WARNING INDICATIONS ON THE MACHINE ............S-17 MEASURES TO TAKE IN CASE OF AN ACCIDENT ............S-19 Composition of the service manual ................. C-1 Notation of the service manual ..................C-2 bizhub 164 Main body OUTLINE ........................1 MAINTENANCE......................7 ADJUSTMENT/SETTING ..................... 69 TROUBLESHOOTING ....................
IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
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SAFETY AND IMPORTANT WARNING ITEMS [2] POWER PLUG SELECTION In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.
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SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
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SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • When using the power cord set (inlet type) that came with this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly.
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SAFETY AND IMPORTANT WARNING ITEMS Wiring WARNING • Never use multi-plug adapters to plug multiple power cords in the same outlet. If used, the risk of fire exists. • When an extension cord is required, use a specified one. Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire.
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SAFETY AND IMPORTANT WARNING ITEMS Ventilation CAUTION • The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
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SAFETY AND IMPORTANT WARNING ITEMS Inspection before Servicing CAUTION • Do not leave the machine unattended during transporta- tion, installation, and inspection of the machine. If it is to be unavoidably left unattended, face protrusions toward the wall or take other necessary risk reducing action. The user may stumble over a protrusion of the machine or be caught by a cable, falling to the floor or being injured.
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SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • When mounting an option on the machine, be careful about the clearance between the machine and the option. You may be injured with your finger or hand pinched between the machine and the option. •...
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SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected. The laser light can enter your eye, leading to a risk of loss of eyesight.
SAFETY AND IMPORTANT WARNING ITEMS Handling of Consumables WARNING • Toner and developer are not harmful substances, but care must be taken not to breathe excessive amounts or let the substances come into contact with eyes, etc. It may be stimulative.
SAFETY AND IMPORTANT WARNING ITEMS [4] Laser Safety • This is a digital machine certified as a Class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual.
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SAFETY AND IMPORTANT WARNING ITEMS All Areas CAUTION • Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. semiconductor laser Maximum power of the laser diode 7 mW Wavelength 770 - 800 nm Denmark...
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SAFETY AND IMPORTANT WARNING ITEMS VARO! • Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättomälle laser- säteilylle. Älä katso säteeseen. VARNING! • Osynlig laserstråining när denna del är öppnad och spärren är urkopplad. Betrakta ej stråien. Norway ADVERSEL • Dersom apparatet brukes på annen måte enn spesifisert i denne bruksanvisn- ing, kan brukeren utsettes för unsynlig laserstrålning, som overskrider grensen for laser klass 1.
SAFETY AND IMPORTANT WARNING ITEMS Laser Safety Label • A laser safety label is attached to the inside of the machine as shown below. A0XXP0E501DA S-15...
SAFETY AND IMPORTANT WARNING ITEMS Laser Caution Label • A laser caution label is attached to the outside of the machine as shown below. A0XXP0E502DA PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT • When laser protective goggles are to be used, select ones with a lens conforming to the above specifications.
SAFETY AND IMPORTANT WARNING ITEMS WARNING INDICATIONS ON THE MACHINE Caution labels shown below are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. CAUTION •...
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SAFETY AND IMPORTANT WARNING ITEMS High voltage • This area generates high voltage. Be careful not to touch here when the power is turned ON to avoid getting an electric shock. High voltage • This area generates high voltage. Be careful not to touch here when the power is turned ON to avoid getting an electric shock.
MEASURES TO TAKE IN CASE OF AN ACCIDENT MEASURES TO TAKE IN CASE OF AN ACCIDENT 1. If an accident has occurred, the distributor who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.
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MEASURES TO TAKE IN CASE OF AN ACCIDENT Blank Page S-20...
Composition of the service manual This service manual consists of Theory of Operation section and Field Service section to explain the main machine and its corresponding options. Theory of Operation section gives, as information for the CE to get a full understanding of the product, a rough outline of the object and role of each function, the relationship between the electrical system and the mechanical system, and the timing of operation of each part.
Notation of the service manual A. Product name In this manual, each of the products is described as follows: (1) bizhub 164 Main body (2) Microsoft Windows NT 4.0: Windows NT 4.0 or Windows NT Microsoft Windows 2000: Windows 2000...
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SERVICE MANUAL FIELD SERVICE 2010.06 Ver. 2.0...
Revision history After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
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Field Service Ver. 2.0 Jun. 2010 CONTENTS bizhub 164 Main body OUTLINE SYSTEM CONFIGURATION................... 1 PRODUCT SPECIFICATIONS ................2 Type ........................2 Functions ......................2 Paper ........................3 Materials ....................... 3 Print volume......................4 Machine specifications..................4 Operating environment ..................4 Print function......................
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Field Service Ver. 2.0 Jun. 2010 4.1.9 Cleaning of the developer scattering prevention plate ........ 23 Conveyance section ................... 25 4.2.1 Cleaning of the timing roller ................ 25 4.2.2 Cleaning of the pre-image transfer guide plate........... 25 Fusing section ....................27 4.3.1 Replacing the fusing unit ................
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Field Service Ver. 2.0 Jun. 2010 5.4.26 Main motor (M1)..................54 5.4.27 Toner supply motor (M2) ................55 5.4.28 Scanner motor (M4) ..................56 5.4.29 DC power supply fan motor (FM5) .............. 57 5.4.30 Registration clutch (CL1) ................58 5.4.31 Tray1 paper feed clutch (CL2) ..............
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Field Service Ver. 2.0 Jun. 2010 9.3.8 LANGUAGE ....................73 CUSTOM SIZE MEMORY .................. 74 USER MANAGEMENT..................74 9.5.1 DRUM DEHUMIDIFY.................. 74 JOB SETTING ....................74 9.6.1 TRAY PRIORITY..................74 9.6.2 TRAY1 PAPER.................... 75 9.6.3 BYPASS PAPER ..................75 9.6.4 PRINT PRIORITY ..................
(Values in conditions of paper fed from tray 1 at a room temperature of 23°C and with a rated power source) Processing speed 77 mm/s Copying/printing speed for bizhub 164 16 sheets/min. (Plain paper) multi-copy cycle 7 sheets/min. (Card1/2) (A4, 8...
Field Service Ver. 2.0 Jun. 2010 2. PRODUCT SPECIFICATIONS Fixed zoom ratios Europe, china Full size: x 1.00 Reduction: x 0.50, x 0.70, x 0.81 Enlargement: x 1.15, x 1.41, x 2.00 Latin america Full size: x 1.00 areas for inch Reduction: x 0.50, x 0.64, x 0.78 Enlargement: x 1.21, x 1.29, x 2.000 Latin america...
2. PRODUCT SPECIFICATIONS Field Service Ver. 2.0 Jun. 2010 Print volume A. bizhub 164 China Average 2,300 prints/month Maximum 12,000 prints/month Non- China Average 1,700 prints/month Maximum 12,000 prints/month Machine specifications Power requirements Voltage AC110 V, AC120-127V, AC220-240V Current 110 V...
Field Service Ver. 2.0 Jun. 2010 2. PRODUCT SPECIFICATIONS Print function Type Built-in printer controller 32 MB (shared with the copier) Interface USB2.0/1.1 Printer language Print resolution 600 x 600 dpi Supported OS for printer Windows 2000 Professional (SP4 or later) driver Windows 2000 Server (SP3 or later) Windows XP Home Edition (SP1 or later)
2. PRODUCT SPECIFICATIONS Field Service Ver. 2.0 Jun. 2010 Scan function Scanner Scannable range Same as the copier Scanning 150/300/600 dpi resolution TWAIN Driver TWAIN Driver Supported OS Windows 2000 Professional (SP4 or later) Windows 2000 Server (SP3 or later) Windows XP Home Edition (SP1 or later) Windows XP Professional (SP1 or later) Windows Server 2003, Standard Edition (SP1 or later)
Field Service Ver. 2.0 Jun. 2010 3. PERIODICAL MIANTENANCE ITEMS MAINTENANCE PERIODICAL MIANTENANCE ITEMS Concept of periodical maintenance • The cleaning or replacement cycle of the parts of the machine and options that need periodical maintenance depends on the total counter value or each counter value provided by [SERVICE MODE] - [COUNTER] - [PM COUNTER].
• Maintenance conditions are based on the case of A4 or 8 x 11, standard mode* and low power mode OFF. * Standard mode bizhub 164 2 pages per job 3.2.1 Main body Descrip Ref.
*3: When the count reaches the maximum life value, printing is not allowed. 3.4.2 Conditions for life specifications values Item Description Copying type 2P/J Paper size A4 or 8 x 11 Average 2,300 (China) / 1,700 (Others except for China) PV/M bizhub 164 Maximum 12,000 Original density B/W 6%...
4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 PERIODICAL MAINTENANCE PROCEDURE NOTE • The alcohol described in the cleaning procedure of maintenance represents the isopropyl alcohol. Processing section 4.1.1 Replacing the developer A. Periodically replacing parts/cycle • Developer: Every 55,000 counts B.
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Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE 4. Remove two screws [1] in the rear of the imaging unit. 5. Remove three screws [2] at the front of the imaging unit. 6. While slightly pulling the area below the drum (diagonally shaded area) in the direction of arrow, separate the drum unit [3] from the developing unit...
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4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 10. While turning the drum [1] in the direction of the arrow, dump the remaining toner from the screw. NOTE • Toner that has caked in the drum unit should be dumped out. So, first lightly tap the drum unit against a table or similar object several times.
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Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE 14. Tilt the developing unit as shown in the illustration. While turning the gear [1] in the direction of the arrow, dump the developer [2]. NOTE • Make sure that the magnet roller [3] is placed on the upper side of the developing unit when dumping the developer [2].
4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 4.1.2 Replacing the drum A. Periodically replacing parts/cycle • Drum: Every 55,000 counts B. Procedure 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3. Release the tabs [1] and disconnect the connector [2] from the imaging unit.
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Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE 7. Place the drum unit [1] as shown in the illustration. NOTE • Developer can spill from the portion [2] shown in the illustration. Place the drum unit on a sheet of paper to prevent developer from making the site dirty.
4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 4.1.3 Replacing the drum charge corona assy A. Periodically replacing parts/cycle • Drum charge corona assy: Every 55,000 counts B. Procedure 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3.
Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE 4.1.5 Application of toner NOTE • Perform these steps when the drum and/or cleaning blade have been replaced. 1. With the imaging unit divided into the drum assy and developing assy, install the drum positioning jig [1] in the rear of the drum assy.
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4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 3. Hold both ends [1] of the drum with your both hands and turn the drum a half turn in the direction of the arrow. A09AF2C507DA 4. Using a brush, apply a light coat of toner to the surface of the cleaning blade [1].
Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE 4.1.6 Replacing the toner bottle A. Periodically replacing parts/cycle • Toner bottle (TN116): Every 11,000 prints B. Procedure NOTE • Do not install or remove the toner bottle while the imaging unit is not installed. Doing so can cause a toner spill.
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4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 7. Insert the toner bottle [1] into the machine. NOTE • Align the tip of the knob of the toner bottle with the mark of ▼ [2] indi- cated on the machine as shown in the illustration.
Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE 4.1.7 Cleaning of the Ds collars A. Periodically cleaning parts/cycle • Ds collars: Every 55,000 counts B. Procedure 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3.
4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 7. Using a cleaning pad with alcohol, wipe the two Ds collars [1] clean of dirt. A0XXF2E009DA 8. To reinstall, reverse the order of removal. 4.1.8 Cleaning of the drum separator fingers A.
Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE 4.1.9 Cleaning of the developer scattering prevention plate A. Periodically cleaning parts/cycle • Developer scattering prevention plate: Every 55,000 counts B. Procedure 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3.
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4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 7. Remove three screws [1], and remove the developer scattering pre- vention plate [2]. NOTE • When securing the developer scat- tering prevention plate, tighten screws in the order of one on one edge (a), one at the center (b), and one on the other edge (c).
Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE Conveyance section 4.2.1 Cleaning of the timing roller A. Periodically cleaning parts/cycle • Timing roller: Every 55,000 counts B. Procedure 1. Open the right door. 2. Using a cleaning pad dampened with alcohol, wipe the timing roller [1] clean of dirt.
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4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 4. Remove two screws [1] in the rear of the imaging unit. 5. Remove three screws [2] at the front of the imaging unit. 6. While slightly pulling the area below the drum (diagonally shaded area) in the direction of arrow, separate the drum unit [3] from the developing unit...
Field Service Ver. 2.0 Jun. 2010 4. PERIODICAL MAINTENANCE PROCEDURE Fusing section 4.3.1 Replacing the fusing unit CAUTION • The temperature gets high in the vicinity of the fusing unit. You may get burned when you come into contact with the area. Before replacement operations, make sure that more than 20 minutes have elapsed since the main and sub power switches were turned off.
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4. PERIODICAL MAINTENANCE PROCEDURE Field Service Ver. 2.0 Jun. 2010 8. Open the right door [1]. 9. Open the fusing unit cover [2]. A0XXF2E517DA 10. Remove the screw [1], and remove the front side cover [2]. A0XXF2E016DA 11. Remove the screw [1], and remove the rear side cover [2].
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS OTHER MAINTENANCE ITEMS Disassembly/adjustment prohibited items A. Paint-locked screws NOTE • To prevent loose screws, a screw lock in blue or green series color is applied to the screws. • The screw lock is applied to the screws that may get loose due to the vibrations and loads created by the use of machine or due to the vibrations created during transportation.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 F. Precautions during setup or transportation • Whenever mounting an option on the machine, be attentive to the motion of the fellow worker of the joint work. The fellow worker may be injured with his or her finger or hand pinched between the machine and the option.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS Disassembly/reassembly parts list Section Part name Ref. page Exterior parts Front door P.32 Front cover P.33 Left cover P.33 Rear right cover/1 P.34 Rear right cover/2 P.34 Rear cover P.34 Scanner right cover P.35 Scanner rear cover...
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 Cleaning parts list Section Part name Ref. page Tray 1 feed roller P.61 Tray 1 Tray 1 Separation pad P.61 Scanner section Original glass P.62 Multi bypass tray separation roller P.62 Manual bypass tray Multi bypass tray feed roller...
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.2 Front cover 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3. Open the front door. 4. Slide out the tray 1. 5. Remove seven screws [1], and remove the front cover [2].
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.4 Rear right cover/1, Rear right cover/2 1. Remove the screw [1], and remove the rear right cover/1 (lower) [2]. NOTE • If the multi bypass tray is installed, remove two screws [3]. •...
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.6 Scanner right cover 1. Remove two screws [1], and remove the scanner right cover [2]. NOTE • While releasing the tab [3], remove the cover as shown in the illustra- tion.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.8 Paper exit tray (left) / Paper exit tray (right) 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3. Remove the front cover. See P.33 4.
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Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 9. Remove two screws [1], and remove the paper exit tray (left) [2]. NOTE • When reinstalling the paper exit tray (left), make sure that the rib [3] of the paper exit tray (left) sits on the top of the left rear cover [4].
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.9 Original glass 1. Remove the left cover. See P.33 2. Remove the scanner right cover. See P.35 3. Remove the operation panel. See P.39 4. Remove the rear cover. See P.34 5.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.10 Operation panel 1. Remove the scanner right cover. See P.35 2. Unlock two tabs [1]. 3. Disconnect the flat cable [2], and remove the operation panel [3]. A0XXF2E523DA 4. To reinstall, reverse the order of removal. 5.4.11 Tray 1 1.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.12 Multi bypass tray 1. Remove the rear right cover/1. See P.34 2. Remove the screw [1], and remove the cover [2]. A0XXF2E510DA 3. Remove the harness from the wire saddle [1].
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.13 Imaging unit 1. Open the right door. 2. Open the front door. 3. Remove the toner bottle. See P.19 NOTE • Do not install or remove the toner bottle while the imaging unit is not installed. Doing so can cause a toner spill.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.14 PH unit CAUTION • Do not replace the printer head unit while the power is ON. Laser beam generated during the above mentioned activity may cause blindness. • Do not disassemble or adjust the printer head unit. Laser beam generated during the above mentioned activity may cause blindness.
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Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 11. Disconnect the flat cable (P001) [1] and the connector (P002) [2]. A0XXF2E028DA 12. Remove the screw [1] and the bracket [2]. A0XXF2E029DA 13. Pull out the flat cable [1] and the har- ness [2], and remove the PH unit [3].
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.15 CIS module (CIS) 1. Remove the original glass. See P.38 2. Remove the screw [1], and remove the cover [2]. A0XXF2E031DA 3. Disconnect the connector (P102) [1] on the printer control board. 4.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.16 Transfer roller unit 1. Open the right door. 2. Remove the transfer roller unit [1] as shown in the illustration. NOTE • Indentations or dirt on the surface of the image transfer roller adversely affect the printed image.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.17 Scanner unit 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3. Remove the front cover. See P.33 4. Remove the left cover. See P.33 5.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.18 Printer control board (PRCB) 1. Remove the rear cover. See P.34 2. Remove the scanner rear cover. See P.35 3. Disconnect all connectors from the printer control board. 4. Remove five screws [1], and remove the printer control board [2].
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.19 High voltage unit (HV1) 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3. Remove the front cover. See P.33 4. Remove the paper exit tray (left) and paper exit tray (right). See P.36 5.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.20 DC power supply (DCPU) 1. Remove the rear cover. See P.34 2. Disconnect all connectors from the DC power supply. 3. Remove three screws [1] and two card spacers [2], and remove the DC power supply [3].
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 6. Snap off the E-ring [1], and remove the tray1 feed roller [2]. A0XXF2E042DA 7. To reinstall, reverse the order of removal. 8. Turn ON the power switch. 9. Select [SERVICE MODE] - [CLEAR DATA] - [PM COUNTER] and clear the counter value of [TRAY1].
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.23 Ozone filter 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3. Remove the drum. See P.14 4. Remove the drum charge corona assy. See P.16 5.
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5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 4. Remove two E-rings [1] and two bearings [2]. 5. Remove the multi bypass tray feed roller assy [3]. A0XXF2E046DA 6. While releasing the tab [1], remove the collar [2]. NOTE •...
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.25 Multi bypass tray separation roller assy 1. Remove the multi bypass tray. See P.40 2. Remove the screw [1]. 3. Remove the fixed sheet metal [2] and the spring [3]. A0XXF2E047DA 4.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.26 Main motor (M1) 1. Remove the rear cover. See P.34 2. Disconnect the connector (CN2) [1] on the DC power supply. 3. Remove the harness from the har- ness guide [2]. A0XXF2E015DA 4.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5.4.27 Toner supply motor (M2) 1. Remove the toner bottle. See P.19 2. Remove the imaging unit. See P.41 3. Remove the front cover. See P.33 4. Remove the paper exit tray (left) and paper exit tray (right). See P.36 5.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.28 Scanner motor (M4) 1. Remove the original glass See P.38 2. Remove the screw [1], and remove the cover [2]. A0XXF2E031DA 3. Disconnect the connector (P101) [1] on the printer control board. 4.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 6. Remove the belt [1]. 7. Remove three screws [2], and remove the scanner motor assy [3]. A0XXF2E056DA 8. Remove two screws [1], and remove the scanner motor [2]. A0XXF2E057DA 9.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 2. Disconnect the connector [1]. 3. Remove two screws [2], and remove the DC power supply fan motor [3]. A0XXF2E059DA 4. To reinstall, reverse the order of removal. 5.4.30 Registration clutch (CL1) 1.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS 5. Disconnect the connector [1], and remove the tray paper feed clutch [2]. A0XXF2E062DA 6. To reinstall, reverse the order of removal. 5.4.32 Bypass paper feed clutch (CL3) 1. Remove the multi bypass tray. See P.40 2.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.4.33 Bypass pick-up solenoid (SD1) 1. Remove the multi bypass tray. See P.40 2. Remove three screws [1], and remove the fixed sheet metal [2]. A0XXF2E063DA 3. Disconnect the connector [1]. 4.
Field Service Ver. 2.0 Jun. 2010 5. OTHER MAINTENANCE ITEMS Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the ethanol isopropyl alcohol. 5.5.1 Tray 1 feed roller 1. Slide out the tray 1. 2. Using a cleaning pad dampened with alcohol, wipe the tray 1 feed roller [1] clean of dirt.
5. OTHER MAINTENANCE ITEMS Field Service Ver. 2.0 Jun. 2010 5.5.3 Original glass 1. Using a cleaning pad, wipe the origi- nal glass [1]. A0XXF2E505DA 5.5.4 Multi bypass tray separation roller 1. Remove the multi bypass tray. See P.40 2. Remove the multi bypass tray separation roller assy. See P.53 3.
Field Service Ver. 2.0 Jun. 2010 6. SERVICE TOOL SERVICE TOOL Service material list Name Shape Material No. Remarks Cleaning pad 000V-18-1 10pcs/1pack A02EF2C526DA ⎯ Isopropyl alcohol A00KF2C506DA CE tool list Tool name Shape Quantity Parts No. Remarks PC positioning jig 4021 4362 ## 4034F2C504DA...
7. FIRMWARE REWRITING Field Service Ver. 2.0 Jun. 2010 FIRMWARE REWRITING Outline • Two types of firmware rewrite, the controller firmware rewrite and the engine firmware rewrite, are available. Both types of firmware rewrite need connecting the PC to the machine with the USB cable and starting the dedicated updater on the PC.
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Field Service Ver. 2.0 Jun. 2010 7. FIRMWARE REWRITING <Engine F/W> <Controller F/W> FIRMWARE UPDATE FIRMWARE UPDATE PLEASE WAITING PLEASE WAITING CHECK SUM CHECK SUM FIRMWARE UPDATE FIRMWARE UPDATE PLEASE WAITING PLEASE WAITING UPDATE M/C F/W UPDATE COPIER F/W FIRMWARE UPDATE FIRMWARE UPDATE FIRMWARE UPDATE PROGRAM TRANSFER...
7. FIRMWARE REWRITING Field Service Ver. 2.0 Jun. 2010 Procedure when upgrading the firmware has failed NOTE • Perform the following procedure only when upgrading from PC using ordinary USB connection has failed and the machine has not started properly. 1.
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Field Service Ver. 2.0 Jun. 2010 7. FIRMWARE REWRITING <Engine F/W> <Controller F/W> FIRMWARE UPDATE FIRMWARE UPDATE PLEASE WAITING PLEASE WAITING CHECK SUM CHECK SUM FIRMWARE UPDATE FIRMWARE UPDATE PLEASE WAITING PLEASE WAITING UPDATE M/C F/W UPDATE COPIER F/W FIRMWARE UPDATE FIRMWARE UPDATE FIRMWARE UPDATE PROGRAM TRANSFER...
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7. FIRMWARE REWRITING Field Service Ver. 2.0 Jun. 2010 Blank Page...
Field Service Ver. 2.0 Jun. 2010 8. HOW TO USE THE ADJUSTMENT SECTION ADJUSTMENT/SETTING HOW TO USE THE ADJUSTMENT SECTION • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. A.
9. UTILITY MODE Field Service Ver. 2.0 Jun. 2010 9.3.4 DENSITY (BOOK) A. Use • To set the reading image density level when the original glass scanning. MODE1: To produce a copy having an image density equivalent to that of the original. MODE2: To lower the image density to prevent a dirty copy from being produced.
Field Service Ver. 2.0 Jun. 2010 9. UTILITY MODE 9.3.8 LANGUAGE A. Use • To select the language displayed on the control panel. • Language selection and default language depends on the [LANGUAGE GROUP] in the SERVICE MODE. B. Procedure •...
9. UTILITY MODE Field Service Ver. 2.0 Jun. 2010 CUSTOM SIZE MEMORY A. Use • To set the custom size paper commonly used. • Up to 2 digits can be set (MEMORY 1/MEMORY 2) • The paper length [X] can be set between 140 mm and 432 mm. The paper width [Y] can be set between 90 mm and 297mm.
Field Service Ver. 2.0 Jun. 2010 9. UTILITY MODE 9.6.2 TRAY1 PAPER A. SIZE (1) Use • To set the paper size loaded in the tray 1. (2) Procedure • The default setting is as follows. Metric area: A4 Inch area: Letter A3/B4/A4S/“A4”/B5S/B5/A5S/A5/FLS/8K/16K S/16K/11x17/Letter S/“Letter”/ Legal/Invoice S/Invoice SIZE INPUT/MEMORY1/MEMORY2...
9. UTILITY MODE Field Service Ver. 2.0 Jun. 2010 B. TYPE (1) Use • To set the media type loaded in the bypass tray. (2) Procedure • The default setting is PLAIN. “PLAIN”/PLAIN-R/CARD1/CARD1-R/CARD2/CARD2-R/ RECYCLE/RECYCLE-R/SPECIAL 9.6.4 PRINT PRIORITY A. Use • Specify whether to give priority to print jobs when the machine receives a print job while printing copies.
Field Service Ver. 2.0 Jun. 2010 9. UTILITY MODE 9.7.2 DENSITY PRIORITY A. Use • To set the priority density that is selected when the power switch is turned ON or the Back/Stop/Reset key is pressed. AUTO : The density level is automatically adjusted. MANUAL : The density level is manually adjusted.
9. UTILITY MODE Field Service Ver. 2.0 Jun. 2010 9.7.5 SORT PRIORITY A. Use • Specify whether to sort copies as they are fed into the output tray. B. Procedure • The default setting is OFF. “OFF”/ON 9.7.6 4IN1 COPY ORDER A.
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Field Service Ver. 2.0 Jun. 2010 9. UTILITY MODE Blank Page...
10. ADJUSTMENT ITEM LIST Field Service Ver. 2.0 Jun. 2010 10. ADJUSTMENT ITEM LIST Tray1 Replacement Part/Service Job Adjustment/Setting Items ID ADJUST VG ADJUST LEADING EDGE SER- TRAILING EDGE VICE’S VERTICAL EDGE CHOICE LOOP Ad. (TRAY1) LOOP Ad. (BYPASS) FUSER TEMP. PRN MAIN PRN SUB CIS MAIN ZOOM...
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Field Service Ver. 2.0 Jun. 2010 10. ADJUSTMENT ITEM LIST ✽ This table shows the list of adjustment items when replacing a part. Items are numbered by the priority if there is any. MB-503 1, 3 *: Check when setting is changed. NOTE •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.1 List of SERVICE MODE SERVICE MODE Ref. page SERVICE’S CHOICE SHIPMENT P.85 POWER SUPPLY P.85 MAINTENANCE COUNT. P.86 IU LIFT STOP MODE P.86 ID ADJUST P.86 VG ADJUST P.87 TRANSFER (PLAIN) P.87...
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Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE SERVICE MODE Ref. page ADJUST CIS SUB REGIST P.106 TCR GAIN P.107 MODEL SETTING P.107 CUSTOMER ID P.107 COUNTER TOTAL COUNTER P.107 SIZE COUNTER P.107 PM COUNTER P.108 MAINTENANCE COUNT. P.108 SUPPLIES COUNTER P.108 APPLICATION COUNT.
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11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 SERVICE MODE Ref. page CLEAR DATA MEMORY CLEAR P.117 TOTAL CLEAR P.118 PM COUNTER P.118 MAINTENANCE COUNT. P.118 SUPPLIES COUNTER P.118 APPLICATION COUNT. P.118 SCAN COUNTER P.118 PAPER SIZE COUNTER P.118 MISFEED COUNTER P.118 TROUBLE COUNTER...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.2 Starting/Exiting 11.2.1 Starting procedure 1. Press the Menu/Select key. 2. Press the following keys in this order. Quick Settings → → → Quick Settings → → 3. The SERVICE MODE menu screen will appear. 11.2.2 Exiting procedure •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.3.3 MAINTENANCE COUNT. A. Use • To enter an appropriate counter value (0 to 999999) as the tentative maintenance time. • Specify the setting on maintenance counter to “1” or “2”: If the maintenance life is reached, the maintenance call (M1) or service call [Call Service (M1)] will appear.
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.3.6 VG ADJUST A. Use • To adjust image density by varying Vg with changing sensitivities as the drum is used for an extended period of time. • Used when image problems (fog, void) occur. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.3.11 FUSER TEMP. (PLAIN) A. Use • To set the temperature of the fusing roller for each type of paper, thereby making up for fusing performance that changes with the operating environment or type of paper. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.3.14 LEADING EDGE A. Use • To adjust the erase width on the leading edge of the image by varying the laser emission timing. • Used when the PH unit has been replaced. B.
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.3.15 TRAILING EDGE A. Use • To adjust the erase width on the trailing edge of the image by varying the laser emission timing. • Used when the PH Unit has been replaced. B.
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.3.17 LOOP Ad. (TRAY1) A. Use • To adjust the length of the loop formed in the paper feed from the tray1 before the syn- chronizing roller. • Used when a skew feed, fold, or misfeed of paper occurs. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.3.20 GDI TIMEOUT A. Use • To specify the time for timeout when data from PC is interrupted during GDI printing. B. Procedure • The default setting is 60 sec. 5 sec/10 sec/20 sec/30 sec/40 sec/50 sec/“60 sec” 11.3.21 ERASER INSTALL •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4 ADJUST 11.4.1 PRN MAIN (TRAY1) A. Use • To adjust by varying the starting position of image writing in the main scanning direction. • Used when the image on the copy deviates in the main scanning direction. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.4.2 PRN MAIN (BYPASS) A. Use • To adjust by varying the starting position of image writing in the main scanning direction. • Used when the image on the copy deviates in the main scanning direction. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4.3 PRN SUB (TRAY1-P) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.4.4 PRN SUB (TRAY1-R) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4.5 PRN SUB (TRAY1-C1) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.4.6 PRN SUB (TRAY1-C2) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4.7 PRN SUB (BYPASS-P) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.4.8 PRN SUB (BYPASS-R) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4.9 PRN SUB (BYPASS-C1) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.4.10 PRN SUB (BYPASS-C2) A. Use • To adjust by varying the starting position of image writing in the sub scanning direction. • Used when the image on the copy deviates in the sub scanning direction. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4.11 CIS MAIN ZOOM A. Use • To adjust variations in machining and installation accuracy of different scanner parts by varying the scanning zoom ratio in the main scanning direction. • Used when the CIS module has been replaced. (After the CIS module has been adjusted for correct position) B.
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.4.12 CIS SUB ZOOM A. Use • To adjust variations in machining and installation accuracy of different scanner parts by varying the scanning zoom ratio in the sub scanning direction. • Used when the CIS module have been replaced. B.
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4.13 CIS MAIN REGIST A. Use • To adjust variations in machining and installation accuracy of different IR parts by varying the starting position of image scanning in the main scanning direction. •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.4.14 CIS SUB REGIST A. Use • To adjust variations in machining and installation accuracy of different scanner parts by varying the starting position of image scanning in the sub scanning direction. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.4.15 TCR GAIN A. Use • To manually adjust the TCR sensor voltage. • To set the TCR sensor control voltage again if the voltage determined by TCR AUTO ADJUST is cleared due to the replacement of the printer control board or memory clear. B.
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.5.3 PM COUNTER A. Use • To display the count of the number of times each of different parts of the machine has been used. • This function is used at the time of maintenance work for the main body and options. •...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.5.6 APPLICATION COUNTER A. Use • To display the count of the number of sheets of paper used for each of different applica- tions. COPY PRINT : Number of copies made PC PRINT : Number of printed pages produced from PC •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.6 DISPLAY 11.6.1 TONER DENSITY A. Use • To display the current output value of TCR sensor. • Refer to the following table for actual T/C values. • Used to check the T/C ratio when the image density is defective. Display 8.0%~8.4% 10.0%~10.4%...
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.6.8 MAIN RAM SIZE A. Use • To display the main memory size. 11.6.9 SERIAL NO. A. Use • To display the serial number of the machine. 11.6.10 CUSTOMER ID A. Use •...
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.7.3 TCR AUTO ADJUST A. Use • To make an automatic adjustment of the TCR sensor. • Used at setup. • Used when developer has been changed. • Used when IU has been replaced. B.
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.7.4 PRN TEST PATTERN A. PATTERN1 (1) Use • To produce a test pattern for image adjustments. • When skew, registration, or zoom ratio has been adjusted. • Here are the details of operation involved in the paper passage motion. The scanner does not make any scan motion.
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11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 B. PATTERN2 (1) Use • To produce halftone and gradation test patterns. • Used when checking for uneven density or uneven pitch. • Used when checking for gradation reproducibility. • Here are the details of operation involved in the paper passage motion. The scanner does not make any scan motion.
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE 11.7.5 SCAN TEST A. Use • To check that the exposure lamp turns ON properly and the scanner moves properly. • Used when the scan motion is faulty. B. Procedure 1. Press the Menu/Select key to start the scan test. 2.
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.9 FIXED ZOOM CHANGE A. Use • FIXED ZOOM CHANGE is used to change the fixed zoom ratios. B. Procedure 1. Select the particular fixed zoom ratio to be changed. 2. Using the 10-key pad, enter the desired fixed zoom ratio. C.
Field Service Ver. 2.0 Jun. 2010 11. SERVICE MODE (6) Latin America (Inch) Setting name Default fixed zoom ratio Setting range REDUCTION2 51% to 64% REDUCTION1 65% to 99% EXPANSION1 121% 101% to 128% EXPANSION2 129% 129% to 199% 11.10 FACTORY TEST 11.10.1 PANEL TEST A.
11. SERVICE MODE Field Service Ver. 2.0 Jun. 2010 11.11.2 TOTAL CLEAR A. Use • To clear the all electronic counters. • The following counters are cleared; SIZE COUNTER PM COUNTER MAINTENANCE COUNTER SUPPLIES COUNTER APPLICATION COUNT. SCAN COUNTER PAPER SIZE COUNTER MISFEED COUNTER TROUBLE COUNTER 11.11.3...
Field Service Ver. 2.0 Jun. 2010 12. SECURITY 12. SECURITY 12.1 List of SECURITY mode SECURITY Ref. page SECURITY TOTAL COUNTER COUNT P.119 SIZE COUNTER COUNT P.119 12.2 Starting/Exiting 12.2.1 Starting procedure 1. Call the SERVICE MODE to the screen. 2.
Field Service Ver. 2.0 Jun. 2010 13. JAM DISPLAY TROUBLESHOOTING 13. JAM DISPLAY 13.1 Misfeed display • When a paper misfeed occurs, the error indicator lights up steadily and the display gives a corresponding message. A0XXF4E501DA Display message Misfeed/paper location Ref.
13. JAM DISPLAY Field Service Ver. 2.0 Jun. 2010 13.2 Sensor layout 13.2.1 System mounted with MB-503. A0XXF4C503DA Exit sensor (PS5) Registration sensor (PS1)
Field Service Ver. 2.0 Jun. 2010 13. JAM DISPLAY 13.3 Solution 13.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial checks. Check item Action Does paper meet product specifications? Replace paper. Is the paper curled, wavy, or damp? Replace paper.
13. JAM DISPLAY Field Service Ver. 2.0 Jun. 2010 13.3.2 Misfeed at tray1 paper feed section A. Detection timing Type Description Tray1 paper feed • If the paper feed from the tray 1 fails, the machine retries twice. However, the section misfeed leading edge of the paper does not unblock the registration sensor (PS1) even detection...
Field Service Ver. 2.0 Jun. 2010 13. JAM DISPLAY 13.3.3 Misfeed at the bypass tray paper feed section A. Detection timing Type Description Manual bypass tray • If the paper feed from the bypass tray fails, the machine retries twice. However paper feed section the leading edge of the paper does not unblock the registration sensor (PS1) misfeed detection...
13. JAM DISPLAY Field Service Ver. 2.0 Jun. 2010 13.3.4 Misfeed at the image transfer section A. Detection timing Type Description Paper image trans- • The exit sensor (PS5) is not blocked even after the lapse of a given period of fer section misfeed time after the paper has unblocked the registration sensor (PS1).
Field Service Ver. 2.0 Jun. 2010 13. JAM DISPLAY 13.3.5 Misfeed at the fusing/exit section A. Detection timing Type Description Fusing/exit section • The exit paper sensor (PS3) is not unblocked even after the lapse of a given misfeed detection period of time after the registration sensor (PS1) has been blocked.
14. MALFUNCTION CODE Field Service Ver. 2.0 Jun. 2010 14. MALFUNCTION CODE 14.1 Trouble code • The copier’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the control panel.
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Field Service Ver. 2.0 Jun. 2010 14. MALFUNCTION CODE Code Item Description C3451 Warming-up failure • The surface temperature of the fusing roller does not reach a given level even after the lapse of a given period of time during a warm-up cycle. C3751 Fusing failure •...
14. MALFUNCTION CODE Field Service Ver. 2.0 Jun. 2010 14.2 Trouble resetting procedure Code Item Procedure C0211 Bypass tray lift-up failure • Turn OFF and ON the power switch. C2351 Suction fan motor malfunction C2557 Abnormally low T/C ratio C2558 Abnormally high T/C ratio C255C TCR sensor adjustment failure...
Field Service Ver. 2.0 Jun. 2010 14. MALFUNCTION CODE 14.3.7 C3451: Warming-up failure 14.3.8 C3751: Fusing failure (Abnormally high fusing temperature 1) 14.3.9 C3752: Fusing failure (Abnormally high fusing temperature 2) 14.3.10 C3851: Fusing failure (Abnormally low fusing temperature) Relevant electrical components Fusing unit Right door switch (SW2) DC power supply (DCPU)
14. MALFUNCTION CODE Field Service Ver. 2.0 Jun. 2010 14.3.13 C5102: Main motor malfunction Relevant electrical components Main motor (M1) Printer control board (PRCB) DC power supply (DCPU) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Check the connector between M1-PRCB CN6 for proper connection and correct as necessary.
Field Service Ver. 2.0 Jun. 2010 14. MALFUNCTION CODE 14.3.15 C9401: Scanner lamp error Relevant electrical components CIS module (CIS) Printer control board (PRCB) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Turn OFF and ON the power switch. –...
14. MALFUNCTION CODE Field Service Ver. 2.0 Jun. 2010 14.3.19 CC163: Engine connection failure Relevant electrical components Printer control board (PRCB) WIRING DIAGRAM Location Step Operations Control signal (Electrical compo- nents) Turn OFF and ON the power switch. Check the PRCB connectors for proper connection and correct as necessary.
Field Service Ver. 2.0 Jun. 2010 15. POWER SUPPLY TROUBLE 15. POWER SUPPLY TROUBLE 15.1 The copier does not turn ON Step Check Result Action A malfunction code appears when the power • Go to step 2. switch is turned ON. •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.1 How to identify problematic part • In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting proce- dures classified by image failures.” • If any image failure has occurred, first make the initial checks, then proceed to the corre- sponding image failure troubleshooting procedure.
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.1.2 Identification of the faulty system • Determine if the failure is attributable to an input system (scanner) or output system (printer). Check Result Action Full-size Reduced Input system Copy made at a reduced ratio (scanner) A09AF3C520DA Full-size...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.2 Scanner section: Black copy A. Typical faulty images A09AF3C523DA B. Troubleshooting procedure Step Check Result Action Exposure lamp turns ON when the power switch is turned Go to step 3. Exposure lamp is abnormally lit (flickers or abnormally Go to step 4.
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.3 Scanner section: Low image density A. Typical faulty images A09AF3C524DA B. Troubleshooting procedure Step Check Result Action Shading sheet reading portion (the portion on the back- • Clean. side of the original glass to which original width scale is affixed) is dirty.
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.4 Scanner section: Foggy background or rough image A. Typical faulty images A09AF3C525DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty. • Clean. CIS module components (glass, lamp) are dirty. •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.5 Scanner section: Black streaks or bands A. Typical faulty images Black streaks Black bands A09AF3C526DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. •...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.6 Scanner section: Black spots A. Typical faulty images A09AF3C527DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty or scratchy. • Clean. CIS module components (glass, lamp, sensor) are dirty, •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.7 Scanner section: White streaks or bands A. Typical faulty images White streaks White bands A09AF3C528DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. •...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.8 Scanner section: Uneven image density A. Typical faulty images A09AF3C529DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.9 Scanner section: Gradation reproduction failure A. Typical faulty images A09AF3C530DA B. Troubleshooting procedure Step Check Result Action Original glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- •...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.10 Scanner section: Periodically uneven image A. Typical faulty images A09AF3C531DA B. Troubleshooting procedure Step Check Result Action Scanner motor (M4) is securely fastened using the dedi- • Secure in position. cated fixing screws.
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.11 Scanner section: Moire A. Typical faulty images A09AF3C532DA B. Troubleshooting procedure Step Check Result Action Moire distortions recur even after the orientation of original • Change the original has been changed. mode (select one other than that resulted in moire).
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.12 Printer section: Blank copy A. Typical faulty images A09AF3C522DA B. Troubleshooting procedure Step Check Result Action Imaging unit is installed correctly. • Reinstall. Connector between the imaging unit and copier is dirty. •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.13 Printer section: Black copy A. Typical faulty images A09AF3C523DA B. Troubleshooting Procedure Step Check Result Action Drum charge corona grid mesh and comb electrode are • Reinstall. loose. Drum charge corona contact is dirty, scratchy, folded, bent, •...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.14 Printer section: Low image density A. Typical faulty images A09AF3C524DA B. Troubleshooting procedure Step Check Result Action The image changes when “TONER SUPPLY” in SERVICE • Replenish the supply of MODE is executed.
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.15 Printer section: Foggy background or rough image A. Typical faulty images A09AF3C525DA B. Troubleshooting procedure Step Check Result Action The image changes when “ID ADJUST” and “VG • Readjust. For details, see ADJUST”...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.16 Printer section: black streaks or bands A. Typical faulty images Black streaks Black bands A09AF3C526DA B. Troubleshooting procedure Step Check Result Action Drum is dirty or scratchy. • Clean or change. Foreign matter (such as paper dust) sticks to the cleaning •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.17 Printer section: Black spots A. Typical faulty images A09AF3C527DA B. Troubleshooting Procedure Step Check Result Action Toner is present along the paper path. • Clean. Drum is dirty or scratchy. •...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.18 Printer section: Blank streaks or bands A. Typical faulty images White streaks White bands A09AF3C528DA B. Troubleshooting procedure Step Check Result Action Drum ground terminal is dirty, scratchy, deformed, or dam- •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.19 Printer section: Void areas A. Typical faulty images A09AF3C533DA B. Troubleshooting procedure Step Check Result Action Foreign matter is present along the paper path. • Remove foreign matter. Paper dust plugs up the paper dust remover. •...
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.20 Printer section: Smear on back A. Typical faulty images A09AF3C534DA B. Troubleshooting procedure Step Check Result Action Toner is spilled over area inside copier. • Clean interior. Toner is present along the paper path. •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.21 Printer section: Uneven image density A. Typical faulty images A09AF3C529DA B. Troubleshooting Procedure Step Check Result Action Drum ground plate is dirty, scratchy, deformed, worn, or • Clean, correct, or damaged.
Field Service Ver. 2.0 Jun. 2010 16. IMAGE QUALITY PROBLEM 16.2.22 Printer section: Gradation reproduction failure A. Typical faulty images A09AF3C530DA B. Troubleshooting Procedure Step Check Result Action Drum is dirty. • Clean. Transfer roller is dirty, scratchy, deformed, worn, or dam- •...
16. IMAGE QUALITY PROBLEM Field Service Ver. 2.0 Jun. 2010 16.2.23 Printer section: Periodically uneven image A. Typical faulty images A09AF3C531DA B. Troubleshooting procedure Step Check Result Action IU is securely fastened using the dedicated fixing screws. • Secure in position. PH unit is securely fastened using the dedicated fixing •...
Field Service Ver. 2.0 Jun. 2010 17. PARTS LAYOUT DRAWING APPENDIX 17. PARTS LAYOUT DRAWING 17.1 Main body A0XXF5C500DA [1] Scanner motor (M4) [2] DC power supply fan motor (FM5) [3] Registration clutch (CL1) [4] Tray1 paper feed clutch (CL2) [5] CIS module (CIS) [6] Toner supply motor (M2) [7] Main motor (M1)
17. PARTS LAYOUT DRAWING Field Service Ver. 2.0 Jun. 2010 [10] A0XXF5C501DA [1] TCR sensor board (TCRSB) [2] Exit sensor (PS5) [3] Right door switch (SW2) [4] Front door switch (SW3) [5] Registration sensor (PS1) [6] Tray1 empty sensor (PS2) [7] Power switch (SW1) [8] DC power supply (DCPU) [9] Printer control board (PRCB)
Field Service Ver. 2.0 Jun. 2010 19. CONNECTOR LAYOUT DRAWING 19. CONNECTOR LAYOUT DRAWING Description Number of Pin ➀ Possible to confirm by removing external cover. Not possible to confirm by removing external cover. A0XXF5C505DA CN No. Location CN No. Location E-10 C-10...
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