Kyocera KM-2530 Service Manual
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Kyocera KM-2530 Service Manual

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SERVICE
MANUAL
Published in Jul.'02
842DF110

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Summary of Contents for Kyocera KM-2530

  • Page 1 SERVICE MANUAL Published in Jul.’02 842DF110...
  • Page 2 CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. CAUTION Double-pole/neutral fusing.

  • Page 3: Safety Precautions

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

  • Page 5: Installation Precautions

    1. Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current..................... •...
  • Page 6 2. Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 7 • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself....................... • Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item.

  • Page 8: Table Of Contents

    CONTENTS 1-1 Specifications 1-1-1 Specifications ............................1-1-1 1-1-2 Parts names and their functions ......................1-1-3 (1) Copier ............................. 1-1-3 (2) Operation panel ..........................1-1-4 1-1-3 Machine cross section .......................... 1-1-5 1-1-4 Drive system ............................1-1-6 (1) Drive system 1 (drive motor and eject motor drive trains) .............. 1-1-6 (2) Drive system 2 (paper feed motor drive train) ................
  • Page 9 1-5-3 Image formation problems ......................... 1-5-42 (1) No image appears (entirely white)....................1-5-43 (2) No image appears (entirely black)....................1-5-44 (3) Image is too light.......................... 1-5-45 (4) Background is visible........................1-5-45 (5) A white line appears longitudinally....................1-5-45 (6) A black line appears longitudinally.
  • Page 10 (38) The message requesting paper to be loaded is shown when paper is present in the upper drawer.................. 1-5-56 (39) The message requesting paper to be loaded is shown when paper is present in the lower drawer................... 1-5-56 (40) The message requesting paper to be loaded is shown when paper is present on the bypass tray.
  • Page 11 1-6-5 Developing section ..........................1-6-34 (1) Detaching and refitting the developing unit .................. 1-6-34 1-6-6 Transfer section ..........................1-6-35 (1) Detaching and refitting the transfer roller assembly ..............1-6-35 1-6-7 Fixing section ............................. 1-6-36 (1) Detaching and refitting the fixing unit ................... 1-6-36 (2) Detaching and refitting the heat roller separation claws ...............
  • Page 12 Maintenance parts list ........................... 2-4-15 Periodic maintenance procedures ........................ 2-4-16 Optional devices supplied parts list ......................2-4-18 General wiring diagram ..........................2-4-20 1-1-5...

  • Page 13: Specifications

    1-1-1 Specifications Type ..........Desktop Copying system ......Indirect electrostatic system Originals ......... Sheets and books Maximum size: A3/11" × 17" Original feed system ...... Fixed Copy paper ........Drawer: Plain paper (64 – 80 g/m Bypass table: Plain paper (60 – 160 g/m Special paper: Transparencies, tracing paper, colored paper, letterhead envelopes (when using the printer function only) Note: Use the bypass table for special paper.
  • Page 14 Fixing system ......... Heat roller Heat source: halogen heaters (120 V specifications:main 600 W, sub 400W/ 220-240 V specifications:main 630 W, sub 420 W) Control temperature: 165°C/329°F (at normal ambient temperature) Abnormally high temperature protection device: 170°C/338°F thermostat Fixing pressure: 107.8 N Charge erasing system ....

  • Page 15: Parts Names And Their Functions

    1-1-2 Parts names and their functions (1) Copier Figure 1-1-1 @ Main switch 1 Original cover # Copy store section 2 Operation panel $ Platen 3 Conveying cover handle % Original size scales 4 Conveying cover ^ Upper drawer 5 Bypass tray &...

  • Page 16: Operation Panel

    (2) Operation panel Printer Facsimile Auto Selection Priority Output Priority Output Management Interrupt Energy Saver Reset Copier Stop Printer Clear Scanner Start & 1 2 3 Figure 1-1-2 1 Start key (Indicator) 0 Auto selection key (Indicator) 2 Stop/clear key ! Facsimile priority output key (Indicator) 3 Reset key @ Printer priority output key (Indicator)

  • Page 17: Machine Cross Section

    1-1-3 Machine cross section Light path Paper path Figure 1-1-4 Machine cross section 1 Paper feed section 2 Main charging section 3 Optical section 4 Developing section 5 Transfer and separation section 6 Cleaning and charge erasing section section 7 Fixing section 8 Eject and switchback section 1-1-5...

  • Page 18: Drive System

    1-1-4 Drive system (1) Drive system 1 (drive motor and eject motor drive trains) As viewed from machine rear Figure 1-1-4 1 Drive motor gear 9 Registration clutch gear 2 Drum gear Z76H/Z30H 0 Gear Z63H/Z45S 3 Drum gear Z70H ! Gear Z37S 4 Gear Z76H/Z35H @ Gear Z24S...

  • Page 19: Drive System 2 (Paper Feed Motor Drive Train)

    (2) Drive system 2 (paper feed motor drive train) As viewed from machine rear Figure 1-1-5 1 Paper feed motor gear ! Lower paper feed clutch gear 2 Gear Z76H/Z35S @ Gear Z41S/P15 3 Feed gear Z25 # Bypass drive belt 4 Feed gear Z25 $ Gear Z60S/P20 5 Feed gear Z25...

  • Page 20: Drum

    1-2-1 Drum Note the following when handling or storing the drum. • When removing the drum unit, never expose the drum surface to strong direct light. • Keep the drum at an ambient temperature between 0°C/32°F and 35°C/95°F and at a relative humidity not higher than 85% RH.

  • Page 21: Unpacking And Installation

    1-3-1 Unpacking and installation (1) Installation procedure Start Unpack. Remove the tapes and pad. Install the optional paper feed desk or large paper deck. Carry out initial developer setting (maintenance item U130). Remove the pins holding light source units 1 and 2. Load paper.
  • Page 22 Moving the machine When moving the machine, pull out the four handles for transport on the right and left sides and hold them. * For the left front handle for transport, open the door and push it into the machine before pulling out the handle. Handle for transport Handle for...
  • Page 23 Unpack Figure 1-3-2 Unpacking 1 Copier 0 Bottom pad 2 Power cord ! Machine cover 3 Upper left pad @ Bar code labels 4 Upper right pad # Belt 5 Outer case $ Eject spacer 6 Inner frame % Spacer* 7 Lower right pad ^ Plastic bag 8 Lower left pad...
  • Page 24 Remove the tapes and pad. 1. Remove the tapes holding the front cover, bypass tray, drawers and original detection switch. 2. Remove the pad at the eject section. Tape Tape Tape Tapes Figure 1-3-3 3. Remove the three tapes holding the pins for light source units 1 and 2.
  • Page 25 6. Pull upper and lower drawers out and remove the tape holding each of the drawer lift. Tape Figure 1-3-5 Install the optional paper feed desk or large paper deck. 1. Install the optional paper feed desk or large paper deck as necessary (see page 1-3-18 to 1-3-24).
  • Page 26 Install the toner container. 1. Open the front cover. 2. Tap the top of the toner container five to six Toner container times. Figure 1-3-7 3. Shake the toner container approximately 10 times in the horizontal direction to stir toner. Toner container Figure 1-3-8 4.
  • Page 27 Install the toner disposal tank. 1. Install the toner disposal tank in the copier. 2. Close the front cover. Toner disposal tank Figure 1-3-10 Connect the power cord. 1. Connect the power cord to the connector on the copier.* *200-240 V specifications only. 2.
  • Page 28 Make test copies. 1. Place an original and make test copies. Attach the function seat. 1. Remove the PET film from the operation panel. PET film 2. Fit the relevant function sheet. If the DF has been installed, select a function sheet among No.

  • Page 29: Setting Initial Copy Modes

    1-3-2 Setting initial copy modes Factory settings are as follows: Maintenance Contents Factory setting item No. U253 Switching between double and single counts Double count Turning auto start function on/off U254 Setting auto clear time U255 Turning auto preheat/energy saver U256 function on/off Switching copy operation at toner...

  • Page 30: Copier Management

    1-3-3 Copier management In addition to a maintenance function for service, the copier is equipped with a management function which can be operated by users (mainly by the copier administrator). In this copier management mode, settings such as default settings can be changed.

  • Page 31: Setting Department Management Items

    (2) Setting department management items (3) Copy default Registering a new department code Exposure mode Sets a department code and the limit of the Selects the exposure mode at power-on. number of copies for that department. 1. Select “Exposure mode” and press the 1.
  • Page 32 Manual exposure adjustment (Mixed) Display register key Adjusts the exposure to be used when text and Sets whether or not to display the Register key in photo original is selected for the image mode. the copy operation screen. 1. Select “Manual exp. adj. (Mixed)” and press 1.

  • Page 33: Machine Default

    (4) Machine default Auto shutoff time Sets the auto shutoff time. Auto drawer switching 1. Select “Auto shut-off time” and press the Sets whether the auto drawer switching function [Change #] key. is available. 2. Press the +/- keys to set the auto shutoff 1.

  • Page 34: Report

    (5) Report Outputs the setting reports. 1. Press the [Print form] key. 2. Select the report. Copy report/Option report/Counter report/ Machine report (6) Language Switches the language to be displayed on the press panel. 1. Press the [Language] key. 2. Select the display language. 1-3-14...

  • Page 35: Installing The Key Counter (Option)

    1-3-4 Installing the key counter (option) Key counter installation requires the following parts: Key counter set (P/N 2A369703) Contents of the set: • Key counter cover (P/N 2A360010) • Key counter retainer (P/N 66060030) • Key counter cover retainer (P/N 66060022) •...
  • Page 36 6. Pass the connector of the key counter through the aperture in the key counter retainer, and insert into the connector of the copier. 7. Seat the projection of the key counter cover retainer in the aperture in the middle right cover.

  • Page 37: Installing The Drawer Heater (Option)

    1-3-5 Installing the drawer heater (option) Drawer heater installation requires the following parts: • Drawer heater (P/N 34860030): for 120 V specifications • Drawer heater (P/N 33960020): for 220 - 240 V specifications • Band (P/N M2107120) Procedure 1. Pull the upper and lower drawers out. Aperture 2.

  • Page 38: Installing The Paper Feed Desk (Option)

    1-3-6 Installing the paper feed desk (option) Preparation 1. Remove the lower drawer from the copier. Lower drawer Figure 1-3-18 2. Place the copier on top of the paper feed desk with the positioning pins at the front left and right of the paper feed desk aligned with the holes in the base of the copier.
  • Page 39 5. Remove the screw and then the cover from the rear of the paper feed desk. 6. Remove the screw from the copier. Screw Screw Cover Figure 1-3-21 7. Insert the 12-P connector of the paper feed desk into the connector on the copier. 12-P connector Figure 1-3-22 8.
  • Page 40 11. Turn the four leveling bolts until they reach the floor and adjust them to level the machine. Leveling bolts Figure 1-3-24 12. Fit the two stays to the left of the paper feed desk (one toward the front and the other the rear) using the two M4 ×...

  • Page 41: Installing The Large Paper Deck (Option)

    1-3-7 Installing the large paper deck (option) Preparation 1. Remove the lower drawer from the copier. Lower drawer Figure 1-3-26 2. Place the copier on top of the large paper deck with the positioning pins at the front left and right of the large paper deck aligned with the holes in the base of the copier.
  • Page 42 5. Remove the screw and then the cover from the rear of the large paper deck. 6. Remove the screw from the rear of the copier. Screw Screw Cover Figure 1-3-29 7. Insert the 12-pin connector of the large paper deck into the connector on the copier.
  • Page 43 10. Turn the four leveling bolts until they reach the floor and adjust them to level the machine. Leveling bolts Figure 1-3-32 11. Fit the stay to the lower left of the large paper deck toward the rear using the two M4 × 16 chrome TP screws such that it makes contact with the floor.
  • Page 44 4. Insert the upper tabs and lower tabs of the front and rear lateral size adjusters into the upper slots and lower slots respectively such that the size indicators point to the size of paper to be used. Secure the lateral size adjusters using the screw for each.

  • Page 45: Installing The Saddle Finisher/Switchback Unit (Option)

    1-3-8 Installing the saddle finisher/switchback unit (option) Preparation 1. Open the conveying cover of the copier. 2. Remove the two screws securing the feedshift guide assembly and then the Screws assembly. Feedshift guide assembly Conveying cover Figure 1-3-37 3. Fit the curl eliminator to the conveying cover Projection Screw Screw...
  • Page 46 7. Remove the two screws securing the shield cover and then the cover. Screws Shield cover Figure 1-3-40 8. Detach the 10-pin connector (four wires) from CN4 on the main PCB and connect it to J2 on the IPC PCB. IPC PCB 10-pin connector CN15...
  • Page 47 12. Align the rail retainer with the groove of the Rail retainer Guide rail guide rail and attach the rail retainer to the guide rail. Make sure that the plate spring of the rail retainer fits into the groove and the edge of the guide rail fits between the pulleys on the reverse side of the rail retainer.
  • Page 48 17. Slightly lift the bottom of the finisher and insert the rail fixing plate into the finisher, and then join them by inserting two M4 × 6 binding screws loosely. Finisher Rail fixing plate M4 × 6 binding screws 18. Insert the guide rail into the rail fixing plate Rail fixing plate and secure it using an M4 ×...
  • Page 49 20. Fit the eject tray to the finisher by hooking the two claws and secure it using two M4 × 6 Claw binding screws. Claw Eject tray M4 × 6 binding screws Figure 1-3-49 21. Open the front panel and insert the stapler unit into the finisher.
  • Page 50 3. Release the hook of the switchback unit by lifting the release lever. Switchback unit Release lever Hook Figure 1-3-52 4. Fit the switchback unit to the finisher by Finisher hanging the hook of the switchback unit on the loosely fitted M3 × 8 binding screws. 5.
  • Page 51 9. Insert the rib of the front cover into the groove in the top cover of the switchback unit, and then fit the front cover to the finisher. 10. Secure the front cover by fitting an M4 × 12 TP screw and M4 × 16 TP screw into the holes where screws were inserted (see step 8).
  • Page 52 3. Loosen the two screws on each of the four casters. 4. Adjust the height of the rear right caster by turning its adjustment bolt using a cross- headed screwdriver so that the axis of the pin of the latch catch is aligned with the middle of the three markings on the right of the slot of the finisher or switchback unit when the finisher is joined to the copier (viewed from...
  • Page 53 6. Adjust the height of the left two casters in the same manner as in step 4 so that the top and bottom gaps (A) between the finisher and the copier are the same when the finisher is detached from the copier. 7.

  • Page 54: Installing The Sheet-Through Document Holder (Option)

    1-3-9 Installing the sheet-through document holder (option) Preparation 1. Insert the DF into the copier. Figure 1-3-62 2. Connect the connector of the DF to the copier. 3. Insert the copier power plug to the wall outlet and turn the main switch on. Connector Figure 1-3-63 4.

  • Page 55: Installing The Facsimile System (Option)

    1-3-10 Installing the Facsimile System (option) Procedure 1. Fit the battery pack into the NCU retainer as shown in the illustration. M3 × 06 chrome 2. Fit the speaker onto the two catches on the binding screws NCU cable NCU retainer, and fasten it into place with one M3 ×...
  • Page 56 • If the printing system is installed Printer system 9. Remove the 2 screws holding the printer system in place, and pull the printing system out of the shield cover. Screws Figure 1-3-67 Shield cover 10. Remove 13 screws and take off the shield cover.
  • Page 57 12. Fasten the NCU unit into place from the NCU board bottom with two M3 × 06 chrome binding connector NCU board screws. NCU unit 13. Connect the three connectors from the NCU board to the corresponding connectors on the fax board, as follows: •...
  • Page 58 Green positive 15. Connect the three positive connectors on the Auxiliary power connector power board to the corresponding connectors source PCB on the auxiliary power source PCB, as follows. • White positive connector → TB1 (white) • Green positive connector → TB2 (green) •...
  • Page 59 This page is intentionally left blank. 1-3-39...
  • Page 60 17. Through the opening of controller-box above 2-pin connector the speaker, connect the FAX-PCB-Power with green cable Fax board cable on the auxiliary power source PCB to 2-pin connector connector CN8 on the fax board. 18. Connect the 2-pin connector to the 2-pin Connector CN8 connector with green cable.
  • Page 61 24. Fasten the shield cover into place with 13 screws. Shield cover Screws Figure 1-3-76 25. Remove 1 screw and take off the modular cover. Screw Modular cover Figure 1-3-77 26. Hang the modular cover onto the holes on the shield cover, and fasten it into place with 1 screw.
  • Page 62 • If the printing system was installed Printing system 27. Reinstall the printing system into the shield cover, fastening it into place with 2 screws. Screws Figure 1-3-79 Rear cover 28. Reattach the rear cover with 13 screws. Screws Figure 1-3-80 29.
  • Page 63 30. Take the power label from the fax-kit label sheet, and adhere it to the copier directly under the main switch. Main switch Power label Figure 1-3-82 31. Take the alphabet labels from the fax-kit label Management Interrupt Alphabet labels Energy Sever sheet, and adhere them above the corresponding numeric keys on the operation...
  • Page 64 Initialization procedure after installation of facsimile system 1. Insert the copier power plug to the wall outlet and turn the main switch on. 2. Run maintenance item U601. 3. Enter a destination code using the numeric keys (refer to the destination code list) and then press the start key.

  • Page 65: Installing The Printing System (Option)

    1-3-11 Installing the Printing System (option) Cover Procedure 1. Remove 2 screws and take off the cover. Screws Figure 1-3-87 Printing system 2. Push the printing system all the way in along the rails, and fasten it with 2 screws. Screws Figure 1-3-88 Install the (optional) network printer board.
  • Page 66 Install the (optional) hard disk. 5. Remove 2 screws and take off the cover. 6. Push the hard disk all the way in along the rails, and fasten it with 2 screws. Hard desk Cover Screws Screws Figure 1-3-90 Installing the Optional Bar-Code Reader 7.

  • Page 67: Installing The Scanning System (Option)

    1-3-12 Installing the Scanning System (option) Procedure 1. Remove 13 screws and take off the rear Rear cover cover. Screws Figure 1-3-93 Printer system • If the printing system is installed 2. Remove the 2 screws holding the printer system in place, and pull the printing system out of the shield cover.
  • Page 68 4. Insert the RTC board at an angle into the RTC board RTC board slot on the main PCB. RTC board slot 5. Push the free end of the RTC board down toward the fax board. Main PCB Figure 1-3-96 6.
  • Page 69 9. Fasten the shield cover into place with 13 screws. Shield cover Screws Figure 1-3-99 • If the printing system was installed Printing system 10. Reinstall the printing system into the shield cover, fastening it into place with 2 screws. Screws Figure 1-3-100 11.

  • Page 70: Installing The Duplex Unit (Option)

    1-3-13 Installing the duplex unit (option) Preparation 1. Open the conveying cover. 2. Remove the screw from the front and rear struts respectively to remove the struts and remove the conveying cover in the horizontal direction. Screws Conveying cover Conveying cover Struts Figure 1-3-102 3.
  • Page 71 6. Insert the 8-pin connector of the duplex unit into the groove of the housing and pull out the Duplex unit harness. 7. Connect the 8-pin connector of the duplex unit to the connector of the copier and Connector arrange wiring so that the harness is placed down.

  • Page 72: Installing The Built-In Finisher (Option)

    1-3-14 Installing the built-in finisher (option) Preparation Note: When placing the transfer unit on the floor or the like, be sure to place it upside down. Transfer unit If not, the stapler mounting plate may be deformed, resulting in a malfunction. Figure 1-3-106-1 1.
  • Page 73 4. Close the conveying cover and the front cover. 5. Remove the two screws and then remove the Ejection cover ejection cover with the mounting plate. Screws Figure 1-3-109 6. Remove the two screws and then remove the inner ejection cover. Inner ejection cover Screws...
  • Page 74 8. Remove the blue screw from the transfer unit and then remove the mounting plate. Transfer unit 9. Remove the securing tape from the 13-pin connector, pass the wire under the stapler motor, and connect the wire with the 13-pin Mounting plate connector.
  • Page 75 12. Remove a screw, turn the metal fittings Metal fittings upward, and fit the screw again to the lower hole. Screw Screw Figure 1-3-113 13. Insert the intermediate tray and connect the connector (white) of the intermediate tray to the transfer unit. Connect the connectors Connector (white) (gray) to the connectors of the copier as shown in the illustration.
  • Page 76 15. Attach the large ejection cover using the two screws that have secured the upper left cover. Large ejection cover Figure 1-3-116 +TP-A chrome screw M3 × 05 16. Open the front cover and the conveying cover. 17. Attach the staple cover. Staple cover * Tighten the two screws on the left side to secure the cover with the copier, secure the...
  • Page 77 19. Attach the copy tray. Copy tray Figure 1-3-119 20. Open the staple cover and insert the staple cartridge into the stapler. 21. Close the staple cover. Staple cover 22. Insert the power plug of the copier into an outlet and turn the main switch on. 23.

  • Page 78: Installing The Job Separator (Option)

    1-3-15 Installing the job separator (option) 2-pin connector 2-pin connector Preparation 1. Insert the LED PCB into the job separator Job separator and connect the 2-pin connector of the LED PCB into the 2-pin connector of the job separator. * Arrange the wire into the two grooves of the job separator.
  • Page 79 6. Remove the two screws and then remove the inner ejection cover. Inner ejection cover Screws Figure 1-3-123 7. Insert the job separator into the copier from the front side and slide it to the left. Secure the front side using a +TP-A bronze screw M3 ×...
  • Page 80 8. Connect the connector of the job separator to the lower connector of the copier. Connector Connector of the copier Figure 1-3-125 9. Attach the job separator tray to the rail of the job separator by sliding it from the front side. * Insert the fitting section on the right side of the job separator tray into the recessed portion of the copier.

  • Page 81: Installing The Network Facsimile System (Option)

    1-3-16 Installing the Network Facsimile System (option) Procedure 1. Remove 13 screws and take off the rear cover. Rear cover Screws Figure 1-3-127 • If the printing system is installed Printer system 2. Remove the 2 screws holding the printer system in place, and pull the printing system out of the shield cover.
  • Page 82 4. Move the film out of the way to the left, and M3 × 06 chrome fasten the fax board into place using four M3 binding screws × 06 chrome binding screws. Fax board Film Figure 1-3-130 5. Connect the NCU cable to connector CN1 on NCU cable the NCU board assembly.
  • Page 83 8. Remove the film that fixes the three positive Optional interface mounting plate connectors of the power source PCB from the optional interface mounting plate. Important: Dispose of the film that has been removed. Film Figure 1-3-133 9. Connect the FAX-PCB-Power cable to FAX-PCB-Power cable connector CN1 on the auxiliary power source PCB assembly.
  • Page 84 11. Fit the catch on the auxiliary power unit into the mount hole in the copier, and fasten the auxiliary power unit into place with one M3 × 06 chrome binding screw. M3 × 06 chrome binding screw Catch Mount hole Figure 1-3-136 Opening 12.
  • Page 85 17. Fasten the shield cover into place with 13 screws. Shield cover Screws Figure 1-3-139 18. Remove 1 screw and take off the modular cover. Screw Modular cover Figure 1-3-140 19. Hang the modular cover onto the holes on the controller-box cover, and fasten it into place with 1 screw.
  • Page 86 • If the printing system was installed Printing system 20. Reinstall the printing system into the shield cover, fastening it into place with 2 screws. Screws Figure 1-3-142 Rear cover 21. Reattach the rear cover with 13 screws. Screws Figure 1-3-143 22.
  • Page 87 23. Take the power label from the fax-kit label sheet, and adhere it to the copier directly under the main switch. Main switch Power label Figure 1-3-145 24. Take the alphabet labels from the fax-lit label Management Alphabet labels Interrupt Energy Sever sheet, and adhere them above the corresponding numeric keys on the operation...

  • Page 88: Maintenance Mode

    1-4-1 Maintenance mode The copier is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the cursor up/down keys The maintenance item is or numeric keys.

  • Page 89: Maintenance Mode Item List

    (2) Maintenance mode item list Item Initial Section Maintenance item contents setting* General U000 Outputting an own-status report — U001 Exiting the maintenance mode — U003 Setting the service telephone number *************** U004 Setting the machine number 000000 U005 Copying without paper —...
  • Page 90 Item Initial Section Maintenance item contents setting* High voltage U100 Checking the operation of main high voltage U101 Setting high voltages • Developing bias AC component frequency at image formation • Developing bias AC component duty at image formation • Developing shift bias potential at image formation •...
  • Page 91 Item Initial Section Maintenance item contents setting* Mode setting U253 Switching between double and single counts Double count U254 Turning auto start function on/off U255 Setting auto clear time U256 Turning auto preheat/energy saver function on/off U258 Switching copy operation at toner empty detection Single mode, U260 Changing the copy count timing After ejection...

  • Page 92: Contents Of Maintenance Mode Items

    (3) Contents of maintenance mode items Maintenance Description item No. U000 Outputting an own-status report Description Outputs lists of the current settings of the maintenance items, and paper jam and service call occurrences. Purpose To check the current setting of the maintenance items, or paper jam or service call occurrences. Before initializing or replacing the backup RAM, output a list of the current settings of the maintenance items to reenter the settings after initialization or replacement.
  • Page 93 Maintenance Description item No. U003 Setting the service telephone number Description Sets the telephone number to be displayed when a service call code is detected. Purpose To set the telephone number to call service when installing the machine. Method Press the start key. The currently set telephone number is displayed. Setting 1.
  • Page 94 Maintenance Description item No. U005 Copying without paper Description Simulates the copy operation without paper feed. Purpose To check the overall operation of the machine. Method 1. Press the start key. The screen for selecting an item is displayed. 2. Select the item to be operated. The selected item is displayed in reverse. Display Operation Only the copier operates.
  • Page 95 Maintenance Description item No. U020 Initializing all data Description Initializes all the backup RAM on the main PCB to return to the original settings. Purpose Used when replacing the backup RAM on the main PCB. Method 1. Press the start key. The screen for executing is displayed. 2.
  • Page 96 Maintenance Description item No. U030 Checking motor operation Description Drives each motor. Purpose To check the operation of each motor. Method 1. Press the start key. The screen for selecting an item is displayed. 2. Select the motor to be operated. The selected item is displayed in reverse and the operation starts. Display Operation FEED...
  • Page 97 Maintenance Description item No. U032 Checking clutch operation Description Turns each clutch on. Purpose To check the operation of each clutch. Method 1. Press the start key. The screen for selecting an item is displayed. 2. Select the clutch to be operated. The selected item is displayed in reverse, and the clutch turns on for 1 s. Display Clutches Upper paper feed clutch (PFCL-U)
  • Page 98 Maintenance Description item No. U035 Setting folio size Description Changes the image area for copying onto folio size paper. Purpose To prevent the image at the trailing edge, or right or left side of the paper from not being copied by setting the actual size of the folio paper used.
  • Page 99 Maintenance Description item No. U053 Performing fine adjustment of the motor speed Description Performs fine adjustment of the speeds of the motors. Purpose Used to adjust the speed of the respective motors when the magnification is not correct. Method Press the start key. The screen for selecting an item is displayed. Setting 1.
  • Page 100 Maintenance Description item No. U060 Adjusting the scanner input properties Description Adjusts the image scanning density in text, text and photo, or photo mode. Purpose Used when the entire image appears too dark or light. Method Press the start key. The screen for executing is displayed. Setting 1.
  • Page 101 Maintenance Description item No. U063 Adjusting the shading position Description Changes the shading position. Purpose Used when white lines continue to appear longitudinally on the image after the shading plate is cleaned. This is due to flaws or stains inside the shading plate. To prevent this problem, the shading position should be changed so that shading is possible without being affected by the flaws or stains.
  • Page 102 Maintenance Description item No. U070 Adjusting the DF magnification Description Adjusts the DF original scanning speed. Purpose To be executed if the correct magnification is not obtained in the auxiliary scanning direction when the optional DF is used. Caution Before making this adjustment, ensure that the following adjustments have been made in maintenance mode. U053 U065 U070...
  • Page 103 Maintenance Description item No. U071 Adjusting the DF scanning timing Description Adjusts the DF original scanning timing. Purpose To be executed if there is a regular error between the leading or trailing edges of the original and the copy image when the optional DF is used. Caution Before making this adjustment, ensure that the following adjustments have been made in maintenance mode.
  • Page 104 Maintenance Description item No. U072 Adjusting the DF center line Description Adjusts the scanning start position for the DF original. Purpose To be executed if there is a regular error between the centers of the original and the copy image when the optional DF is used.
  • Page 105 Maintenance Description item No. U073 Checking scanner operation Description Simulates the scanner operation under arbitrary conditions. Purpose To check scanner operation. Method 1. Press the start key. The screen for selecting an item is displayed. 2. Select the item to be changed. The selected item is displayed in reverse. 3.
  • Page 106 Maintenance Description item No. U087 Turning the DF scanning position adjust mode on/off Description Turns on or off the DF scanning position adjust mode, in which the DF original scanning position is adjusted automatically by determining the presence or absence of dust on the slit glass. Also changes the reference data for identifying dust.
  • Page 107 Maintenance Description item No. U088 Setting the input filter (moiré reduction mode) Description Turns moiré reduction mode on and off by switching the input filter on and off. Purpose Used to prevent regular density unevenness (moiré) on halftone image areas of the copy image in text mode and text and photo mode.
  • Page 108 Maintenance Description item No. U091 Checking shading Description Performs scanning under the same conditions as before and after shading is performed, displaying the original scanning values at nine points of the contact glass. Purpose To check the change in original scanning values before and after shading. The results may be used to decide the causes for fixing unevenness (uneven density) of the gray area of an image: either due to optical (shading or CCD) or other problems.
  • Page 109 Maintenance Description item No. U092 Adjusting the scanner automatically Description Makes auto scanner adjustments in the order below using the specified original. • Adjusting the scanner center line (U067) • Adjusting the scanner leading edge registration (U066) • Adjusting scanner magnification in the auxiliary direction (U065) When this maintenance item is performed, the settings in U065, U066 and U067 are also changed.
  • Page 110 Maintenance Description item No. U093 Setting the exposure density gradient Description Changes the exposure density gradient in manual density mode, depending on respective image modes (text, text and photo, photo, text in fax mode, photo in fax mode). Purpose To set how the image density is altered by a change of one step in the manual density adjustment. Also used to make copy image darker or lighter.
  • Page 111 Maintenance Description item No. U099 Checking and setting the original size detection sensor Description Checks the operation of the original size detection sensor and sets the sensing threshold value. Purpose To adjust the sensitiveness of the sensor and size judgement time if the original size detection sensor malfunctions frequently due to incident light or the like.
  • Page 112 Maintenance Description item No. U100 Checking the operation of main high voltage Description Performs main charging. Purpose To check main charging. Start Press the start key. The screen for selecting an item is displayed. Display Description MC ON Turning the main charger on ON TIME(SEC) Turning the main charger on and the laser scanner unit on and off Method...
  • Page 113 Maintenance Description item No. U109 Drum type display Description Displays the drum surface potential set as EEPROM of the drum unit. Purpose To check the drum surface potential. Method Press the start key. * Drum surface potential (V) is displayed. Completion Press the stop/clear key.
  • Page 114 Maintenance Description item No. U113 Performing drum refresh operation Description Executes drum refresh operation. Purpose To operate when image flow occurs. Method 1. Press the start key. The screen for executing is displayed. 2. Press the start key. Drum refresh operation starts. (approximately 3 minutes) 3.
  • Page 115 Maintenance Description item No. U150 Checking sensors and switches for toner Description Displays the on-off status of each sensor or switch related to toner. Purpose To check if the sensors and switches operate correctly. Method 1. Press the start key. A list of the switches, the on-off status of which can be checked, are displayed. 2.
  • Page 116 Maintenance Description item No. U158 Checking/clearing the developing count Description Displays the developing count for checking, clearing or changing a figure, which is used as a reference when correcting the toner control. It is automatically cleared when U130 is executed. Purpose To check the developing count after replacing the developing unit.
  • Page 117 Maintenance Description item No. U161 Setting the fixing correct temperature 1. Select the item to be set. The selecting item is displayed in reverse. 2. Change the setting using the cursor up/down keys. Display Description Setting range Initial setting COPY UP TEMP(L) Fixing correct temperature -30 to +30 (°C) for large size copying...
  • Page 118 Maintenance Description item No. U165 Checking/clearing fixing counts Description Displays or clears fixing counts. Purpose To check fixing counts after replacing the fixing unit. Method Press the start key. The fixing counts are displayed. Clearing 1. Press the reset key. 2.
  • Page 119 Maintenance Description item No. U200 Turning all LEDs on Description Turns all the LEDs on the operation panel on. Purpose To check if all the LEDs on the operation panel light. Method Press the start key. All the LEDs on the operation panel light. Press the stop/clear key or wait for 10 s.
  • Page 120 Maintenance Description item No. U203 Operating DF separately Description Simulates the original conveying operation separately in the optional DF. Purpose To check the DF. Method 1. Press the start key. The screen for selecting an item is displayed. 2. Place an original in the DF if running this simulation with paper. 3.
  • Page 121 Maintenance Description item No. U206 Setting the presence or absence of the coin vender Description Sets the presence or absence of the optional coin vender. Also sets the details for coin vender operation, such as mode and unit price. This is an optional device which is currently supported only by Japanese specification machines, so no setting is necessary.
  • Page 122 Maintenance Description item No. " × × × × × 13" paper U217 Setting 8 Description " × 13" paper. Turn on the setting when using 8 Purpose To change the setting as needed. Method Press the start key. The screen for selscting an item is displayed. Setting 1.
  • Page 123 Maintenance Description item No. U237 Setting finisher stack quantity Description Sets the number of sheets of each stack on the main tray and on the intermediate tray in the optional finisher. Purpose To change the setting when a stack malfunction has occurred. Method 1.
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  • Page 125 Maintenance Description item No. U243 Checking the operation of the DF motors, solenoids and clutch Description Turns the motors, solenoids or clutch in the optional DF on. Purpose To check the operation of the DF motors, solenoids and clutch . Method 1.
  • Page 126 Maintenance Description item No. U244 Method for the volume switch 1. Move the original insertion guides to check the detection status of the original size width switch. The detected original width is displayed as a numerical value with the decimals omitted. Numerical Original width to be detected value...
  • Page 127 Maintenance Description item No. U245 Checking messages Description Displays a list of messages on the touch panel of the operation panel. Purpose To check the messages to be displayed. Method 1. Press the start key. 2. Select the item to be displayed. 3.
  • Page 128 Maintenance Description item No. U246 Left stapling Right stapling Adjustment method Proper Decrease the preset value. Upper side is longer. Lower side is longer. Increase the preset value. Lower side is longer. Upper side is longer. 3. Press the start key. The value is set. 4.
  • Page 129 Maintenance Description item No. U247 Checking the operation of large paper deck and paper feed desk Description Turns on motors and clutches of optional large paper deck or paper feed desk. Purpose To check the operation of motors and clutches of paper feed device. Start 1.
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  • Page 131 Maintenance Description item No. U249 Checking the paper ejection to optional devices Description Ejects paper to an optional mailbox or job separator, or to the ejection slot at the machine left. Purpose To check paper conveying operation to optional paper eject devices or the ejection slot at the machine left. Method 1.
  • Page 132 Maintenance Description item No. U251 Checking/clearing the maintenance count Description Displays, clears and changes the maintenance count. Purpose To check the maintenance count. Also to clear the count during maintenance service. Method Press the start key. The maintenance count is displayed. Clearing 1.
  • Page 133 Maintenance Description item No. U253 Switching between double and single counts Description Switches the count system for the total counter and other counters. Purpose According to user (copy service provider) request, select if A3/11" × 17" paper is to be counted as one sheet (single count) or two sheets (double count).
  • Page 134 Maintenance Description item No. U255 Setting auto clear time Description Sets the time to return to initial settings after copying is complete. Purpose To be set according to frequency of use. Set to a comparatively long time for continuous copying at the same settings, and a comparatively short time for frequent copying at various settings.
  • Page 135 Maintenance Description item No. U258 Switching copy operation at toner empty detection Description Selects if continuous copying is enabled after toner empty is detected, and sets the number of copies that can be made after the detection. Method Press the start key. The current setting is displayed. Setting 1.
  • Page 136 Maintenance Description item No. U264 Setting the display order of the date Description Selects year, month and day as the order of that appears on lists, etc. Purpose Set according to the user preference. Method Press the start key. The screen for selecting an item is displayed. Setting 1.
  • Page 137 Maintenance Description item No. U329 Default setting Auto rotation copy/Sort copy Description Sets the initial mode for the Auto rotation copy/Sort copy selected when auto clear is triggered or the reset key is pressed. Purpose To be set as required according to the user. Method 1.
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  • Page 139 Maintenance Description item No. U332 Setting the size conversion factor Description Sets the factor for converting each paper size into A4/11" × 8 ". The black ratio is converted for the A4/11" × " size using the factor set in this maintenance item. Values set are displayed in the user simulation. Purpose To set the factor to convert the black ratio of each paper size for A4/11"...
  • Page 140 Maintenance Description item No. U342 Setting the ejection restriction Description Sets or cancels the restriction on the number of sheets to be ejected continuously when the internal eject tray is selected as the eject location. Purpose According to user request, sets or cancels restriction on the number of sheets. Method 1.
  • Page 141 Maintenance Description item No. U344 Setting preheat/energy saver mode Description Changes the control for preheat/energy saver mode. Purpose According to user request, selects which has priority, the recovery time from preheat or energy saver. Method Press the start key. The screen for selecting an item is displayed. Setting 1.
  • Page 142 Maintenance Description item No. U404 Adjusting margins for scanning an original from the DF Description Adjusts margins for scanning the original from the DF. Purpose Used if margins are not correct when the optional DF is used. Caution Before making this adjustment, ensure that the following adjustments have been made in maintenance mode. U402 U403 U404...
  • Page 143 Maintenance Description item No. U500 Setting the limit on data size for email transmission Description Sets the limit on the amount of data (number of originals) sent via email from the optional network scanner. Purpose To change the setting according to the network environment. Method Press the start key.
  • Page 144 Maintenance Description item No. U504 Initializing the scanner NIC Description Initializing the optional scanner NIC to its factory default. Purpose To return to a setup at the time of factory shipments. Method 1. Press the start key. The screen for executing is displayed. 2.
  • Page 145 Maintenance Description item No. U901 Checking/clearing copy counts by paper feed locations Description Displays or clears copy counts by paper feed locations. Purpose To check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts. Method 1.
  • Page 146 Maintenance Description item No. U903 Checking/clearing the paper jam counts Description Displays or clears the jam counts by jam locations. Purpose To check the paper jam status. Also to clear the jam counts after replacing consumable parts. Method 1. Press the start key. The jam count is displayed by jam codes. 2.
  • Page 147 Maintenance Description item No. U905 Checking/clearing counts by optional devices Description Displays or clears the counts of the optional DF or finisher. Purpose To check the use of the DF and finisher. Also to clear the counts after replacing consumable parts. Method 1.
  • Page 148 Maintenance Description item No. U908 Changing the total counter value Description Displays, clears and changes the total counter value. Purpose To check the total counter value. Method Press the start key. The screen for selecting an item is displayed. Display Description COUNT (PRINTER) The total count value at the time of printer use...
  • Page 149 Maintenance Description item No. U937 Model name setting Description Sets the product name to be displayed on the printer status screen, etc. when installing a printer board (optional). Purpose To set the name if initialization is performed. Method Press the start key. The screen for selecting an item is displayed. Setting 1.
  • Page 150 Maintenance Description item No. U990 Checking/clearing the time for the exposure lamp to light Description Displays, clears or changes the accumulated time for the exposure lamp to light. Purpose To check duration of use of the exposure lamp. Also to clear the accumulated time for the lamp after replacement.
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  • Page 152 Maintenance Description item No. U992 Checking or clearing the printer/fax count Description Displays, clears or changes the print count of the printer or fax when the optional printer board or fax unit is installed. Purpose To check the frequency of use of the printer or fax. Method Press the start key.
  • Page 153 Maintenance Description item No. U993 Outputting a VTC-PG pattern Description Selects and outputs a VTC-PG pattern created in the copier. Purpose When performing respective image printing adjustments, used to check the machine status apart from that of the scanner with a non-scanned output VTC-PG pattern. Method 1.

  • Page 154: Paper Misfeed Detection

    1-5-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the copier immediately stops copying and displays the jam location on the operation panel. Paper misfeed counts sorted by the detection condition can be checked in maintenance item U903. To remove paper jammed in the copier, open the front cover, conveying cover, side cover or drawer.
  • Page 155 Jam code Contents See pape No paper feed from the upper drawer P.1-5-4 No paper feed from the lower drawer P.1-5-4 No paper feed from large paper deck*/paper feed desk* upper drawer P.1-5-4 No paper feed from paper feed desk* lower drawer P.1-5-4 No paper feed from bypass P.1-5-5...

  • Page 156: Paper Misfeed Detection Conditions

    (2) Paper misfeed detection conditions OFSW SRDF OSBSW DFTSW Built-in finisher PCSW FSSW Duplex unit DUPPCSW DUPFCL BYPFCL BYPPFCL FCL1 FSW1 BYPFSW PFCL-U FCL2 FSW2 PFCL-L FCL3 FSW3 PPSENS1 PPSENS3 DPFCL-U PPSENS2 PFCL2 PFCL1 DFCL DFSW DPFCL-L Paper feed desk Large paper deck Figure 1-5-1 1-5-3...
  • Page 157 1. Paper feed section • No paper feed from the upper drawer (jam code 10) Feed switch 1 (FSW1) does not turn on within 841 ms of the upper paper feed clutch (PFCL-U) turning on; the clutch is then successively turned off for 1 s and turned back on, but the switch again fails to turn on within 841 ms. PFCL-U FSW1 841 ms...
  • Page 158 • No paper feed from bypass (jam code 14) The bypass feed switch (BYPFSW) does not turn on within 1730 ms of the bypass paper feed clutch (BYPPFCL) turning on; the clutch is then successively held off for 1 s and turned back on, but the switch again fails to turn on within 1730 ms. BYPPFCL BYPFSW 1730 ms...
  • Page 159 Feed switch 1 (FSW1) does not turn on within 1079 ms of feed switch 2 (FSW2) turning on. FSW2 FSW1 1079 ms Timing chart 1-5-11 Feed switch 2 (FSW2) does not turn on within 1203 ms of feed switch 3 (FSW3) turning on. FSW3 FSW2 1203 ms...
  • Page 160 Feed switch 3 (FSW3) does not turn off within the time required to convey the length of the used paper size plus 635 ms of turning on. FSW3 Paper size + 635 ms Timing chart 1-5-17 The desk feed switch (DFSW) does not turn off within the time required to convey the length of the used paper size plus 635 ms of turning on.
  • Page 161 • Multiple sheets in copier vertical conveying section (jam code 22) Feed switch 1 (FSW1) does not turn off within 1910 ms of feed switch 2 (FSW2) turning off. FSW2 1910 ms FSW1 Timing chart 1-5-23 Feed switch 2 (FSW2) does not turn off within 1203 ms of feed switch 3 (FSW3) turning off. FSW3 1203 ms FSW2...
  • Page 162 The registration switch (RSW) does not turn off within 1505 ms of the bypass feed switch (BYPFSW) turning on. BYPFSW 1505 ms Timing chart 1-5-28 2. Paper conveying section • Misfeed in registration/transfer section (jam code 30) The registration switch (RSW) does not turn off within 1657 ms of feed switch 1 (FSW1) turning off. FSW1 1657 ms Timing chart 1-5-29...
  • Page 163 4. Eject section • Misfeed in eject section (jam code 50) The eject switch (ESW) does not turn off within 2898 ms of the registration switch (RSW) turning off. 2898 ms Timing chart 1-5-33 The eject switch (ESW) does not turn off within 2898 ms of the registration clutch (RCL) turning on. 2898 ms Timing chart 1-5-34 •...
  • Page 164 5. Feedshift section • Misfeed in feedshift section (jam code 52) The feedshift switch (FSSW) does not turn on within 873 ms of the start of eject motor (EM) reverse rotation. Fwd. rotation Rev. rotation FSSW 873 ms Timing chart 1-5-38 During paper switchback operation, the feedshift switch (FSSW) does not turn off within the time required to convey the length of the used paper size plus 317 ms of turning on.
  • Page 165 The switchback eject switch (SBESW) does not turn on within 1421 ms (2797 ms) of the feedshift switch (FSSW) turning on. FSSW SBESW 1421(2797) ms The value in the parentheses indicates the value in switchback operation. Timing chart 1-5-43 The switchback eject switch (SBESW) does not turn off within 1421 ms (2797 ms) of the feedshift switch (FSSW) turning off. FSSW SBESW 1421(2797) ms...
  • Page 166 Feed switch 1 (FSW1) does not turn off within 1126 ms of the duplex paper conveying switch (DUPPCSW) turning off. DUPPCSW 1126 ms FSW1 Timing chart 1-5-48 8. SRDF* • No original feed (jam code 70) When the DF START signal is received, switches other than the original set switch (OSSW) and original size length switch (OSLSW) on the contact glass are on.
  • Page 167 • An original jam in the original feed section (jam code 72) During original switchback operation in the double-sided original mode, the original feed switch (OFSW) remains on when the original switchback switch (OSBSW) turns off. OSBSW OFSW Timing chart 1-5-52 •...
  • Page 168 • An original jam in the switchback section 2 (jam code 76) While scanning the first face (reverse face) of the original in the double-sided original mode, the original switchback switch (OSBSW) does not turn on within 770 ms of the DF timing switch (DFTSW) turning on. DFTSW OSBSW 770 ms...

  • Page 169: Paper Misfeeds

    (3) Paper misfeeds Problem Causes/check procedures Corrective measures A piece of paper torn from Check visually and remove it, if any. A paper jam in the copy paper is caught paper feed, convey- around feed switch 1/2/3, ing or eject section registration switch, eject is indicated as soon switch or feedshift switch.
  • Page 170 Problem Causes/check procedures Corrective measures Paper in the lower drawer Change the paper. A paper jam in the is extremely curled. paper feed section Check if the lower paper Check visually and replace any deformed pulleys. is indicated during feed pulley, separation copying (no paper pulley or forwarding pulley feed from lower...
  • Page 171 Problem Causes/check procedures Corrective measures Check if the desk upper Run maintenance item U247 and select the desk upper paper A paper jam in the paper feed clutch malfunc- feed clutch on the operation panel to be turned on and off. paper feed section tions.
  • Page 172 Problem Causes/check procedures Corrective measures Paper in the large paper Change the paper. A paper jam in the deck is extremely curled. paper feed section Check if the paper side Check visually and replace. is indicated during guides are deformed. copying (jam in large paper deck* Defective paper path sen-...
  • Page 173 Problem Causes/check procedures Corrective measures (11) Defective feed switch 2. Run maintenance item U031 and turn feed switch 2 on and off A paper jam in the manually. Replace feed switch 2 if indication of the correspond- paper feed section ing switch on the operation panel is not displayed in reverse.
  • Page 174 Problem Causes/check procedures Corrective measures (14) Defective feed switch 3. Run maintenance item U031 and turn feed switch 3 on and off A paper jam in the manually. Replace feed switch 3 if indication of the correspond- paper feed section ing switch on the operation panel is not displayed in reverse.
  • Page 175 Problem Causes/check procedures Corrective measures (15) Defective feed switch 3. Run maintenance item U031 and turn feed switch 3 on and off A paper jam in the manually. Replace feed switch 3 if indication of the correspond- paper feed section ing switch on the operation panel is not displayed in reverse.
  • Page 176 Problem Causes/check procedures Corrective measures (19) Check if the registration Run maintenance item U032 and select the registration clutch A paper jam in the clutch malfunctions. on the operation panel to be turned on and off. Check the status fixing section is indi- and remedy if necessary.
  • Page 177 Problem Causes/check procedures Corrective measures (23) Broken feedshift switch Check visually and replace the feedshift switch if its actuator is A paper jam in the actuator. broken. switchback section Defective feedshift switch. Run maintenance item U031 and turn the feedshift switch on is indicated during and off manually.
  • Page 178 Problem Causes/check procedures Corrective measures (27) Defective DF timing Run maintenance item U244 and turn the DF timing switch on An original jams in switch. and off manually. Replace the switch if indication of the corre- the SRDF* is indi- sponding switch on the operation panel is not displayed in re- cated during copy- verse.
  • Page 179 Problem Causes/check procedures Corrective measures (32) Defective paper conveying With 5 V DC present at CN4-9 on the finisher main PCB, check Paper jams in the switch. if CN4-10 on the finisher main PCB remains high or low when built-in finisher* dur- the paper conveying switch is turned on and off.

  • Page 180: Self-Diagnosis

    1-5-2 Self-diagnosis (1) Self-diagnostic function This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled and the problem displayed as a code consisting of "C" followed by a number between 0030 and 8500, indicating the nature of the problem. A message is also displayed requesting the user to call for service.

  • Page 181: Self-Diagnostic Codes

    (2) Self diagnostic codes Remarks Code Contents Causes Check procedures/corrective measures C0030 Fax board* problem Defective fax Replace the fax board and check for cor- • Problems with data from fax board. board. rect operation. C0110 Backup memory data problem Problem with the Turn safety switch 1 off and back on and •...
  • Page 182 Remarks Code Contents Causes Check procedures/corrective measures C0440 Finisher* communication problem Poor contact in Check the connection of connectors CN4, • Communication errors from the com- the connector ter- CN5 on the main PCB and CN2 on the fin- munication microcomputer on the minals.
  • Page 183 Remarks Code Contents Causes Check procedures/corrective measures C1010 Upper lift motor problem Broken gears or Replace the upper lift motor. • When the upper drawer is inserted, couplings of the the upper lift limit switch does not turn upper lift motor. on within 6 s of the upper lift motor Defective upper Check for continuity across the coil.
  • Page 184 Remarks Code Contents Causes Check procedures/corrective measures C1030 Desk upper lift motor problem Poor contact of Reinsert the connector. Also check for con- • When the upper drawer of the paper the desk upper lift tinuity within the connector cable. If none, feed desk* is inserted, the desk upper limit switch con- repair or replace the cable.
  • Page 185 Remarks Code Contents Causes Check procedures/corrective measures C1120 Deck right lift* position problem Defective deck Check if CN5-4 on the desk main PCB • Deck level switch 2 does not turn on level switch 2. goes low when desk level switch 2 is within 30 s of paper deck motor 2 turned off.
  • Page 186 Remarks Code Contents Causes Check procedures/corrective measures C1170 Large paper deck* (paper feed desk*) Deck/desk for the Replace the deck/desk fot the copier. incorrect type problem printer is installed. C2000 Drive motor problem Poor contact in Reinsert the connector. Also check for con- •...
  • Page 187 Remarks Code Contents Causes Check procedures/corrective measures C3100 Scanner carriage problem Poor contact in Check the connection of connector CN37 • The home position is not correct the connector ter- on the main PCB and the continuity across when the power is turned on or at the minals.
  • Page 188 Remarks Code Contents Causes Check procedures/corrective measures C4010 Polygon motor steady-state problem Poor contact in Reinsert the connector. Also check for con- • When high-speed rotation from low- the polygon motor tinuity within the connector cable. If none, speed rotation is requested, the motor connector termi- remedy or replace the cable.
  • Page 189 Remarks Code Contents Causes Check procedures/corrective measures C6050 Abnormally low fixing unit thermis- Poor contact in Check the connection of connector CN10 tor temperature the fixing unit on the main PCB and the continuity across • The fixing thermistor detects tempera- thermistor con- the connector terminals.
  • Page 190 Remarks Code Contents Causes Check procedures/corrective measures C7410 Drum unit connector insertion prob- Drum unit connec- Reinsert the drum unit connector if neces- tor inserted incor- sary. • Absence of the drum unit is detected rectly. continuously for 1500 ms while there Defective drum Replace the drum unit.
  • Page 191 Remarks Code Contents Causes Check procedures/corrective measures C8140 Finisher* tray elevation motor prob- Poor contact in Reinsert the connector. Also check for con- the tray elevation tinuity within the connector cable. If none, • The sort tray is not detected in the motor connector remedy or replace the cable.
  • Page 192 Remarks Code Contents Causes Check procedures/corrective measures C8190 Finisher* trailing edge registration The trailing edge Reinsert the connector. Also check for con- motor problem registration motor tinuity within the connector cable. If none, • If the trailing edge registration home connector makes remedy or replace the cable.
  • Page 193 Remarks Code Contents Causes Check procedures/corrective measures C8320 Booklet stitcher* rear jog motor A problem is de- See the booklet stitcher service manual. problem tected with the rear jog motor. C8330 Booklet stitcher* front jog motor A problem is de- See the booklet stitcher service manual.
  • Page 194 Remarks Code Contents Causes Check procedures/corrective measures C8460 Booklet stitcher* punch backup RAM A problem is de- See the booklet stitcher service manual. data problem tected with the punch backup RAM data. C8470 Booklet stitcher* punch dust sensor A problem is de- See the booklet stitcher service manual.

  • Page 195: Image Formation Problems

    1-5-3 Image formation problems (1) No image appears (2) No image appears (3) Image is too light. (4) Background is visible. (entirely white). (entirely black). See page 1-5-43 See page 1-5-44 See page 1-5-45 See page 1-5-45 (8) One side of the copy (5) A white line appears (7) A black line appears (6) A black line appears...
  • Page 196 (1) No image appears Causes (entirely white). 1. No transfer charging. 2. No LSU laser is output. 3. No developing bias is output. Causes Check procedures/corrective measures 1. No transfer charging. A. The connector terminals of the high-voltage Reinsert the connector. Also check for continuity within the connector cable.
  • Page 197 (2) No image appears Causes (entirely black). 1. No main charging. 2. Exposure lamp fails to light. Causes Check procedures/corrective measures 1. No main charging. A. Broken main charger wire. Replace the main charger unit. B. Leaking main charger housing. Clean the main charger wire, grid and shield.
  • Page 198 (3) Image is too Causes light. 1. Insufficient toner. 2. Deteriorated toner. 3. The transfer voltage is not output properly. 4. Dirty main charger wire. Causes Check procedures/corrective measures 1. Insufficient toner. If the display shows the message requesting toner replenishment, replace the cartridge.
  • Page 199 (6) A black line appears Causes longitudinally. 1. Dirty contact glass. 2. Dirty or flawed drum. 3. Deformed or worn cleaning blade. 4. Dirty scanner mirror. 5. Dirty main charger wire. Causes Check procedures/corrective measures 1. Dirty contact glass. Clean the contact glass. 2.
  • Page 200 (9) Black dots appear Causes on the image. 1. Dirty or flawed drum. 2. Dirty contact glass. 3. Deformed or worn cleaning blade. 4. Dirty drum separation claws. 5. Dirty heat roller separation claws. Causes Check procedures/corrective measures 1. Dirty or flawed drum. Perform the drum refresh operation.
  • Page 201 (12) The leading edge of Causes the image is sporadi- 1. Feed clutch, paper feed clutch, bypass paper cally misaligned with feed clutch or registration clutch installed or the original. operating incorrectly. Causes Check procedures/corrective measures 1. Feed clutch, paper feed clutch, bypass paper Check the installation position and operation of the feed clutch, feed clutch or registration clutch installed or paper feed clutch, bypass paper feed clutch and registration clutch.
  • Page 202 Causes (15) Image is partly miss- 1. Paper damp. ing. 2. Paper creased. 3. Drum condensation. 4. Flawed drum. Causes Check procedures/corrective measures 1. Paper damp. Check the paper storage conditions. 2. Paper creased. Replace the paper. 3. Drum condensation. Perform the drum refresh operation.
  • Page 203 (18) Image center does not Causes align with the original 1. Misadjusted center line of image printing. center. 2. Misadjusted scanner center line. 3. Original placed incorrectly. Causes Check procedures/corrective measures 1. Misadjusted center line of image printing. Readjust the center line of image printing (see page 1-6-19). 2.
  • Page 204 1-5-4 Electrical problems Problem Causes Check procedures/corrective measures No electricity at the power Measure the input voltage. The machine does outlet. not operate when The power cord is not Check the contact between the power plug and the outlet. the main switch is plugged in properly.
  • Page 205 Problem Causes Check procedures/corrective measures Defective main PCB. Run maintenance item U030 and check if CN16-B11, CN16- The eject motor B12, CN16-B13 and CN16-B14 on the main PCB go low. If not, does not operate. replace the main PCB. Broken upper lift motor Check for continuity across the coil.
  • Page 206 Problem Causes Check procedures/corrective measures (12) Broken cooling fan motor 5 Check for continuity across the coil. If none, replace cooling fan Cooling fan motor 5 coil. motor 5. does not operate. Poor contact in the cooling Reinsert the connector. Also check for continuity within the con- fan motor 5 connector ter- nector cable.
  • Page 207 Problem Causes Check procedures/corrective measures (20) Broken feed clutch 2 coil. Check for continuity across the coil. If none, replace feed clutch Feed clutch 2 does not operate. Poor contact in feed clutch Reinsert the connector. Also check for continuity within the con- 2 connector terminals.
  • Page 208 Problem Causes Check procedures/corrective measures (27) Poor contact in the clean- Reinsert the connector. Also check for continuity within the con- The cleaning lamp ing lamp connector termi- nector cable. If none, remedy or replace the cable. does not turn on. nals.

  • Page 209: The Message Requesting Paper To Be Loaded Is Shown When Paper Is Present In The Upper Drawer

    Problem Causes Check procedures/corrective measures (34) Defective main PCB. See page 1-5-43. No developing bias Defective high-voltage is output. transformer PCB. (35) Defective original detec- If the level of CN5-2 on the scanner drive PCB does not change The original size is tion switch.

  • Page 210: The Size Of Paper In The Lower Drawer Is Not Displayed Correctly

    Problem Causes Check procedures/corrective measures (42) Poor contact in the lower Reinsert the connector. Also check for continuity within the con- The size of paper in paper length switch con- nector cable. If none, remedy or replace the cable. the lower drawer is nector terminals.

  • Page 211: The Message Requesting Covers To Be Closed Is Displayed When The Front Cover And Conveying Cover Are Closed

    Problem Causes Check procedures/corrective measures (45) Poor contact in the con- Reinsert the connector. Also check for continuity within the con- The message re- nector terminals of safety nector cable. If none, remedy or replace the cable. questing covers to switch 1 or 2.

  • Page 212: Mechanical Problems

    1-5-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following rollers Clean with isopropyl alcohol. No primary paper feed. or pulleys are dirty with paper powder: up- per/lower forwarding pulleys, upper/lower paper feed pulleys, upper/lower separation pulleys, feed rollers, registration rollers, by- pass forwarding pulleys, bypass paper feed pulleys and bypass separation pulleys.

  • Page 213: Toner Drops On The Paper Conveying Path

    Problem Causes/check procedures Corrective measures Check if the developing unit is extremely Clean the developing unit. Toner drops on the pa- dirty. per conveying path. Check if the pulleys, rollers and gears oper- Grease the bearings and gears. Abnormal noise is ate smoothly.

  • Page 214: Precautions For Assembly And Disassembly

    1-6-1 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 215: Running A Maintenance Item

    (2) Running a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the cursor up/down keys The maintenance item is or numeric keys. selected. Press the start key. The selected maintenance item is run. Press the stop/clear key.

  • Page 216: Paper Feed Section

    1-6-2 Paper feed section (1) Detaching and refitting the forwarding, paper feed and separation pulleys Follow the procedure below to replace the forwarding, paper feed and separation pulleys. Procedure • Removing the primary paper feed units 1. Open the front cover and pull out the upper and lower drawers.
  • Page 217 • Removing the paper feed pulley Paper feed shaft 6. Remove the two stop rings. Stop rings 7. Pull the paper feed shaft toward the rear of the primary paper feed unit (in the direction of the arrow) and remove the paper feed pulley. Paper feed pulley Figure 1-6-4 •...
  • Page 218 (2) Detaching and refitting the bypass separation, bypass paper feed and bypass forwarding pulleys Follow the procedure below to replace the bypass separation, bypass paper feed and bypass forwarding pulleys. Procedure • Removing the bypass unit 1. Remove the four screws holding the lower right cover and then the cover.
  • Page 219 4. Raise the bypass separation shaft as shown in the diagram, remove the holder plate and the bushing, and then remove the bypass Holder plate separation pulley. * Take care not to remove the spring pin of Bushing the gear at the rear of the bypass separation shaft.
  • Page 220 8. Raise the bypass paper feed shaft as shown Stop ring in the illustration, remove the stop ring, and Bypass paper feed shaft then remove the bypass paper feed pulley. Caution: • When fitting the bypass paper feed pulley, keep the blue end of the paper feed toward the machine rear.
  • Page 221 12. Remove the stop ring of the bypass paper Stop ring Bushing feed shaft and slide the bushing in the direction of the arrow. Bypass paper feed shaft Figure 1-6-16 13. Slide the bypass forwarding pulley shaft Bypass forwarding pulley shaft temporarily toward the rear side and then raise it to remove from the bypass unit.

  • Page 222: Bypass Forwarding Pulleys

    15. Remove the stop ring and slide the bypass forwarding pulley with the forwarding pulley Stop ring retainer from the shaft to remove it. 16. Replace the bypass separation, bypass paper feed and bypass forwarding pulleys. Bypass forwarding pulley Forwarding pulley retainer Figure 1-6-19 Bypass paper feed shaft 17.

  • Page 223: Adjustment After Roller And Clutch Replacement

    (3) Adjustment after roller and clutch replacement Perform the following adjustment after refitting rollers and clutches. (3-1) Adjusting the leading edge registration of image printing Make the following adjustment if there is a regular error between the leading edges of the copy image and original. U066 U071 U034...

  • Page 224: Adjusting The Leading Edge Registration For Memory Image Printing

    (3-2) Adjusting the leading edge registration for memory image printing Make the following adjustment if there is a regular error between the leading edge of the copy image and the leading edge of the original during memory copying. U066 U053 U034 U065 U407...

  • Page 225: Adjusting The Center Line Of Image Printing

    (3-3) Adjusting the center line of image printing Make the following adjustment if there is a regular error between the center lines of the copy image and original when paper is fed from the drawer. U067 U072 U034 (P. 1-6-30) (P.

  • Page 226: Adjusting The Margins For Printing

    (3-4) Adjusting the margins for printing Make the following adjustment if the margins are not correct. U403 U404 U402 (P. 1-6-31) (P. 1-4-49) Caution: Check the copy image after the adjustment. If the margins are still incorrect, perform the above adjustments in maintenance mode.

  • Page 227: Adjusting The Amount Of Slack In The Paper

    (3-5) Adjusting the amount of slack in the paper Make the following adjustment if the leading edge of the copy image is missing or varies randomly, or if the copy paper is Z-folded. Procedure Start Original Copy Copy example 1 example 2 Enter maintenance mode.

  • Page 228: Optical Section

    1-6-3 Optical section Contact glass Upper rear cover (1) Detaching and refitting the exposure lamp Replace the exposure lamp as follows. Procedure 1. Remove the original cover or the DF. 2. Remove the upper right cover, upper front cover, upper rear cover and contact glass. Upper right cover Figure 1-6-26 3.

  • Page 229: Detaching And Refitting The Scanner Wires

    (2) Detaching and refitting the scanner wires Take the following procedure when the scanner wires are broken or to be replaced. Caution: After replacing the scanner wire, make a test copy and check the copy image. If the image is incorrect, perform the adjustments (see pages 1-6-25 to 31).

  • Page 230: Refitting The Scanner Wires

    5. Unhook the round terminal of the scanner wire from the scanner tension spring on the Scanner tension spring left side of the scanner unit. 6. Remove the scanner wire. Scanner wire Scanner wire Figure 1-6-32 (2-2) Fitting the scanner wires Caution: When fitting the wires, be sure to use those specified below.
  • Page 231 3. Insert the two frame securing tools into the Frame securing tools positioning holes at the front and rear of the scanner unit to pin the mirror 2 frame in position. Mirror 2 frame Figure 1-6-34 4. Loop the inner ends of the scanner wires around the grooves in the pulleys at the right of the scanner unit, winding from below to above.
  • Page 232 7. Loop the outer ends of the scanner wires around the grooves in the scanner wire pulleys at the left of the scanner unit, winding from below to above..................... 4 8. Loop the scanner wires around the outer grooves in the pulleys on the mirror 2 frame, winding from below to above.

  • Page 233: Detaching And Refitting The Laser Scanner Unit

    (3) Detaching and refitting the laser scanner unit Take the following procedure when the laser scanner unit is to be checked or replaced. Procedure 1. Remove the developing unit and drum unit (see pages 1-6-32 and 34). 2. Remove the four screws holding the lower right cover and then the cover.
  • Page 234 5. Remove the two screws and detach the Fan duct Connector connector and then remove the fan duct. Figure 1-6-41 Toner container retainer 6. Remove the six screws holding the toner container retainer and then the retainer. Figure 1-6-42 7. Remove the four screws and detach the Connector connector and then remove the laser scanner unit.

  • Page 235: Adjusting The Skew Of The Laser Scanner Unit (Reference)

    (4) Adjusting the skew of the laser scanner unit (reference) Perform the following adjustment if the leading and trailing edges of the copy image are laterally skewed (lateral squareness not obtained). Caution: • After adjusting the skew of the laser scanner unit, make a test copy and check the copy image. If lateral squareness is still not obtained, perform "(6) Adjusting the position of the ISU"...

  • Page 236: Detaching And Refitting The Isu (Reference)

    (5) Detaching and refitting the ISU (reference) Take the following procedure when the ISU is to be checked or replaced. Caution: After replacing the ISU, make a test copy and check the copy image. If the image is incorrect, perform the adjustments (see pages 1-6-25 to 31).
  • Page 237 • Refitting the ISU 1. Fit the ISU using the two positioning pins. Positioning pins 2. Secure the ISU using the four screws. 3. Remove the two positioning pins and refit all the removed parts. Figure 1-6-49 1-6-24...

  • Page 238: Adjusting The Position Of The Isu (Reference)

    (6) Adjusting the position of the ISU (reference) Perform the following adjustment if the leading and trailing edges of the copy image are laterally skewed (lateral squareness not obtained). Caution: • Be sure to perform “(4-1) Adjusting the skew of the laser scanner unit” (page 1-6-22) first. •...

  • Page 239: Adjusting The Longitudinal Squareness (Reference)

    (7) Adjusting the longitudinal squareness (reference) Perform the following adjustment if the copy image is longitudinally skewed (longitudinal squareness not obtained). Caution: • Adjust the amount of slack in the paper (page 1-6-14) first. Check for the longitudinal squareness of the copy image, and if it is not obtained, perform the longitudinal squareness adjustment.

  • Page 240: Adjusting Magnification Of The Scanner In The Main Scanning Direction

    (8) Adjusting magnification of the scanner in the main scanning direction Perform the following adjustment if the magnification in the main scanning direction is not correct. U065 U065 U053 U067 (auxiliary scanning (main scanning (P. 1-4-12) (P. 1-6-30) direction) (P. 1-6-28) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 241: Adjusting Magnification Of The Scanner In The Auxiliary Scanning Direction

    (9) Adjusting magnification of the scanner in the auxiliary scanning direction Perform the following adjustment if the magnification in the auxiliary scanning direction is not correct. U065 U065 U053 U070 (main scanning (auxiliary scanning (P. 1-4-12) (P. 1-4-15) direction) (P. 1-6-27) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 242: Adjusting The Scanner Leading Edge Registration

    (10) Adjusting the scanner leading edge registration Perform the following adjustment if there is regular error between the leading edges of the copy image and original. U034 U071 U066 (P. 1-6-10) (P. 1-4-16) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner leading edge registration Start...

  • Page 243: Adjusting The Scanner Center Line

    (11) Adjusting the scanner center line Perform the following adjustment if there is a regular error between the center lines of the copy image and original. U034 U072 U067 (P. 1-6-12) (P. 1-4-17) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner center line Start...

  • Page 244: Adjusting The Margins For Scanning An Original On The Contact Glass

    (12) Adjusting the margins for scanning an original on the contact glass Perform the following adjustment if the margins are not correct. U402 U404 U403 (P. 1-6-13) (P. 1-4-49) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Start Enter maintenance mode.

  • Page 245: Drum Section

    1-6-4 Drum section (1) Detaching and refitting the drum unit Follow the procedure below to replace the drum unit. Cautions: • Avoid direct sunlight or strong light when detaching and refitting the drum unit. • Never touch the drum surface when holding the drum unit. Procedure 1.

  • Page 246: Detaching And Refitting The Drum Separation Claw Assemblies

    (3) Detaching and refitting the drum separation claw assemblies Follow the procedure below to replace the drum separation claw assemblies. Procedure 1. Remove the drum unit (see page 1-6-32). Drum separation claw assemblies 2. Push the drum separation claw assemblies with the minus driver from the top of the corner hole and remove the claw assemblies.

  • Page 247: Developing Section

    1-6-5 Developing section (1) Detaching and refitting the developing unit Follow the procedure below to replace the developing unit. Procedure 1. Open the front cover. 2. Remove the toner container and toner disposal tank. 3. Remove the screw and turn the developing release lever in the direction of the arrow.

  • Page 248: Transfer Section

    1-6-6 Transfer section (1) Detaching and refitting the transfer roller assembly Follow the procedure below to replace the transfer roller assembly. Procedure 1. Open the conveying cover. Transfer roller assembly 2. While holding down the projection, slide the transfer roller assembly toward the front to remove it.

  • Page 249: Fixing Section

    1-6-7 Fixing section (1) Detaching and refitting the fixing unit Follow the procedure below to check or replace the fixing unit. Procedure 1. Open the front cover and conveying cover. 2. Remove the three screws holding the front left cover and then the cover. Front left cover Figure 1-6-65 3.

  • Page 250: Detaching And Refitting The Press Roller

    3. Remove the heat roller separation claws from the upper fixing cover. 4. Replace the heat roller separation claws and refit all the removed parts. Heat roller separation claws Figure 1-6-68 (3) Detaching and refitting the press roller Follow the procedure below to replace the press roller. Press spring Procedure 1.

  • Page 251: Detaching And Refitting The Fixing Heater M And S

    (4) Detaching and refitting the fixing heater M and S Follow the procedure below to replace the fixing heater M and S. Procedure 1. Remove the fixing unit (see page 1-6-36). 2. Remove the upper fixing cover (see page 1- 6-36).

  • Page 252: Detaching And Refitting The Heat Roller

    (5) Detaching and refitting the heat roller Follow the procedure below to replace the heat roller. Procedure 1. Remove the fixing unit (see page 1-6-36). Fixing gear 2. Remove the upper fixing cover (see page 1- 6-36). 3. Remove the press roller and fixing heater M and S (see pages 1-6-37 and 38).

  • Page 253: Detaching And Refitting The Fixing Unit Thermistor

    (6) Detaching and refitting the fixing unit thermistor Follow the procedure below to replace the fixing unit thermistor. Procedure 1. Remove the fixing unit (see page 1-6-36). 2. Remove the upper fixing cover (see page 1- 6-36). 3. Disconnect the connector of the fixing unit thermistor.

  • Page 254: Upgrading The Firmware On The Main Pcb

    1-7-1 Upgrading the firmware on the main PCB Firmware upgrading requires the following tools: Compact Flash (Products manufactured by SANDISK are recommended.) NOTE When writing data to a new Compact Flash from a computer, be sure to format it in advance. (For formatting, insert a Compact Flash and select a drive.) For a desktop computer, connect a Compact Flash card reader/writer to it.

  • Page 255: Replacing The Backup Rom

    1-7-2 Replacing the backup ROM Replacing the backup ROM requires the following tools: ROM replacing tool Procedure 1. Insert the claw of the ROM replacing tool into the groove of the backup ROM. ROM replacing tool 2. Press the ROM replacing tool from both the right and the left sides.

  • Page 256: Adjustment-Free Variable Resisters (Vr)

    1-7-3 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. • High-voltage transformer PCB: VR42, VR201, VR204, VR205 • Inverter PCB: VR1, VR2 1-7-3...

  • Page 257: Paper Feed Section

    2-1-1 Paper feed section The paper feed section consists of the primary feed and secondary feed subsections. Primary feed conveys paper from the upper drawer, lower drawer or bypass tray to the left and right registration rollers, at which point secondary feed takes place and the paper travels to the transfer section in sync with the printing timing.
  • Page 258 The bypass table can be hold up to 200 sheets of paper at one time. Paper is fed from the bypass table by the rotation of the bypass forwarding pulley and bypass paper feed pulley. Also during paper feed, the bypass separation pulley prevents multiple sheets from being fed at one time by the torque limiter.
  • Page 259 MPCB CN16-B6 CN10-A2 FCL1 CN11-14 CN11-17 FSW1 PSW-U LICSW-U CN13-B9 PFCL-U CN13-B12 CN16-B1 FCL2 CN13-A12 PSW-L LICSW-L CN13-B15 FSW2 PFCL-L CN13-B18 CN16-B4 FCL3 CN13-A5 FSW3 CN13-A2 CN13-A7 Figure 2-1-3 Paper feed section block diagram (upper and lower drawers) BYPFCL BYPPFCL BYPPSW BYPFSW MPCB...
  • Page 260 Image ready Start key 100 ms 48 ms 124 ms 30 ms FCL1 75 ms 17 ms PFCL-U FSW1 Timing chart 2-1-1 Paper feed from the upper drawer a:100 ms after the start key is pressed, the drive motor (DM) turns on to start the drive for the paper feed section. At the same time, the upper paper feed clutch (PFCL-U) turns on, and the forwarding and paper feed pulleys rotate to start primary paper feed.

  • Page 261: Main Charging Section

    2-1-2 Main charging section The main charging section consists of the main charger assembly, drum and so on. The drum is electrically charged uniformly (500 µA) by means of a grid to form a latent image on the surface. The main charger unit charges the drum so that a latent image is formed on the surface, the shield grid ensuring the charge is applied uniformly.
  • Page 262 Start key 100 ms MC REM 100 ms 409 ms Timing chart 2-1-3 Main charging section operation a:100 ms after the start key is pressed, the drive motor (DM) turns on. b:100 ms after the drive motor (DM) turns on, main charging (MC REM) starts. c:The leading edge of the paper turns on the eject switch (ESW), and at the same time the eject motor (EM) turns on.

  • Page 263: Optical Section

    2-1-3 Optical section The optical section consists of the scanner, mirror frame and image scanning unit for scanning and the laser scanner unit for printing. Figure 2-1-7 Optical section 1 Mirror 1 frame 2 Mirror 2 frame 3 Exposure lamp (EL) 4 Mirror 1 5 Mirror 2 6 Mirror 3...

  • Page 264: Original Scanning

    (1) Original scanning The original image is illuminated by the exposure lamp (EL) and scanned by the CCD PCB (CCDPCB) in the image scanning unit via the three mirrors, the reflected light being converted to an electrical signal. The scanner and mirror frames travel to scan on the optical rails on the front and rear of the machine to scan from side to side.

  • Page 265: Image Printing

    (2) Image printing The image data scanned by the CCD PCB (CCDPCB) is processed on the main PCB (MPCB) and transmitted as image printing data to the laser scanner unit (LSU). By repeatedly turning the laser on and off, the laser scanner unit forms a latent image on the drum surface.
  • Page 266 Drum Figure 2-1-10 Laser scanner unit (2) 1 Laser diode: Generates the laser beam which forms a latent image on the drum. 2 Collimator lens: Collimates the diffused laser beam emitted from the laser diode to convert it into a cylindrical beam. 3 Cylindrical lens: Shapes the collimated laser beam to suit the printing resolution.
  • Page 267 The dimensions of the laser beam are as shown in Figure 2-1-11. Less than 100 µm Less than 85 µm Figure 2-1-11 Scanning in the main direction is provided by the rotating polygon mirror, while scanning in the auxiliary direction is provided by the rotating drum, forming a static latent image on the drum.

  • Page 268: Developing Section

    2-1-4 Developing section The developing section consists of the developing unit and the toner container. The developing unit consists of the developing roller where a magnetic brush is formed, the doctor blade and the developing spirals that agitate the toner. When the toner sensor (TNS) detects a low toner level in the developing unit, the toner replenishment signal is output to the main PCB (MPCB).

  • Page 269: Formation Of Magnetic Brush

    (1) Formation of magnetic brush The developing roller consists of a magnet roller with four poles and a sleeve roller. Rotation of the sleeve roller around the magnet roller entrains toner, which in turn forms a magnetic brush at pole N1 on the magnet roller. The height of the magnetic brush is regulated by the doctor blade;...

  • Page 270: Computing The Absolute Humidity

    (2) Computing the absolute humidity The humidity sensor (HUMSENS) converts the relative humidity detected by the humidity sensing element into a voltage and sends it to the main PCB (MPCB). The main PCB (MPCB) computes the absolute humidity based on this HUMSENS signal and the temperature (ETTH signal) detected by the external temperature thermistor (ETTH).

  • Page 271: Single Component Developing System

    (3) Single component developing system This machine uses the single component developing system, and reversal processing is performed with a + charged drum (a-Si) and a + charged magnetic toner. With the single component developing system, toner is electrically charged by friction with the developing sleeve and + charged when it passes through the magnetic doctor blade.
  • Page 272 Developing bias parameters For the bias to the developing sleeve, an alternating current (AC) is applied. Parameters for the developing bias are shown below. Duty Vp-p: Difference between the maximum and the minimum of applied voltage 1.72 kV (fixed) Vf: Frequency Typically 2.6 kHz.

  • Page 273: Transfer And Separation Sections

    2-1-5 Transfer and separation sections The transfer and separation section consists mainly of the transfer roller, separation electrode and drum separation claws. A high voltage generated by the high-voltage transformer PCB (HVTPCB) is applied to the transfer roller for transfer charging (100 µA).
  • Page 274 Image ready Secondary paper Secondary paper feed end feed start 48 ms 124 ms 190 ms 323 ms TC REM SC REM 1 ms 1 ms Timing chart 2-1-5 Transfer and separation sections operation a: 190 ms after the registration clutch (RCL) turns on to start secondary paper feed, transfer charging (TC REM) starts. b: 1 ms after transfer charging (TC REM) starts, separation bias (SC REM) turns on.

  • Page 275: Cleaning And Charge Erasing Sections

    2-1-6 Cleaning and charge erasing sections The cleaning section consists of the cleaning blade that removes residual toner from the drum surface after the transfer process, and the cleaning spiral that carries the residual toner back to the waste toner tank. The cleaning lamp (CL) consists of LEDs and removes residual charge on the drum before main charging.

  • Page 276: Fixing Section

    2-1-7 Fixing section The fixing section consists of the parts shown in Figure 2-1-22. When paper reaches the fixing section after the transfer process, it passes between the press roller and heat roller, which is heated by fixing heaters M or S (FH-M or FH-S). Pressure is applied by the fixing unit pressure springs so that the toner on the paper is melted, fused and fixed onto the paper.
  • Page 277 Fixing temperature 165°C/329°F (secondary stabilization) Fixing temperature 110°C/230°F Copying enabled Aging end (primary stabilization) 500 ms FH-M 13 s 500 ms FH-S 30 s 100 ms DB REM 900 ms Half speed Full speed Half speed 15 s (for second speed) Full speed (for first speed) 10 s...

  • Page 278: Eject And Switchback Sections

    2-1-8 Eject and switchback sections The eject and switchback sections eject paper on which fixing has ended with the eject roller that is rotated by forward rotation of the eject motor. In duplex copying, paper is turned over by reverse rotation of the eject motor. When paper is transferred to the job separator or the internal finisher, the feedshift solenoid (FSSOL) is turned on to activate the feedshift guide to switch the paper transfer path.
  • Page 279 Secondary paper feed end Rev. rotation Fwd. rotation Fwd. rotation 50 ms 50 ms 40 ms 518 ms FSSW Timing chart 2-1-7 Eject and switchback sections operation a: The leading edge of paper (front face) turns on the eject switch (ESW), and at the same time the eject motor (EM) starts forward rotation.

  • Page 280: Electrical Parts Layout

    2-2-1 Electrical parts layout (1) PCBs Machine front Machine inside Machine rear Figure 2-2-1 PCBs 1. Main PCB (MPCB) ........Controls the other PCBs, electrical components and optional devices. 2. Power source PCB (PSPCB) ....... Generates +24 V DC, 12 V DC and 5V DC; controls the fixing heater. 3.

  • Page 281: Switches And Sensors

    (2) Switches and sensors Machine front Machine inside Machine rear Figure 2-2-2 Switches and sensors 1. Main switch (MSW) ........Turns the AC power on and off. 2. Interlock switch (ILSW) ........ Turns the AC power for the fixing heater on and off. 3.
  • Page 282 15. Bypass paper size width switch (BYPPWSW) ..........Detects the width of paper on the bypass tray. 16. Feed switch 1 (FSW1) ......... Controls feed clutch 1 drive timing. 17. Feed switch 2 (FSW2) ......... Controls feed clutch 2 drive timing 18.

  • Page 283: Motors

    (3) Motors 12,13,14 Machine front Machine inside Machine rear Figure 2-2-3 Motors 1. Drive motor (DM) ......... Drives the machine. 2. Paper feed motor (PFM) ......Drives paper feed section. 3. Upper lift motor (LM-U) ........ Drives upper drawer lift. 4.

  • Page 284: Other Electrical Components

    (4) Other electrical components 13 14 Machine front Machine inside Machine rear Figure 2-2-4 Other electrical components 1. Upper paper feed clutch (PFCL-U) ....Primary paper feed from the upper drawer. 2. Lower paper feed clutch (PFCL-L) ....Primary paper feed from the lower drawer. 3.

  • Page 285: Power Source Pcb

    2-3-1 Power source PCB Power source PCB Rectifier circuit D101 AC input 24 V DC D102 C101 24 V DC C102 output circuit 5 V DC Zero-cross circuit 5 V DC output C201 circuit Switching control circuit Fixing heater Overvoltage control circuit detection circuit IC201...
  • Page 286 100V C212 L202 T5A 250V Q120 F203 +5VADJ L203 TRA2 BEA1 IC201 CN5 1 D201 TRA1 R204 IC101 H15A 250V BEA4 Q1 F2 T10A 125V VR101 C130 T10A 125V C302 C201 C131 BEA101 C107 L103 C104 BEA104 T2.5A 125V C106 C102 NTC2 BEA103...
  • Page 287 Terminals (CN) Voltage Remarks TB-1 TB-2 120V AC 120 V AC supply, input TB-1 TB-2 220-240 V AC 220-240 V AC supply, input 24 V DC 24 V DC supply for SSW1, output 5 V DC 5 V DC supply for MPCB, output 24 V DC 24 V DC supply for MPCB, output 0 - 5 V DC...

  • Page 288: Main Pcb

    2-3-2 Main PCB Main PCB Scan signal Operation unit Operation Detection signal input unit PCB Operation LCD display data controller FLASH U29, 34 Address bus Compact Operation unit Flash Data bus Fax transmission/ reception data Fax board* converter U17,18 Analog image data SDRAM S/H IC CCD PCB...
  • Page 289 The main PCB (MPCB) consists of the main CPU and operation unit CPU. The main CPU U8 communicates with other PCBs, the image processing system and the engine drive system. The operation unit CPU U26 controls the LCD display and the entire operation section. The main CPU U8 operates on an 8-bit bus.
  • Page 290 CN34 CN37 CN32 CN33 CN41 CN42 CN38 CN46 CN31 CN50 CN44 CN43 CN14 CN15 CN45 CN13 CN12 CN35 CN16 CN10 CN11 Figure 2-3-4 Main PCB silk-screen diagram 2-3-6...
  • Page 291 Terminals (CN) Voltage Remarks 0/5 V DC SLEEP signal, output 0/5 V DC CFM5 remote signal, output 0/5 V DC (pulse) Zero-cross signal, input 5 V DC 5V DC supply for PSPCB, output 0/5 V DC FH-M on/off, output 0/5 V DC FH-S on/off, output 0 - 5 V DC Heater current monitor signal, input...
  • Page 292 Terminals (CN) Voltage Remarks 0/5 V DC LSU VIDEO - signal, output 0/5 V DC LSU PD signal, input 8-10 8-11 24 V DC 24 V DC supply for PM, output 8-12 8-11 0/24 V DC PM SCAN signal, output 8-13 0/5 V DC PM READY signal, input...
  • Page 293 Terminals (CN) Voltage Remarks 13-A5 13-A16 0/24 V DC FCL3 on/off, output 13-A7 13-A6 0/5 V DC FSW2 on/off, input 13-A8 13-A6 5 V DC 5 V DC supply for FSW2, output 13-A10 13-A9 0/5 V DC SCSW on/off, input 13-A11 13-A16 24 V DC...
  • Page 294 Terminals (CN) Voltage Remarks 32-4 0/5 V DC OCM* ENABLE signal, output 32-5 0/5 V DC OCM* RET signal, output 32-6 0/5 V DC (pulse) OCM* CLOCK signal, output 32-7 0/5 V DC OCM* CWB signal, output 32-8 OCM* current control voltage Vref, output 32-9 0/5 V DC OCM* drive control signal M3, output...
  • Page 295 Terminals (CN) Voltage Remarks 36-9 42-B4 0/5 V DC (pulse) OPCB-L SCAN2 signal, output 36-10 42-B4 0/5 V DC (pulse) OPCB-L SCAN1 signal, output 36-11 42-B4 0/5 V DC OPCB-L DIGKEY3 signal, input 36-12 42-B4 0/5 V DC OPCB-L DIGKEY2 signal, input 36-13 42-B4 0/5 V DC...
  • Page 296 Terminals (CN) Voltage Remarks 43-A6 43-A2 5/0 V DC (pulse) Printer board* SO signal, input 43-A7 43-A2 5/0 V DC (pulse) Printer board* RESET signal, output 43-A8 43-A2 5/0 V DC (pulse) Printer board* PDOUT signal, output 43-A10 43-A2 5/0 V DC (pulse) Printer board* VDATAP signal, input 43-A12 43-A2...

  • Page 297: Operation Unit Pcb

    2-3-3 Operation unit PCB Operation unit right PCB DIGKEY4 KEY1 KEY2 KEY3 KEY4 CN3-1 DIGKEY5 KEY5 KEY6 KEY7 KEY8 CN3-2 KEY9 KEY10 KEY11 DIGKEY6 KEY12 CN3-3 DIGKEY7 KEY13 KEY14 KEY15 KEY16 CN3-4 DIGKEY8 KEY17 KEY18 KEY19 KEY20 CN3-5 KEY21 KEY22 DIGKEY9 CN3-6 SCAN5...
  • Page 298 The operation unit PCB (OPCB) consists of the operation unit left PCB (OPCB-L) and the operation unit right PCB (OPCB- The operation unit right PCB (OPCB-R) consists of key switches and LEDs. The lighting of LEDs is determined by scan signals (SCAN5 to SCAN8) and LED lighting selection signals (DIGLED7 to DIGLED8) from the main PCB (MPCB).
  • Page 299 Figure 2-3-6 Operation unit right PCB silk-screen diagram C111 C110 B100 C100 C101 L11 K27 Figure 2-3-7 Operation unit left PCB silk-screen diagram 2-3-15...
  • Page 300 Terminals (CN) Voltage Remarks 3-14 0/5 V DC OPCB-L DIGKEY1 signal, output 3-14 0/5 V DC OPCB-L DIGKEY2 signal, output 3-14 0/5 V DC OPCB-L DIGKEY3 signal, output 3-14 0/5 V DC (pulse) OPCB-L SCAN1 signal, input 3-14 0/5 V DC (pulse) OPCB-L SCAN2 signal, input 3-14 0/5 V DC (pulse)
  • Page 301 Terminals (CN) Voltage Remarks 3-14 0/5 V DC LCD DISPLAY signal, output 3-14 0/5 V DC (pulse) LCD D0 data, output 5-10 3-14 0/5 V DC (pulse) LCD D1 data, output 5-11 3-14 0/5 V DC (pulse) LCD D2 data, output 5-12 3-14 0/5 V DC (pulse)

  • Page 302: Scanner Drive Pcb

    2-3-4 Scanner drive PCB SDPCB SM Vref SM A SM M1 SM _A SM M2 SM B SM M3 SM _B SM M4 Stepping motor SM M5 driver SM CLK SM CWB MPCB SM RET SM ENABLE EL ON REM INPCB ODSW ODSW...
  • Page 303 C115 C111 JP102 C114 C110 C117 C112 E C B JP11 Figure 2-3-9 Scanner drive motor PCB silk-screen diagram Terminals (CN) Voltage Remarks 0/5 V DC SHPSW on/off, output 0/5 V DC EL on/off, input 0/5 V DC SM ENABLE signal, input 0/5 V DC SM RET signal, input 0/5 V DC...

  • Page 304: Ccd Pcb

    2-3-5 CCD PCB CCD PCB Clock driver Differential IC1, 4 receiver Main PCB SHIFT SHIFT Transistor Q2 Even Even Transistor Q1 Figure 2-3-10 CCD PCB block diagram The CCD PCB (CCDPCB) is equipped with a CCD sensor IC2 for original scanning. The clock signals (CLK, RS, CLP, and SHIFT) for driving the CCD sensor (IC2) are sent as differential signals from the main PCB (MPCB), reconstructed to normal signals by the differential receiver (IC3), and then input to the CCD sensor (IC2) via the clock driver (IC1 and IC4).
  • Page 305 Figure 2-3-11 CCD PCB silk-screen diagram Terminals (CN) Voltage Remarks 0/5 V DC (pulse) CCDPCB RS – signal, input 0/5 V DC (pulse) CCDPCB RS + signal, input 0/5 V DC (pulse) CCDPCB CLOCK – signal, input 0/5 V DC (pulse) CCDPCB CLOCK + signal, input 0/5 V DC (pulse) CCDPCB SHIFT signal, input...
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  • Page 320: Maintenance Parts List

    Maintenance parts list Maintenance part name Part No. Fig. No. Ref. No. Name used in service manual Name used in parts list Upper/lower paper feed pulley PULLEY, PAPER FEED 2AR07220 Upper/lower separation pulley PULLEY, SEPARATION 2AR07230 Upper/lower fowarding pulley PULLEY, LEADING FEED 2AR07240 Bypass paper feed pulley UPPER PULLEY, BYPASS...

  • Page 321: Periodic Maintenance Procedures

    Periodic maintenance procedures Maintenance Section Method Maintenance cycle Points and cautions Page part/location Test copy and Perform at the maximum Test copy Every service test print copy size Maintenance Section Method Maintenance cycle Points and cautions Page part/location Paper feed Upper/lower paper feed Replace Every service...
  • Page 322 Maintenance Section Method Maintenance cycle Points and cautions Page part/location Transfer/ Transfer roller unit Replace Every service Replace. 1-6-35 separation section Maintenance Section Method Maintenance cycle Points and cautions Page part/location Developing Developing unit Replace Every service Replace. 1-6-34 section Maintenance Section Method...

  • Page 323: Optional Devices Supplied Parts List

    Optional devices supplied parts list Paper feed desk Name used in service manual Name used in installation guide Part No. Retainer Retainer 3AT02150 74315200 CVM4 × 06 cross-head chromate binding screw Cross-head chromate binding screw, CVM4 × 06 B1004060 Stay Stay 3AT02250 M4 ×...
  • Page 324 Scanning System Name used in service manual Name used in installation guide Part No. RTC board RTC board 3CS01010 Sccaner board Sccaner board 3B301010 CD-ROM (scanner) CD-ROM (scanner) 3B327010 CD-ROM (document processing) CD-ROM (document processing) 3BJ27060 Duplex unit Name used in service manual Name used in installation guide Part No.

  • Page 325: General Wiring Diagram

    General wiring diagram C114 C25-12 GY RESET CFM5 C25-11 GY SET SIG C25-10 GY C25-9 GY C25-8 GY C103 C25-7 GY C29-B10 YW C25-6 GY 5V(200Ω) C29-B11 YW BYPPLSW C25-5 GY BYPPLSW C29-B12 YW C25-4 GY (Optional for 120V spec. C25-3 GY C104 and 220-240V spec.)
  • Page 326 Olaf Helsetsvei 6, NO 0694 Oslo CORPORATION Phone: (22) 62 73 00 2-28, 1-chome, Tamatsukuri, Chuo-ku Osaka 540-8585, Japan Phone: (06) 6764-3555 ©2002 KYOCERA MITA CORPORATION is a trademark of Kyocera Corporation is a registered trademark of KYOCERA MITA CORPORATION Printed in Holland...

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