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Kyocera Mita DC-2560 Service Manual

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Table of Contents

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DC-2060/2560
SERVICE
MANUAL
Published in Oct. '99
841AH110

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Table of Contents
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Summary of Contents for Kyocera Mita DC-2560

  • Page 1: Service Manual

    DC-2060/2560 SERVICE MANUAL Published in Oct. ’99 841AH110...
  • Page 2 Service Manual DC-2050/2560...
  • Page 3 CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY RE- PLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE REC- OMMENDED BY THE MANUFACTURER. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER'S INSTRUCTIONS. CAUTION: DOUBLE-POLE / NEUTRAL FUSING ATTENTION: IL Y A DANGER D'EXPLOSION S'IL Y A REMPLACEMENT IN- CORRECT DE LA BATTERIE.

  • Page 5: Safety Precautions

    Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.
  • Page 6 Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

  • Page 7: Installation Precautions

    indicates that action is required. The specific action required is shown inside the symbol. General action required. Remove the power plug from the wall outlet. Always ground the copier. 1. Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock.
  • Page 8 • Always handle the machine by the correct locations when moving it..• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause the copier to move unexpectedly or topple, leading to injury................•...
  • Page 9 • Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it is dirty, clean it to remove the risk of fire or electric shock..................• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may damage eyesight.
  • Page 10 • After maintenance, always check that all the parts, screws, connectors and wires that were removed, have been refitted correctly. Special attention should be paid to any forgotten connector, trapped wire and missing screws..................• Check that all the caution labels that should be present on the machine according to the instruction handbook are clean and not peeling.
  • Page 11 CONTENTS THEORY AND CONSTRUCTION SECTION 1-1 Specifications 1-1-1 Specifications DC 2560 ..............1-1-1 1-1-4 Specifications DC 2560 ..............1-1-4 1-2 Handling Precautions 1-2-1 Drum ....................1-2-1 1-2-2 Developer and toner ................. 1-2-1 1-2-3 Dehumidifier ..................1-2-1 1-2-4 Copy paper ..................1-2-1 1-3 Mechanical Construction 1-3-1 Machine parts names and their functions .........
  • Page 12 3-4 PCB Initial Setting 3-4-1 Replacing the main PCB ..............3-4-1 3-4-2 Adjustment-free variable resistors (VR) ........... 3-4-4 3-5 Self-diagnostics 3-5-1 Self diagnostic function ..............3-5-1 3-6 Troubleshooting 3-6-1 Image problems ................3-6-1 3-6-2 Paper misfeeds ................3-6-14 3-6-3 PCB terminal voltages..............3-6-21 3-6-4 Electrical problems .................
  • Page 13 THEORY AND CONSTRUCTION SECTION 1AH/MCE...

  • Page 14: Specifications Dc 2560 1

    1-1 Specifications 1-1-1 Specifications DC 2560..........1-1-1 1-1-4 Specifications DC 2060..........1-1-4...
  • Page 15 1-1-1 Specifications DC-2560 Type ......Desktop Copying system ..Dry, indirect electrostatic system Originals ...... Sheets, books, three-dimensional objects Maximum size: A3/11" × 17" Original feed system ... Fixed Copy paper ....(1) Plain paper: Paper feed from cassettes (60 - 80g/m...
  • Page 16 Warmup time ....45 s or less (room temperature 20°C/68°F, 65% RH) From preheat/energy saving mode (room temperature 20°C/68°F, 65% RH) At energy saving priority mode: 30 s or less At return time priority mode: 10 s or less Paper feed system ..Automatic feed with two front-loading cassettes (capacity: 550 sheets of 80 g/m each), and with bypass tray (capacity: 50 sheets of 80 g/m...
  • Page 17 (16) Program copy (17) Copy management (18) Cover copying (19) Presentation copying (20) Change language (21) Duplex copy (with duplex unit installed) (22) Auto selection (with RADF installed) Power source ....230 V AC, 50 Hz, 8 A 120 V AC, 60 Hz, 12 A Power consumption ..
  • Page 18 1-1-4 Specifications DC-2060 Type ......Desktop Copying system ..Dry, indirect electrostatic system Originals ...... Sheets, books, three-dimensional objects Maximum size: A3/11" × 17" Original feed system ... Fixed Copy paper ....(1) Plain paper: Paper feed from cassettes (60 - 80g/m Bypass feed (60 - 160 g/m (2) Special paper: Bypass feed (OHP film, transparencies and colored paper)
  • Page 19 Warmup time ....45 s or less (room temperature 20°C/68°F, 65% RH) From preheat/energy saving mode (room temperature 20°C/68°F, 65% RH) At energy saving priority mode: 30 s or less At return time priority mode: 10 s or less Paper feed system ..Automatic feed with two front-loading cassettes (capacity: 550 sheets of 80 g/m each), and with bypass tray (capacity: 50 sheets of 80 g/m...
  • Page 20 (16) Program copy (17) Copy management (18) Cover copying (19) Presentation copying (20) Change language (21) Duplex copy (with duplex unit installed) (22) Auto selection (with RADF installed) Power source ....230 V AC, 50 Hz, 8 A 120 V AC, 60 Hz, 12 A Power consumption ..

  • Page 21: Handling Precautions

    1-2 Handling Precautions 1-2-1 Drum ....................1-2-1 1-2-2 Developer and toner ................. 1-2-1 1-2-3 Dehumidifier ..................1-2-1 1-2-4 Copy paper ..................1-2-1...

  • Page 22: Copy Paper

    1-2-1 Drum Note the following when handling or storing the drum. • While the cleaning unit and the developing unit are detached from the copier or the drum is being replaced, make sure that the drum surface is protected from strong, direct light.

  • Page 23: Table Of Contents

    1-3 Mechanical Construction 1-3-1 Machine parts names and their functions ......... 1-3-1 1-3-2 Machine cross sections ..............1-3-4 1-3-3 Drive system ..................1-3-6 1-3-4 Mechanical construction ..............1-3-10 ( 1 ) Paper feed section ..............1-3-10 (1-1) Paper feed from the cassettes ........1-3-10 (1-2) Paper feed from bypass tray ..........

  • Page 25: Machine Parts Names And Their Functions

    1-3-1 Machine parts names and their functions (1) Main body ‹ ¤ & › fi ⁄ Metric fl Inch fl Figure 1-3-1 Machine parts names and their functions 1 Front cover 0 Toner cartridge ( Ejection cover 2 Original cover ! Drawer 1 ) Copy tray 3 Operation panel...
  • Page 26 (2) Operation panel Metric Œ · ‡ fl fi › ‹ ´ ¤ ⁄ RADF Reset RADF Folio 3 . 5 . 7 … Folio 2 . 4 . 6 … ‰ ¤ Á ˇ „ ‚ ° ¤ & Œ...
  • Page 27 Metric Inch 1 Interrupt key/Interrupt indicator 1 Interrupt key/Interrupt indicator 2 Preheat key/Preheat indicator 2 Energy saver key/Energy saver 3 Auto selection key/Auto selection indicator indicator 3 Auto selection key/Auto selection 4 All clear key indicator 5 Print key/Print indicator 4 Reset key 6 Stop/clear key 5 Print key/Print indicator...

  • Page 28: Machine Cross Sections

    1-3-2 Machine cross sections Light path Paper path 1 Paper feed section (page 1-3-10) 4 Transfer and separation sections 2 Image formation section (page 1-3-18) (page 1-3-38) • Main charging section (page 1-3-19) 5 Charge erasing section (page 1-3-41) • Developing section (page 1-3-23) 6 Fixing and eject sections (page 1-3-44) •...
  • Page 29 Paper path 1 Feedshift section (page 1-3-48) 2 Duplex section (page 1-3-49) Figure 1-3-4 Machine cross section – feedshift and duplex sections (optional) Special tray (page 1-3-56) Paper path Figure 1-3-5 Machine cross section – special tray (optional) 1-3-5...

  • Page 30: Drive System

    1-3-3 Drive system Å ˝ Ø Ï Í ∏ Î Ô  ˆ  ı ¨ Ò ˜ Ó ¯ Á Œ & ˇ ‰ ´ „ ‚ ˘ Ú ¿ ˛ · Ç ° ‡ ¸ ◊ fl ⁄ fi...

  • Page 31: Forwarding Pulley

    1 Scanner wire pulley ¨ Thrust gear 31 (Image formation 2 Scanner wire pulley section) (Light source unit 2) ˆ Tension pulley 20 3 Scanner wire Ø Drum drive belt ∏ Motor gear 108/38 4 Scanner motor pulley 5 Scanner drive belt Å...
  • Page 32 Figure 1-3-7 Drive system – feedshift section (optional) 1 Gear 38T (Copier) 5 Forwarding pulley 22 2 Separation idle gear 6 Feedshift drive belt 3 SB gear 24 7 Forwarding pulley 22 4 Forwarding pulley 22 8 Toner roller gear &...

  • Page 33: Pulley

    1 Developing gear 21 6 Feed clutch (ST) gear 2 Paper feed clutch (ST) gear 7 Switchback feed gear 25 3 Gear 16T 8 Paper feed motor gear 4 Gear 67/32 9 Forwarding pulley gear 5 Switchback feed gear 25 0 Lift motor (ST) Figure 1-3-9 Drive system –...

  • Page 34: Mechanical Construction

    1-3-4 Mechanical construction (1) Paper feed section The paper feed section consists of the primary and secondary paper feed sections. In the primary paper feed section, paper placed in the first/second cassette or on the bypass tray is fed to the upper and lower registration rollers. In the secondary paper feed section, the paper is further fed to the transfer/separation section in sync with the exposure timing.
  • Page 35 ( Lower paper feed pulley ˇ Lift operating plate ) Right feed pulley Á Cassette ⁄ Desk paper conveying roller ¨ Cassette lift ¤ Left feed guide ˆ Upper paper switch (PSW-U) ‹ Lower paper feed switch (PFSW-L) Ø Upper lift limit switch (LICSW-U) ∏...
  • Page 36 Print Key SHPSW 583 ms 40 ms 1958 P Forward Reverse Forward 100 ms PFCL-U 304 ms 20 ms FCL-U 95 ms 29 ms 130 ms * 209 ms Automatic exposure mode, original size: A4/11" × 8 ", magnification ratio 100% *1: Varies depending on the setting by simulation 27.
  • Page 37 A When the print key is pressed, the drive motor (DM) comes on. B 100 ms after the drive motor (DM) comes on, the upper paper feed clutch (PFCL-U) comes on. This transmits the drive from the drive motor to the forwarding pulley, the upper paper feed pulley, and the lower paper feed pulley and starts the primary paper feed.

  • Page 38: Paper Feed From Bypass Tray

    (1-2) Paper feed from bypass tray The bypass tray can hold up to 50 sheets of paper at the one time. When copying starts, the bypass solenoid (BYPSOL) comes on and the bypass stopper is released and at the same time, the SB forwarding pulley comes down into contact with the paper and the paper set on the bypass table is feed to the SB upper paper feed pulley and the SB lower paper feed pulley.
  • Page 39 MPCB CN2-10 BYPSOL BYPPSW CN2-14 CN2-13 BYPCL Figure 1-3-13 Bypass paper feed section block diagram 1-3-15...
  • Page 40 Print Key SHPSW 40 ms 5236 P Forward Reverse 180 ms 100 ms BYPSOL 152 ms BYPCL 150 ms 172 ms * 300 ms 209 ms 50 ms Manual exposure mode, original size: A3/11" × 7", " × 8 copy paper: A5R/5 ", magnification ratio 50% *1: Varies depending on the setting by simulation 27.
  • Page 41 A When the print key is pressed, the drive motor (DM) comes on. B 100 ms after the drive motor (DM) comes on, the bypass solenoid (BYPSOL) comes on, the bypass stopper is released, and at the same time, the SB forwarding pulley comes down and presses on the paper set on the bypass tray.

  • Page 42: Main Charging Section

    (2) Image formation section As shown in the figure, the image formation section comprises the drum, main charging section, developing section, and the cleaning section. These are combined in a single unit. 1 Cleaning section 3 Drum 2 Main charging section 4 Developing section Figure 1-3-14 Image formation section CN5-11...
  • Page 43 (2-1) Main charging section The main charging section consists of the drum and the main charger. The drum is electrically charged uniformly by means of a grid to form a latent image on the surface. 1 Main charger 2 Tungsten wire 3 Main charger grid Figure 1-3-16 Main charging section Figure 1-3-17 Main charger assembly...
  • Page 44 Print Key 300 ms 133 ms * All on All on Side erasure MC REM 300 ms 1122 ms * 209 ms Automatic exposure mode, original size: A4/11" × 8 ", magnification ratio 100%, paper feed from the 1st cassette *1: Varies depending on the setting by simulation 54 and copy paper size.
  • Page 45 Surface potential correction control The drum surface potential is corrected for the external temperature and humidity. If the external temperature is 24°C/75.2°F or less or the absolute humidity exceeds 25.0 g/m , the drum surface potential is corrected as in the table bellow. The external temperature and humidity (relative/relative) are detected by the external temperature/humidity sensor (T/ HSENS) and the absolute humidity is calculated from these values.
  • Page 46 100% (°C) (°F) Temperature (°C/°F) Figure 1-3-18 Absolute humidity vs. relative humidity Table 1-3-2 Surface potential correction value vs. external temperature Temperature Correction Temperature Correction Temperature Correction (°C/°F) value (V) (°C/°F) value (V) (°C/°F) value (V) 0/32 0.75 13/55.4 0.36 26/78.8 1/33.8 0.72...
  • Page 47 (2-2) Developing section The developing section consists of the developing assembly and the toner hopper. The developing assembly consists of the developing roller where a magnetic brush is formed, the doctor blade and the developing spirals that agitate the developer. This machine has the toner recycling assembly that new toner from the toner cartridge is mixed with residual toner recovered from the cleaning section.
  • Page 48 Formation of magnetic brush The developing roller consists of a magnet roller with five poles and a sleeve roller. Rotation of the sleeve roller around the magnet roller entrains developer, which in turn forms a magnetic brush at pole N1 on the magnet roller. The height of the magnet brush is regulated by the doctor blade;...
  • Page 49 Toner level detection The toner level in the toner hopper is monitored by the toner level detection switch (TEDSW). Vibration shaft Hopper paddle B Toner level detection switch (TEDSW) Magnet Hopper housing Figure 1-3-22 Toner level detection The toner level detection switch (TEDSW) is a magnetic proximity switch. It goes on when the magnet installed on hopper paddle B comes near it.
  • Page 50 DB REM CN1-7 HVTPCB TNS CNTL CN5-17 TNS SENS CN5-15 TEDSW CN5-9 ET-TH CN23-1 TEDSW T/HSENS HUM-SENS CN23-3 Developing bias TFM1 CN5-12 TFM2 CN5-13 MPCB Figure 1-3-23 Toner density control The toner density is detected by the toner sensor (TNS) installed on the developing unit. When a certain quantity of the developer passes the sensor detection section, the carrier proportion by weight is converted into a voltage and output to the main PCB (MPCB).
  • Page 51 When no toner is detected by the TEDSW, the toner empty state is displayed here. Toner sensor Message is displayed output voltage (V) AP detection level max. 3min. (3.56) If the level does not go down even after the additional forced toner feed, the toner empty state is displayed here.
  • Page 52 5 If the toner sensor output voltage does not return to the toner empty end level within the additional forced feed operation time, after the end of the additional forced feed operation time, “Add toner” is shown on the message display. If the toner sensor output voltage falls to the toner empty end level within the additional forced feed operation time, the copier returns to the ready state and intermittent feed operations (3 minutes max.) are carried out until the toner sensor output voltage drops...
  • Page 53 • Correction based on the absolute humidity When high absolute humidity is detected, the toner sensor control voltage (TNS CNTL) is decreased. The external temperature and relative humidity are read from the external temperature/ humidity sensor (T/HSENS) and the absolute humidity is calculated from these values. (Refer to Figure 1-3-18 “Absolute humidity vs.
  • Page 54 (2-3) Cleaning section The cleaning section consists of the cleaning blades which remove residual toner from the drum surface after transfer, and the cleaning spiral that carries the residual toner back to the toner hopper. The cleaning unit employs the blade cleaning method. Figure 1-3-27 Cleaning section 1 Drum 4 Cleaning spiral...
  • Page 55 (3) Exposure section 6 7 8 9 0 @ › & ⁄ ¤ ‹ flfi Figure 1-3-28 Exposure section 1 Scanner home position switch $ Mirror 4 (SHPSW) % Mirror 5 2 Light source unit 2 ^ Mirror 1 3 Mirror 2 &...
  • Page 56 Original SHPSW ODSW CPCB ODS3-4 ODS5-6 LHPSW CN10-1 MHPSW CN10-3 CN6-2 1, 2 *1: Optional for metric models *2: For metric models only Figure 1-3-29 Exposure section block diagram AE sensor detection width Original leading edge AE detection (prescan) Exposure Scanner movement 148 mm...
  • Page 57 Print Key SHPSW 130 ms 10 P 10 P 583 ms 40 ms 40 ms 1958 P 2750 P Prescan Forward verse verse 720 ms 10 ms 100 ms Automatic exposure mode, original size: A4/11" × 8 ", magnification ratio 100%, paper feed from 1st cassette *1: Varies depending on the setting by simulation 27.
  • Page 58 Exposure control The light intensity for the halogen lamp is controlled by controlling the voltage applied from the AVR section to the halogen lamp (HL) by varying the light intensity data output to the composite PCB (CPCB) AVR section from the main board HLPWM terminal (varying the output pulse duty ratio).
  • Page 59 • Photo mode exposure control In photo-mode, the drum surface potential is lowered according to the simulation 32 setting (Drum surface potential setting) and the intensity of light from the halogen lamp is controlled as follows from the photo mode exposure value data set with Simulation 24 (exposure adjustment).
  • Page 60 • Automatic exposure mode control In automatic exposure mode, prescanning is carried out with the halogen lamp (HL) lit the light intensity for EXP4 and the exposure intensity for copying is determined by the output voltage of the AE sensor (AES). The light intensity for the halogen lamp for copying is controlled with the NTC original and NPTC original scanner AE sensor voltage values obtained by executing simulation 22 made to correspond to EXP4 and EXP7-2 for manual exposure.
  • Page 61 • Exposure volume correction When the absolute humidity exceeds 26.0 g/m , the exposure volume (light intensity data) is corrected as follows. The external temperature and relative humidity are read from the external temperature/humidity sensor (T/HSENS) and the absolute humidity is calculated from these values.

  • Page 62: 4 ) Transfer And Separation Sections

    (4) Transfer and separation sections The transfer/separation section comprises the transfer charger assembly, separation claws, etc. 4 5 6 7 Figure 1-3-34 Transfer and separation sections 1 Separation guide 5 Separation charger 2 Separation claw (Tungsten wires) 3 Separation pulley 6 Transfer charger 4 Transfer shield (Tungsten wires)
  • Page 63 Figure 1-3-35 Transfer charger assembly 1 Transfer rear lid 8 Transfer charger cleaning knob 2 Charger spring 9 Transfer front lid 3 Transfer rear housing 0 Charger pin 4 Charger cleaning pad ! Separation charger 5 Separation guide (Tungsten wire) 6 Transfer shield @ Transfer charger 7 Transfer front housing...
  • Page 64 Print Key 209 ms 600 ms TC REM 721 ms SC REM 739 ms Automatic exposure mode, original size: A4/11" × 8 ", magnification ratio 100%, paper feed from 1st cassette Timing chart 1-3-5 Transfer and separation A When the print key is pressed, the drive motor (DM) comes on. B 600 ms after the drive motor (DM) comes on, the TC REM signal and the SC REM signal come on, high voltage is applied from the high-voltage transformer PCB (HVTPCB) to the transfer charger and the separation charger and the transfer charging and separation...

  • Page 65: 5 ) Charge Erasing Section

    (5) Charge erasing section The charge erasing section comprises the blank lamps (BL) and the cleaning lamp (CL). Cleaning lamp (CL) Blank lamps (BL) Figure 1-3-37 Charge erasing section Cleaning lamp ..After the toner is removed in the cleaning section, the cleaning lamp removes the residual charge on the drum to prepare for the next copy.
  • Page 66 Print Key SHPSW 1500 ms MC REM 300 ms 1122 ms 322 ms 133 ms 446 ms 300 ms All on All on All off Side erasure Automatic exposure mode, original size: A4/11" × 8 ", magnification ratio 100% * 1: Varies depending on the setting by simulation 54 and magnification ratio. Timing chart 1-3-6 Charge erasing 1-3-42...
  • Page 67 A When the print key is pressed, the drive motor (DM) comes on. At the same time, the cleaning lamp (CL) lights up to remove the residual charge on the drum to prepare for the next copy. B 300 ms after the cleaning lamp (CL) lights up, the blank lamps (BL) all light up and the leading edge margin is formed (leading edge blank cut).

  • Page 68: 6 ) Fixing And Eject Sections

    (6) Fixing and eject sections The fixing and eject sections comprise the parts shown in the figure. When the paper for which transfer has been completed is conveyed to the fixing section, it passes between the press roller and the heat roller heated by the fixing heater (H). Between the heat roller and the press roller, pressure is applied by the fixing pressure spring and the toner on the paper passing between the rollers is thermally fused by the heat and press rollers to fix it to the paper.
  • Page 69 AC power supply CN11-1 MPCB H REM CN10-3 CN6-3 CN11-3 CN11-7 Figure 1-3-40 Fixing section block diagram 1-3-45...
  • Page 70 Fixing temperature control 400 ms 10 s or more 1000 ms 200 ms 2000 ms Full speed Half speed Full speed Half speed 500 ms PCFM Print indicator ON (D-1) ON (D-2) ON (D-3) Timing Chart 1-3-7 Fixing temperature control A 200 ms after the main switch (MSW) comes on, the internal cooling fan motor (CFM) rotates at full speed.
  • Page 71 • If the heat roller surface temperature is 13°C/55.4°F or more when the main switch (MSW) comes on and the external temperature detected by the external temperature/ humidity sensor (T/HSENS) is 18°C/64.4°F or more: When the fixing stabilization drive start temperature is reached and 43 more seconds pass (D-2). •...

  • Page 72: Feedshift Section

    (7) Feedshift and duplex sections (optional) For duplex copy mode, the paper for which copying on the rear side has been completed is conveyed to the duplex section by the feedshift section operation. After the conveyed paper is horizontally aligned and inverted, it is fed again for front side copying. (7-1) Feedshift section Figure 1-3-41 Feedshift section 1 Upper right feedshift guide...

  • Page 73: Duplex Section

    CN11-9 CN11-5 FSSW CN11-1 FSSOL MPCB Figure 1-3-42 Feedshift section block diagram (7-2) Duplex section 1 @ 8 $ 7 4 Figure 1-3-43 Duplex section 1 Duplex forwarding pulley 0 Duplex upper eject pulley 2 Duplex paper press plate ! Duplex lower eject pulley 3 Duplex paper tapping guide @ Side registration guide 4 Refeed roller...
  • Page 74 For paper stocking, the duplex paper tapping solenoid comes on, then the duplex paper tapping guide descends and the duplex forwarding pulley pulls the paper one sheet at a time to the switchback roller and switchback separation belt. For paper refeed, each time one sheet of paper is fed, the paper is pressed to the refeed roller by the duplex paper press plate.
  • Page 75 MPCB PCCL SENS STKSW SRHPSW RFCL DUPPTSOL DUPRSW DUPESW PCSW PPSOL FWDSOL Figure 1-3-45 Duplex section block diagram 1-3-51...
  • Page 76 Duplex copying operation timing Print key DUPPTSOL 104 ms 127 ms DUPFWDSOL 191 ms RFCL step step step STKSW FSSW 100 ms PFCL-L FSSOL 1111 ms " × 11", Automatic exposure mode, original size: A4R/8 " × 11", magnification ratio 100%, paper copy paper: A4R/8 feed from the 2nd cassette Timing chart 1-3-8 Feedshift and side registration...
  • Page 77 A When the print key is pressed, the drive motor (DM) comes on and 100 ms later, the lower paper feed clutch (PFCL-L) comes on and the rear side copying starts. B The registration clutch (RCL) comes on and secondary paper feed starts, then 1111 ms later, the feed shift solenoid (FSSOL) comes on, the conveying shift guide operates, and the paper path is switched.
  • Page 78 Print key DUPPTSOL 100 ms DUPPPSOL 100 ms 275 ms RFCL 76 ms DUPRCL 195 ms DUPPCCL DUPRSW DUPPCSW DUPESW FCL-U 95 ms J K LM N O P Q " × 11", Automatic exposure mode, original size: A4R/8 " × 11", magnification ratio 100%, paper copy paper: A4R/8 feed from the 2nd cassette Timing chart 1-3-9 Refeed...
  • Page 79 J 100 ms after the print key is pressed and the drive motor (DM) comes on, the duplex paper tapping solenoid (DUPPTSOL) and the duplex paper press solenoid (DUPPPSOL) come on, the duplex paper trapping guide and the duplex paper press plate descend, and the paper is pressed by the switchback roller and refeed roller.

  • Page 80: ( 8 ) Special Tray (Optional)

    (8) Special tray (optional) The special tray is a stacking type option cassette and comprises the parts shown in the figure. Figure 1-3-46 Special tray 1 Upper paper feed housing 9 Right feed pulley 2 Lift limit switch (ST) (LICSW(ST)) 0 Paper feed switch (ST) (PFSW(ST)) 3 Paper switch (ST) (PSW(ST)) ! Left feed guide...
  • Page 81 Print key 95 ms FCL-U 100 ms 165 ms PFCL(ST) Automatic exposure mode, copy paper: A3/11" × 17", magnification ratio 100% Timing chart 1-3-10 Paper feed from the special tray A 100 ms after the print key comes on, the paper feed clutch (ST) (PFCL (ST)) comes on, the forwarding pulley, the upper paper feed pulley, and the lower paper feed pulley rotate, and paper conveying starts.

  • Page 82: Electrical Section

    ELECTRICAL SECTION 1AH/MCE...
  • Page 83 2-1 Electrical Parts Layout 2-1-1 Electrical parts layout ................ 2-1-1...
  • Page 85 2-1-1 Electrical parts layout Machine front Machine inside Machine rear Figure 2-1-1 Layout of electrical parts: copier PCBs 1. Main PCB (MPCB) ........Controls the other PCBs and electrical components. 2. Composite PCB (CPCB) ......Supplies power to the other electrical components (generates 24 V and 5 V DC).
  • Page 86 26 27 19, 22 16 7 Machine front Machine inside Machine rear Figure 2-1-2 Layout of electrical parts: copier switches and sensors 1. Main switch (MSW) ......... Turns the AC power on and off. 2. Safety switch 1 (SSW1) ......Breaks the safety circuit when the front cover is opened, and resets paper misfeed detection.
  • Page 87 *1 14. Lower paper width switch (PWSW-L) ..Detects the width of paper in the 2nd cassette. 15. Upper paper switch (PSW-U) ....Detects the presence of paper in the 1st cassette. 16. Lower paper switch (PSW-L) ....Detects the presence of paper in the 2nd cassette.
  • Page 88 Machine front Machine inside Machine rear Figure 2-1-3 Layout of electrical parts: copier motors 1. Drive motor (DM) ......... Drives the machine. 2. Lens motor (LM) .......... Drives the lens. 3. Mirror motor (MM) ........Drives mirrors 4 and 5. 4.
  • Page 89 Machine front Machine inside Machine rear Figure 2-1-4 Layout of electrical parts: copier clutches and solenoids 1. Registration clutch (RCL) ......Secondary paper feed. Controls the drive of the registration roller. 2. Upper feed clutch (FCL-U) ......Controls the drive of the feed roller. 3.
  • Page 90 2, 3 Machine front Machine inside Machine rear Figure 2-1-5 Layout of electrical parts: copier other electrical parts 1. Fixing heater (H) ........Heats the heat roller. 2. Fixing unit thermostat 1 (TH1) ....Prevents overheating in the fixing section. 3.
  • Page 91 Machine front Machine inside Machine rear Figure 2-1-6 Layout of electrical parts: feedshift and duplex sections 1. Feedshift switch (FSSW) ....Detects a paper misfeed in the feedshift section. 2. Stock switch (STKSW) ....Detects the presence of paper in the duplex unit.
  • Page 92 Machine front Machine inside Machine rear Figure 2-1-7 Layout of electrical parts: special tray (Optional) 1. Cover open detection switch (ST) (COSW (ST)) .......... Breaks the safety circuit when the right cover (special tray) is opened, and resets paper misfeed detection. 2.
  • Page 93 2-2 Detection of Paper Misfeeds 2-2-1 Paper misfeed detection ..............2-2-1 2-2-2 Paper misfeed detection conditions ..........2-2-2 ( 1 ) Paper feed, conveying and eject sections ......... 2-2-2 ( 2 ) Special tray (optional) ..............2-2-5 ( 3 ) Feedshift/duplex section (optional) ..........2-2-6 ( 4 ) DF (optional) ................

  • Page 95: Paper Misfeed Detection

    1AA-1 2-2-1 Paper misfeed detection When a paper misfeed occurs, LED of the paper misfeed on the operation section blinks, and at the same time paper misfeed location display lights to indicate paper misfeed location. To remove paper misfeed in the copier, open the front cover, the right cover, or the cassette, depending on the location indicated.

  • Page 96: Paper Misfeed Detection Conditions

    2-2-2 Paper misfeed detection conditions (1) Paper feed, conveying and eject sections BYPCL RCL RSW FCL-U PFCL-U FCL-L PFSW-U PFCL-L Figure 2-2-2 Paper feed, conveying and eject sections 1. Paper feed section • No paper feed from the upper cassette (JAM code 10) The feed switch (FSW) fails to turn on within 1714 ms after the upper paper feed clutch (PFCL-U) has turned on.
  • Page 97 • No paper feed from the lower cassette (JAM code 11) The upper paper feed switch (PFSW-U) fails to turn on within 1714 ms after the lower paper feed clutch (PFCL-L) has turned on. PFCL-L PFSW-U 1714 ms Timing chart 2-2-2 •...
  • Page 98 2. Paper conveying section • The registration/transfer (JAM code 30) The eject switch (ESW) fails to turn off within 3277 ms after the registration clutch (RCL) has turned on. 3277 ms Timing chart 2-2-6 The registration switch (RSW) fails to turn off within 3850 ms after the registration clutch (RCL) has turned on.

  • Page 99: ( 2 ) Special Tray (Optional)

    (2) Special tray (optional) PFSW-L PFCL(ST) Figure 2-2-3 Special tray • No paper feed from the special tray (JAM code 12) The lower paper feed switch (PFSW-L) fails to turn on within 1868 ms after the paper feed clutch (ST) (PFCL(ST)) has turned on. PFCL (ST) 1868 ms PFSW-L...

  • Page 100: ( 3 ) Feedshift/Duplex Section (Optional)

    (3) Feedshift/duplex section (optional) FSSW DUPPCCL STKSW DUPRCL DUPFWDSOL RFCL DUPESW DUPPCSW DUPRSW Figure 2-2-4 Feedshift/duplex section 1. Feedshift section • The feedshift (JAM code 51) The feedshift switch (FSSW) fails to turn on within 2006 ms after the eject switch (ESW) has turned on.
  • Page 101 The feedshift switch (FSSW) fails to turn off within the time shown in Table 2-2-1 after the feedshift switch (FSSW) has turned on. Paper size Time 201 ms 174 ms A4R* 142 ms B5R* 123 ms A5R* 100 ms 100 ms 87 ms 11×17* 206 ms...
  • Page 102 • The main body vertical paper conveying (JAM code 19) The feed switch (FSW) fails to turn on within 2363 ms after the duplex eject switch (DUPESW) has turned on. DUPESW 2363 ms Timing chart 2-2-13 • The duplex section (JAM code 19) The duplex paper conveying switch (DUPPCSW) fails to turn on within 2335 ms after the duplex registration clutch (DUPRCL) has turned on.

  • Page 103: ( 5 ) Sorter (Optional)

    (4) DF (optional) • No original feed from the original table (JAM code 70) (See the DF service manual) • DF original feed section (JAM code 71) (See the DF service manual) • DF conveying belt section (JAM code 72) (See the DF service manual) •...
  • Page 104 2-3 Operation of the PCB 2-3-1 Composite PCB .................. 2-3-1 ( 1 ) Power source section ..............2-3-1 ( 2 ) AVR/Fixing heater control section ..........2-3-8 2-3-2 Main PCB ..................2-3-11 ( 1 ) Abnormally high fixing temperature detection circuit ....2-3-12 ( 2 ) Reset circuit ................

  • Page 106: Composite Pcb

    2-3-1 Composite PCB (1) Power source section TRNS 24 V DC 24 V DC output/ Rectifier output error Noise filter /active detection circuit 2 filter circuit circuit Q102 Overvoltage detection circuit Switching control/ overcurrent 5 V DC detection circuit 5 V DC input output output...
  • Page 107 a. Noise filter circuit LIVE NUTRAL F001 D001 L001 C005 C002 C001 C003 Figure 2-3-2 Noise filter circuit The noise filter circuit has two circuits which consists of coil (L1) and capacitors (C1 to C4) and coil (L001) and capacitors (C001 to C003, C005). It prevents high-frequency noise peculiar to the switching regulator from escaping out of the copier via the AC line input and also protects the internal circuits from the adverse effects of external noise.
  • Page 108 b. Rectifier/active filter circuit D001 L102 D107 D108 Q101 C101 R128 R129 Controller IC (IC1) Figure 2-3-3 Rectifier/active filter circuit AC voltage through the noise filter is full-wave-rectified by the full-wave rectifier (D001) and is input to the active filter circuit. When AC power turned on, the surge currents generated at power up go into the circuit.
  • Page 109 c. Switching control/overcurrent detection circuit TRNS R112 C102 R113 R111 D105 C101 C103 Q102 R108 C104 R109 R118 Switching control IC (IC2) Figure 2-3-4 Switching control/overcurrent detection circuit Switching control IC (IC2) in the switching control circuit emits a pulse signal to FET (Q102).
  • Page 110 d. 24 V DC output (smoothing)/error detection circuit C201 R201 D201 TRNS R202 C203 C202 24 V DC output L201 R206 C205 R203 R207 R205 C206 R204 C207 Figure 2-3-5 24 V DC output (smoothing)/error detection circuit In the 24 V DC output circuit, the voltage generated on the secondary side of the transformer (TRNS) is rectified by diode (D201) and is then smoothed into 24 V DC by the choke coil (L201) and the capacitor (C203).
  • Page 111 e. 5 V DC output circuit 24 V DC output circuit L301 L302 R301 Q301 R302 C306 R303 R306 R307 D301 5 V DC C301 output R304 8 7 6 5 C302 1 2 3 4 R305 C303 Figure 2-3-6 5 V DC output circuit The 24 V DC output from the 24 V DC output circuit is stepped down to 5 V DC in the 5 V DC output circuit.
  • Page 112 f. Overvoltage/5 V DC output overcurrent detection circuit ZD401 R401 24 V DC 24 V DC output output circuit ZD402 Switching control circuit Q102 R402 R301 C306 R306 R307 5 V DC 5 V DC Switching control IC (IC2) output C301 output Q302...

  • Page 113: 2 ) Avr/Fixing Heater Control Section

    (2) AVR/Fixing heater control section signal/ HL PWM voltage conversion circuit DB601 AC input MPCB Q602 TH601 TH602 H REM Figure 2-3-8 AVR/Fixing heater control section block diagram The AVR/fixing heater control section on the composite PCB consists of the PWM signal/voltage conversion circuit, halogen lamp control circuit (HIC) and fixing heater control circuit.
  • Page 114 a. Halogen lamp intensity control The halogen lamp control circuit (HIC) detects the moment when AC supply reaches 0 V every 1/2 cycle, using the AC supply fully-rectified by diode bridge (DB601); and generates a zero-crossing signal that serves as the trigger pulse to turn the halogen lamp triac (TH601) on.
  • Page 115 b. Fixing heater control circuit AC (LIVE) DB601 CN11-1 AC (NEUTRAL) R624 C608 Q602 TH602 R24 V CN6-1 CN11-3 R613 R502 5, 9 H REM CN6-3 Figure 2-3-11 Fixing heater control circuit The fixing heater control circuit regulates the output of the trigger pulse to the fixing heater triac (TH602).

  • Page 116: Main Pcb

    2-3-2 Main PCB HVTPCB Option (IC11) (IC32) (IC18) OPPCB Clutch Solenoid Switch ODS1, 2 Sensor ODS3, 4 ODS5, 6 (IC16) (IC27) ODS7, 8 (IC22) (IC21) Reset circuit (IC17) (IC39) (IC1) BUPCB Figure 2-3-12 Main PCB block diagram The main PCB (MPCB) consists of two CPU (IC18, IC32), RAM (IC17, IC1), EPROM (IC21, IC22), and I/O control LSI (IC16, IC27).

  • Page 117: 1 ) Abnormally High Fixing Temperature Detection Circuit

    (1) Abnormally high fixing temperature detection circuit (IC32) (IC27) IC47D IC35B CN11-7 – H ALARM CN10-3 H REM TR11 R149 R150 Figure 2-3-13 Abnormally high fixing temperature detection circuit CPU (IC32) of the main PCB monitor the fixing temperature by voltage of the fixing unit thermistor (FTH) input at pin 1 (A/D input) and controls the fixing heater on/off that it output the fixing heater control signal (H REM) to the composite PCB via pin 67 of the I/ O control LSI (IC27).

  • Page 118: 2 ) Reset Circuit

    (2) Reset circuit BUPCB _RESET (IC18) _RES2 IC39 (IC32) IC37 (IC16, IC27) Figure 2-3-14 Reset circuit When the power is turned on or if the power voltage drops excessively, reset IC (IC39) emits a reset signal to CPUs (IC18, IC32) and each I/O control LSI to prevent CPU from behaving erroneously.

  • Page 119: 3 ) Scanner Drive Circuit

    (3) Scanner drive circuit Parallel control signal Address latch (IC23) (IC32) Serial control signal (IC22) (IC18) Scanner motor drive SHRPSW circuit LHPSW MHPSW Figure 2-3-15 Scanner drive circuit block diagram The scanner drive circuit consists of CPU (IC18) on the main PCB and each motor drive The CPU (IC18) communicate timing and control data with CPU (IC32) through the parallel and serial circuit, and controls the scanner system in time with CPU (IC32) according to the program stored in EPROM (IC22).
  • Page 120 (4) Scanner motor control circuit P67/TB2in P66/TB1in P65/TB0in R24 V CN4-2 P64/INT2 R24 V CN4-5 SM B CN4-1 (IC18) SM B CN4-3 SM A CN4-6 SM A CN4-4 OUT IN Figure 2-3-16 Scanner motor control circuit The scanner motor (SM) control circuit consists of motor driver IC (IC5) and the coil current section (TR5, TR4, TR3, TR2).

  • Page 121: Operation Unit Pcb

    2-3-3 Operation unit PCB OPCB Key switch section KS0~KS7 SCLK Key Switch KIN0~KIN4 FSYNC MPCB ASIC LED display section DEG0~DEG7 7-segment SEG0~SEG15 Reset circuit Figure 2-3-17 Operation unit PCB block diagram Operation unit PCB (OPPCB) consists of controller ASIC (IC1), key switch matrix, LED display matrix.

  • Page 122: 1 ) Key Switch And Led Display Matrix

    (1) Key switch and LED display matrix Key switch ASIC Key Switch section Scan signals (KS0~KS7) 5 V DC Return signals (KIN0~KIN4) 7-segment LED LED display section Sink driver Scan signals (DEG0~DEG7) LED display signals (SEG0~SEG15) (LED lights terminal) Source driver Figure 2-3-18 Key switch and LED display matrix The key switches are laid out as a matrix and scan signals are constantly input from the scan signal terminals (KS0 - KS7).

  • Page 123: 2 ) Reset Circuit

    (2) Reset circuit 5 V DC (ASIC) RESET Figure 2-3-19 Reset circuit The reset circuit consists of reset IC (IC5). The reset IC (IC5) initializes the ASIC by emitting a reset signal to ASIC (IC1) at 5 V power on or if the power voltage drops excessively. A supply voltage monitor is always applied to the reset IC (IC5).
  • Page 124 SET UP AND ADJUSTMENT SECTION 1AH/MCE...
  • Page 125 3-1 Installation 3-1-1 Unpacking and installation ..............3-1-1 ( 1 ) Installation environment ............3-1-1 ( 2 ) Installation procedure ..............3-1-2 3-1-2 Setting initial copy modes ............... 3-1-13 3-1-3 Installing the key counter (optional) ..........3-1-14 3-1-4 Installing the cassette heater (optional) .......... 3-1-17 3-1-5 Installing the original size sensor (optional) ........

  • Page 127: Unpacking And Installation

    3-1-1 Unpacking and installation ( 1 ) Installation environment 1. Temperature: 10-35°C/50-95°F 2. Humidity: 15-85%RH 3. Power supply: 230 V AC, 8 A 4. Power source frequency: 50 Hz ± 0.3% 5. Installation location • Avoid direct sunlight or bright lighting. Make sure that the photoconductor will not be exposed to direct sunlight or other strong light when removing paper jams.

  • Page 128: 2 ) Installation Procedure

    ( 2 ) Installation procedure Start Unpack. Set the cleaning blade. Remove the tapes. Connect the power plug. Remove the tapes and the pins hold- ing light source units 1 and 2. Initialize the toner control level (simulation 60). Install the original holder. Exit simulation mode.
  • Page 129 Unpack. ^&* Figure 3-1-3 Unpacking 1 Outer case 0 Original holder 2 Top board ! Plastic bag 3 Inner frame @ Plastic bag 4 Hinge joints (4) # Accessories case 5 Bottom pads $ Copy tray 6 Machine cover (Bottom) % Skid 7 Main body ^ Instruction handbook...
  • Page 130 Remove the tapes. 1. Remove the tape holding the front cover, bypass tray and the right cover. 2. Remove the tape holding the actuator of the original detection switch. 3. Remove the tape holding the power cord. 4. Remove the tape holding each cassette. 5.
  • Page 131 Install the original holder. 1. Install the original holder to the machine. Original holder Figure 3-1-6 Remove the tapes and the pin holding the lens unit. 1. Open the front cover. 2. Remove the tape holding the front paper conveying guide. 3.
  • Page 132 Secure the pressure adjustment nuts. 1. Loosen the fixing unit retainer pin and take the fixing unit out of the machine as shown in Figure. Fixing unit retainer pin Fixing unit Figure 3-1-8 2. Tighten the pressure adjustment nuts (B) at the lower side for right and left of the fixing unit until it comes to the end of the spring pressure adjustment plate.
  • Page 133 Remove the image formation unit. 1. Release the paper conveying release lever in the direction of the arrow. 2. Remove the 12-pin image formation unit connector from the machine. 3. Remove the two screws and take the image formation unit out of the machine. 12-pin connector Image formation unit Paper conveying release lever...
  • Page 134 Load developer. 1. Slide the upper developing lid at the front of the machine as shown by the arrow in Figure and remove the upper developing lid from the hook of the developing unit. Remove the upper developing lid from the developing unit. Upper developing lid Figure 3-1-12 2.
  • Page 135 Set the cleaning blade. * The cleaning blade at the factory setting is secured at the release position with the blade release lever. Set the cleaning blade at the normal position (contacted on the drum) at an installation. 1. Turn the main switch off and unplug the power plug from a wall outlet. 2.
  • Page 136 Initialize the toner control level (simulation 60). 1. Turn the main switch on. 2. After the machine is stabilized, enter simulation mode (Enter 10871087 with the numeric keys). 3. Run simulation 60 (Enter 60 with the numeric keys and press the print key). * The machine starts driving and the setting of the toner control voltage is automatically made.
  • Page 137 Install a toner cartridge. 1. Open the front cover. 2. Hold a new toner cartridge and shake it four or five times up and down to agitate the toner. 3. Pull off the toner cartridge lid. Figure 3-1-15 4. Install the toner cartridge on the developing unit. 5.
  • Page 138 Install the copy tray. 1. Insert the projections of the copy tray into the two square holes of the eject cover and install the copy tray to the machine. Make test copies. 1. Load paper in the cassette. 2. Insert the power plug into a wall outlet. 3.

  • Page 139: Setting Initial Copy Modes

    3-1-2 Setting initial copy modes Factory settings are as follows: • Factory settings SIM No. Contents Default Setting folio size *1 width: 210 mm length: 330 mm Setting the duplex unit Duplex/Cassette selecting Cassette Priority mode Simplex mode Setting the preheat mode Energy saving mode Selecting between single/double counts Double count...

  • Page 140: Installing The Key Counter (Optional)

    3-1-3 Installing the key counter (optional) • Parts required for the installation Key counter set (P/N 66069780) Key counter socket (P/N 41529210) Contents of the set: Key counter cover (P/N 66060010) Key counter cover retainer (P/N 66060020) Key counter retainer (P/N 66060030) Key counter mount (P/N 66060040) Four M4 ×...
  • Page 141 3. Remove the rear cover from the copier. 4. Cut out the area in the right cover using a nipper. 5. Remove the two screws holding the right cover at the machine rear as shown in figure. 6. Peel off the seal attached to the cutout of the rear side plate. 7.
  • Page 142 8. Hook the projection of the key counter cover retainer onto the cutout in the right cover, and fasten them together to the copier with the two screws. 9. Pass the 4-pin connector of the copier through the cutout in the right cover and fit it to the 4-pin connector of the key counter.

  • Page 143: Installing The Cassette Heater (Optional)

    3-1-4 Installing the cassette heater (optional) * When installing the cassette heater to the special tray, perform the same procedure. <Procedure> 1. Take out the 2nd cassette. 2. Remove the four screws and take the cassette out of the copier. Screws Screws Cassette...
  • Page 144 3. Remove the two screws (M4X8 Tap tight screws) installing at the base of the copier. 4. Secure the cassette heater to the base of the copier with the removed two screws. 5. Pass the wire of the cassette heater through the square hole of the rear side plate. Square hole Base Cassette heater...
  • Page 145 6. Remove the two set screws and take off the power source supply assembly. Power source supply assembly Figure 3-1-22 7. Connect the cassette heater connector to the 2-pin connector on the copier. 8. Bind the wire of the cassette heater to the cord clump of the copier. Wire of the cassette heater Cord clump...

  • Page 146: Installing The Original Size Sensor (Optional)

    3-1-5 Installing the original size sensor (optional) • Parts required for the installation Two original size sensors 115 (P/N 33912230) Two original size sensors 60 (P/N 33427430) Original size sensor relay wire (P/N 34827140) Two wiring bands with snap (P/N M2107120) Four M3 ×...
  • Page 147 4. Insert the two projections on the original size sensor into the square holes in the optical unit, then fix each projection with a bind bronze screw (M3 × 5). * Be careful of the installing position of the original size sensor 3. * Be careful of the installing position of original size sensor 3.
  • Page 148 6. Insert the projection on the wiring band into the hole in the optical unit. 7. Insert the projection on the wiring band (M2107120) into the holes in the optical unit, then attach the two wiring bands. 8. Bind the wires connected to the original size sensors 1 and 2 so that they do not get in the way when the light source units 1, 2 are moved.
  • Page 149 10. Refit the optical unit wire cover. * When refitting the optical unit wire cover, pass the wires connected to the original size sensors 1 and 2 through the notch in the cover. Notch Optical unit wire cover Figure 3-1-29 11.
  • Page 150 3-2 Simulation 3-2-1 Simulation ..................3-2-1 ( 1 ) Running a simulation ..............3-2-1 ( 2 ) Simulation list ................3-2-2 ( 3 ) Contents of simulation ............... 3-2-8...

  • Page 152: Simulation

    3-2-1 Simulation This copier has a simulation function that simulates various machine operations to check and adjust each section. (1) Running a simulation Start Enter 10871087 with the numeric - - - - - - Simulation mode is entered. keys. Simulation mode is entered and the copy number/zoom - - - - - -...

  • Page 153: 2 ) Simulation List

    (2) Simulation list Sim. Section Contents Default Canceling a simulation ——— Copying without paper — — — Copying at standard zoom ratios —— — Checking DF operation in sync with the copier —— — without original feed Checking DF operation independently with original —...
  • Page 154 Sim. Section Contents Default Paper (cont.) feed and Mode Switches Remarks conveying (cont.) Upper paper switch or Stock When a switch is switch (When the Duplex unit is turned off, the installed.) corresponding Lower paper switch LED lights. Paper switch (ST) (Special tray) 4 –...
  • Page 155 Sim. Section Contents Default Paper feed and (cont.) Mode Switches Remarks conveying (cont.) Toner cartridge detection switch When a switch is (cont.) 4 – 8 —— turned on, the corresponding LED lights. Checking the paper conveying related clutches and solenoids Mode Numeric Clutches and solenoids Upper paper feed clutch...

  • Page 156: Mirror

    Sim. Section Contents Default Paper Checking for skewed paper feed with test copies ——— feed and Adjusting the duplex unit ——— conveying Adjusting the leading edge registration ——— (cont.) Adjusting the DF leading edge registration ——— Adjusting the leading/trailing edge margin ———...
  • Page 157 Sim. Section Contents Default Develop- Initializing the toner control level ——— Forced toner supply ——— Checking and setting the toner control level ——— Initializing Initializing the backup memory ——— memory Counts Checking and setting the maintenance cycle 80000 Checking and setting the maintenance count Cleared Checking and clearing the service call history All cleared...
  • Page 158 Sim. Section Contents Default Copy Setting the auto cassette change 0 (enabled) modes Setting the limit to the number of continuous copies (cont.) Selecting copy mode Number of limited copies: 0 (unlimited) with low toner Copy operation: 0 (single copies) Turning the auto start function on/off 1 (enabled) Setting the destination...

  • Page 159: 3 ) Contents Of Simulation

    (3) Contents of simulation Sim. Description Remarks Canceling a simulation 1 Enter 01 with the numeric keys. 2 Press the print key. * The copier returns to the normal mode. Copying without paper Checks mechanical 1 Place an original (A3/11" × 17" blank paper) on the operation.
  • Page 160 Sim. Description Remarks 5 Press the print key. (cont.) * A test copy is made at each magnification ratio in the following order: 100% → 86% → 70% → 61% → 50% → 100% → 115% → 122% → 141% → 163% → 200% * To halt the operation midway, press the stop/clear key.
  • Page 161 Sim. Description Remarks Checking DF operation independently with original feed Checks the DF operation. (Run 1 Enter 06 with the numeric keys. only when the DF 2 Press the print key. is installed.) 3 Select the mode No. to be executed with exposure adjustment keys.
  • Page 162 Sim. Description Remarks Checking the paper conveying related switches Checks the switch operations 1 Enter 11 with the numeric keys. in the paper 2 Press the print key. conveying systems. 3 Select the mode number to be executed with the exposure adjustment keys.
  • Page 163 Sim. Description Remarks (cont.) Mode Switches Remarks Upper paper switch or Stock When a switch is switch (When the Duplex unit is turned off, the installed.) corresponding Lower paper switch LED lights. Paper switch (ST) (Special tray) 4 – 7 ——— Bypass paper switch Upper lift limit switch When a switch is...
  • Page 164 Sim. Description Remarks (cont.) Mode Switches Remarks Toner cartridge detection switch When a switch is (cont.) 4 – 8 —— turned on, the corresponding LED lights. 7 Press the stop/clear key. Checking the paper conveying related clutches and Checks operation solenoids of the paper conveying related...
  • Page 165 Sim. Description Remarks (cont.) Mode Numeric Clutches and solenoids Registration clutch (RCL) Bypass paper feed clutch (BYPCL) Bypass solenoid (BYPSOL) Refeed clutch Duplex registration clutch Duplex paper conveying clutch Feedshift solenoid Duplex paper tapping solenoid Duplex forward solenoid Duplex paper press solenoid 0 –...
  • Page 166 Sim. Description Remarks Checking for skewed paper feed with test copies Checks mechanical 1 Enter 16 with the numeric keys. distortion or 2 Press the print key. positioning error in the drum and 3 Select the largest size with the paper select key. the paper 4 Open the original holder.
  • Page 167 Sim. Description Remarks Setting the duplex unit Set the selected mode at the auto 1 Enter 17 with the numeric keys. clear when the 2 Press the print key. duplex unit existence and 3 Select the mode number to be executed with the power source is exposure adjustment keys.
  • Page 168 Sim. Description Remarks Checking scanning operation Checks scanning operation. 1 Enter 21 with the numeric keys. 2 Press the print key. * The message display shows the current magnification ratio. 3 Select the original size and magnification ratio with the following keys. * When the magnification ratio is changed, moves the lens to the position for the selected magnification ratio.
  • Page 169 Sim. Description Remarks Turning the lens motor on Checks the lens unit operation. 1 Enter 23 with the numeric keys. 2 Press the print key. 3 Select the mode No. to be executed with the exposure adjustment keys. * Selected Mode No. is shown on the message display.
  • Page 170 Sim. Description Remarks Adjusting the leading edge registration • See page 3-3-18. Adjusting the amount of exposure for enlargement/ reduction copying • See page 3-3-59. Setting the transfer voltage See page 3-3-82. 1 Enter 31 with the numeric keys. 2 Press the print key. 3 Select the mode number to be executed with the exposure adjustment keys.
  • Page 171 Sim. Description Remarks 4 Press the interrupt key. (cont.) * Main charging starts for the selected output condition and the drive motor turns on. 5 Press the interrupt key. * Main charging ends and the drive motor turns off. 6 Press the stop/clear key. Outputting the separation voltage See page 3-3-83.
  • Page 172 Sim. Description Remarks Making a blank lamp test copy Checks the blank lamps. 1 Enter 42 with the numeric keys. 2 Press the print key. 3 Select the largest size with the paper select key. 4 Open the original holder. 5 Press the print key.
  • Page 173 Sim. Description Remarks Setting the fixing temperature Run this simulation when 1 Enter 46 with the numeric keys. a fixing error 2 Press the print key. occurs. 3 Select the mode number to be executed with the exposure adjustment keys. * Selected Mode No.
  • Page 174 Sim. Description Remarks Setting the preheat mode 1 Enter 49 with the numeric keys. 2 Press the print key. * The copy number/zoom ratio indicator shows the current setting. 3 Change the setting with the zoom key. Setting Setting preheat mode Remarks Energy saving mode The fixing temperature is...
  • Page 175 Sim. Description Remarks Adjusting the DF leading edge registration Adjusting stop position of the 1 Enter 52 with the numeric keys. RADF original. 2 Press the print key. 3 Select the mode number to be executed with the exposure adjustment keys. * Selected Mode No.
  • Page 176 Sim. Description Remarks Initializing the original size sensor • See page 3-3-70. Setting the original size sensor installed or not installed Effectiveness only when the 1 Enter 59 with the numeric keys. original size 2 Press the print key. sensor (optional) is installed.
  • Page 177 This page is intentionally left blank.
  • Page 178 Sim. Description Remarks Initializing the toner control level Run at machine setup and after 1 Enter 60 with the numeric keys. replacing the 2 Press the print key. developer or the developing unit. * The following operation starts, and the toner control voltage is set for the new developer.
  • Page 179 Sim. Description Remarks Checking and setting the toner control level Run to check or change the toner 1 Enter 62 with the numeric keys. control level. 2 Press the print key. * The copy number/zoom ratio indicator shows the current setting. 3 Change the setting with the zoom keys.
  • Page 180 Sim. Description Remarks (cont.) Contents Default Adjusting exposure EXP. 1 EXP. 4 EXP. 7 EXP. 7-2 EXP. 1 (Photo mode) EXP. 4 (Photo mode) EXP. 7 (Photo mode) Adjusting lateral magnification (lens and mirrors adjustment) Lens home position Lens position at enlargement Lens position at reduction Mirror home position Mirror position at enlargement...
  • Page 181 Sim. Description Remarks (cont.) Contents Default Setting the preheat mode 0 (Energy saving mode) Adjusting the DF leading edge registration ADF mode RADF mode Adjusting the leading/trailing edge margin Leading edge margin (100%) Leading edge margin (Enlargement) Trailing edge margin Adjusting the blank cut margin with the DF 0 (normal) Initializing the original size sensor...
  • Page 182 Sim. Description Remarks (cont.) Contents Default Cassette self-diagnostic function switching 0 (cutoff disabled) Setting the auto clear time 3 (87 s) Setting the auto preheat time 3 (15 min) Setting the auto shutoff time 4 (59 min) Setting the initial paper source 1 (First paper feed device) Setting the auto cassette change...
  • Page 183 Sim. Description Remarks Checking and setting the maintenance cycle 1 Enter 71 with the numeric keys. 2 Press the print key. * The copy number/zoom ratio indicator shows the current setting (the top three digits). 3 Select the mode No. (digits) to be confirmed or changed with the exposure adjustment key.
  • Page 184 Sim. Description Remarks Checking and setting the maintenance count 1 Enter 72 with the numeric keys. 2 Press the print key. * The copy number/zoom ratio indicator shows the current setting (the top three digits). 3 Select the mode No. (digits) to be confirmed or changed with the exposure adjustment key.
  • Page 185 This page is intentionally left blank.
  • Page 186 Sim. Description Remarks Checking and clearing the service call history 1 Enter 73 with the numeric keys. 2 Press the print key. • To check the service call history 3 Select the history No.(1-10) with the exposure adjustment keys. * The copy number/zoom ratio indicator shows the selected history No..
  • Page 187 Sim. Description Remarks Checking and clearing the jam counts 1 Enter 74 with the numeric keys. 2 Press the print key. • To check the jam counts 3 Select the jam code with the exposure adjustment keys. * The copy number/zoom ratio indicator shows the selected jam code count.
  • Page 188 Sim. Description Remarks Jam code Type of paper jam Setting range (cont.) Jam in the first paper feed device (no 000 – 999 Jam in DF Jam in conveying belt in DF Jam in DF loop section Jam in eject section in DF Jam between copier and sorter Jam in the sorter •...
  • Page 189 Sim. Description Remarks Checking and clearing service call counts 1 Enter 76 with the numeric keys. 2 Press the print key. • To check the service call counts 3 Select the service call code (C code) with the exposure adjustment keys. * The copy number/zoom ratio indicator shows the selected service call code (C code) (The display shows C and service call No.
  • Page 190 Sim. Description Remarks C code Service call name Setting range (cont.) C010 Backup memory data problem 000 – 999 C030 CPU communication problem C210 Drive motor problem C220 Duplex side registration motor problem C240 – C250 First paper feed lift motor problem C251 Second paper feed lift motor problem C252...
  • Page 191 Sim. Description Remarks • To change the count by the code (cont.) 3 Select the service call code (C code) with the exposure adjustment keys. * The copy number/zoom ratio indicator shows the selected service call code (C code) (The display shows C and service call No. alternately.) 4 Press the print key.
  • Page 192 Sim. Description Remarks Checking and clearing the paper feed counts 1 Enter 77 with the numeric keys. 2 Press the print key. • To check the paper feed counts 3 Select the paper source with the paper select key. * The LED corresponding to the selected paper source lights.
  • Page 193 Sim. Description Remarks • To change the count by the paper source (cont.) 3 Select the paper source with the paper select key. * The LED corresponding to the selected paper source lights. * The copy number/zoom ratio indicator shows the top three digits of the paper feed count of the selected paper source.
  • Page 194 Sim. Description Remarks Checking and clearing the each option counts 1 Enter 78 with the numeric keys. 2 Press the print key. • To check the each option counts 3 Select the counter No. with the exposure adjustment keys. * The copy number/zoom ratio indicator shows the selected counter No..
  • Page 195 Sim. Description Remarks • To change the count by the counter (cont.) 3 Select the counter No. with the exposure adjustment keys. * The copy number/zoom ratio indicator shows the selected counter No. 4 Press the print key. * The copy number/zoom ratio indicator shows the selected the top three digits count of the counter 5 Select the mode No.
  • Page 196 Sim. Description Remarks 3 Use the number keys to enter 79. (cont.) Setting Description Detection disabled 1 to 999999 Count 4 Select the counter No. with the exposure 5 Press the stop/clear key. Selecting between single/double counts Run to change 1 Enter 80 with the numeric keys.
  • Page 197 Sim. Description Remarks Selecting between manual/auto mode Sets initial copy mode. 1 Enter 82 with the numeric keys. 2 Press the print key. * The copy number/zoom ratio indicator shows the current setting. 0: auto mode 1: manual mode 3 Change the setting with the zoom keys. 4 Press the print key.
  • Page 198 Sim. Description Remarks The auto clear time is 147 s at a setting of 5, and (cont.) 237 s at a setting of 8. 4 Press the print key. * The setting is stored and blinks. The interrupt indicator blinks at the same time. 5 Press the stop/clear key.
  • Page 199 Sim. Description Remarks Press the print key. (cont.) * The setting is stored and blinks. The interrupt indicator blinks at the same time. 5 Press the stop/clear key. Setting the initial paper source Sets the paper source selected 1 Enter 87 with the numeric keys. at initial.
  • Page 200 Sim. Description Remarks Setting the limit to the number of continuous copies Sets the number of continuous 1 Enter 89 with the numeric keys. copies enabled. 2 Press the print key. * The copy number/zoom ratio indicator shows the current setting. 3 Change the setting with the numeric keys.
  • Page 201 Sim. Description Remarks Selecting copy mode with low toner 1 Enter 91 with the numeric keys. 2 Press the print key. 3 Select the mode No. to be executed with the exposure adjustment keys. * The exposure scale indicator corresponding to the selected mode No.
  • Page 202 Sim. Description Remarks Turning the auto start function on/off 1 Enter 92 with the numeric keys. 2 Press the print key. * The copy number/zoom ratio indicator shows the current setting. 0: disabled 1: enabled 3 Change the setting with the zoom keys. 4 Press the print key.
  • Page 203 Sim. Description Remarks Setting the memory switch 1 1 Enter 94 with the numeric keys. 2 Press the print key. 3 Select the mode No. with the exposure adjustment keys. * The exposure scale indicator corresponding to the selected mode No. (digit) blinks and the copy number/zoom ratio indicator shows the current setting of the selected mode.
  • Page 204 Sim. Description Remarks Setting the memory switch 2 1 Enter 95 with the numeric keys. 2 Press the print key. 3 Select the mode No. with the exposure adjustment keys. * The exposure scale indicator corresponding to the selected mode No. (digit) blinks and the copy number/zoom ratio indicator shows the current setting of the selected mode.
  • Page 205 Sim. Description Remarks Setting scanner fan motor control When the scanner system 1 Enter 98 with the numeric keys. are frequently 2 Press the print key. stained, shorten the scanner fan * The copy number/zoom ratio indicator shows the motor is on to current setting.

  • Page 206: Light Source Unit

    3-3 Assembly and Disassembly 3-3-1 Precautions for assembly and disassembly ........3-3-1 ( 1 ) Precautions ................3-3-1 ( 2 ) Running a simulation ..............3-3-2 3-3-2 Paper feed section ................3-3-3 ( 1 ) Detaching and refitting the forwarding, upper and lower paper feed pulleys ..........

  • Page 207: Mirror

    (10-1) Adjusting the exposure amount for enlargement mode (200%) ........3-3-60 (10-2) Adjusting the exposure amount for reduction mode (50%) ..........3-3-61 (11) Adjusting lateral magnification (lens and mirror adjustment) ... 3-3-62 (11-1) Adjusting the lens home position ......... 3-3-63 (11-2) Adjusting the lens position for enlargement mode ..
  • Page 208 ( 4 ) Adjusting tension of the upper paper feed belt ...... 3-3-106 ( 5 ) Adjusting tension of the drum drive belt ........ 3-3-107 3-3-12 Special tray section (optional) ............3-3-108 ( 1 ) Replacing the forwarding, upper and lower paper feed pulleys ........3-3-108 (1-1) Removing the primary paper feed unit ......

  • Page 210: Precautions For Assembly And Disassembly

    3-3-1 Precautions for assembly and disassembly ( 1 ) Precautions • Be sure to turn the main switch off and disconnect the power plug before starting disassembly. • When handling PCBs, do not touch connectors with bare hands or damage the board. •...

  • Page 211: 2 ) Running A Simulation

    ( 2 ) Running a simulation Start. Enter 10871087 with the numeric · · · · · · · · · · · · Simulation mode is entered. keys. Enter the number of the simulation · · · · · · · · · · · · The simulation No. is selected. to be run with the numeric keys.

  • Page 212: Paper Feed Section

    3-3-2 Paper feed section ( 1 ) Detaching and refitting the forwarding, upper and lower paper feed pulleys Clean or replace the forwarding, upper and lower paper feed pulleys as follows. (1-1) Removing the primary paper feed unit Procedure 1. Remove the first cassette. (see page 3-3-12) 2.

  • Page 213: Removing The Forwarding Pulley

    (1-2) Removing the forwarding pulley Procedure 1. Removing the primary paper feed unit. (see page 3-3-3) 2. Raise the forwarding pulley retainer in the directions of the arrows as shown in Figure 3-3-2 and remove it from the primary paper feed unit. Forwarding pulley retainer Figure 3-3-2...

  • Page 214: Removing The Upper Paper Feed Pulley

    (1-3) Removing the upper paper feed pulley Procedure 1. Removing the primary paper feed unit. (see page 3-3-3) 2. Remove the two stop rings. 3. Remove the paper feed clutch wires from the notches on the rear of the paper feed housing.

  • Page 215: Removing The Lower Paper Feed Pulley

    (1-4) Removing the lower paper feed pulley Procedure 1. Removing the primary paper feed unit. (see page 3-3-3) 2. Remove the stop ring of the lower paper feed shaft. 3. Pull the lower paper feed shaft in the direction of the arrow as shown (Figure 3-3-5) and remove the lower paper feed pulley.

  • Page 216: 2 ) Detaching And Refitting The Sb Forwarding, Upper And Lower Paper Feed Pulleys

    ( 2 ) Detaching and refitting the SB forwarding, upper and lower paper feed pulleys Clean or replace the SB forwarding, upper and lower paper feed pulleys. (2-1) Removing the SB paper feed unit Procedure 1. Remove the inner cover and loosen the screw at the right side of the operation unit. 2.

  • Page 217: Removing The Sb Forwarding Pulley

    (2-2) Removing the SB forwarding pulley Procedure 1. Removing the SB paper feed unit. (see page 3-3-7) 2. Remove the stop ring and pull out the SB forwarding pulley shaft in the direction of the arrow as shown in Figure 3-3-8, and remove the SB forwarding pulley. SB forwarding pulley shaft SB forwarding pulley Stop ring...

  • Page 218: Removing The Sb Upper Paper Feed Pulley

    (2-3) Removing the SB upper paper feed pulley Procedure 1. Removing the SB paper feed unit. (see page 3-3-7) 2. Remove the stop ring and remove the bushing in front of the SB forwarding pulley retainer in the direction of arrow 1. 3.
  • Page 219 4. Remove the stop ring and bushing, then remove the SB paper feed shaft from the SB front frame in the direction of the arrow. SB front frame Stop ring SB paper feed shaft Bushing Figure 3-3-10 5. Remove the bushing and SB upper paper feed pulley from the SB paper feed shaft. SB upper paper feed pulley Bushing SB paper feed shaft...
  • Page 220 (2-4) Removing the SB Iower paper feed pulley Procedure 1. Removing the SB paper feed unit. (see page 3-3-7) 2. Remove the stop ring, then remove the SB separation retainer in the direction of the arrow as shown in Figure 3-3-12. * Never loose the spring SB lower paper feed pulley Stop ring...

  • Page 221: ( 3 ) Detaching And Refitting The Upper And Lower Paper Width Switches (For Inch Models Only)

    ( 3 ) Detaching and refitting the upper and lower paper width switches (For inch models only.) Check or replace the upper and lower paper width switch as follows. Caution: After replacing a paper width switch, be sure to perform ( 5 ) Adjusting the position of the width size changing knob.
  • Page 222 3. Remove the two screws and 8-pin socket from the rear of the cassette. 4. Remove the 8-pin paper width switch connector from the 8-pin socket. * When refitting the 8-pin socket, keep the convex part toward the upper side. 5.
  • Page 223 7. Remove the two screws from the back of the width size changing knob and then the paper width switch. Screws Paper width switch Figure 3-3-16 8. Apply the specified grease to the printed surface of the new paper width switch (shaded area in the figure) and fit the switch to the width size changing knob.

  • Page 224: 4 ) Adjusting The Position Of The Original Size Indicator

    ( 4 ) Adjusting the position of the original size indicator Perform the following adjustment if there is a regular error between the centers of the original and the copy image. Procedure Start Enter simulation mode. Enter 16 with the numeric keys. Test copy example Press the print key.

  • Page 225: 5 ) Adjusting The Position Of The Width Size Changing Knob

    ( 5 ) Adjusting the position of the width size changing knob Perform the following adjustment if there is a regular error between the centers of the original and the copy image on the paper feed from a cassette. Caution: Before starting this adjustment, ensure ( 4 ) Adjusting the position of the original size indicator (see page 3-3-15) has been completed.

  • Page 226: 6 ) Adjusting The Position Of The Bypass Adjuster

    ( 6 ) Adjusting the position of the bypass adjuster Perform the following adjustment if there is a regular error between the centers of the original and the copy image on the paper feed from a bypass. Caution: Before starting this adjustment, ensure ( 4 ) Adjusting the position of the original size indicator (see page 3-3-15) has been completed.

  • Page 227: 7 ) Adjustments After Installing Rollers And Clutches

    ( 7 ) Adjustments after installing rollers and clutches Perform the following adjustments after detaching and refitting the rollers and clutches. (7-1) Adjusting the leading edge registration Adjust the secondary paper feed timing if there is a regular error between the leading edges of the original and the copy image.
  • Page 228 * Setting range: 0~60 Reference Adjust for another mode? 100% copying: 44 Enlargement copying: 42 Reduction copying: 45 Changing the value by 1 moves the leading edge by 0.5 mm. Press the stop/clear key. * Increasing the value delays the second- ary feed timing, and decreasing it ad- vances the timing.

  • Page 229: Adjusting The Leading Edge Margin

    (7-2) Adjusting the leading edge margin Perform the following adjustment if the leading edge margin does not meet specifications. Caution: Before starting this adjustment, ensure (7-1) Adjusting the leading edge registration on page 3-3-18 has been completed. Procedure Start Enter simulation mode. Enter 54 with the numeric keys.
  • Page 230 * Setting range: 0~50 Reference Adjust for another mode? 100% copying: 42 Enlargement copying: 45 Changing the value by 1 moves the leading edge by 0.5 mm. * Increasing the value makes the leading Press the stop/clear key. edge margin wider, and decreasing it makes the margin narrower.

  • Page 231: Adjusting The Trailing Edge Margin

    (7-3) Adjusting the trailing edge margin Perform the following adjustment if the trailing edge margin is not 0 mm. Caution: Before starting this adjustment, ensure (7-1) Adjusting the leading edge registration on page 3-3-18 has been completed. Procedure Start Enter simulation mode. Enter 54 with the numeric keys.
  • Page 232 * Setting range: 0~40 Press the stop/clear key. Reference: 30 Changing the value by one changes the trailing edge margin width by 0.5 Exit simulation mode. * Increasing the value makes the trailing edge margin wider, and decreasing it makes the margin narrower. A3/11"...

  • Page 233: 8 ) Detaching And Refitting The Lower Registration Cleaner

    ( 8 ) Detaching and refitting the lower registration cleaner Clean and replace the lower registration cleaner as follows. Procedure 1. Remove the screw and draw out the lower registration cleaner. Screw Lower registration cleaner Figure 3-3-29 2. Refit all the removed parts. 3-3-24...

  • Page 234: 9 ) Detaching And Refitting The Upper Registration Cleaner

    ( 9 ) Detaching and refitting the upper registration cleaner Clean and replace the upper registration cleaner as follows. Procedure 1. Removing the image formation unit. (see page 3-3-29) 2. Remove the pin and draw out the upper registration cleaner. Upper registration cleaner Figure 3-3-30 3.

  • Page 235: Detaching And Refitting The Feed Unit

    (10) Detaching and refitting the feed unit Clean the lower registration roller as follows. Procedure 1. Removing the SB paper feed unit. (see page 3-3-7) 2. Remove the 8-pin connector and the two screws, then take the feed unit out of the machine.
  • Page 236 3. Rub the lower registration roller with a dry cloth or a cloth with alcohol. Lower registration roller Figure 3-3-32 4. Refit all the removed parts. 3-3-27...

  • Page 237: Main Charging Section

    3-3-3 Main charging section ( 1 ) Replacing the charger wire and main charger grid Take the following procedure when the charger wire is broken or to be replaced. Precautions • Use the specified tungsten wire for the charger wire. •...
  • Page 238 Procedure 1. Open the front cover. 2. Push the paper conveying release lever down in the direction of the arrow. 3. Remove the two screws and 12 pin connector and remove the image formation unit from the machine. * In this time, raise the developing handle in the direction of the arrow. While releasing the developing stopper, take the image formation unit out of the machine.
  • Page 239 4. Raise the main charger and remove it from the image formation unit sliding toward the rear. Main charger Figure 3-3-34 5. Remove the screw, the grid tension plate and the main charger grid. 6. Remove the main charger front and rear lid. 7.
  • Page 240 8. Wind the new tungsten wire at least five turns around one end of the charger spring and trim the end of the wire. * The length of the twists and the cut wire must be less than 2 mm. 9.
  • Page 241 13. Refit the front and rear of the main charger front and rear lid. 14. Refit the main charger grid and the grid tension plate. * When refitting the main charger grid, take care to keep the marking toward the upper side and not to allow the grid to ride over the film.

  • Page 242: Exposure Section

    3-3-4 Exposure section ( 1 ) Detaching and refitting the halogen lamp Clean or replace the halogen lamp as follows. Procedure 1. Remove the upper right cover, and then detach the contact glass. 2. Move light source unit 1 to the center of the machine (notch). 3.

  • Page 243: 2 ) Detaching And Refitting The Optical Thermostat

    ( 2 ) Detaching and refitting the optical thermostat Check or replace the halogen lamp as follows. * The optical thermostat is reset by pressing the button after it has been triggered. If it does not resume normal operation, replace the thermostat. * After replacing the optical thermostat, proceed to ( 6 ) Adjusting focus (refitting of light source unit 1) (see page 3-3-51).
  • Page 244 3. Remove the halogen lamp. (see page 3-3-32) 4. Remove the two screws, and then remove the main reflector. Screw Main reflector Screw Figure 3-3-40 5. Remove the faston connector. 6. Check for continuity across the thermostat using a tester. If there is no continuity, press the button and check for continuity again.

  • Page 245: 3 ) Adjusting The Positions Of The Exposure Adjusters

    ( 3 ) Adjusting the positions of the exposure adjusters Perform the following adjustment after replacing the exposure adjusters, or if the copy image is abnormally light or dark on one side. * Before starting this adjustment, be sure that the main and transfer chargers, mirrors and dust filter are not stained with toner.

  • Page 246: 4 ) Detaching And Refitting The Scanner Wires

    ( 4 ) Detaching and refitting the scanner wires Replace the scanner wires as follows. * After replacing the scanner wires, proceed to ( 5 ) Adjusting longitudinal image squareness (see page 3-3-49), ( 6 ) Adjusting focus (see page 3-3-51) and ( 2 ) Adjusting tension of the scanner drive belt.
  • Page 247 6. Remove the screw and then the original size sensor set plate. Original size sensor set plate Screw Figure 3-3-44 7. Remove the six screws and then the right reinforcement plate. Screws Right reinforcement plate Screws Figure 3-3-45 3-3-38...
  • Page 248 8. Remove the screw and then the wiring cover. 9. Remove the each one 2 pin, 20 pin * , and 24 pin connector. *1: Only when the original size sensor (option) is installed. 20 pin connector * 24 pin connector 2 pin connector Screw Wiring cover...
  • Page 249 11. Remove the screw and then the wiring of the halogen lamp from the clamp. 12. Remove the light source unit 1. (see page 3-3-34) Screw Clamp Wiring of the halogen lamp Figure 3-3-48 13. Remove each screw and then the front and rear tension spring respectively. 14.

  • Page 250: Refitting The Scanner Wires

    (4-2) Refitting the scanner wires Required tool for attachment • Scanner wire drum stopper (P/N 34968130) Procedure 1. Loosen the two screws, move the scanner drive motor assembly in the direction of the arrow, remove the scanner drive belt from the scanner drive pulley. Screw Screw Scanner drive motor assembly...
  • Page 251 2. Remove the screw of the each front and rear scanner wire drum respectively. 3. Remove the E-ring, pull the scanner motor shaft out in the direction of the arrow, and remove the scanner wire drum. Screw Screw Scanner wire drum Scanner motor shaft Scanner wire drum E-ring...
  • Page 252 4. Attach the new scanner wire to the scanner wire drum. Perform the following procedure 1 - 4. * When attaching, be careful that the front and rear side of the scanner wire is different. Be sure to use the wire of the silver to the machine front and that of the black to the machine rear.
  • Page 253 2 Wind the end of the scanner wire with the round terminal one turn around the scanner wire drum. * The drum of the machine front: Wind toward the machine rear. The drum of the machine rear: Wind toward the machine front. 3 Wind the end of the scanner wire with the ball seven turns around the scanner wire drum.
  • Page 254 5. Refit the front and rear scanner wire drum to the scanner drive shaft. (see page 3-3- * Do not fix the scanner wire drum to the scanner drive shaft with the screw in this time. 6. Pull light source unit 2 to the end of the machine right and secure it with the screw. Right scanner retainer Light source unit 2 Figure 3-3-54...
  • Page 255 7. Attach the scanner wire of the machine front to the each pulley with the following procedure. 1 Run the scanner wire with the round terminal along the groove in the inner scanner (machine rear) pulley on light source unit 2, from bottom to top. 2 Fit the round terminal of the Step 1 to the pressure adjuster at the right side of the machine.
  • Page 256 8. Attach the scanner wire of the machine rear to the each pulley with the following procedure. 1 Run the scanner wire with the round terminal along the groove in the inner scanner (machine front) pulley on light source unit 2, from bottom to top. 2 Fit the round terminal of the Step 1 to the pressure adjuster at the right side of the machine.
  • Page 257 9. Secure the front and rear scanner wire drum to the each scanner drive shaft with the screw. (see page 3-3-42) 10. Remove the scanner wire drum stopper from the front and rear scanner wire drum. (see page 3-3-44) 11. Attach light source unit 1 with the two screws. (see page 3-3-34) * When securing light source unit 1, pull light source unit 1 to the end of the right side, make sure that the tub (front and rear side) described in the circle is secured with coming to the right scanner retainer.

  • Page 258: ( 5 ) Adjusting Longitudinal Image Squareness (Inclination Of Secondary Mirror)

    ( 5 ) Adjusting longitudinal image squareness (inclination of secondary mirror) Make the following adjustment when the scanner wire is replaced or if the copy image is longitudinally skewed (longitudinal squareness is not obtained). Procedure Start Make a test copy with A3/11" × Adjust the inclination of secondary 17"...
  • Page 259 Secondary mirror inclination adjustment screw Secondary mirror Figure 3-3-59 3-3-50...

  • Page 260: ( 6 ) Adjusting Focus (Refitting Of Light Source Unit 1)

    ( 6 ) Adjusting focus (refitting of light source unit 1) Make the following adjustment when the scanner wires are replaced or if the entire copy image is out of focus. Procedure Start Make a test copy with A3/11" × Loosen the two screws.
  • Page 261 ( 7 ) Adjusting lateral image squareness (inclination of the fourth/fifth mirror) Make the following adjustment if the copy image is longitudinally skewed (lateral squareness is not obtained). Procedure Start Make a test copy with A3/11" × Adjust the inclination of the 17"...

  • Page 262: ( 7 ) Adjusting Laterel Image Squareness (Inclination Of The Fourth/Fifth Mirror)

    Fourth mirror Fourth/fifth mirror inclination adjustment screw Fifth mirror Figure 3-3-62 3-3-53...

  • Page 263: 8 ) Setting Exposure Amount

    ( 8 ) Setting exposure amount Perform the following adjustment when the main PCB and/or the drum is replaced. Adjust for both normal and photo modes. Precautions • Check that the developer density is correct. • Check that the halogen lamp has not deteriorated. •...
  • Page 264 Procedure Start Enter simulation mode. Enter 24 with the numeric keys. Press the print key. Place the NTC on the contact glass and select mode 2 with the · · · · · · · The current setting is displayed. exposure adjustment keys.
  • Page 265 Select mode 1 with the exposure · · · · · · · The current setting is displayed. adjustment keys. Press the zoom key and set mode * Setting range: 102~242 Reference: 162 2 setting minus 10. Press the print key. ·...
  • Page 266 Select mode 3 with the exposure · · · · · · · The current setting is displayed. adjustment keys. * Setting range: 102~242 Press the zoom key and set mode Reference: 192 4 setting plus 5. Press the print key. ·...
  • Page 267 Select mode 7 with the exposure · · · · · · · The current setting is displayed. adjustment keys. Press the zoom key and set the * Setting range: 102~242 difference between mode 3 setting Reference: 179 and mode 2 setting plus mode 6 setting.
  • Page 268 • Setting method 2 of the simulation 24 (When MTC (Test chart 103) is used.) <Mode setting sequence> Start Set mode 1 (manual mode Exp.1). Set mode 2 (manual mode Exp.4). Set mode 3 (manual mode Exp.7). Set mode 4 (manual mode Exp.7- (Precaution) Check the copying image density using the gray scale A1.
  • Page 269 Procedure Start Enter simulation mode. Enter 24 with the numeric keys. Press the print key. Place the MTC on the contact glass and select mode 1 with the · · · · · · The current setting is displayed. exposure adjustment keys. Press the print key.
  • Page 270 Place the MTC on the contact glass and select mode 2 with the · · · · · · The current setting is displayed. exposure adjustment keys. Press the print key. The new setting is stored. Press the interrupt key. ·...
  • Page 271 Place the MTC on the contact glass and select mode 3 with the · · · · · · The current setting is displayed. exposure adjustment keys. Press the print key. The new setting is stored. Press the interrupt key. ·...
  • Page 272 Place the MTC on the contact glass and select mode 4 with the · · · · · · The current setting is displayed. exposure adjustment keys. Press the print key. The new setting is stored. Press the interrupt key. ·...

  • Page 273: ( 9 ) Correcting The Amount Of Exposure For Ae (Auto Exposure)

    ( 9 ) Correcting the amount of exposure for AE (auto exposure) Procedure Start Check that exposure is correctly set Select mode 2 with the exposure in ( 8 ) Setting exposure amount. adjustment keys. Enter simulation mode. Place the NTC on the contact glass.

  • Page 274: Adjusting The Exposure Amount For Enlargement/Reduction Mode

    (10) Adjusting the exposure amount for enlargement/reduction mode Make the following adjustment after replacing the main PCB or the drum. Procedure Start Check that exposure is correctly set in ( 8 ) Setting exposure amount. Perform (10-1) Adjusting the expo- sure amount for enlargement mode (200%) Perform (10-2) Adjusting the expo-...
  • Page 275 (10-1) Adjusting the exposure amount for enlargement mode (200%) Procedure Start Enter simulation mode. Enter 29 with the numeric keys. Press the print key. Select mode 1 with the exposure · · · · · · · The current setting is displayed. adjustment keys.
  • Page 276 (10-2) Adjusting the exposure amount for reduction mode (50%) Procedure Start Enter simulation mode. Enter 29 with the numeric keys. Press the print key. Select mode 2 with the exposure · · · · · · · The current setting is displayed. adjustment keys.

  • Page 277: Adjusting Lateral Magnification (Lens And Mirror Adjustment)

    (11) Adjusting lateral magnification (Iens and mirror adjustment) Make the following adjustment after replacing the optical unit or if the lateral magnification is not correct. Procedure Start Check that exposure is correctly set in ( 8 ) Setting exposure amount. Perform (11-1) Adjusting the lens home position.

  • Page 278: Adjusting The Lens Home Position

    (11-1) Adjusting the lens home position Procedure Start Enter simulation mode. Enter 25 with the numeric keys. Press the print key. Select mode 1 with the exposure · · · · · · · The current setting is displayed. adjustment keys. Place the NTC on the contact glass and ensure there is A3/11"...

  • Page 279: Adjusting The Lens Position For Enlargement Mode

    (11-2) Adjusting the lens position for enlargement mode Procedure Start Enter simulation mode. Enter 25 with the numeric keys. Press the print key. Select mode 2 with the exposure · · · · · · · The current setting is displayed. adjustment keys.

  • Page 280: Adjusting The Lens Position For Reduction Mode

    (11-3) Adjusting the lens position for reduction mode Procedure Start Enter simulation mode. Enter 25 with the numeric keys. Press the print key. Select mode 3 with the exposure · · · · · · · The current setting is displayed. adjustment keys.

  • Page 281: Adjusting The Mirror Home Position

    (11-4) Adjusting the mirror home position Procedure Start Enter simulation mode. Enter 25 with the numeric keys. Press the print key. Select mode 4 with the exposure · · · · · · · The current setting is displayed. adjustment keys. Place the NTC on the contact glass and ensure there is A3/11"...

  • Page 282: Adjusting Focus For Enlargement Mode

    (11-5) Adjusting focus for enlargement mode (position of the mirrors) Procedure Start Enter simulation mode. Enter 25 with the numeric keys. Press the print key. Select mode 5 with the exposure · · · · · · · The current setting is displayed. adjustment keys.

  • Page 283: Adjusting Focus For Reduction Mode

    (11-6) Adjusting focus for reduction mode (position of the mirrors) Procedure Start Enter simulation mode. Enter 25 with the numeric keys. Press the print key. Select mode 6 with the exposure · · · · · · · The current setting is displayed. adjustment keys.

  • Page 284: Adjusting Longitudinal Magnification (Scanning Speed)

    (12) Adjusting longitudinal magnification (scanning speed) Procedure Start Enter simulation mode. Enter 26 with the numeric keys. Press the print key. · · · · · · · The current setting is displayed. Place the NTC on the contact glass and ensure there is A3/11" × 17"...
  • Page 285 (13) Initializing of the original size sensor * When installing the original size sensor, be sure to initialize the original size sensor. Replacing the original size sensor, the main PCB and the backup PCB. • Initializing and operation check of the original size sensor Performing the Initializing and operation check of the original size sensor.

  • Page 286: Initializing Of The Original Size Sensor

    • Initializing of the original size sensor * Perform each sensor operation. Procedure Start Enter simulation mode. Enter 57 with the numeric keys. Press the print key. The current setting is displayed. Place 5 sheets of the maximum size paper on the contact glass. Press the interrupt key.

  • Page 287: Drum Section

    3-3-5 Drum section ( 1 ) Replacing the drum Perform the following steps when cleaning or replacing the drum. Precautions • Avoid direct sunlight and strong light when detaching and refitting the drum. • Hold the drum at the ends and never touch the drum surface. •...
  • Page 288 4. Remove the main charger from the image formation unit. (see page 3-3-30) 5. Pull the drum shaft out of the rear side of the drum. 6. Holding the both ends of the drum, remove the drum from the image formation unit. 1 mm Rear Front...

  • Page 289: 2 ) Cleaning The Drum

    ( 2 ) Cleaning the drum Clean the drum as follows when an image problem occurs, or if the drum is dirty. Precautions • Avoid direct sunlight and strong light when cleaning the drum. • Dust in the air and from the cleaning pad may damage the drum during operation. Avoid working in dusty places.

  • Page 290: ( 3 ) The Image Adjustment When Replacing The Drum (Reference)

    ( 3 ) The image adjustment when replacing the drum (reference) Perform this adjustment when proper image is not obtained, even if each adjustment carries out. Procedure Start Make a test copy to check the im- age. Is the image abnormally light or dark? Enter simulation mode.

  • Page 291: Developing Section

    3-3-6 Developing section ( 1 ) Adjusting the position of the magnetic brush (developing roller) (reference) Perform the following adjustment if the image is abnormally light. * Before starting this adjustment, ensure that the doctor blade is installed correctly and that the correct amount of developer is present.

  • Page 292: ( 2 ) Adjusting The Position Of The Doctor Blade (Reference)

    ( 2 ) Adjusting the position of the doctor blade (reference) Perform the following adjustment if carrier or background appears on the copy image. Procedure 1. Take the image formation unit out of the machine. (see page 3-3-29) 2. Remove the two screws, and then the upper developing cover. Screws Upper developing cover Figure 3-3-69...

  • Page 293: ( 3 ) Adjusting Developing Bias Voltage (Reference)

    ( 3 ) Adjusting developing bias voltage (reference) The developing bias voltage is factory-adjusted. Be sure to perform the following adjustment only when carrier or background appears on the copy image after VR 202 control on the high-voltage transformer PCB had been turned accidentally. Adjustment tool: tester 1P connector High-voltage...

  • Page 294: Transfer And Separation Section

    3-3-7 Transfer and separation section ( 1 ) Replacing the charger wires Take the following steps when the transfer or separation charger wire is broken or is to be replaced. Precautions • Use only the specified tungsten wire for the charger wire. •...
  • Page 295 3. Remove the transfer charger front and rear lids. 4. Remove the ten claws described in the circle, and then take off the separation guide. 5. Remove the charger wire retainer pins, charger spring and then the charger wires. Transfer charger rear lid Separation guide Transfer charger front lid Charger springs...
  • Page 296 6. Wind one end of the new wire at least five turns around the end of the charger spring. 7. Hook the other end of the spring onto the claw on the transfer charger terminal. 8. Pass the charger wire through the U notch in rear of the transfer charger and V notch in front of the transfer charger to pull the wire and fix it with the charger pin.

  • Page 297: ( 2 ) Setting Transfer Voltage (Reference)

    ( 2 ) Setting transfer voltage (reference) Perform the following steps after replacing the transfer/separation high-voltage transformer PCB or if a transfer error occurs at extremely high humidity or low atmospheric. Procedure Start Make a test copy to check the im- age.

  • Page 298: ( 3 ) Setting The Separation Shift Bias Voltage (Reference)

    ( 3 ) Setting the separation shift bias voltage (reference) Replace the high voltage transformer PCB and main PCB. Defect is occurred and paper misfeed is occurred in the separation section. When using the thin paper, wrinkles is occurred in the separation section. Adjustment tool: tester High-voltage transformer PCB...

  • Page 299: Cleaning Section

    3-3-8 Cleaning section ( 1 ) Detaching and refitting the cleaning blade Check or replace the cleaning blade as follows. Procedure 1. Open the front cover and remove the image formation unit from the machine. (see page 3-3-29) 2. Push up the blade attachment plate, slide the blade lever toward the rear side, take the cleaning blade out of the drum.
  • Page 300 4. Remove the three screws, and then the cleaning blade. * Attach the cleaning blade not so as to run on to the projection of the blade attachment plate. Screws Cleaning blade Projection Blade atta- chment plate Figure 3-3-77 5. Refit all the removed parts. 6.

  • Page 301: 2 ) Detaching And Refitting The Drum Separation Claws

    ( 2 ) Detaching and refitting the drum separation claws Clean or replace the drum separation claws. Procedure 1. Open the front cover and remove the image formation unit from the machine. (see page 3-3-29) 2. Remove the main charger and the drum. (see page 3-3-30, see page 3-3-72) 3.

  • Page 302: Paper Conveying Section

    3-3-9 Paper conveying section ( 1 ) Detaching and refitting the conveying belt Clean or replace the conveying belt as follows. Procedure 1. Remove the image formation unit. (see page 3-3-29) 2. Remove the stop ring and front paper conveying guide. 3.
  • Page 303 4. Pull the paper conveying shaft in the direction of the arrow 1 and remove it from the paper conveying guide. 5. Remove the paper conveying shaft with the paper conveying pulley in the direction of the arrow 2. Paper conveying guide Paper conveying shaft Paper conveying pulley Figure 3-3-81...
  • Page 304 6. Remove the E-ring and bushing. 7. Move the paper conveying roller in the direction of the arrow 1 and remove it from the paper conveying guide. Remove the paper conveying belt in the direction of the arrow 2. * After replacing the paper conveying belt, check if operation moves smoothly. E-ring Bushing Paper conveying guide...

  • Page 305: Fixing Section

    3-3-10 Fixing section ( 1 ) Detaching and refitting the fixing heater Check or replace the fixing heater as follows. Procedure 1. Open the front cover. 2. Loosen the pin holding the fixing unit and take the fixing unit out of the machine. Pin holding the fixing unit Fixing unit...
  • Page 306 5. Remove the faston terminal of the fixing heater from the terminal of the fixing thermostat 2 of the fixing unit front side. 6. Remove the 2-pin connector of the fixing heater wire of the fixing unit rear side taking the part of the arrow with fingers. 7.
  • Page 307 8. Take the fixing heater out of the fixing unit rear side. Fixing heater Figure 3-3-86 9. Refit all the removed parts. 3-3-92...

  • Page 308: 2 ) Detaching And Refitting The Fixing Unit Thermistor

    ( 2 ) Detaching and refitting the fixing unit thermistor Check or replace the fixing unit thermistor as follows. Procedure 1. Remove the fixing unit from the machine. (see page 3-3-90) 2. Remove the upper fixing cover. (see page 3-3-90) 3.

  • Page 309: 3 ) Detaching And Refitting The Fixing Unit Thermostats

    ( 3 ) Detaching and refitting the fixing unit thermostats Check or replace the fixing unit thermostats as follows. Caution: Use the specified thermostat for replacement. Do not substitute a simple wire or similar; otherwise, the copier will be seriously damaged. Procedure 1.

  • Page 310: 4 ) Detaching And Refitting The Press Roller

    ( 4 ) Detaching and refitting the press roller Clean or replace the press roller as follows. Procedure 1. Remove the fixing unit from the machine. (see page 3-3-90) 2. Pressing the upper fixing cover in the direction of the arrow 1, turn the press release lever in the direction of the arrow 2, and open the fixing unit in the direction of the arrow 3.
  • Page 311 3. Open the lower fixing guide plate in the direction of the arrow and remove the press roller. 4. Remove the press roller bushing. Press roller Press roller Press roller bushings Lower fixing guide plate Figure 3-3-91 5. Refit all the removed parts. 3-3-96...

  • Page 312: 5 ) Detaching And Refitting The Heat Roller

    ( 5 ) Detaching and refitting the heat roller Clean or replace the press roller as follows. Procedure 1. Remove the fixing unit from the machine. (see page 3-3-90) 2. Take out the fixing heater. (see page 3-3-90) 3. Open the fixing unit. (see page 3-3-95) 4.
  • Page 313 5. Remove the C-circlip on the front of the fixing unit, and the heat roller bushing. 6. Remove the C-circlip on the rear of the fixing unit. Remove the heat roller gear 40, the heat roller bushing, and then the heat roller. * When fitting the heat roller bushing, fit it the part indicated with the arrow in figure toward the lower side with closing the unit.

  • Page 314: 6 ) Detaching And Refitting The Fixing Unit Blade

    ( 6 ) Detaching and refitting the fixing unit blade Clean or replace the fixing unit blade as follows. Procedure 1. Remove the fixing unit from the machine. (see page 3-3-90) 2. Remove the upper fixing cover. (see page 3-3-90) 3.

  • Page 315: 7 ) Detaching And Refitting The Heat Roller Claws

    ( 7 ) Detaching and refitting the heat roller claws Clean or replace the heat roller claws as follows. Procedure 1. Remove the fixing unit from the machine. (see page 3-3-90) 2. Remove the upper fixing guide plate. (see page 3-3-97) 3.

  • Page 316: 8 ) Detaching And Refitting The Press Roller Claws

    ( 8 ) Detaching and refitting the press roller claws Clean or replace the press roller claws as follows. Procedure 1. Remove the fixing unit from the machine. (see page 3-3-90) 2. Open the lower fixing guide plate. (see page 3-3-96) 3.

  • Page 317: ( 9 ) Adjusting Fixing Pressure (Reference)

    ( 9 ) Adjusting fixing pressure (reference) Adjust fixing pressure when paper creases, fixing is defective, or after a fixing pressure spring has been replaced. Procedure 1. Make a copy with the original holder opened and turn off the main switch immediately as the paper leading edge is ejected (when the center of the paper is passing the fixing unit).

  • Page 318: Others

    3-3-11 Others ( 1 ) Detaching and refitting the ozone filter Replace the ozone filter as follows. Procedure 1. Remove the rear cover. 2. Remove the ozone filter. Ozone filter Figure 3-3-98 3. Refit all the removed parts. 3-3-103...

  • Page 319: 2 ) Adjusting Tension Of The Scanner Drive Belt

    ( 2 ) Adjusting tension of the scanner drive belt Replace the scanner wire, scanner drive motor, or scanner drive belt as follows. Procedure 1. Loosen the two screws. 2. Move the scanner drive motor assembly within long hole and adjust tension not so as to break the scanner drive belt tooth.

  • Page 320: 3 ) Adjusting Tension Of The Fixing Drive Belt

    ( 3 ) Adjusting tension of the fixing drive belt Detach and refit or replace the fixing drive belt as follows. Procedure 1. Loosen the screw. 2. Set the marking of the fixing tension plate at the center of the rear retainer. 3.

  • Page 321: 4 ) Adjusting Tension Of The Upper Paper Feed Belt

    ( 4 ) Adjusting tension of the upper paper feed belt Detach and refit or replace the upper paper feed belt as follows. Procedure 1. Loosen the screw. 2. Set the marking of the paper feed tension plate at the center of the rear retainer. 3.

  • Page 322: 5 ) Adjusting Tension Of The Drum Drive Belt

    ( 5 ) Adjusting tension of the drum drive belt Detach and refit or replace the drum drive belt as follows. Procedure 1. Loosen the screw. 2. Set the marking of the drum tension plate at the center of the rear retainer. 3.

  • Page 323: Special Tray Section (Optional)

    3-3-12 Special tray section (optional) ( 1 ) Replacing the forwarding, upper and lower paper feed pulleys Clean or replace the forwarding, upper and lower paper feed pulleys as follows. (1-1) Removing the primary paper feed unit Procedure 1. Draw out the cassette. 2.
  • Page 324 3. Open the right cover of the copier. 4. Remove the screw holding the primary paper feed unit and then the unit. Screw Right cover Primary paper feed unit Figure 3-3-104 3-3-109...

  • Page 325: Removing The Forwarding Pulley

    (1-2) Removing the forwarding pulley Procedure 1. Removing the primary paper feed unit. (see page 3-3-109) 2. Raise the forwarding pulley retainer in the directions of the arrows as shown in Figure 3-3-105 and remove it from the primary paper feed unit. Forwarding pulley retainer Figure 3-3-105...

  • Page 326: Removing The Upper Paper Feed Pulley

    (1-3) Removing the upper paper feed pulley Procedure 1. Removing the primary paper feed unit. (see page 3-3-109) 2. Remove the two stop rings. 3. Remove the paper feed clutch wires from the notches on the rear of the paper feed housing.

  • Page 327: Removing The Lower Paper Feed Pulley

    (1-4) Removing the lower paper feed pulley Procedure 1. Removing the primary paper feed unit. (see page 3-3-109) 2. Remove the stop ring of the lower paper feed shaft. 3. Pull the lower paper feed shaft in the direction of the arrow as shown (Figure 3-3- 108) and remove the lower paper feed pulley.

  • Page 328: 2 ) Detaching And Refitting The Paper Width Switche

    ( 2 ) Detaching and refitting the paper width switch (For inch models only.) Check or replace the paper width switch as follows. Caution: After replacing a paper width switch, be sure to perform ( 3 ) Adjusting the position of the width size changing knob. (see page 3-3-115) Procedure 1.
  • Page 329 6. Remove the two screws from the back of the width size changing knob and then the paper width switch. Screws Paper width switch Figure 3-3-110 7. Apply the specified grease to the printed surface of the new paper width switch (shaded area in the figure) and fit it to the width size changing knob.

  • Page 330: 3 ) Adjusting The Position Of The Width Size Changing Knob

    ( 3 ) Adjusting the position of the width size changing knob Perform the following adjustment if there is a regular error between the centers of the original and the copy image on the paper feed from a cassette. Caution: Before starting this adjustment, ensure ( 4 ) Adjusting the position of the original size indicator (see page 3-3-15) has been completed.

  • Page 331: Feedshift And Duplex Sections (Optional)

    3-3-13 Feedshift and duplex sections (optional) ( 1 ) Detaching and refitting the duplex forwarding pulley Clean or replace the duplex forwarding pulley as follows. Procedure 1. Remove the stop ring and duplex forwarding pulley. 2. Refit all the removed parts. * When refitting the duplex forwarding pulley, align the projections of the duplex forwarding pulley with the slots in the leading edge pulley.

  • Page 332: 2 ) Detaching And Refitting The Switchback Separation Belts

    ( 2 ) Detaching and refitting the switchback separation belts Clean or replace the switchback separation belts as follows. Procedure 1. Remove the two screws holding the duplex unit front cover and detach the cover. 2. Loosen the three screws on the front and the two screws on the top to detach the duplex unit cover.
  • Page 333 3. Remove the two screws holding the separation assembly and then the assembly. 4. Remove the E-ring, gear, shim and bushing. 5. Remove the three screws holding the separation guide and detach the guide. Screws Screws Separation assembly Separation guide Bushing Shim Gear...
  • Page 334 6. Disengage the two hooks and remove the separation front guide mount. 7. Remove the two stop rings and detach the separation roller and switchback separation belts. * Always replace the switchback separation belts as a pair. * When fitting the switchback separation belts, keep the shiny surface facing out. Switchback separation belts Stop ring...

  • Page 335: 3 ) Detaching And Refitting The Switchback Roller, Duplex Upper Registration Roller And Refeed Roller

    ( 3 ) Detaching and refitting the switchback roller, duplex upper registration roller and refeed roller Clean or replace the switchback roller, duplex upper registration roller and refeed roller as follows. (3-1) Detaching the switchback roller Procedure 1. Remove the duplex unit from the rails. 2.
  • Page 336 7. Remove the E-ring and idle gear 18/36. 8. Remove the E-ring, switchback roller gear, pin and bushing. 9. Remove the stop ring and then the switchback roller from the shaft in the direction of the black arrow. * Refit the switchback roller so that it turns in the same direction as the shaft when the shaft is turned in the direction of the white arrow (e).
  • Page 337 10. Refit all the removed parts. * Install the side registration section while raising the pulse disc guide. After the installation, check that the pulse disc guide is in the down position. * After installing the side registration section, always proceed to ( 8 ) Adjusting the position of the side registration section.

  • Page 338: Detaching The Duplex Upper Registration Roller

    (3-2) Detaching the duplex upper registration roller Procedure 1. Remove the duplex unit from the rail. 2. Remove the switchback roller. (see page 3-3-120) 3. Remove the E-ring and idle gear 34. 4. Remove the E-ring and the bushing of the duplex upper registration roller from the shaft.
  • Page 339 5. Remove the two screws holding the switch retainer and detach the retainer. 6. Loosen the hex. socket head screws holding the duplex registration clutch and detach the clutch. 7. Remove the E-ring and duplex joint gear. 8. Remove the E-ring and duplex drive gear. 9.
  • Page 340 10. Refit all the removed parts. * Replace the duplex registration clutch so that the notch in the duplex registration clutch engages with the tab of the frame and that end of the shaft is aligned with the end of the projection that holds the hex. socket head screws in place. Duplex registration clutch Hex.

  • Page 341: Detaching The Refeed Roller

    (3-3) Detaching the refeed roller Procedure 1. Remove the duplex unit from the rail. 2. Remove the switchback roller and the duplex upper registration roller. (see page 3- 3-120, P. 3-3-123) 3. Remove the E-ring, refeed roller gear, pin and bushing. 4.

  • Page 342: 4 ) Adjusting The Position Of The Refeed Solenoid

    ( 4 ) Adjusting the position of the refeed solenoid Check or replace the refeed solenoid as follows. Procedure 1. Loosen the screws holding the reteed solenoid. 2. With the plunger pressed, adjust the position of the refeed solenoid by moving it up and down until part A of the plate contacts the refeed roller.

  • Page 343: 5 ) Adjusting The Position Of The Duplex Paper Tapping Solenoid

    ( 5 ) Adjusting the position of the duplex paper tapping solenoid Check or replace the position after the duplex paper tapping solenoid as follows. Procedure 1. Loosen the screws holding the duplex paper tapping solenoid. 2. With the plunger pressed, adjust the position of the duplex paper tapping solenoid by moving it right and left so that the bottom surface A of the paper tapping guide sits on the frame.

  • Page 344: 6 ) Adjusting The Side Registration Amount

    ( 6 ) Adjusting the side registration amount Perform the following steps when paper is fed askew during refeed from the duplex unit. Procedure Start Enter simulation mode. Enter 18 with the numeric keys. Press the print key. Select mode 1 with the exposure ·...
  • Page 345 Remove the paper and reinstall the duplex unit. Press the stop/clear key. Exit simulation mode. Side registration guide Copy paper Side registration front guide A: 0.5 mm Figure 3-3-128 3-3-130...

  • Page 346: 7 ) Adjusting The Duplex Forwarding Amount

    ( 7 ) Adjusting the duplex forwarding amount Adjust the duplex forwarding solenoid on time when paper misfeeds frequently during refeed from the duplex unit. Procedure Start Enter simulation mode. Enter 18 with the numeric keys. Press the print key. Select the mode No.
  • Page 347 Remove the paper and reinstall the duplex unit. Press the stop/clear key. Exit simulation mode. 3-3-132...

  • Page 348: 8 ) Adjusting The Position Of The Side Registration Section

    ( 8 ) Adjusting the position of the side registration section Perform the following steps when there is a regular error between the centers of the original and copy image during duplex copying. Procedure Start Original Copy example 1 Copy example 2 Figure 3-3-129 Make a test copy at 100% with the maximum size of copy paper.

  • Page 349: 9 ) Adjusting Tension Of The Feed Shift Drive Belt

    ( 9 ) Adjusting tension of the feed shift drive belt Detach and refit and replace the feed shift drive belt as follows. Procedure 1. Loosen the screw. 2. Set the edge of the feed shift drive tension plate at the scale between forth and fifth marked on the feed shift front plate as shown in figure 3-3-131.
  • Page 350 3-4 PCB Initial Setting 3-4-1 Replacing the main PCB ..............3-4-1 3-4-2 Adjustment-free variable resistors (VR) ..........3-4-4...
  • Page 352 3-4-1 Replacing the main PCB After replacing the main PCB, remove the backup PCB from the old main PCB and fit it to the new main PCB. If the new backup PCB is used, perform the following steps. <Procedure> • Before removing the old backup PCB: 1.
  • Page 353 • After installing the new backup PCB: 7. Insert the power plug and turn the main switch on. 8. Enter simulation mode. 9. Run simulation 70. 10. Run simulation 97 to initialize the original size sensors. * Metric models: Only when the original size sensor (optional) installed. 11.
  • Page 354 Sim. No. Contents Setting the original size sensor installation or not Checking and setting the toner control level Checking and setting the maintenance cycle Checking and setting the maintenance count Checking and clearing the service call history Checking and clearing the jam counts Checking and clearing the service call counts Checking and clearing the paper feed counts Checking and clearing the each option counts...
  • Page 355 3-4-2 Adjustment-free variable resistors (VR) The variable resistors listed below are set at the factory prior to shipping and cannot be adjusted in the field. • Composite PCB : VR601, VR602, VR603 • High-voltage transformer PCB: VR101, VR201, VR202, VR301, VR401, VR402 3-4-4...
  • Page 356 3-5 Self-diagnostics 3-5-1 Self diagnostic function ..............3-5-1 ( 1 ) Automatic initialization of backup data ........3-5-1 ( 2 ) Self diagnostic display ............... 3-5-1 ( 3 ) Partial operation control ............3-5-1...
  • Page 358 3-5-1 Self diagnostic function ( 1 ) Automatic initialization of backup data This function checks to see if there is a problem in the backup memory each time the main switch is turned ON. If an abnormality is detected, the backup data is initialized, and the initial data is input, hence it is necessary to re-enter the data for each function.
  • Page 359 (List of self diagnostic display) Item Code Rank C call Contents CPU and pe- C010 Backup memory data problem ripheral circuit C030 C (A) CPU communication problem problem Cool and drive C210 Drive motor problem system problem C220 Side registration motor problem (Duplex unit) C250 Upper lift motor problem...
  • Page 360 Item Code Rank C call Contents DF problem C910 DF original feed motor problem * C920 DF conveying motor problem * C930 DF reversing/eject motor problem * *1 Displayed that CPU does not return, even if resetting the optical control side. *2 Detects at the side of the sorter.
  • Page 361 (Self diagnostic codes) Code Contents Causes Check procedures/corrective measures C010 Backup memory Backup memory Turn safety switch 1 off and back on data problem data has a prob- and run simulation 70 to set the • No specified data lem. backup memory contents again.
  • Page 362 Code Contents Causes Check procedures/corrective measures C250 Upper lift motor The upper lift mo- Check for motor system in the upper problem tor lock (Increase lift motor . Remedy or replace if any. • The upper lift limit in mechanical load) switch does not Defective upper Check for continuity across the coil.
  • Page 363 Code Contents Causes Check procedures/corrective measures C252 Lift motor (ST) The lift motor (ST) Check for motor system in the lift problem lock (Increase in motor (ST). Remedy or replace if (Special tray) mechanical load) any. • The lift limit switch Defective lift mo- Check for continuity across the coil.
  • Page 364 Code Contents Causes Check procedures/corrective measures C310 Scanner problem Defective scanner Check for continuity across the coil. • The scanner motor. If none, replace the scanner motor. home position Poor contact in Check for continuity across the con- switch does not the scanner motor nector terminals.
  • Page 365 Code Contents Causes Check procedures/corrective measures C420 Mirror problem Defective mirror Check for continuity across the coil. • The mirror home motor. If none, replace the mirror motor. position switch Poor contact in Check for continuity across the con- does not turn on the mirror motor nector terminals.
  • Page 366 Code Contents Causes Check procedures/corrective measures C610 Broken fixing The fixing unit Check and remedy if necessary. heater wire thermistor is in- • Fixing tempera- stalled incorrectly. ture fails to stabi- Defective com- Check if the fixing heater turns on lize within 2 min- posite PCB.
  • Page 367 Code Contents Causes Check procedures/corrective measures C740 External tempera- External tempera- Replace the external temperature/ ture/humidity sen- ture/humidity sen- humidity sensor. sor problem sor problem. • The output voltage Poor contact in Check for continuity across the con- of external tem- the external tem- nector terminals.

  • Page 368: Troubleshooting

    3-6 Troubleshooting 3-6-1 Image problems ................3-6-1 ( 1 ) No image (entirely white)............3-6-3 ( 2 ) No image (entirely black)............3-6-4 ( 3 ) Image is too light............... 3-6-5 ( 4 ) Background is visible..............3-6-5 ( 5 ) A white line appears longitudinally.
  • Page 369 ( 3 ) The misfeed indicator for the paper feed with refeed from the duplex section lights during duplex copying....3-6-19 ( 4 ) The misfeed indicator for the paper feed section lights during duplex copying............ 3-6-19 • Special tray (optional) ( 1 ) The misfeed indicator for the special tray lights as soon as the main switch is turned on.
  • Page 370 (29) Auto prescan is not performed..........3-6-38 (30) Correct original size detection is not performed...... 3-6-38 (31) “No paper” message is shown when paper is present in the upper and lower cassettes..........3-6-39 (32) Bypass copying cannot be performed........3-6-39 (33) No cassette size or wrong cassette size is displayed when the upper and lower cassettes are installed.
  • Page 371 ( 2 ) Paper is refeed askew.............. 3-6-47 ( 3 ) Multiple sheets of paper are fed at one time......3-6-47 ( 4 ) Paper misfeed................3-6-47 ( 5 ) Abnormal noise is heard............3-6-47 • Special tray (optional) ( 1 ) No paper feed from special tray ..........

  • Page 372: Image Problems

    3-6-1 Image problems <Contents> (1) No image (en- (2) No image (en- (3) Image is too (4) Background is tirely white). tirely black). light. visible. See page 3-6-3. See page 3-6-4. See page 3-6-5. See page 3-6-5. (5) A white line ap- (6) A black line ap- (7) A black line ap- (8) One side of the...

  • Page 373: Paper Creases

    (13) Paper creases. (14) Offset occurs. (15) Black lines ap- (16) Image is party pear on both missing. sides of the image in re- duction copies. See page 3-6-10. See page 3-6-11. See page 3-6-11. See page 3-6-12. (17) Fixing is poor. (18) Image is out of (19) Image is not (20) Image is not...
  • Page 374 (1) No image (en- Causes tirely white). 1. No original present. 2. No main charging. 3. No transfer charging. 4. Deteriorated developer. Check procedures/corrective measures Causes No original present. Place an original in the correct position. No main charging. Broken main charger wire. Replace the main charger wire.
  • Page 375 (2) No image (en- Causes tirely black). 1. Broken halogen lamp filament. 2. Halogen lamp fails to light. Check procedures/corrective measures Causes Broken halogen lamp filament. Take the halogen lamp of the unit and check for continuity across the terminals. If none, replace it (see page 3-3-33).
  • Page 376 (3) Image is too Causes light. 1. Insufficient toner. 2. Deteriorated developer. 3. Misadjusted developing section. 4. Dirty or deteriorated drum. Check procedures/corrective measures Causes Insufficient toner. If the add toner message is on the display, re- place the toner cartridge. Deteriorated developer.
  • Page 377 (5) A white line ap- Causes pears longitudi- 1. Dirty or flawed main charger wire. nally. 2. Foreign matter in the developing section. 3. Flawed drum. Check procedures/corrective measures Causes Dirty or flawed main charger Clean the main charger wire or, if it is flawed, re- wire.
  • Page 378 (7) A black line ap- Causes pear laterally. 1. Flawed drum. 2. Poor developing bias wire contact. 3. Dirty developing section. 4. No developing bias output. Check procedures/corrective measures Causes Flawed drum. Check the drum visually. If it is flawed, replace (see page 3-3-72).
  • Page 379 (8) One side of the Causes copy image is 1. Unevenly distributed halogen lamp light. darker than the 2. Dirty optical section. other. 3. Dirty main charger wire. Check procedures/corrective measures Causes Unevenly distributed halogen Adjust the positions of the exposure adjusters lamp light.
  • Page 380 (10) Image is Causes blurred. 1. Scanner moving erratically. 2. Foreign matter on the scanner rail. 3. Deformed press roller. 4. Drive system problem. Check procedures/corrective measures Causes Scanner moving erratically. Check for the state of the installation, if it is defec- tive, replace it (see page 3-3-37).
  • Page 381 (12) The leading Causes edge of the im- 1. Registration clutch installation or operation problem. age is sporadi- cally misa- ligned with the original. Check procedures/corrective measures Causes Registration clutch installation Check the installation condition or operation of the or operation problem. registration clutch.
  • Page 382 (14) Offset occurs. Causes 1. Cleaning blade installation problem. 2. Defective cleaning blade. 3. Cleaning lamp fails to light. Check procedures/corrective measures Causes Cleaning blade installation Check the installation condition of the cleaning problem. blade (see page 3-3-84). Defective cleaning blade. Replace the cleaning blade.
  • Page 383 (16) Image is party Causes missing. 1. Paper damp. 2. Paper creased. 3. Drum condensation. 4. Flawed drum. Check procedures/corrective measures Causes Paper damp. Check the paper storage conditions. Paper creased. Change the paper. Drum condensation. Clean the drum (see page 3-3-74). Flawed drum.
  • Page 384 (19) Image is not Causes square longitu- 1. Misadjusted longitudinal image squareness (inclination of dinally. secondary mirror). Check procedures/corrective measures Causes Misadjusted longitudinal image Readjust the longitudinal image squareness (incli- squareness (inclination of sec- nation of secondary mirror) (see page 3-3-49). ondary mirror).

  • Page 385: Paper Misfeeds

    3-6-2 Paper misfeeds • Copier Problem Causes/check procedures Corrective measure A piece of paper torn from Check visually and remove it, if any. The misfeed copy paper is caught around indicator for the the feed, registration or eject paper feed, switch.
  • Page 386 Problem Causes/check procedures Corrective measure Paper in the cassette is Change the paper. The misfeed extremely curled. indicator for the Check if the forwarding Check visually and replace any paper feed pulley, upper and lower deformed pulleys (see page 3-3-3). section lights paper feed pulley is during copying...
  • Page 387 Problem Causes/check procedures Corrective measure Defective registration switch. If CN2-18 on the MPCB remains low The misfeed when the registration switch is turned indicator for the on while 5 V DC is present at CN2-17 paper feed or on the MPCB, replace the registration conveying switch.

  • Page 388: Lights During Copying

    Problem Causes/check procedures Corrective measure Broken eject switch Check and replace the eject switch if The misfeed actuator. the actuator is broken. indicator for the Defective eject switch. If CN11-9 on the MPCB remains low fixing section when the eject switch is turned on and lights during off while 5 V DC is present at CN11-8 copying.

  • Page 389: Feed Shift And Duplex Sections (Optional)

    • Feed shift and duplex sections (optional) Problem Causes/check procedures Corrective measure A piece of paper torn from Check visually and remove it, if any. The misfeed copy paper is caught around indicator for the the duplex paper conveying duplex section switch.

  • Page 390: During Duplex Copying

    Problem Causes/check procedures Corrective measure Defective duplex eject If CN16-5 on the MPCB remains low The misfeed switch. when the duplex eject switch is turned indicator for the on and off while 5 V DC is present at duplex section CN15-4 on the MPCB, replace the lights during duplex eject switch.
  • Page 391 • Special tray (optional) Problem Causes/check procedures Corrective measure A piece of paper torn from Check visually and remove it, if any. The misfeed copy paper is caught around indicator for the the lower paper feed switch special tray in copier. lights as soon Defective lower paper feed If CN18-3 on the desk MPCB remains...
  • Page 392 3-6-3 PCB terminal voltages Precautions • When handling the circuit boards, do not touch the components with bare hands. • ICs can be damaged by static discharges. If a PCB contains ICs, do not touch the ICs, cable connectors or edge connectors. •...
  • Page 393 Terminals (CN) Voltage Remarks Local voltage AC power supply 24 V DC * 24 V DC supply to DMPCB, output 5 V DC * 5 V DC supply to DMPCB, output 24 V DC Connect with CN7-1 24 V DC Safety switch 2 24 V DC 24 V DC supply to MPCB, output...
  • Page 394 ( 2 ) MPCB 3-6-23...
  • Page 395 Terminals (CN) Voltage Remarks 5/0 V DC ODSW off/on, input 5 V DC 5 V DC supply to ODSW, output 14-3 5/0 V DC DM off/on, output 14-3 5/0 V DC DM motor lock detection off/on, input 14-3 5/0 V DC DM forward/reverse, output 14-4 24/0 V DC...
  • Page 396 Terminals (CN) Voltage Remarks 2-26 14-4 24 V DC 24 V DC supply to RCL, output 2-27 2-28 5/0 V DC * Key counter disconnected/connected, input 2-29 14-4 24/0 V DC * Key counter off/on, output 2-30 14-4 24 V DC * 24 V DC supply to key counter, output 14-3 5 V DC...
  • Page 397 Terminals (CN) Voltage Remarks 5-16 5-14 24 V DC 24 V DC supply to TNS, output 5-17 5-14 TNS control voltage, output 5-19 5-23 5/0 V DC (pulse) Serial data from OPPCB, input 5-20 5-23 5/0 V DC (pulse) Serial data to OPPCB, output 5-21 5-23 5/0 V DC (pulse)
  • Page 398 Terminals (CN) Voltage Remarks 7-10 5/0 V DC (pulse) ODS 5, 6 control voltage, output 7-11 7-14 5/0 V DC ODS 3, 4 LED off/on, output 7-12 7-14 5 V DC 5 V DC supply to ODS 3, 4, output 7-13 7-14 5/0 V DC (pulse)
  • Page 399 Terminals (CN) Voltage Remarks 13-1 14-4 24/0 V DC PCFM off/on, output 13-2 14-4 24 V DC 24 V DC supply to PCFM, output 14-1 14-4 24 V DC 24 V DC power supply 14-2 14-3 5 V DC 5 V DC power supply 14-5 14-4 24 V DC...
  • Page 400 Terminals (CN) Voltage Remarks 17-14 17-15 5/0 V DC PSW-U off/on, input 17-16 17-15 5 V DC 5 V DC supply to PSW-U, output 17-17 17-18 5/0 V DC LICSW-U off/on, input 17-19 17-17 5 V DC 5 V DC supply to LICSW-U, output 17-20 14-3 5/0 V DC (pulse)
  • Page 401 Terminals (CN) Voltage Remarks 19-21 14-3 5/0 V DC (pulse) * Scan to PLSW (ST), output 19-22 19-23 5/0 V DC * COSW (ST) off/on, input 19-24 19-25 24 V DC * 24 V DC supply to PFM, output 19-26 19-25 24/0 V DC * PFM off/on, output...
  • Page 402 ( 3 ) Operation unit PCB Terminals (CN) Voltage Remarks 5 V DC 5 V DC power supply 5/0 V DC (pulse) Serial data from MPCB, input 5/0 V DC (pulse) Serial data to MPCB, output 5/0 V DC (pulse) Serial data communication data sync from MPCB, input 5/0 V DC (pulse)
  • Page 403 3-6-4 Electrical problems • Copier Problem Causes Check procedures/corrective measures No electricity at the Measure the input voltage. The machine power outlet. does not The power cord is not Check the contact between the power plug operate when plugged in properly. and the outlet.
  • Page 404 Problem Causes Check procedures/corrective measures Broken lens motor Check for continuity across the coil. If none, The lens coil. replace the lens motor. motor does Poor contact in the Check for continuity across the connector not operate lens motor connector terminals.
  • Page 405 Problem Causes Check procedures/corrective measures Defective MPCB. With CN5-30 on the MPCB held low, check if The scanner the scanner fan motor 1 operates. If it does, fan motor 1 replace the MPCB. does not operate. Broken scanner fan Check for continuity across the coil. If none, The scanner motor 2 coil.
  • Page 406 Problem Causes Check procedures/corrective measures (13) Broken registration Check for continuity across the coil. If none, clutch coil. replace the registration clutch. registration Poor contact in the Check for continuity across the connector clutch does registration clutch terminals. If none, replace them. not operate.
  • Page 407 Problem Causes Check procedures/corrective measures (17) Defective MPCB. With CN17-13 on the MPCB held low, check if The upper the upper paper feed clutch operates. If it paper feed does, replace the MPCB. clutch does not operate. (18) Broken upper feed Check for continuity across the coil.
  • Page 408 Problem Causes Check procedures/corrective measures (22) Defective MPCB. If CN10-2 on the MPCB remains HL CONT The halogen (PWM) all the time, replace the MPCB. lamp does not Defective CPCB. Halogen lamp turns on if there is HL CONT turn off. (PWM) to the CN6-2 on the CPCB.
  • Page 409 Problem Causes Check procedures/corrective measures (27) Broken separation Replace the separation charger wire (see Separation charger wire. page 3-3-79). charging is Poor contact in the Check for continuity across the connector not performed HVTPCB connector terminals. If none, replace them. (C500).
  • Page 410 Problem Causes Check procedures/corrective measures (31) Defective upper paper Check if CN17-14 on the MPCB goes low “No paper” switch (for the upper when paper is put close to the upper paper message is cassette). switch. If not, replace the upper paper switch. shown when Defective lower paper Check if CN18-14 on the MPCB goes low...
  • Page 411 Problem Causes Check procedures/corrective measures (35) Defective registration Check if CN2-18 on the MPCB remains low The misfeed switch. when the registration switch is turned on and indicator for off. If it does, replace the registration switch. the paper Defective eject switch. Check if CN11-9 on the MPCB remains low conveying or when the eject switch is turned on and off.
  • Page 412 • Feed shift and duplex sections (optional) Problem Causes Check procedures/corrective measures Poor contact in the Check for continuity across the connector The side side registration motor terminals. If none, replace them. registration connector terminals. motor does Broken side Check visually and replace the side not operate registration motor registration motor if necessary.
  • Page 413 Problem Causes Check procedures/corrective measures Poor contact in the Check for continuity across the connector The duplex duplex registration terminals. If none, replace them. registration clutch connector clutch does terminals. not operate. Broken duplex Check for continuity across the coil. If none, registration clutch coil.
  • Page 414 • Special tray (Optional) Problem Causes Check procedures/corrective measures Poor contact in the Check for continuity across the connector The feed feed clutch (ST) in terminals. If none, replace them. clutch (ST) in special tray connector special tray terminals. does not Broken feed clutch Check for continuity across the coil.
  • Page 415 Problem Causes Check procedures/corrective measures Defective paper If CN19-14 on the MPCB remains low when “No paper” switch (ST) in special the paper switch (ST) in special tray is turned message is tray. on while 5 V DC is present at CN19-16 on the shown when MPCB, replace the paper switch in special paper is...

  • Page 416: Mechanical Problems

    3-6-5 Mechanical problems • Copier Problem Causes/check procedures Corrective measure Check if the surfaces of the following Clean each pulley with a No primary rollers or pulleys are dirty: forwarding rubber recovery and the paper feed. pulleys, upper and lower paper feed other with isopropyl alcohol.
  • Page 417 Problem Causes/check procedures Corrective measure Check if the paper is excessively Change the paper if Paper misfeed. curled. necessary. The guide plate along the paper Check visually and correct conveying path is deformed. or replace if necessary. Check if the upper and lower Repair if necessary.
  • Page 418 • Feedshift and duplex sections (optional) Problem Causes/check procedures Corrective measure Check for the following roller surface Clean Duplex forwarding No refeed. are stained with Duplex forwarding pulley with a rubber pulley, refeed roller, switchback roller, recovery and the other with Duplex upper registration roller, isopropyl alcohol.
  • Page 419 • Special tray (optional) Problem Causes/check procedures Corrective measure Check if the surfaces of the following Clean with a rubber No paper feed pulleys are dirty with paper powder: recovery. from special forwarding pulley and upper&lower tray paper feed pulleys in special tray. Check if the upper or lower paper Replace (see page 3-3-111, feed pulley is deformed.
  • Page 420 3-7 Appendixes Timing chart No. 1 ..................3-7-1 Timing chart No. 2 ..................3-7-2 Timing chart No. 3 ..................3-7-3 Timing chart No. 4 ..................3-7-4 Timing chart No. 5 ..................3-7-5 Timing chart No. 6 ..................3-7-6 Timing chart No. 7 ..................3-7-7 Timing chart No.
  • Page 421 Timing chart No. 1 From the main switch being turned on to copier stabilization H (CN10-3) 400 ms 1000 ms DM (CN1-4) 100 ms 300 ms MC REM (CN1-8) 500 ms 500 ms DB REM (CN1-7) CL (CN3-17) 1000 ms BL (CN3-3~15) 127 ms All off...
  • Page 422 Timing chart No. 2 A single copy, A3/11" × 17" original and A5R/5 " × 8 " copy paper, paper feed from bypass tray, manual exposure, magnification ratio 50% Print key SHPSW (CN6-20) Input (CN2-18) (CN11-9) 1500 ms (CN1-4) 500 ms DB REM (CN1-7) 1122 ms *...
  • Page 423 Timing chart No. 3 A single copy, A4/11" × 8 " original and copy paper, paper feed from copier 1 st cassette, automatic exposure, magnification ratio 100% Print key SHPSW (CN6-20) Input (CN2-20) (CN2-18) (CN11-9) 1500 ms (CN1-4) 500 ms DB REM (CN1-7) 1122 ms *...
  • Page 424 " × 8 " original and A3/11" × 17" copy paper, paper feed from Timing chart No. 4 Two continuous copies, A5R/5 copier 2nd cassette, manual exposure, magnification ratio 200% Print key SHPSW (CN6-20) (CN2-20) Input PFSW-U (CN17-3) (CN2-18) (CN11-9) 1500 ms (CN1-4) 500 ms...
  • Page 425 Timing chart No. 5 Two continuous copies, A3/11" × 17" original and copy paper, paper feed from special tray, automatic exposure, magnification ratio 100% Print key SHPSW (CN6-20) PFSW-L (CN18-3) Input PFSW-U (CN17-3) (CN2-20) (CN2-18) (CN11-9) 1500 ms (CN1-4) DB REM (CN1-7) 500 ms 553 ms...
  • Page 426 Timing chart No. 6 Two continuous copies, Duplex copies from (open) book originals, A3/11" × 17" original and A4/11" × 8 " copy paper, paper feed from copier 2nd cassette, manual exposure, magnification ratio 100% Print key PFSW-U (CN17-3) (CN2-20) (CN2-18) (CN11-9) FSSW...
  • Page 427 " × 11" original Timing chart No. 7 Two continuous copies, Duplex copies from 1-side originals (back side), A4R/8 and copy paper, paper feed from copier 2nd cassette, magnification ratio 100% Print key PFSW-U (CN17-3) (CN2-20) (CN2-18) Input (CN11-9) FSSW (CN11-5) DUPSENS (CN16-3)
  • Page 428 " × 11" original Timing chart No. 8 Two continuous copies, Duplex copies from 1-side originals (front side), A4R/8 and copy paper, paper feed from duplex tray (refeed), magnification ratio 100% Print key (CN2-20) (CN2-18) (CN11-9) DUPSENS (CN16-3) Input STKSW (CN16-7) DUPRSW (CN16-6)
  • Page 429 Composite PCB (Power source section CN9-1 CH L R3 C1 ACIN L MSWIN MSWOUT1 CN10-1 HL L MSWOUT2 CN9-5 CH (ST) L OUTLET L CN12-1 CN11-1 CN8-1 DHSW CN9-2 CH N CN8-4 DH L ACIN N CN9-3 CH (ST) N CN8-5 DH L 24 V...
  • Page 430 Composite PCB (Power source section C201 R201 CN1-1 24 V ZD401 CN2-3 R24 V R401 CN2-1 24 V D201 CN2-4 R24 V CN3-1 24 V CN2-5 R24 V CN4-5 24 V CN3-5 R24 V CN4-6 24 V CN5-4 R24 V R202 CN5-6 R24 V...
  • Page 431 Composite PCB (AVR/Fixing heater control section) R24 V CN6-1 R616 R617 5, 9 R618 R501 R620 R619 HL PWM CN6-2 CN10-1 HL L DB601 R615 CN11-1 VR603 5, 9 C606 R621 R502 H REM CN6-3 R614 R610 TH601 R609 R606 CR601 C609 VR602...
  • Page 432 Backup PCB CN2-14 M RD CN1-4 M WR CN1-9 CN2-18 S GND CN2-4 CN2-5 CN2-6 I/O0 CN2-7 I/O1 CN2-8 I/O2 CN2-9 I/O3 CN2-10 CN1-2 I/O4 RESET CN2-11 I/O5 I/O6 I/O7 CN2-3 CN2-2 CN2-1 CN1-16 CN1-15 CN1-14 CN1-13 CN1-12 CN1-7 CN1-6 CN2-12 MA10 CN1-1...
  • Page 433 Main PCB D22B IC46D IC42D 1C20D R239 D22A R211 _RD M CN20-9 CNB-14 R115 IC38D IC38A _RESET CNA-2 RESET R244 IC44B IC44C IC42C R243 CNA-4 M RD MA19 1C38C CN20-10 φ D20B 1C38B _WR M CN20-16 CNA-9 M WR D20A IC43A RA6A IC36...
  • Page 434 Main PCB [PORT] NO CONNECT R171 CN5-18 CN12-2 IC6D H ALARM CN5-31 CN17-22 R198 FSYNC CN5-22 FSYNC CN5-32 CN18-30 PC00 IC6E KCNT DET CN2-27 CN8-1 CN19-30 PC01 R170 TC DET CN5-3 SCLK CN5-21 SCLK CN8-2 CN23-6 PC02 IC6F CNT DET CN2-28 R228 R229...
  • Page 435 Main PCB SCAN READY SCAN F/R IC33B CN3-17 CL REM IC7B LCD TH CN5-24 AN LOAD – CN3-3 SIGNAL13 IC4D CN3-4 SIGNAL12 IC4A CN3-5 SIGNAL11 IC4B CN3-6 SIGNAL10 IC4C MODE CN3-7 SIGNAL9 IC4E _RESET _RESET CN3-8 SIGNAL8 – IC4F SELECT CN9-9 CN3-9 SIGNAL7...
  • Page 436 Operation unit PCB 1AH-1 7SEGMENT LED. IC2, 3 KEY SW CN1-1 S GND CN1-2 CN1-3 CN1-4 KIN6 FSYNC KIN5 SCLK KIN4 TEST KIN3 ETCON0 KIN2 ETCON1 KIN1 /SELDEGN KIN0 /SELSEGN FSYNC CN1-5 DEG7 /BZEN DEG6 BZIN0 DEG5 OPEN DEG4 OPEN DEG3 DEG2 DEG1...
  • Page 437 KYOCERA MITA DANMARK A/S KYOCERA MITA Industrivej 11, DK-4632 Bjæverskov, CORPORATION Denmark 2-28, 1-chome, Tamatsukuri, Chuo-ku, Phone: 53671100 Osaka 540-8585, Japan Phone: (06) 6764-3555 Fax: (06) 6764-3981 are registered trade marks of KYOCERA CORPORATION and KYOCERA MITA CORPORATION. Printed in Holland DC-2060/2560 1AH...

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