2-Sided Stop Position

    8. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 7. Make sure that Result is OK. Then, touch [SET]. 8. Touch [END]. 9. Touch [Exit] on the Service Mode screen. If the Result is Unable: • Check and correct the skew of the document.

  • Page 554: Auto Adjust: Main Scanning Direction Image Scan Start Position

    Field Service Ver. 1.0 Jul. 2005 8. Mechanical adjustment 8.4.3 Auto adjust: Main Scanning Direction Image scan start position A. Adjustment procedure 1. Set the mode to the Service Mode. 2. Touch [ADF]. 3. Touch [Auto Stop Position Adjustment]. 4. Touch [Main Scanning Direction]. 4582F3E522DA 5.

  • Page 555: Manual Adjust: Sub Scanning Direction 1-Sided / 2-Sided Document Stop Position Adjustment

    8. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 8.4.4 Manual adjust: Sub Scanning Direction 1-Sided / 2-Sided document stop position adjustment Adjusted range: -7 mm to + 7 mm A. Adjustment procedure 1. Set the mode to the Service Mode. 2.

  • Page 556: Manual Adjust: Main Scanning Direction Image Scan Position Adjustment

    Field Service Ver. 1.0 Jul. 2005 8. Mechanical adjustment 8.4.5 Manual adjust: Main Scanning Direction Image scan position adjustment Adjusted range: -3 mm to + 3 mm A. Adjustment procedure 1. Set the mode to the Service Mode. 2. Touch [ADF]. 3.

  • Page 557: Adjustment Of The Loop Value

    8. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Adjustment of the loop value Adjusted range: -5 mm to + 5 mm Default value: 0 (Loop value: 5 mm) • The loop value is increased by the entered + value and decreased by the entered - value. •...

  • Page 558: Automatic Adjustment Of The Sensor

    Field Service Ver. 1.0 Jul. 2005 8. Mechanical adjustment Automatic adjustment of the sensor • The detection level of the document through path sensor is automatically adjusted. • The adjustment has two modes: [Initialize And Sensor Auto Adj.] and [ADF Sensor Auto Adj.].
  • Page 559 8. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 560: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 9. Jam Display Troubleshooting Jam Display Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.

  • Page 561: Sensor Layout

    9. Jam Display Field Service Ver. 1.0 Jul. 2005 Sensor layout 4582fs4502c0 [1] Exit Sensor PC6-DF [3] Pick-up Sensor PC2-DF [2] Turnover Sensor PC5-DF [4] Registration Sensor PC1-DF Solution 9.4.1 Paper Exit / Turnover section misfeed A. Detection timing Type Description Misfeed due to paper Misfeed is detected if the Turnover Sensor (PC5-DF) is not turned OFF...

  • Page 562: Paper Take-Up Section Misfeed

    Field Service Ver. 1.0 Jul. 2005 9. Jam Display 9.4.2 Paper Take-Up section misfeed A. Detection timing Type Description Misfeed due to paper not Misfeed is detected if the Registration Sensor (PC1-DF) is not turned reached the Registration ON within a preset time after the Take-up Motor (M1-DF) started normal Sensor rotation.

  • Page 563: Transport Section Misfeed

    9. Jam Display Field Service Ver. 1.0 Jul. 2005 9.4.3 Transport section misfeed A. Detection timing Type Description Misfeed due to paper Misfeed is detected if the Pick-up Sensor (PC2-DF) is not turned OFF remaining at the Pick-Up within a preset time after the Take-up Motor (M1-DF) started reverse Sensor rotation.

  • Page 564: Transport Tray Section Misfeed

    Field Service Ver. 1.0 Jul. 2005 9. Jam Display 9.4.4 Transport Tray section misfeed A. Detection timing Type Description Misfeed due to paper not Misfeed is detected if the Exit Sensor (PC6-DF) is not turned ON within a reached the Exit Sensor preset time after exit operation started in the 1-Sided Mode.

  • Page 565: 10. Set Error Detection

    10. Set error detection Field Service Ver. 1.0 Jul. 2005 10. Set error detection • When the ADF or cover set error for some reason is detected, the Panel of the main unit will have the following display. 4582F4E501DA <Panel display and detection timing for each> Panel Description of error Detection start...
  • Page 566 SERVICE MANUAL FIELD SERVICE PC-103/PC-203 2005.07 Ver. 1.0...
  • Page 567 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 568 Field Service Ver. 1.0 Jul. 2005 CONTENTS PC-103/PC-203 General Product specifications ..................... 1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Replacing the Separation Roller Assy............3 2.1.2 Replacing the Paper Take-up Roller.............. 4 2.1.3 Replacing the Pick-up Roller.................
  • Page 569 Field Service Ver. 1.0 Jul. 2005 Troubleshooting Jam Display......................19 Misfeed display....................19 7.1.1 Misfeed display resetting procedure ............19 Sensor layout...................... 20 Solution ......................21 7.3.1 Initial check items ..................21 7.3.2 Tray3 Paper Take-Up section/Vertical Transport section misfeed (PC-103/PC-203) ..................

  • Page 570: Product Specifications

    Field Service Ver. 1.0 Jul. 2005 1. Product specifications General Product specifications A. Type Name 2 way Paper Take-Up Cabinet Type Front loading type 2 way paper take-up device Installation Desk type Document Alignment Center B. Paper type Plain paper 60 to 90 g/m (16 to 24 lb) Type...
  • Page 571 1. Product specifications Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 572: Periodical Check

    Field Service Ver. 1.0 Jul. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) 2.1.1 Replacing the Separation Roller Assy 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Jam Access Cover [2]. 4348fs2611c0 3.

  • Page 573: Replacing The Paper Take-Up Roller

    2. Periodical check Field Service Ver. 1.0 Jul. 2005 NOTES • Install the Separation Roller Assy while pressing the holder down so that it aligns to the metal bracket of the machine. • Make sure that the Separation Roller Assy is not tilted to the right or left when installed.
  • Page 574 Field Service Ver. 1.0 Jul. 2005 2. Periodical check 7. Remove two screws [6] and remove the Paper Take-up Cover [7]. 4348fs2605c0 8. Remove the C-ring [8] and remove the bushing [9]. 4348fs2606c0 [10] 9. Shift the Shaft Assy [10] in the orien- tation as shown on the left, and remove the C-ring [11] and the gear [12].

  • Page 575: Replacing The Pick-Up Roller

    2. Periodical check Field Service Ver. 1.0 Jul. 2005 [18] 11. Remove two E-rings [16] and the [16] [16] bushing [17], and remove the Pick- up Roller Fixing Bracket Assy [18]. [17] 4348fs2609c0 12. Remove the C-ring [19] and remove the Paper Take-up Roller [20].
  • Page 576 Field Service Ver. 1.0 Jul. 2005 2. Periodical check 6. Remove two screws [4] and remove the Paper Separation Roller Mount- ing Bracket Assy [5] together with frame. 4348fs2617c0 7. Remove two screws [6] and remove the Paper Take-up Cover [7]. 4348fs2605c0 8.

  • Page 577: Other

    3. Other Field Service Ver. 1.0 Jul. 2005 Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 578: Disassembly/Assembly/Cleaning List (Other Parts)

    Field Service Ver. 1.0 Jul. 2005 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page ☞ Right Door ☞ Rear Right Cover ☞ Exterior parts Lower Right Cover ☞ Front Right Cover ☞ Rear Cover 3.2.2 Cleaning parts list Section...

  • Page 579: Disassembly/Assembly Procedure

    3. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly procedure 3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover 4061F2C503DA 1. Open the Right Door [1]. 2. Remove the Right Door [1]. 3. Remove two screws [2] and remove the Rear Right Cover [3]. 4.

  • Page 580: Cleaning Procedure

    Field Service Ver. 1.0 Jul. 2005 3. Other Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Separation Roller 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Jam Access Cover [2].

  • Page 581: Pick-Up Roller

    3. Other Field Service Ver. 1.0 Jul. 2005 3.4.3 Pick-up Roller 1. Remove the Tray3.(Remove the Tray4 from 4th row.) 2. Remove the Paper Separation Roller Mounting Bracket Assy. ☞ See the procedures 1 to 3 in page 11 “Cleaning of the Separation Roller.” 3.

  • Page 582: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance Checks Before attempting to solve the customer problem, the following advance checks must be made.Check to see if:...

  • Page 583: Sensor Check

    5. Sensor check Field Service Ver. 1.0 Jul. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).

  • Page 584: Sensor Check List

    Field Service Ver. 1.0 Jul. 2005 5. Sensor check 5.2.2 Sensor check list A. Sensor monitor 1 (PC-103/PC-203) Operation characteris- tics/Panel display Symbol Panel display Part/Signal name PC112-PC Tray3 Device Detection Tray3 Device Detection Sensor Out of position PC115-PC Paper Empty Tray3 Empty Sensor Paper not Paper...

  • Page 585: Mechanical Adjustment

    6. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Mechanical adjustment Adjusting the paper reference position NOTE • Make this adjustment after any of the following procedures has been performed. When the PH Unit has been replaced. When the image on the print is offset in the sub scan direction. When a faint image occurs on the leading edge of the image.
  • Page 586 Field Service Ver. 1.0 Jul. 2005 6. Mechanical adjustment • If adjustment cannot be completed only by inputting numeric value, perform adjustment according to the following procedure. 8. Slide out the drawer [1] and unload paper from it. 9. Loosen three screws [2] at the center of the Paper Lifting Plate.

  • Page 587: Dup Print Positioning: Side Edge

    6. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 6.1.2 Dup Print Positioning: Side Edge 1. Call the Service Mode to the screen. ☞ For details of how to display the Service Mode screen, see the Adjustment/Setting of the Main Unit Service Manual. 2.

  • Page 588: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. 4061F4C800DA Code Misfeed location Misfeed access location Action 1301...

  • Page 589: Sensor Layout

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 Sensor layout 4061F4C802DA [1] Tray2 Vertical Transport Sensor PC8-PC [4] Tray4 Vertical Transport Sensor PC126-PC [2] Tray3 Vertical Transport Sensor PC117-PC [5] Tray4 Take-up Sensor PC125-PC [3] Tray3 Take-up Sensor PC116-PC...

  • Page 590: Solution

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.

  • Page 591: Tray3 Paper Take-Up Section/Vertical Transport Section Misfeed (Pc-103/Pc-203)

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 7.3.2 Tray3 Paper Take-Up section/Vertical Transport section misfeed (PC-103/PC-203) A. Detection timing Type Description The leading edge of the paper does not block the Tray3 Vertical Transport Sensor (PC117-PC) even after the set period of time has elapsed after the Tray3 Take-up Tray3 Paper Take- Motor (M122-PC) is energized.

  • Page 592: Tray4 Paper Take-Up Section/Vertical Transport Section Misfeed (Pc-203)

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display 7.3.3 Tray4 Paper Take-Up section/Vertical Transport section misfeed (PC-203) A. Detection timing Type Description The leading edge of the paper does not block the Tray4 Vertical Transport Sensor (PC126-PC) even after the set period of time has elapsed after the Tray4 Take-up Tray4 Paper Take- Motor (M123-PC) is energized.

  • Page 593: Trouble Code

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 Trouble code Trouble code display • The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4061F4E504DA Trouble code list Code Item Description...

  • Page 594: Solution

    Field Service Ver. 1.0 Jul. 2005 8. Trouble code Solution 8.3.1 C0206: Tray3 Lift-Up Failure C0208: Tray4 Lift-Up Failure Relevant electrical parts Tray3 Lift-up Motor (M124-PC) Control Board (PWB-C2 PC) Tray4 Lift-Up Motor (M125-PC) Main unit Mechanical Control Board (PWB-M) Tray3 Lift-up Upper Sensor (PC114-PC) Main unit DC Power Supply (PU1) Tray4 Lift-up Upper Sensor (PC123-PC)
  • Page 595 8. Trouble code Field Service Ver. 1.0 Jul. 2005 Blank Page...
  • Page 596 SERVICE MANUAL FIELD SERVICE PC-403 2005.07 Ver. 1.0...
  • Page 597 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 598 Field Service Ver. 1.0 Jul. 2005 CONTENTS PC-403 General Product specification ....................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Replacing the Separation Roller Assy............3 2.1.2 Replacing the Paper Take-up Roller.............. 4 2.1.3 Replacing the Pick-up Roller.................
  • Page 599 Field Service Ver. 1.0 Jul. 2005 6.1.1 Print Positioning: Side Edge ............... 20 6.1.2 Dup Print Positioning: Side Edge..............22 Shifter movement timing belt adjustment ............22 Troubleshooting Jam Display......................25 Misfeed display....................25 7.1.1 Misfeed display resetting procedure ............25 Sensor layout......................

  • Page 600: Product Specification

    Field Service Ver. 1.0 Jul. 2005 1. Product specification General Product specification A. Type Name Large Capacity Cabinet Type Front loading type LCC Installation Desk type Document Alignment Center B. Paper type Type Plain paper 60 to 90 g/m (16 to 24 lb) Recycled paper 60 to 90 g/m (16 to 24 lb)
  • Page 601 1. Product specification Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 602: Periodical Check

    Field Service Ver. 1.0 Jul. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) 2.1.1 Replacing the Separation Roller Assy 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Paper Separation Roller Mount- ing Bracket Assy [2].

  • Page 603: Replacing The Paper Take-Up Roller

    2. Periodical check Field Service Ver. 1.0 Jul. 2005 2.1.2 Replacing the Paper Take-up Roller 1. Remove the Rear Cover and the Rear Right Cover. ☞ 10 2. Remove the Tray3. 3. Remove the Paper Separation Roller Mounting Bracket Assy. ☞...
  • Page 604 Field Service Ver. 1.0 Jul. 2005 2. Periodical check 8. Remove two C-rings [8] and remove the bushing [9]. 4348fs2505c0 9. Shift the Shaft Assy [10] in the orien- [10] tation as shown on the left, and remove the C-ring [11] and the gear [12].

  • Page 605: Replacing The Pick-Up Roller

    2. Periodical check Field Service Ver. 1.0 Jul. 2005 12. Remove the C-ring [16] and remove the Paper Take-up Roller [17]. [16] [17] 4348fs2508c0 NOTE • Replace the Separation Roller Assy, Paper Take-up Roller and Pick-up Roller at the same time. 2.1.3 Replacing the Pick-up Roller 1.
  • Page 606 Field Service Ver. 1.0 Jul. 2005 2. Periodical check 7. Remove two screws [6] and remove the Paper Take-up Cover [7]. 4348fs2515c0 8. Remove two C-rings [8], two bush- ings [9], and the Pick-up Roller Assy [10]. [10] 4348fs2517c0 9. Remove the C-ring [11] and remove the Pick-up Roller [12].

  • Page 607: Other

    3. Other Field Service Ver. 1.0 Jul. 2005 Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 608: Disassembly/Assembly/Cleaning List (Other Parts)

    Field Service Ver. 1.0 Jul. 2005 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page ☞ Right Door ☞ Rear Right Cover ☞ Exterior Parts Lower Right Cover ☞ Front Right Cover ☞ Rear Cover ☞...

  • Page 609: Disassembly/Assembly Procedure

    3. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly procedure 3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover 4061F2C504DA 1. Open the Right Door [1]. 2. Remove the Right Door [1]. 3. Remove two screws [2] and remove the Rear Right Cover [3]. 4.

  • Page 610: Drawer

    Field Service Ver. 1.0 Jul. 2005 3. Other 3.3.3 Drawer 1. Press the Drawer Eject Button [1] and slide out the drawer [2]. 2. Remove the paper. 3. Remove four screws [3] and slide out the drawer [2]. 4348fs2522c0 4. Remove two screws [4], the connec- tor [5], and remove the Connector Board [6].
  • Page 611 3. Other Field Service Ver. 1.0 Jul. 2005 5. Remove two screws [6] and remove the Driver Cover [7]. 4348fs2527c0 6. Remove three screws [8] and remove the Driver Mounting Plate Assy [9]. 4348fs2528c0 NOTE [10] • When assembling, be sure to engage rib of gear 1 [10] with con- vex section of gear 2 [11].
  • Page 612 Field Service Ver. 1.0 Jul. 2005 3. Other 11. Remove the Ground Plate [17]. [18] 12. Remove four Cable Holding Jigs [18] [19] [18] and remove the Main Drawer [19]. NOTE [18] • Use care not to bend the wires. [18] [17] 4348fs2532c0...

  • Page 613: Cleaning Procedure

    3. Other Field Service Ver. 1.0 Jul. 2005 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Separation Roller 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Paper Separation Roller Mount- ing Bracket Assy [2].

  • Page 614: Vertical Transport Roller

    Field Service Ver. 1.0 Jul. 2005 3. Other 3.4.4 Vertical Transport Roller 1. Open the Right Door. 2. Using a soft cloth dampened with alcohol, wipe the Vertical Transport Roller [1] clean of dirt. 4348fs2519c0...
  • Page 615 3. Other Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 616: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance Checks Before attempting to solve the customer problem, the following advance checks must be made.Check to see if:...

  • Page 617: Sensor Check

    5. Sensor check Field Service Ver. 1.0 Jul. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).

  • Page 618: Sensor Check List

    Field Service Ver. 1.0 Jul. 2005 5. Sensor check 5.2.2 Sensor check list Sensor monitor 2 Operation characteristics/ Panel display Symbol Panel display Part/Signal name PC4-LCT Lift-Up Upper Lift-Up Upper Sensor Raised Not raised Position PC13-LCT Lift-Up Lower Lift-Up Lower Sensor Lowered Not lowered Position...

  • Page 619: Mechanical Adjustment

    6. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Mechanical adjustment Adjusting the paper reference position NOTE • Make this adjustment after any of the following procedures has been performed. When the PH Unit has been replaced. When the image on the print is offset in the sub scan direction. When a faint image occurs on the leading edge of the image.
  • Page 620 Field Service Ver. 1.0 Jul. 2005 6. Mechanical adjustment 8. Press the Drawer Release button [1] and then slide out the drawer [2] from the Paper Feed Cabinet. 4348fs3510c0 9. Open the Right Door. 10. Loosen the adjustment screw [3] and turn screw D [4] to make the adjust- ment.

  • Page 621: Dup Print Positioning: Side Edge

    6. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 6.1.2 Dup Print Positioning: Side Edge 1. Call the Service Mode to the screen. ☞ For details of how to display the Service Mode screen, see the Adjustment/Setting of the Main Unit Service Manual. 2.
  • Page 622 Field Service Ver. 1.0 Jul. 2005 6. Mechanical adjustment 3. Remove two screws [3] and remove the Shifter [4]. 4348fs3502c0 4. Push the tab [6] of the Shift Tray [5] as shown on the left and release the lock. 5. Remove the Shift Tray [5]. 4348fs3503c0 6.
  • Page 623 6. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 624: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. 4061F4C801DA Code Misfeed location Misfeed access location Action 1501...

  • Page 625: Sensor Layout

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 Sensor layout 4061F4C803DA [1] Tray 2 Vertical Transport Sensor PC8-PC [3] Paper Take-up Motor PC1-LCT [2] Vertical Transport Sensor PC2-LCT...

  • Page 626: Solution

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.

  • Page 627: Lct Paper Take-Up Section/Vertical Transport Section Misfeed

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 7.3.2 LCT Paper Take-Up section/Vertical Transport section misfeed A. Detection timing Type Description LCT Paper Take-Up The leading edge of the paper does not block the Paper Take-up Motor (PC1- section misfeed LCT) or the Vertical Transport Sensor (PC2-LCT) even after the set period of time detection has elapsed after the Take-up Motor (M1-LCT) is energized.

  • Page 628: Trouble Code

    Field Service Ver. 1.0 Jul. 2005 8. Trouble code Trouble code Trouble code display • The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4061F4E704DA...

  • Page 629: Trouble Code List

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 Trouble code list Code Item Description C0001 LCT communication error • Due to a software malfunction, etc., the time on the watchdog timer has run out and a reset is performed. C0102 LCT Vertical Transport Motor •...
  • Page 630 Field Service Ver. 1.0 Jul. 2005 8. Trouble code Code Item Description C0214 LCT shifting failure • The Shift Tray Stop Sensor (PC11-LCT) is not blocked even after the set period of time has elapsed after the shift operation began (shift to the right). •...

  • Page 631: Solution

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 Solution 8.3.1 C0001: LCT communication error Relevant electrical parts Control Board (PWB-C1 LCT) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Turn OFF the Main Power Switch, wait for 10 sec. or more, and turn ON the —...

  • Page 632: C0210: Lct Lift Failure

    Field Service Ver. 1.0 Jul. 2005 8. Trouble code 8.3.3 C0210: LCT Lift Failure Relevant electrical parts Lift-Up Upper Sensor (PC4-LCT) Control Board (PWB-C1 LCT) Lift-Up Lower Sensor (PC13-LCT) Elevator Motor Pulse Sensor (PC10-LCT) Lower Over Run Sensor (PC7-LCT) WIRING DIAGRAM Location Step Action...

  • Page 633: C0213: Lct Shift Gate Operation Failure

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 8.3.5 C0213: LCT Shift Gate Operation Failure Relevant electrical parts Division Board Position Sensor (PC14-LCT) Control Board (PWB-C1 LCT) Division Board Motor (M3-LCT) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the motor and sensor connectors for proper connection, and correct as...
  • Page 634 Field Service Ver. 1.0 Jul. 2005 8. Trouble code 8.3.7 C0215: LCT Shift Motor Failure Relevant electrical parts Shift Tray Motor (M4-LCT) Control Board (PWB-C1 LCT) Shift Motor Pulse Sensor (PC8-LCT) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the motor and sensor connectors for proper connection, and correct as —...
  • Page 635 8. Trouble code Field Service Ver. 1.0 Jul. 2005 Blank Page...
  • Page 636 SERVICE MANUAL FIELD SERVICE AD-503 2005.07 Ver. 1.0...
  • Page 637 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 638 Field Service Ver. 1.0 Jul. 2005 CONTENTS AD-503 General Product specifications ..................... 1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Cleaning Transport Roller / Roll 1, 2 ............. 3 2.1.2 Cleaning Transport Roller / Roll 3 ..............3 2.1.3 Cleaning Ventilation Section .................
  • Page 639 Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 640: Product Specifications

    Field Service Ver. 1.0 Jul. 2005 1. Product specifications General Product specifications A. Type Name Duplex Unit Type Switchback and Circulating Duplex Unit Installation Mounted on the right side door of main unit Document Alignment Center B. Paper type Type Plain paper 64 to 256 g/m (17 to 68 lb)
  • Page 641 1. Product specifications Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 642: Periodical Check

    Field Service Ver. 1.0 Jul. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol. 2.1.1 Cleaning Transport Roller / Roll 1, 2 1.

  • Page 643: Cleaning Ventilation Section

    2. Periodical check Field Service Ver. 1.0 Jul. 2005 2.1.3 Cleaning Ventilation Section 1. Using a soft cloth dampened with alcohol, wipe the outside of the Ventilation Section [1] clean of dirt. 4066F2C505DA 2. Open the Duplex Unit Door [2]. 3.

  • Page 644: Other

    Field Service Ver. 1.0 Jul. 2005 3. Other Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 645: Disassembly/Assembly List (Other Parts)

    3. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Unit Duplex Unit Disassembly/Assembly procedure 3.3.1 Duplex Unit 1. Release the tab [1], and remove the Connector Cover [2]. 4066F2C500DA 2. Disconnect the Connector [3]. 4066F2C501DA 3.

  • Page 646: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance Checks Before attempting to solve the customer problem, the following advance checks must be made.Check to see if:...

  • Page 647: Sensor Check

    5. Sensor check Field Service Ver. 1.0 Jul. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).

  • Page 648: Mechanical Adjustment

    Field Service Ver. 1.0 Jul. 2005 6. Mechanical adjustment Mechanical adjustment Adjusting the paper reference position 1. Call the Service Mode to the screen. ☞ For details of how to display the Ser- vice Mode screen, see the Adjust- ment/Setting of the main unit service manual.
  • Page 649 6. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 650: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. Code Misfeed location Misfeed access location Action ☞...

  • Page 651: Solution

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.

  • Page 652: Duplex Unit Pre-Registration Section Misfeed (Ad-503)

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display 7.3.2 Duplex Unit pre-registration section misfeed (AD-503) A. Detection timing Type Description Detection of The Registration Roller Sensor (PC1) is not blocked even after the lapse of a misfeed at Duplex given period of time after the Duplex Paper Take-up sequence started.

  • Page 653: Duplex Unit Transport Section Misfeed (Ad-503)

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 7.3.3 Duplex Unit transport section misfeed (AD-503) A. Detection timing Type Description The Duplex Unit Transport Sensor 2 (PC2 DU) is not blocked even after the set period of time has elapsed after the Duplex Unit Transport Sensor 1 (PC1 DU) is blocked by the paper.
  • Page 654 SERVICE MANUAL FIELD SERVICE FS-501 2005.07 Ver. 1.0...
  • Page 655 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 656 Field Service Ver. 1.0 Jul. 2005 CONTENTS FS-501 General Product specification ....................1 Maintenance Other ........................5 Disassembly/Adjustment prohibited items ............5 Disassembly/Assembly list (Other parts) .............. 6 Disassembly/Assembly procedure................ 6 2.3.1 Upper Cover/Upper Front Cover/Lower Front Cover/Rear Cover....6 2.3.2 Stapling Unit....................
  • Page 657 Field Service Ver. 1.0 Jul. 2005 7.3.3 Finisher Tray Exit ..................16 7.3.4 Shifting Operation ..................16 7.3.5 Aligning Plate Operation ................17 7.3.6 Stapling Unit CD Movement................ 17 7.3.7 Exit Roller/Rolls Spacing ................17 7.3.8 Storage Roller/Rolls Spacing..............18 7.3.9 Elevator Tray Operation ................

  • Page 658: Product Specification

    Field Service Ver. 1.0 Jul. 2005 1. Product specification General Product specification A. Type Type Single Staple Finisher Installation Freestanding Document Alignment Center Supplies Staple Cartridge Option Job separator (JS-601) B. Functions Modes Group, Sort, Offset/Group, Offset/Sort, Sort Staple and Group Staple C.
  • Page 659 1. Product specification Field Service Ver. 1.0 Jul. 2005 D. Stapling Staple Filling Mode Dedicated Staple Cartridge Mode (3000 staples) Staple Detection Available (Nearly Empty: 40 remaining staples) Diagonal back side (45 °C) 1 point Stapling Position Rear Parallel 1 point B5R/B5 to A3 Stapled Paper Size 8-1/2 ×...
  • Page 660 Field Service Ver. 1.0 Jul. 2005 1. Product specification F. Machine specifications DC 24 V (supplied from the main unit) Power Requirements DC 5 V (generated by Finisher) Max. Power 63 W or less Consumption 538 mm (W) × 637 mm (D) × 978 mm (H) Dimensions 21-1/4 inch (W) ×...
  • Page 661 1. Product specification Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 662: Other

    Field Service Ver. 1.0 Jul. 2005 2. Other Maintenance Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 663: Disassembly/Assembly List (Other Parts)

    2. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Upper Cover ☞ Upper Front Cover Exterior Parts ☞ Lower Front Cover ☞ Rear Cover ☞ Unit Stapling Unit ☞ Option Job Separator JS-601 Disassembly/Assembly procedure 2.3.1 Upper Cover/Upper Front Cover/Lower Front Cover/Rear Cover...

  • Page 664: Stapling Unit

    Field Service Ver. 1.0 Jul. 2005 2. Other 2.3.2 Stapling Unit 1. Holding both sides of the cover [1], lift the cover up and take it off. 4684fs2501c0 2. Remove two screws [2], disconnect the connector [3], and remove the Stapling Unit [4] from the moving cradle.
  • Page 665 2. Other Field Service Ver. 1.0 Jul. 2005 3. Remove two screws [5] and the con- nector [6], and remove the Job Sepa- rator [7]. 4683F2C506DA...

  • Page 666: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 3. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance Checks Before attempting to solve the customer problem, the following advance checks must be made.Check to see if:...

  • Page 667: Sensor Check

    4. Sensor Check Field Service Ver. 1.0 Jul. 2005 Sensor Check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
  • Page 668 Field Service Ver. 1.0 Jul. 2005 4. Sensor Check A. Sensor monitor 3 Operation characteristics/ Panel display Symbol Panel display Part/Signal name PC1-FN Exit (Non-sort1) 1st Tray Exit Sensor Paper Paper not present present PC19-FN Exit (Non-sort3) Job Tray Exit Sensor Paper Paper not present...

  • Page 669: Mechanical Adjustment

    5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Mechanical adjustment Adjustment of the solenoids 5.1.1 Adjustment of the Upper / Lower Entrance Switching Solenoid (SL1-FN) 1. Loosen the screw [1] that secures the solenoid in position. 2. Move the solenoid [2] up and down and lower the lever [3] downward.

  • Page 670: Adjustment Of The Exit Motor (M3-Fn) Timing Belt

    Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment 5.2.3 Adjustment of the Exit Motor (M3-FN) Timing Belt 1. Loosen three screws [1]. 2. Tighten three screws [1] so that the distance D between the upper end face of the head of three screws [1] and the upper end face of the slot in the mounting bracket [2] measures about 0.5 mm.

  • Page 671: Board Switch

    6. Board switch Field Service Ver. 1.0 Jul. 2005 Board switch 4684fs4503c0 Symbol Description Used to run the Test Mode operation. Used to run the Test Mode operation. DIP switch used to set the Test Mode operation. Turn ON or OFF, or blink to indicate a specific condition during Test Mode LED1 to 4 operations.

  • Page 672: Test Mode

    Field Service Ver. 1.0 Jul. 2005 7. Test mode Test mode Test mode setting procedure <Setting Procedure> 1. Turn OFF the Main Power Switch of the main unit. 2. Flip keys of the DIP switch into the ON or OFF position as necessary. (See Table below.) 3.

  • Page 673: Operation In Each Test Mode Operation

    7. Test mode Field Service Ver. 1.0 Jul. 2005 Operation in each test mode operation 7.3.1 1st Tray Exit S1-FN: ON Motors and solenoids: Energized Entrance Motor (M1-FN), Upper Entrance Motor (M4-FN), Upper/Lower Entrance Switching Solenoid (SL1-FN), 1st Tray Entrance Switching Solenoid (SL2-FN) S2-FN: ON Motors and solenoids: Deenergized Entrance Motor (M1-FN), Upper Entrance Motor (M4-FN), Upper/Lower Entrance...

  • Page 674: Aligning Plate Operation

    Field Service Ver. 1.0 Jul. 2005 7. Test mode 7.3.5 Aligning Plate Operation S1-FN: ON At the home position S1-FN: ON At a position to align A4 paper S1-FN: ON At a position to align Letter paper S1-FN: ON At a position to align A4R paper S1-FN: ON At a position to align Letter R paper 7.3.6...

  • Page 675: Storage Roller/Rolls Spacing

    7. Test mode Field Service Ver. 1.0 Jul. 2005 7.3.8 Storage Roller/Rolls Spacing S1-FN: ON Pressed S2-FN: ON Separated 7.3.9 Elevator Tray Operation S1-FN: ON Goes up until the Elevator Tray Upper Limit Sensor PQ (PWB-D FN) is blocked. S2-FN: ON Goes down until the Elevator Tray Upper Limit Sensor PQ (PWB-D FN) is unblocked.

  • Page 676: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 8. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. [2] [6] 4684F4C501DA Code Misfeed location Misfeed access location...

  • Page 677: Sensor Layout

    8. Jam Display Field Service Ver. 1.0 Jul. 2005 Sensor layout 4684fs4502c0 [1] Job Tray Exit Sensor PC19-FN [5] Turnover Empty Sensor PC6-HO [2] 1st Tray Exit Sensor PC1-FN [6] Paper Sensor PC1-HO [3] Upper Entrance Sensor PC4-FN [7] Storage Sensor PC3-FN [4] Lower Entrance Sensor PC2-FN...

  • Page 678: Solution

    Field Service Ver. 1.0 Jul. 2005 8. Jam Display Solution 8.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.

  • Page 679: Transport Section Misfeed

    8. Jam Display Field Service Ver. 1.0 Jul. 2005 8.3.2 Transport section misfeed A. Detection timing Type Description The 1st Tray Exit Sensor (PC1-FN) is not blocked even after the lapse of a given period of time after the leading edge of the paper has blocked the Paper Sensor (PC1-HO) of the Horizontal Transport Unit.

  • Page 680: Tray1 Exit Section Misfeed

    Field Service Ver. 1.0 Jul. 2005 8. Jam Display 8.3.3 Tray1 Exit section misfeed A. Detection timing Type Description Tray1 Exit section The 1st Tray Exit Sensor (PC1-FN) is not unblocked even after the lapse of a misfeed detection given period of time after it has been blocked. B.

  • Page 681: Elevator Tray Exit Section Misfeed

    8. Jam Display Field Service Ver. 1.0 Jul. 2005 8.3.5 Elevator Tray Exit section misfeed A. Detection timing Type Description Elevator Tray Exit The Storage Sensor (PC3-FN) is not unblocked even after the lapse of a given section misfeed period of time after it has been blocked. detection B.

  • Page 682: Stapler Section Misfeed

    Field Service Ver. 1.0 Jul. 2005 8. Jam Display 8.3.7 Stapler section misfeed A. Detection timing Type Description Stapler section The Stapler does not return to its home position within a given period of time after misfeed detection the forward drive of the Stapler has been started. B.

  • Page 683: Trouble Code

    9. Trouble code Field Service Ver. 1.0 Jul. 2005 Trouble code Trouble code display • The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4684F4E502DA Trouble code list Code Item Description...

  • Page 684: Solution

    Field Service Ver. 1.0 Jul. 2005 9. Trouble code Solution 9.3.1 C1182: Shift Motor drive malfunctions Relevant electrical parts Shift Home Position Sensor (PC10-FN) Control Board (PWB-A FN) Shift Motor Pulse Sensor (PC11-FN) Shift Motor (M8-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical...

  • Page 685: C1190: Cd Aligning Motor Drive Malfunction

    9. Trouble code Field Service Ver. 1.0 Jul. 2005 9.3.3 C1190: CD Aligning Motor drive malfunction Relevant electrical parts CD Aligning Home Position Sensor (PC9-FN) Control Board (PWB-A FN) CD Aligning Motor (M5-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the motor and sensor connectors...

  • Page 686: C11A2: Storage Roller/Rolls Spacing Motor Drive Malfunction

    Field Service Ver. 1.0 Jul. 2005 9. Trouble code 9.3.5 C11A2: Storage Roller/Rolls Spacing Motor drive malfunction Relevant electrical parts Storage Roller Home Position Sensor (PC12-FN) Control Board (PWB-A FN) Storage Roller/Rolls Spacing Motor (M12-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components)

  • Page 687: C11B2: Stapling Motor Drive Malfunction

    9. Trouble code Field Service Ver. 1.0 Jul. 2005 9.3.7 C11B2: Stapling Motor drive malfunction Relevant electrical parts Stapling Motor WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the Stapling motor connectors for proper connection, and correct as nec- —...
  • Page 688 SERVICE MANUAL FIELD SERVICE FS-603 2005.07 Ver. 1.0...
  • Page 689 Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
  • Page 690 Field Service Ver. 1.0 Jul. 2005 CONTENTS FS-603 General Product specification ....................1 Maintenance Other ........................5 Disassembly/Adjustment prohibited items ............5 Disassembly/Assembly list (Other parts) .............. 6 Disassembly/Assembly procedure................ 7 2.3.1 Exit Tray ......................7 2.3.2 Front Cover ....................7 2.3.3 Rear Cover....................
  • Page 691 Field Service Ver. 1.0 Jul. 2005 Adjustment/Setting How to use the adjustment section ............... 23 Sensor check ......................24 Check procedure ....................24 Sensor check list ....................24 4.2.1 Sensor check screen .................. 24 Mechanical adjustment ..................26 Adjustment of the stapling position..............26 5.1.1 Adjustment procedure.................
  • Page 692 Field Service Ver. 1.0 Jul. 2005 7.3.4 Folding position section misfeed ..............54 7.3.5 Stapler section misfeed................55 7.3.6 Paper Stack Exit section misfeed..............55 Trouble code......................56 Trouble code display ................... 56 Trouble code list....................56 Solution....................... 59 8.3.1 C1180: Transport System Drive malfunctions..........
  • Page 693 Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 694: Product Specification

    Field Service Ver. 1.0 Jul. 2005 1. Product specification General Product specification A. Type Type Multi Staple Finisher with Saddle (Booklet) Installation Freestanding Document Alignment Center Supplies Staple Cartridge B. Functions Modes Normal Group, Sort, Group Offset, Sort Offset, Sort Staple, Center Staple &...
  • Page 695 1. Product specification Field Service Ver. 1.0 Jul. 2005 (3) Sort staple No. of Sheets to Type Size Weight Tray Capacity Exit Tray be Stapled Plain Paper B5R/B5 to Normal Mode A4R/ Normal Mode *1 8.5 × 11R 8.5 × 14 Thick Paper paper 60 to 90 g/m...
  • Page 696 Field Service Ver. 1.0 Jul. 2005 1. Product specification E. No. of sheets to be stapled (sort staple) (1) A4R, 8.5 × 11R or smaller No. of Sets No. of Sheets to be Stapled Rear: Parallel Center: Parallel Front: Parallel 3 to 5 6 to 10 11 to 20...
  • Page 697 1. Product specification Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 698: Other

    Field Service Ver. 1.0 Jul. 2005 2. Other Maintenance Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.

  • Page 699: Disassembly/Assembly List (Other Parts)

    2. Other Field Service Ver. 1.0 Jul. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Exit Tray ☞ Front Cover ☞ Rear Cover Exterior Parts ☞ Upper Door ☞ Finisher Tray Upper Cover ☞ Upper Cover ☞ Side Guide ☞...

  • Page 700: Disassembly/Assembly Procedure

    Field Service Ver. 1.0 Jul. 2005 2. Other Disassembly/Assembly procedure 2.3.1 Exit Tray 1. Remove four screws [1], and remove the Exit Tray [2]. 4583fs2526c0 2.3.2 Front Cover 1. Remove the Middle Transport Unit. ☞ 10 2. Open the Front Door [1]. 3.

  • Page 701: Upper Door

    2. Other Field Service Ver. 1.0 Jul. 2005 2.3.4 Upper Door 1. Open the Upper Door [1], and remove the Door Band Holder [2] by turning it clockwise. 2. Remove the Door Band [3]. 3. Remove the screw [4], and remove the grounding wire.

  • Page 702: Upper Cover

    Field Service Ver. 1.0 Jul. 2005 2. Other 2.3.6 Upper Cover 1. Remove the Front Cover. ☞ 7 2. Remove the Rear Cover. ☞ 7 3. Remove two screws [1]. 4. Open the Upper Door[2],and remove the Upper Cover [3]. 4583fs2535c0 4583fs2536c0 2.3.7...

  • Page 703: Middle Transport Unit

    2. Other Field Service Ver. 1.0 Jul. 2005 2.3.8 Middle Transport Unit 1. Remove four screws [1]. 2. Hold up the Middle Front Cover [2] and the Middle Rear Cover [3], and remove them while shifting them back and forth. 4583fs2540c0 3.

  • Page 704: Saddle Section

    Field Service Ver. 1.0 Jul. 2005 2. Other 2.3.10 Saddle Section 1. Remove the Front Cover. ☞ 7 2. Remove the Rear Cover. ☞ 7 3. Remove the Punch Dust Box. 4. Open the Jam Access Cover [1], remove two screws [2], and remove the Right Stay [3].
  • Page 705 2. Other Field Service Ver. 1.0 Jul. 2005 4. Pull out the Finisher Stopper Base [3], and disengage the front claw [5] and the rear claw [6] of the Finisher Stopper [4]. 4583fs2522c0 5. Remove the Motor Harness [8] from two Harness Saddles [7].

  • Page 706: Paddle Section

    Field Service Ver. 1.0 Jul. 2005 2. Other 2.3.12 Paddle Section 1. Remove the Finisher Tray. ☞ 11 2. Place the Finisher Tray [1] as shown in the figure. NOTE • Be careful not to damage the Align- ing Plate [2]. 4583fs2548c0 3.

  • Page 707: Exit Roller (Upper)

    2. Other Field Service Ver. 1.0 Jul. 2005 2.3.13 Exit Roller (Upper) 1. Remove the Paddle Section. ☞ 13 2. Place the Paddle Section [1] as shown in the figure. 4583fs2551c0 3. Turn the gear [2] in the direction indi- cated by an arrow to move up the Exit Roller (Upper) section [3].

  • Page 708: Exit Roller (Lower) And Paper Exit Belt

    Field Service Ver. 1.0 Jul. 2005 2. Other 3. Turn the gear [2] in the direction indicted by an arrow to move up the Exit Roller (Upper) section [3]. 4583fs2555c0 4. Push up the Safety Guide [4] from the bottom to release it on one side from the shaft [5].
  • Page 709 2. Other Field Service Ver. 1.0 Jul. 2005 3. Remove two Holders [4], and remove the Finisher Tray Stopper [5]. 4583fs2560c0 4. Remove the screw [6], and remove the Paper Guide (Front) [8] while dis- engaging two claws [7]. 4583fs2561c0 5.

  • Page 710: Stapler/Folding Drive Unit

    Field Service Ver. 1.0 Jul. 2005 2. Other 8. Remove the Exit Roller (Lower) [16] [17] and two Paper Exit Belts [17]. [16] 4583fs2565c0 NOTE • When installing, align the edge of claws of the Paper Exit Belt [18]. [18] 4583fs2566c0 2.3.16 Stapler/Folding Drive Unit...

  • Page 711: Transport Roller

    2. Other Field Service Ver. 1.0 Jul. 2005 8. Remove the screw [9], and remove the claw of Harness Guide [11] from the square hole [10] in the base plate. [11] [10] 4583fs2570c0 9. Disconnect two connectors [12], and remove the Harness from the Wire Saddle.

  • Page 712: Middle Transport Roller

    Field Service Ver. 1.0 Jul. 2005 2. Other 4. Remove the Transport Motor Unit. ☞ 22 5. Remove the screw [3]. 6. Remove the C-clip [4], and remove the bushing [5]. 4583fs2575c0 7. Remove two screws [6]. 4583fs2577c0 8. Remove the gear 1 [7], and remove [10] the gear 2 [8] while disengaging the [12]...

  • Page 713: Punch Unit

    2. Other Field Service Ver. 1.0 Jul. 2005 3. Remove the C-clip[3], and remove the bushing [4]. 4583fs2582c0 4. Shift the Shaft Assy in the orientation as shown on the left. 5. Remove the C-clip [5], the Gear [6], the bushing [7], and remove the Mid- dle Transport Roller [8].

  • Page 714: Finisher Control Board

    Field Service Ver. 1.0 Jul. 2005 2. Other 9. Remove four screws [11], and [12] [11] remove the Sensor Unit (Upper) [12] and the Sensor Unit (Lower) [13]. [13] [11] [11] [11] 4583fs2589c0 10. Remove the spring[14]. [15] [16] 11. Remove the Punch Unit [16] from the Side Registration Motor section [15].

  • Page 715: Transport Motor Unit

    2. Other Field Service Ver. 1.0 Jul. 2005 2.3.22 Transport Motor Unit 1. Remove the Rear Cover. ☞ 7 2. Disconnect the connector [1]. 3. Remove screw [2], and remove the Harness Guide [3]. 4. Remove three screws [4], and remove the Transport Motor Unit [5].

  • Page 716: Adjustment/Setting

    Field Service Ver. 1.0 Jul. 2005 3. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. Advance Checks Before attempting to solve the customer problem, the following advance checks must be made.Check to see if:...

  • Page 717: Sensor Check

    4. Sensor check Field Service Ver. 1.0 Jul. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
  • Page 718 Field Service Ver. 1.0 Jul. 2005 4. Sensor check Operation characteristics/ Panel display Symbol Panel display Part/Signal name PI13-FN Crease Tray Saddle Tray Sensor Paper Paper not present present PI11-FN Crease Home Folding Home Position Sensor PI12-FN Crease Roller Home Folding Roller Home Position Sensor PI14-FN Crease Clock...

  • Page 719: Mechanical Adjustment

    5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Mechanical adjustment Adjustment of the stapling position • The stapling position is adjusted by aligning the stapling position to the folding position. • This adjustment is made in the Service Mode of the main unit. Since the adjustment is made in increments of 1 mm, this adjustment is useful for eliminating a displacement of 1mm or more.
  • Page 720 Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment Standard:0 ± 2 mm <To - side> <Standard> <To + side> 4583fs3501c0 10. Press the Clear Key. 11. Adjust with the [+]/[-] Keys. When the stapling position is shifted to the direction A: Adjust the value to the - side.

  • Page 721: Adjustment Of The Folding Position

    5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Adjustment of the folding position • The folding position is adjusted by aligning the folding position to the stapling position. • This adjustment is made in the Service Mode of the main unit. Since the adjustment is made in increments of 1 mm, this adjustment is useful for eliminating a displacement of 1 mm or more.
  • Page 722 Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment 9. Press the Clear Key. 10. Adjust with the [+]/[-] Keys. When the stapling position is shifted to the direction A: Adjust the value to the + side.When the stapling position is shifted to the direction B: Adjust the value to the - side.

  • Page 723: Adjustment Of Height And Inclination

    5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Adjustment of height and inclination 1. Gently move the finisher toward the machine and check for following. • Is the positioning pin aligned with the hole in the finisher? 4583fs3503c0 • Does the horizontal transport unit run excessively slantwise? •...
  • Page 724 Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment 4. Loosen two caster fixing screws [4]. (4 points) 4583fs3507c0 5. Turn the adjustment screw [5] to make adjustment. • To heighten: Turn the screw counter- clockwise. • To bring down: Turn the screw clock- wise.

  • Page 725: Adjustment Of The Folding Position

    5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Adjustment of the Folding Position • Folding position is adjusted by adjusting the Tray Section and the Saddle Section. • Adjust the folding position by aligning the Tray Section. Adjust the position of the Saddle Section if the position is still not proper.
  • Page 726 Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment 3. Remove the Middle Transport Unit. ☞ 10 4. Remove the front cover. ☞ 7 5. Loosen two screws [2] on the Tray Section. 4583F3C519DA 6. Move the Tray Section [3] back and forth, and move the positioning dow- els [4] right and left to adjust.
  • Page 727 5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 • If it is deviated downward <A>, move the positioning dowels to the left. <A> • If it is deviated upward <B>, move the positioning dowels to the right. NOTE • The folding line will move along with the staples.
  • Page 728 Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment 9. Move the two positioning dowels [6] to adjust. 4583F3C522DA • If it is deviated downward <C>, move the positioning dowel to the left. <C> • If it is deviated upward <D>, move the positioning dowel to the right.

  • Page 729: Adjustment Procedure

    5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 Stapler Phase Adjustment • Make phase adjustment of the Stapler following the procedures given below whenever the Gear or Timing Belt in front of the Stapler has been replaced or removed for some reason, since such replacement or removal will cause mistiming between the staple driving by the Staple Driver (the lower...
  • Page 730 Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment 10. Remove the Timing Belt [18]. 11. Remove the E-Ring [19], and remove [19] [20] the Staple Position Confirm Gear [20]. [18] 4583fs2507c0 12. Turn the Gear [21] to position the hole [22] in the Gear of the Staple Driver to the hole behind.
  • Page 731 5. Mechanical adjustment Field Service Ver. 1.0 Jul. 2005 16. Set the Timing Belt [27] to the Gear [28] and Gear [29] with the Gear and the Cam in the fixed condition. [28] [29] [27] 4583fs2512c0 17. Install the Staple Position Confirm Gear [32] in such a way that the blue [31] mark [30] of the Gear comes face to...

  • Page 732: Adjustment Procedure

    Field Service Ver. 1.0 Jul. 2005 5. Mechanical adjustment Saddle Gear Phase Adjustment • Whenever the Gear in front of the Saddle or the Folding Roller has been replaced or removed for some reason, make gear phase adjustment following the procedures given below.

  • Page 733: Board Switch

    6. Board switch Field Service Ver. 1.0 Jul. 2005 Board switch PWB-A FN (Finisher Control Board) 12 1 CN22 CN18 CN10 CN13 LED2 LED1 PSW2 PSW1 CN21 CN11 4583fs3509c0 Symbol Description Used to adjust the folding position, adjust the center 2-point stapling position and adjust the alignment plate position.

  • Page 734: Adjustment Of The Folding Positions

    Field Service Ver. 1.0 Jul. 2005 6. Board switch 6.1.1 Adjustment of the folding positions • When a folding position is adjusted, adjust the folding position to the stapling position. Make this adjustment after replacing the Finisher Control Board or when the folding posi- tion must be changed for some reason.

  • Page 735: Adjustment Of The Center Stapling Position

    6. Board switch Field Service Ver. 1.0 Jul. 2005 6.1.2 Adjustment of the center stapling position • When a stapling position is adjusted, adjust the stapling position to the folding position. Make this adjustment after replacing the Finisher Control Board or when the stapling position must be changed for some reason.

  • Page 736: Adjustment Of The Alignment Plate Position

    Field Service Ver. 1.0 Jul. 2005 6. Board switch 6.1.3 Adjustment of the Alignment Plate position • Alignment plate should be adjusted when there is a faulty alignment, the staple position deviates. A. Alignment procedure NOTE • If a step or steps are wrongly performed in mid procedure, stop the procedure immediately.
  • Page 737 6. Board switch Field Service Ver. 1.0 Jul. 2005 6. After the initial operation of the Fin- isher, press the PSW1 [1] on the Fin- isher Control Board and make sure that the alignment plate moves to the selected paper size area. 7.
  • Page 738 Field Service Ver. 1.0 Jul. 2005 6. Board switch PWB-B PK (Punch Control Board) J1007 SW1001 SW1002 SW1003 LED1001 LED1002 LED1003 J1003 J1004 4583fs3514c0 Symbol Description SW1001 Used to register the number of punched holes and adjust the sensor output. SW1002 Used to register the number of punched holes and adjust the sensor output.

  • Page 739: Adjustment Of The Sensor Output

    6. Board switch Field Service Ver. 1.0 Jul. 2005 6.2.1 Adjustment of the sensor output • Be sure to make this adjustment after replacing the Punch Control Board, the Side Reg- istration Sensor (Photosensor Board or LED Board) or the Punch Dust Full Sensor (Punch Dust Full Sensor Board or Punch Dust Full LED Board).

  • Page 740: Procedure After Replacing The Eep-Rom (Ic1002)

    Field Service Ver. 1.0 Jul. 2005 6. Board switch 6.2.3 Procedure after replacing the EEP-ROM (IC1002) 1. Turn OFF the Main Power Switch of the main unit. 2. Set the bits 1 through 4 of DIPSW1001 on the Punch Control Board as shown on the Left figure.
  • Page 741 6. Board switch Field Service Ver. 1.0 Jul. 2005 8. Turn OFF key 4 of SW1 of the Fin- isher Control Board. 9. Wait until the machine becomes capable of paper feed. 4583fs3526c0 10. Feed one sheet of paper through the machine.
  • Page 742 Field Service Ver. 1.0 Jul. 2005 6. Board switch 16. Turn ON key 7 of SW1 of the Fin- isher Control Board. NOTE • Flipping ON key 7 of SW1 validates the setting made to the fixed sys- tem based on the paper size as changed from the lateral registra- tion motion (automatic through end 4583fs3530c0...
  • Page 743 6. Board switch Field Service Ver. 1.0 Jul. 2005 Blank Page...

  • Page 744: Troubleshooting

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. 4583F4C505DA Code Misfeed location Misfeed access location Action ☞...

  • Page 745: Sensor Layout

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 Sensor layout 4583fs4521c0 [1] Turnover Empty Sensor PC6-HO [3] Folding Position Sensor PI10-FN [2] Entrance Sensor PI1-FN [4] Staple Drive Home Position Sensor PI19-FN...

  • Page 746: Solution

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.

  • Page 747: Horizontal Transport Section Misfeed

    7. Jam Display Field Service Ver. 1.0 Jul. 2005 7.3.3 Horizontal Transport section misfeed A. Detection timing Type Description horizontal The Turnover Empty Sensor (PC6-HO) is not unblocked even after the lapse of a transport section given period of time after the leading edge of the paper has blocked the Turnover misfeed detection Empty Sensor (PC6-HO).

  • Page 748: Stapler Section Misfeed

    Field Service Ver. 1.0 Jul. 2005 7. Jam Display 7.3.5 Stapler section misfeed A. Detection timing Type Description The Staple Drive Home Position Sensor (PI19-FN) is not turned OFF or does not Stapler section return to its home position even after the set period of time after the stapler has misfeed detection been driven.

  • Page 749: Trouble Code

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 Trouble code Trouble code display • The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4583F4E504DA NOTE •...
  • Page 750 Field Service Ver. 1.0 Jul. 2005 8. Trouble code Code Item Description C1192 Front Aligning Plate • The Front Aligning Plate Home Position Sensor (PI4-FN) is not Motor malfunctions unblocked even after the lapse of a given period of time after the Front Aligning Plate has started moving from its home position to a position out of the home position.
  • Page 751 8. Trouble code Field Service Ver. 1.0 Jul. 2005 Code Item Description C11B4 Stapler/Folding Motor • The Staple Drive Home Position Sensor (PI19-FN) is not blocked malfunctions even after the lapse of a given period of time after the clinch operation has started.

  • Page 752: Solution

    Field Service Ver. 1.0 Jul. 2005 8. Trouble code Solution 8.3.1 C1180: Transport System Drive malfunctions Relevant electrical parts Folding Roller Home Position Sensor (PI12-FN) Finisher Control Board (PWB-A FN) Transport Motor (M1-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the motor connectors for proper...

  • Page 753: C1183: Elevate Mechanism Malfunctions

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 8.3.3 C1183: Elevate Mechanism malfunctions (1) Upper Limit Sensor Relevant electrical parts Shift Upper Limit Sensor (PI15-FN) Finisher Control Board (PWB-A FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the sensor connectors for proper —...

  • Page 754: C1193: Rear Aligning Plate Motor Malfunctions

    Field Service Ver. 1.0 Jul. 2005 8. Trouble code 8.3.5 C1193: Rear Aligning Plate Motor malfunctions Relevant electrical parts Rear Aligning Plate Home Position Sensor Finisher Control Board (PWB-A FN) (PI5-FN) Rear Aligning Motor (M5-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components)

  • Page 755: C11B1: Stapler Unit Slide Motor Malfunctions

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 8.3.7 C11B1: Stapler Unit Slide Motor malfunctions Relevant electrical parts Slide Home Position Sensor (PI18-FN) Finisher Control Board (PWB-A FN) Slide Motor (M8-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the motor and sensor connectors for proper connection, and correct as...
  • Page 756 Field Service Ver. 1.0 Jul. 2005 8. Trouble code (2) Stapler/Crease Clock Sensor (Stapler Section) Relevant electrical parts Staple/Folding Motor Clock Sensor (PI14-FN) Finisher Control Board (PWB-A FN) Staple/Folding Motor (M7-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the motor and sensor connectors for proper connection, and correct as —...

  • Page 757: C11C1: Punch Control Board Malfunctions

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 Stapler/Crease Clock Sensor (Saddle Section) Relevant electrical parts Staple/Folding Motor Clock Sensor (PI14-FN) Finisher Control Board (PWB-A FN) Staple/Folding Motor (M7-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the motor and sensor connectors for proper connection, and correct as —...

  • Page 758: C11C2: Punch Side Registration Motor Malfunctions

    Field Service Ver. 1.0 Jul. 2005 8. Trouble code 8.3.10 C11C2: Punch Side Registration Motor malfunctions Relevant electrical parts Side Registration Home Sensor (PI2P-PK) Punch Control Board (PWB-B PK) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the sensor connectors for proper —...

  • Page 759: C11C5: Punch Sensor Malfunctions

    8. Trouble code Field Service Ver. 1.0 Jul. 2005 8.3.12 C11C5: Punch Sensor malfunctions (1) Side Registration Sensor Relevant electrical parts Side Registration Home Sensor (PI2P-PK) Punch Control Board (PWB-B PK) WIRING DIAGRAM Location Step Action Control signal (Electrical components) Check the sensor connectors for proper —...

  • Page 760: C1401: Backup Ram Malfunction

    Field Service Ver. 1.0 Jul. 2005 8. Trouble code (3) Finisher Control Board Relevant electrical parts Exit Tray Home Position Sensor (PI9-FN) Finisher Control Board (PWB-A FN) Shift Motor Clock Sensor (PI17-FN) Shift Motor (M6-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical components)
  • Page 761 8. Trouble code Field Service Ver. 1.0 Jul. 2005 Blank Page...
  • Page 762 © 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. © 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Printed in Japan Use of this manual should be strictly supervised to Use of this manual should be strictly supervised to DD4038PE1-0800 DD4038PE1-0800 avoid disclosure of confidential information.

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