Minolta Di551 Service Manual
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Minolta Di551 Service Manual

Minolta Di551 Service Manual

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Table of Contents

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Service Manual
[General]
Di551/Di650

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Summary of Contents for Minolta Di551

  • Page 1 Service Manual [General] Di551/Di650...
  • Page 2 There are using both Official Options name and Popular Options name in the Di551 / Di650 Service Manual and Option Service Manual. : RADF FN-6, FN-112, FN-113 : FNS C-403, C-404 : LT & LCT Cover Inserter B : PI...

  • Page 4: Table Of Contents

    OUTLINE OF SYSTEM ..........1-1 IMPORTANT NOTICE ....S-1 PRODUCT SPECIFICATIONS ........1-2 Di551/ Di650 LIST OF DIFFERENCE .......1-4 DANGER, WARNING, AND CAUTION  CENTRAL CROSS-SECTIONAL VIEW ....1-5 SYMBOLS AND EXPRESSIONS DRIVE SYSTEM DIAGRAM ........1-6 .
  • Page 5 CONTENTS DEVELOPING UNIT ..........2-G-1 FIXING UNIT ............2-O-1 Composition........... 2-G-1 Composition ...........2-O-1 Mechanisms .......... 2-G-1 Mechanisms ...........2-O-1 M3 (Developing) Control......2-G-2 M16 (Web Drive) Control .......2-O-3 Developing Bias Control ......2-G-3 Fixing Temperature Control ....2-O-4 Dmax Control......... 2-G-4 OTHER KINDS OF CONTROL ......2-P-1 Gradation Correction Control....

  • Page 6: Safety And Important Warning Items

    IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this copier as well as the risk of damage to the copier, Minolta Corporation strongly recommends that all servicing be performed only by Minolta-trained ser- vice technicians. Changes may have been made to this copier to improve its performance after this Service Manual was printed.
  • Page 7 SAFETY WARNINGS MODIFICATIONS NOT AUTHORIZED BY MINOLTA Minolta copiers are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Copier design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
  • Page 8 CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE Minolta copiers are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engineer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
  • Page 9 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Power Plug and Cord • Do not bundle or tie the power cord. Overheating may occur there, leading to a risk of fire. • Check whether dust is collected around the power plug and wall outlet. Using the power plug and wall outlet without removing dust may result in fire.
  • Page 10 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Ground Lead • Pay attention to the point to which the ground lead is connected. Connecting the ground lead to an improper point such as the points listed below results in a risk of explosion and electric shock: a.
  • Page 11 SAFETY AND IMPORTANT WARNING ITEMS CAUTION: Ventilation • The copier generates ozone gas during operation, but it is not sufficient to be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
  • Page 12 SAFETY AND IMPORTANT WARNING ITEMS DANGER: Work Performed with the Copier Powered • Take every care when servicing with the external cover detached. High-voltage exists around the drum unit. A risk of electric shock exists. WARNING: Safety Checkpoints • Check the exterior and frame for edges, burrs, and other damages. The user or CE may be injured.
  • Page 13 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Safety Checkpoints • After replacing a part to which AC voltage is applied (e.g., optical lamp and fixing lamp), be sure to check the installation state. A risk of fire exists. • Check the interlock switch and actuator for loosening and check whether the interlock functions properly.
  • Page 14 SAFETY INFORMATION DANGER: HANDLING OF MATERIALS FOR SERVICING • 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. If the substances get in the eye, rinse with plenty of water immediately.
  • Page 15 SAFETY INFORMATION SAFETY CIRCUITS This machine is provided with the following safety cir- Protection by L2, L3 and L4 (fixing cuits to prevent machine faults from resulting in seri- heater lamps) overheating prevention ous accidents. circuit Overall protection circuit L2 and L3 (fixing heater lamps) overheating DCPS prevention circuit These safety circuits are described below to provide...
  • Page 16 SAFETY INFORMATION Protection by the hardware circuit The output voltages from TH1 and TH2 (fixing temperature sensors) are compared with the abnormality judgment reference value in the comparator circuit. If the output voltage from TH1 or TH2 exceeds the reference value, L2 (fixing heater lamp 1), L3 (fixing heater lamp 2), L4 (fixing heater lamp 3) and RL1 (main relay) are turned OFF in hardware means.
  • Page 17 SAFETY INFORMATION INDICATION OF WARNING 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 DO NOT INSERT your finger into the two...
  • Page 18 SAFETY INFORMATION (Finisher with Cover Inserter B only) CAUTION DO NOT insert your finger into the bottom of the feeder upper part when returning to its original position; otherwise you may be injured. (All trays) CAUTION your hand between the main body and (FN-6/FN-112 Finisher) tray;...
  • Page 19 SAFETY INFORMATION <SCANNER SECTION> <WRITE UNIT> <REAR COVER> CAUTION You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself away from. Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot be read, Contact our Service Office.

  • Page 20: Outline

    OUTLINE...
  • Page 21 Blank page...

  • Page 22: Outline Of System

    Key counter Hard disk Expansion memory Cover Inserter [Cover Inserter B] A4LCT [C-403] Paper exit tray Punch kit [PK-2 / PK-5] Di551 / Di650 A3LCT Punch with Adapter for ZK [C-404] Z folding function [ZK A kit] [ZK-2] Finisher [FN-6 *1/FN-112]...

  • Page 23: Product Specifications

    MAIN BODY PRODUCT SPECIFICATIONS [1] Type Warm-up time: Installation type: ∞ 55-cpm 5.5 minutes max. 20 Console type (floor-mounted) rated voltage 65-cpm 6 minutes max. Copying method: Indirect electrostatic method ∞ 6 minutes max. (20 C, rated voltage) Document tray type: First copy out time (FCOT) Fixed Mode...
  • Page 24 MAIN BODY [4] Options [7] Consumables Developer: Exclusively for Minolta Di551/Di650 Key counter Toner: Exclusively for Minolta Di551/Di650 : C-403, C-404 Drum: Exclusively for Minolta Di551/Di650 (φ80) Expansion memory unit : 64 MB, 128 MB 256 MB *1 [8] Environmental Conditions Temperature: 10 to 30 °C...

  • Page 25: Di551/Di650 List Of Difference

    MAIN BODY Di551/Di650 LIST OF DIFFERENCE Classification Di551 Di650 Reason Warm-up time 5.5 minutes max 6 minutes max CPM change First copy out time (A4) 3.4 seconds or shorter 3.1 seconds or shorter Continuous copy speed (A4) 55 copies 65 copies...

  • Page 26: Central Cross-Sectional View

    MAIN BODY CENTRAL CROSS-SECTIONAL VIEW 13. Vertical conveyance section Charging corona section 14. ADU RADF (EDH) 15. Separation corona section Image write section 16. Paper conveyance section Image read section 17. Tray 3 Toner supply section 18. Tray 2 Developing section 19.
  • Page 27 MAIN BODY DRIVE SYSTEM DIAGRAM [1] Fixing/Web Drive Section FRONT Cleaning web wind-up shaft Fixing upper roller Web SD (SD2) Fixing lower roller Ratchet Decurler roller Cleaning web unwinding shaft 10. Reverse gate SD (SD7) Fixing input gear 11. Reverse/exit switching gate Fixing motor (M4)
  • Page 28 MAIN BODY [2] Drum Drive Section Separation claw swing cam Toner conveyance screw Separation claw SD (SD1) Toner guide roller Drum Toner conveyance screw Drum motor (M2) Drum motor (M2) Separation claw section [3] Developing Drive Section Developing motor (M3) Agitator wheel Developing sleeve Agitator screws...
  • Page 29 MAIN BODY [4] Paper Feed/Vertical Conveyance/Tray Up Drive Sections Feed roller 10. Vertical conveyance roller (upper) Paper feed MC (MC3/5/7) 11. Vertical conveyance MC/2 (MC12) Paper feed roller 12. Vertical conveyance roller (middle) Pre-registration MC (MC4/6/8) 13. Paper feed motor (M1) Pre-registration roller 14.
  • Page 30 MAIN BODY [5] Bypass Paper Feed /ADU Pre-registration Drive Section Paper feed roller Loop roller motor (M6) Feed roller Up/down motor/BP (M20) Loop roller Paper up/down plate ADU pre-registration roller...
  • Page 31 MAIN BODY [6] Charger and Transfer/Separation Wire Cleaning Drive Section [Charging corona unit] Charging cleaning motor (M14) [Transfer and separation corona unit] FRONT Transfer/separation cleaning motor (M10) 1-10...
  • Page 32 MAIN BODY [7] ADU Conveyance Drive Section FRONT Pre-transfer roller 11. Reverse/exit roller Registration roller 12. Reverse/exit motor (M8) Registration MC (MC1) 13. Reverse/exit gate Registration roller knob 14. ADU reverse motor (M9) ADU conveyance roller/4 15. ADU reverse roller Conveyance motor (M5) 16.

  • Page 33: Paper Exit Drive Section

    MAIN BODY [8] Paper Exit Drive Section Paper exit motor (M7) Exit conveyance roller Paper exit roller [9] Toner Supply Drive Section Rear View Front View Toner cartridge Toner supply screw Toner supply screws Toner supply motor (M12) Toner bottle motor (M13) Toner conveyance screw 1-12...

  • Page 34: Optics Drive Section

    MAIN BODY [10] Optics Drive Section FRONT Scanner motor (M11) Scanner drive wire (front) Scanner drive wire (rear) V-mirror unit Exposure unit 1-13...
  • Page 35 Blank page...

  • Page 36: Unit Explanation

    UNIT EXPLANATION...
  • Page 37 Blank page...

  • Page 38: External Section

    EXTERNAL SECTION EXTERNAL SECTION [1] Composition Sub power switch (SW2) 12. Tray 2 Operation panel 13. Tray 1 RADF 14. Front left door Right side cover (upper) 15. Front right door Developing suction filter cover 16. Toner access door Bypass tray 17.
  • Page 39 Blank page...

  • Page 40: Drive Section

    DRIVE SECTION DRIVE SECTION [1] Composition Scanner motor (M11) Drum motor (M2) Toner bottle motor (M13) Developing motor (M3) Fixing motor (M4) Loop roller motor (M6) Paper feed motor (M1) [2] Mechanisms *1 Independent drive mechanisms Drive mechanisms of this machine are driven by Mechanism Driven Parts Method...

  • Page 41: M2 (Drum) Control

    DRIVE SECTION [3] M2 (Drum) Control 2. Signals Input signal (1) DRUM_EM (M2 to PRCB) M2 (drum) rotation abnormality detection signal [H]: Rotation error (when motor speed changes P.GND DRUM CONT by 6.5 % more or less than the motor speed DRUM CLK CW/CCW specified value)

  • Page 42: M4 (Fixing) Control

    DRIVE SECTION [4] M4 (Fixing) Control 2. Signals Input signal (1) MAINM_EM (M4 to PRCB) M4 (fixing) rotation error detection signal P.GND MAINM CONT [H]: Rotation error (when motor speed changes MAINM CLK MAINM F/R by 6.5% more or less than the motor speed MAINM EM specified value) PRCB...
  • Page 43 Blank page...

  • Page 44: Scanner Section

    SCANNER SECTION SCANNER SECTION [1] Composition Slit glass Optical rail (R) V-mirror unit Scanner drive wire Exposure unit 10. A/D converter board (ADB) Scanner HP PS (PS61) 11. CCD unit APS sensor 3 (PS65) 12. L1 inverter (L1 INVB) APS sensor 1 (PS63) 13.

  • Page 45: M11 (Scanner) Control

    SCANNER SECTION [3] M11 (Scanner) Control Exposure unit home position search When SW2 (sub power switch) or the START button is pressed, M11 (scanner) searches for SCAN CLK the home position of the exposure unit. However, SCAN FR SCAN MGN this operation is performed in different ways SCAN CUR1 SCAN CUR2 depending on whether PS61 (scanner HP) is ON...
  • Page 46 SCANNER SECTION ADF copy operation Platen APS read position After completion of the shading correction PS61 started by pressing the START button, M11 (scanner) moves the exposure unit toward the First white correction paper exit side. After being driven by the speci- fied number of steps from the position where Second white correction PS61 (scanner HP) was turned ON, it stops.
  • Page 47 SCANNER SECTION Platen copy operation 2. Signals Platen copy operation is performed in different Input signals ways depending on whether AE control is per- (1) SIG/SCANHP_PS (PS61 to SCDB to PRCB) formed. Scanner home position detection signal After completion of the shading correction The reference position of the home position of started by pressing the START button, AE scan- the exposure unit is detected.

  • Page 48: Exposure Control

    SCANNER SECTION [4] Exposure control [5] Original Read Control 12V2 EXP CONT 12V2 ADRST L1 INVB CONT PDWN LAMP.PG /TCK PRCB /RCK S.GND LCLK1 24V1 /LCLK1 S.GND P.GND SCLK L.PG /SEN DCPS SCDB CLAMP L1 (exposure lamp) is driven by L1 INVB (L1 BCLAMP inverter) and is controlled by PRCB (printer con- trol board) via SCDB (scanner drive board).

  • Page 49: Aps Control

    SCANNER SECTION [6] APS Control Relationships between sensors and paper sizes are as follows: Sensor S.GND APC CONT APS TIM PS51 PS65 PS63 PS64 COVER SIG Paper size APS.1 SIG APS.2 SIG S.GND APS.3 SIG APS.1 PS63 Min. size APS 5V S.GND PS64 APS.2...

  • Page 50: Ae Control

    SCANNER SECTION 2. Signals [7] AE Control Input signals (1) APS_TIM (PS51 to SCDB) 12V2 ADF open/close detection signal 12V2 [L]: ADF is closed. ADRST [H]: ADF is open. PDWN (2) APS.1/APS.1_SIG (PS63 to SCDB to ICB) /TCK Paper size detection signal [L]: Paper is detected.
  • Page 51 SCANNER SECTION (2) ADF mode The image at the leading edge of the original is read when the PRINT button is pressed. The read data is used to measure the image den- sity on the original. <AE sampling area> 1) Main scanning direction 10 mm area inside the original detected by APS 2) Sub-scanning direction 2-to-4 mm area from the leading edge of the orig-...

  • Page 52: Write Unit

    WRITE UNIT WRITE UNIT [1] Composition Collimator lens unit Index mirror Laser driver board (LDB) fθ lens Index sensor board (INDXSB) Polygon mirror Cylindrical lens 2 Cylindrical lens 1 Write mirror [2] Mechanisms Mechanism Method Scan*1 Polygon mirror Light source*2 1-chip, 2-beam laser diode (Power: 15 mW per beam) Reference posi- Index sensor...

  • Page 53: M15 (Polygon) Control

    WRITE UNIT *2 Light source [3] M15 (Polygon) Control Conventionally, two parallel beams were gener- ated from two laser beams. The laser diode 24V1 adopted for this machine can generate two P.GND POLM CONT beams using a single chip, requiring neither fine- POLM CLK POLM LOCK adjustment prism nor beam composition prism.

  • Page 54: Image Write Control

    WRITE UNIT 2. Signals [4] Image Write Control Input signals (1) POLM_LOCK (PMDB to PRCB) SGND This signal indicates the clock synchronization /IND SGND INDXSB /INDPR state of M15 (polygon). [L]: Synchronous (normal) VIDEO2 /VIDEO2 [H]: Asynchronous (abnormal) LPR5V LD5V LD5V Output signals VIDEO1 (1) POLM_CONT (PRCB to PMDB)
  • Page 55 WRITE UNIT 1. Operation (2) APC (Automatic Power Control) Image processing After MPC is set, the ICB (image control board) The following processing is performed by the ICB outputs an APC start instruction to LDB (laser (image control board): driver board) at the following timing: (1) AOC (Automatic Offset Control) <APC timing>...
  • Page 56 WRITE UNIT Output signals (1) /S/H1 (ICB to LDB) APC sampling signal for one line (for laser 1) (2) /ENB1 (ICB to LDB) Laser APC function ON/OFF control signal (for laser 1) Laser beam emission stops when it is OFF. (3) /S/H2 (ICB to LDB) APC sampling signal for one line (for laser 2) (4) /ENB2 (ICB to LDB) Laser APC function ON/OFF control signal (for...
  • Page 57 Blank page...

  • Page 58: Drum Unit

    DRUM UNIT DRUM UNIT [1] Composition Cleaning/toner recycle section Charging corona unit Charging corona unit Drum 10. Drum Developing unit 11. Developing unit Separation claw SD (SD1) 12. TSL Separation claws 13. Transfer and separation corona unit Toner guide roller (TGR) 14.

  • Page 59: Separation Claw Control

    DRUM UNIT [3] Separation Claw Control [4] Paper Guide Plate Control MC24V 2 GP.CONT SPSD DRV PRCB P.GND DRUM CONT DRUM CLK CW/CCW 24V2 DRUM EM P.GND DCPS PRCB 24V2 To prevent toner from adhering to the paper P.GND guide plate, a constant voltage is applied to the DCPS paper guide plate.

  • Page 60: Corona Unit Section

    CORONA UNIT SECTION CORONA UNIT SECTION [1] Composition <Charging corona unit> <Transfer and separetion corona unit> Charging control plate Guide rollers Charging corona wire Transfer corona wire Charging wire cleaning motor (M14) Plunging prevention plate (front) Separation corona wire Transfer entrance guide plate 10.

  • Page 61: Charging Control

    CORONA UNIT SECTION [3] Charging Control Output signals (1) C.CONT (PRCB to HV) C.CONT This signal turns ON/OFF the charging wire. EM(C).SIG [L]: Charging voltage ON LATCH [H]: Charging voltage OFF CHARGING PRCB (2) TXD (PRCB to HV) Output level of each high voltage electrode. 24V2 Serial data signal for control P.GND...

  • Page 62: Transfer/Separation Control

    CORONA UNIT SECTION [4] Transfer/Separation Control PRCB output signals (1) T.CONT (PRCB to HV) This signal turns ON/OFF the voltage applied to T.CONT EM(T).SIG the transfer wire. S.CONT EM(S).SIG [L]: Transfer voltage ON TRANSFER [H]: Transfer voltage OFF LATCH (2) S.CONT (PRCB to HV) PRCB SEPARATION This signal turns ON/OFF the voltage applied to...

  • Page 63: M14 (Charger Cleaning) Control

    CORONA UNIT SECTION [5] M14 (Charger Cleaning) Control 2. Signals Output signal (1) CHGM_A, B (PRCB to M14) CHGM A M14 (charger cleaning) drive control signal. CHGM B The drive direction of M14 is controlled by switch- ing between the drive current directions of two signals.

  • Page 64: M10 (Transfer/Separation Cleaning) Control

    CORONA UNIT SECTION [6] M10 (Transfer/Separation Cleaning) 2. Signals Input signals Control (1) IO_URXD (ADUDB to PRCB) Serial data used to report the ADUDB (ADU IO DTXD drive board) operation state to PRCB (printer IO DCLK ADU LATCH IO UCLK control board) REQ1 IO URXD (2) REQ1 (ADUDB to PRCB)

  • Page 65: Pcl/Tsl Control

    CORONA UNIT SECTION [7] PCL/TSL Control MC 24V2 PCL CONT IO DTXD IO DCLK ADU LATCH IO UCLK REQ1 IO URXD ACK1 ERR OUT1 MC24V PRCB TSL DR S.GND 24V1 P.GND 24V1 S.GND P.GND DCPS ADUDB LEDs are used for PCL (pre-charging exposure lamp) and TSL (transfer synchronization lamp).

  • Page 66: Developing Unit

    DEVELOPING UNIT DEVELOPING UNIT [1] Composition Developing unit cover Developing regulation plate Developing regulation plate Agitator screws Developing sleeve Agitator wheel Agitator screws Developing sleeve Splash prevention sheet (upper) [2] Mechanisms Mechanism Method Developing 2-component developer Developing bias DC bias Developer Main agitator agitation Auxiliary agitator...

  • Page 67: M3 (Developing) Control

    DEVELOPING UNIT [3] M3 (Developing) Control 2. Signals Input signals (1) DEVM_EM (M3 to PRCB) P.GND M3 (developing) abnormality detection signal DEVM CONT DEVM CLK [H] Abnormal rotation (when motor speed DEVM CW/CCW DEVM GAIN changes by 6.5% more or less than the motor DEVM EM PRCB speed specified value)

  • Page 68: Developing Bias Control

    DEVELOPING UNIT [4] Developing Bias Control B.CONT LATCH BIAS PRCB 24V1 P.GND DCPS The developing bias voltage is supplied from HV (high voltage unit) and is controlled by PRCB (printer control board). The output level of the developing bias voltage is transmitted using 8-bit serial data.

  • Page 69: Dmax Control

    DEVELOPING UNIT [5] Dmax Control A.GND P.GND DMLED CONT DRUM CONT DM MONI EX DRUM CLK DJLED CONT CW/CCW DM SIG EX DRUM EM DRUM JSIG EX TNLED REF TEMP 3.3V2 TCSB P.GND DEVM CONT DEVM CLK DEVM CW/CCW DEVM GAIN DEVM EM PRCB 12V2...
  • Page 70 DEVELOPING UNIT 2. Signals Input signals (1) DM_SIG_EX (TCSB to PRCB) Output voltage of Dmax detection sensor (PC1) on TCSB (toner control sensor board) Reference voltage: 2.5 V (2) DM_MONI_EX (TCSB to PRCB) This signal monitors the light reflected by the drum surface (without toner).

  • Page 71: Gradation Correction Control

    DEVELOPING UNIT [6] Gradation Correction Control A.GND P.GND DRUM CONT G SIG EX DRUM CLK LED CONT CW/CCW DRUM EM TNLED REF TCSB P.GND DEVM CONT DEVM CLK DEVM CW/CCW DEVM GAIN DEVM EM PRCB 12V2 S.GND MS1 MS2 24V2 P.GND DCPS Gradation correction control is performed by (2) Timing...

  • Page 72: Dot Diameter Correction Control

    DEVELOPING UNIT [7] Dot Diameter Correction Control [8] Toner Density Control TNSM24V TNSM24V A.GND A.GND TNSM A DMLED CONT DM MONI EX TNSM AB G SIG EX DJLED CONT TNSM B LED CONT DM SIG EX TNSM BB DRUM JSIG EX TNLED REF TNLED REF TEMP...

  • Page 73: Fm4 (Developing Suction) Control

    DEVELOPING UNIT [9] FM4 (Developing Suction) Control SUCTFAN D SFAN EM P.GND PRCB 24V1 S.GND P.GND DCPS FM4 (developing suction) is controlled by PRCB (printer control board). 1. Operation ON timing FM4 (developing suction) is turned ON when M2 (drum) is turned ON. OFF timing FM4 (developing suction) is turned OFF after a lapse of the specified time from turning OFF of...

  • Page 74: Toner Supply Unit

    TONER SUPPLY UNIT TONER SUPPLY UNIT [1] Composition Toner cartridge Toner level detection sensor (TLD) Toner bottle motor (M13) Toner supply screws Hopper Toner supply motor (M12) [2] Mechanisms Mechanism Method Toner supply Supply by screw Toner level detection Piezoelectric method 100 ± 25 g Toner agitation*1 Agitator plate Toner cartridge*2...

  • Page 75: Toner Level Detection Control

    TONER SUPPLY UNIT *2 Toner cartridge [3] Toner Level Detection Control When the toner cartridge rotates, toner is fed to the outlet of the cartridge through the spiral S.GND groove on the surface of the toner cartridge. TONER SIG T SENSE CONT When the outlet of the cartridge faces downward, toner flows out of the outlet into the agitation/con- P.GND...

  • Page 76: M12 (Toner Supply) Control

    TONER SUPPLY UNIT 2. Signals [4] M12 (Toner Supply) Control Input signals (1) TONER_SIG (TLD to PRCB) TNSM24V When the level of toner in the toner supply unit TNSM24V TNSM A becomes low, this signal goes low ([L]), display- TNSM AB TNSM B ing a message on the LCD connected to OB1 TNSM BB (operation board/1).
  • Page 77 TONER SUPPLY UNIT Toner supply When the voltage detected by TCSB (toner con- trol sensor board) is below the specified value, PRCB issues a control signal to drive M12 (toner supply). The relationship between the paper size and toner supply time is summarized in the fol- lowing table: Paper size Supply time (sec)

  • Page 78: Cleaning/Toner Recycle Unit

    CLEANING/TONER RECYCLE UNIT CLEANING/TONER RECYCLE UNIT [1] Composition Cleaning blade Drum Cleaning/toner recycle section Separation claw Toner recycle MC (MC14) Toner conveyance screw Toner guide roller (TGR) Scraper Cleaning blade [2] Mechanisms HV Terminal Mechanism Method Drum cleaning Cleaning blade Cleaning blade Toner collection *1 Toner guide roller (TGR) Toner recycle *2 Screw conveyance + Toner...

  • Page 79: Tgr (Toner Guide Roller) Control

    CLEANING/TONER RECYCLE UNIT [3] TGR (Toner Guide Roller) Control [4] Other Control To improve durability of the cleaning blade, the following control is performed: TGR.CONT Blade setting mode LATCH A blade setting mode is available in the 36 mode. PRCB This mode will perform a task that is required after blade replacement during maintenance, 24V2 etc.

  • Page 80: Tray 1/2 Paper Feed Unit

    TRAY 1/2 PAPER FEED UNIT TRAY 1/2 PAPER FEED UNIT [1] Composition Tray up drive motor /1/2 (M16/17) Drive pulley (for wire A/B) Drive pulley (for wire C/D) Paper size VR /1/2 (VR1/2) Feed roller Paper size PS /1-1/1-2 (PS5/11) Paper feed roller 10. Paper size PS /2-1/2-2 (PS6/12) Double feed prevention roller 11.
  • Page 81 TRAY 1/2 PAPER FEED UNIT b) Lowering of tray 1st paper feed paper loop mechanism When the paper feed tray is pulled out, the When paper feed starts, paper is fed to the pre- coupling shaft of the tray is disengaged from registration roller by the feed roller and paper the coupling gear of the tray up drive motor on feed rollers.

  • Page 82: First Paper Feed Control

    TRAY 1/2 PAPER FEED UNIT [3] First Paper Feed Control 24V1 MC24V_1 P.GND T1FEED_DRV S.GND MC24V_1 Tray 1 T1PREMC_DRV 24V2 P.GND T1PRE_PS DCPS SGND MC24V_1 FEEDM_CONT FEEDM_CLK FEEDM_F/E MC24_1 Tray 2 FEEDM_EM T2PREMC_DRV P.GND T2PRE_PS SGND PRCB The 1st paper feed from tray 1/2 takes place as 1.
  • Page 83 TRAY 1/2 PAPER FEED UNIT 2. Signals PRCB input signals (1) T1PRE_PS (PS1 to PRCB) Paper passage detection signal (tray 1) [L]: Detected. [H]: Not detected. (2) T2PRE_PS (PS7 to PRCB) Paper passage detection signal (tray 2) [L]: Detected. [H]: Not detected. PRCB output signals (1) T1FEED_DRV (PRCB to MC3) MC3 drive control signal (tray 1) [L]: MC3 ON...

  • Page 84: Paper Up Drive Control

    TRAY 1/2 PAPER FEED UNIT [4] Paper Up Drive Control 24V1 TIUP_PS P.GND SGND Tray 1 S.GND TIRM_PS DCPS SGND TIUP_PS T1RISEM_24V SGND Tray 2 T1RISEM_D PS10 TIRM_PS SGND T2RISEM_24 T2RISEM_D PRCB Paper stacked in the tray is pushed up by trans- Paper up drive timing mitting the drive force of M16/17 (tray up drive/ (1) ON timing 1/2) to the up/down plate in the tray via drive...

  • Page 85: Paper Size Detection Control

    TRAY 1/2 PAPER FEED UNIT 2. Signals [5] Paper Size Detection Control PRCB input signals Tray 1 (1) TIUP_PS (PS2 to PRCB) Paper upper limit detection signal (tray 1) T1SIZE_S_PS SGND [L]: Not detected. T1SIZE_L_PS [H]: Detected. SGND (2) TIRM_PS (PS4 to PRCB) 3.3V2 T1SIZE_VR Remaining paper detection signal (tray 1) AGND...

  • Page 86: No Paper Detection Control

    TRAY 1/2 PAPER FEED UNIT 2. Signals [6] No paper detection control PRCB input signals (1) T1SIZE_S_PS (PS5 to PRCB) T1_0PS Paper size detection signal (tray 1) SGND [L]: Paper does not exist. T2_0PS [H]: Paper exists. SGND (2) T1SIZE_L_PS (PS6 to PRCB) Paper size detection signal (tray 1) [L]: Paper does not exist.
  • Page 87 Blank page...

  • Page 88: Tray 3 Paper Feed Unit

    TRAY 3 PAPER FEED UNIT TRAY 3 PAPER FEED UNIT [1] Composition Tray up drive motor /3 (M16/17) Drive pulley (for wire A/B) Drive pulley (for wire C/D) Paper size VR/3 (VR3) Feed roller Paper size PS/1-3 (PS17) Paper feed roller 10. Paper size PS/2-3 (PS18) Double feed prevention roller 11.
  • Page 89 TRAY 3 PAPER FEED UNIT b) Lowering of tray First paper feed paper loop mechanism When the paper feed tray is pulled out, the When paper feed starts, paper is fed to the pre- coupling shaft of the tray is disengaged from registration roller by the feed roller and paper the coupling gear of the tray up drive motor on feed rollers.

  • Page 90: First Paper Feed Control

    TRAY 3 PAPER FEED UNIT [3] First Paper Feed Control MC24V_1 24V1 T3FEED_DRV P.GND S.GND MC24V_1 Tray 3 T3PREMC_DRV 24V2 P.GND T3PREM_PS PS13 DCPS SGND FEEDM_CONT FEEDM_CLK FEEDM_F/E FEEDM_EM P.GND PRCB The 1st paper feed from tray 3 takes place as the 1. Operation result of the transmission of the drive force from Operation of the MC7 (paper feed MC/3) M1 (paper feed) to each paper feed roller by MC7...
  • Page 91 TRAY 3 PAPER FEED UNIT 2. Signals PRCB input signals (1) T3PREM_PS (PS13 to PRCB) Paper passage detection signal (tray 3) [L]: Detected. [H]: Not detected. PRCB output signals (1) T3FEED_DRV (PRCB to MC7) MC7 drive control signal (tray 3) [L]: MC7 ON [H]: MC7 OFF (2) T3PREM_PS (PRCB to MC8) MC8 drive control signal (tray 3) [L]: MC8 ON...

  • Page 92: Paper Up Drive Control

    TRAY 3 PAPER FEED UNIT [4] Paper Up Drive Control 24V1 PS14 TIUP_PS P.GND SGND Tray 3 S.GND PS16 TIRM_PS DCPS SGND T3RISEM_24 T3RISEM_D PRCB Paper stacked in the tray is pushed up by trans- Paper up drive timing mitting the drive force of M18 (tray up drive/3) to (1) ON timing the up/down plate in the tray via drive wires.

  • Page 93: Paper Size Detection Control

    TRAY 3 PAPER FEED UNIT 2. Signals [5] Paper Size Detection Control PRCB input signals (1) TIUP_PS (PS14 to PRCB) Tray 3 Paper upper limit detection signal T3SIZE_S_PS PS17 [L]: Not detected. SGND [H]: Detected. PS18 T3SIZE_L_PS (2) TIRM_PS (PS16 to PRCB) SGND 3.3V2 Remaining paper detection signal T3SIZE_VR [L]: Not detected.

  • Page 94: No Paper Detection Control

    TRAY 3 PAPER FEED UNIT 2. Signals [6] No Paper Detection Control PRCB input signals (1) T3SIZE_S_PS (PS17 to PRCB) Paper size detection signal T3_0PS PS15 SGND [L]: Paper does not exist. [H]: Paper exists. (2) T3SIZE_L_PS (PS18 to PRCB) Paper size detection signal S.GND [L]: Paper does not exist.
  • Page 95 Blank page...

  • Page 96: By-Pass Tray

    BY-PASS TRAY BY-PASS TRAY [1] Composition By-pass paper feed roller By-pass tray Up/down motor/BP (M20) Loop roller By-pass feed roller By-pass double feed prevention roller [2] Mechanisms *1 Paper lift-up The up/down motor/BP (M20) drives the paper Mechanism Method up/down plate via gears. Paper is automatically First paper feed By-pass feed roller pushed up to the paper feed position, when the...

  • Page 97: First Paper Feed Control

    BY-PASS TRAY *2 Paper size detection [3] First Paper Feed Control The paper size is automatically detected by the following three sensors: • Lateral: Paper size detection VR/BP (VR5) 24V2 P.GND • Longitudinal: Paper size PS/1, 2-BP (PS31/ S.GND PS36 LOOP_PS S.GND 2ND_PS PS44...

  • Page 98: Paper Up/Down Control

    BY-PASS TRAY PRCB output signals [4] Paper Up/Down Control (1) A and /A (PRCB to M6) A-phase drive control pulse signal for M6 (2) B and /B (PRCB to M6) BPUDM_A PS34 BPUP_PS BPUDM_B SGND B-phase drive control pulse signal for M6 PS35 BPDN_PS SGND...

  • Page 99: Paper Size Detection Control

    BY-PASS TRAY 2. Signals [5] Paper Size Detection Control PRCB input signals (1) BPUP_PS (PS34 to PRCB) S.GND BPSIZE_S_PS PS31 Paper upper limit position detection signal (by- SGND DCPS pass tray) PS32 BPSIZE_L_PS [L]: Not detected. SGND [H]: Detected. BPSIZE_VR (2) BPDN_PS (PS35 to PRCB) PRCB Paper lower limit position detection signal (by- pass tray)

  • Page 100: No Paper Detection Control

    BY-PASS TRAY [6] No Paper Detection Control S.GND PS33 BP_OPS SGND DCPS PRCB No paper in the tray is detected by PS33 (no paper/BP) which is controlled by PRCB (printer control board). 1. Operation When the tray becomes empty, PS33 (no paper/ BP) is turned OFF, displaying a message on the LCD via OB1 (operation board/1).
  • Page 101 Blank page...

  • Page 102: Vertical Conveyance Section

    VERTICAL CONVEYANCE SECTION VERTICAL CONVEYANCE SECTION [1] Composition Vertical conveyance MC/1 (MC11) Vertical conveyance roller (upper) Vertical conveyance MC/2 (MC12) Vertical conveyance roller (lower) [2] Mechanisms Mechanism Method Paper conveyance Rollers Conveyance drive Vertical conveyance roller (upper): Paper feed motor (M1) Vertical conveyance roller (lower): Paper feed motor (M1) 2-M-1...

  • Page 103: Vertical Conveyance Control

    VERTICAL CONVEYANCE SECTION [3] Vertical Conveyance Control 2. Signals PRCB input signals (1) T1PASS_PS (PS25 to PRCB) MC24V_2 24V1 MC11 VFMC1_DRV P.GND Paper passage detection signal (for tray 1) S.GND MC24V_2 [L]: Not detected. MC12 VFMC2_DRV 24V2 [H]: Detected. P.GND PS25 T1PASS_PS (2) T2PASS_PS (PS26 to PRCB) DCPS S.GND...

  • Page 104: Adu

    [1] Composition ADU conveyance roller 1 ADU conveyance roller 3 ADU conveyance roller 2 ADU reverse roller Conveyance belt 10. ADU gate Pre-transfer roller 11. Reverse/exit roller Registration roller 12. Reverse/exit gate ADU pre-registration roller 13. Paper exit conveyance roller ADU conveyance roller 4 14.

  • Page 105: Mechanisms

    [2] Mechanisms Mechanisms Method Second paper feed paper loop *1 Loop roller (trays 1-3/LCT), Feed roller (by-pass tray), ADU pre-registration roller (ADU) Image position correction *2 Image position is corrected according to the information detected by PS43 (leading edge) and PS70 (paper mis- centering).
  • Page 106 *1 Second paper feed paper loop mechanism <ADU> A paper loop is formed before the registration roller to correct mis-centering of paper during Registration roller second paper feed. The paper loop is formed by pushing the fed paper against the registration Loop formation point roller for the prescribed time.
  • Page 107 *3 Second paper feed auxiliary mechanism Reverse/exit paper path selection The distance between the registration roller and The reverse/exit selection gate in the fixing unit the transfer and separation corona unit is made determines whether the paper is to be ejected long to achieve the time required for correcting straight or reversed and ejected.
  • Page 108 Fixing roller (upper) Fixing roller (lower) Fixing exit PS (PS30) Exit roller Reverse/exit selection gatet Main body exit roller ADU paper conveyance In the two-sided copy mode, the paper finished with printing on the front side is fed, through the path under the reverse/exit selection gate, into the reverse/exit section just like the reverse/exit operation.
  • Page 109 *6 Non-stack paper feed mechanism ON/OFF the drive force of ADU conveyance roll- In the two-sided copy mode, the ADU reverse ers 1 and 2 in order to stop the looped paper tem- roller starts rotating in the opposite direction porarily and to adjust the loop size.

  • Page 110: Loop/Second Paper Feed Control

    [3] Loop/Second Paper Feed Control LOOP PS PS36 S.GND PGND START/STOP CW/CCW IO DTXD IO DCLK ADU LATCH PGND IO UCLK +24V REQ1 IO URXD MC24V ACK1 ERR OUT1 2ND MC 2NDM CLK REG PS PS43 EDGE PS S.GND PS44 2ND PS S.GND PRCB...
  • Page 111 A contact image sensor is used as PS70 (paper (5) DEF_CLK (ADUDB to PS70) mis-centering). The paper edge position is PS70 (paper mis-centering) drive clock signal detected by paper mis-centering sensors. Based (6) DEF_LED (ADUDB to PS70) on the edge position information, the image write PS70 (paper mis-centering) LED control signal position is shifted to correct mis-centering and (7) CW/CCW (ADUDB to M5)

  • Page 112: Paper Conveyance Control

    [4] Paper Conveyance Control 2. Signals Input signals (1) MAINEXIT_PS (PS37 to PRCB) MAINEXIT PS PS37 S.GND Main body exit section paper passage detection IO DTXD signal IO DCLK ADU LATCH [L]: Detected. IO UCLK REQ1 IO URXD SUC FAN [H]: Not detected.

  • Page 113: Paper Reverse And Exit Control

    [5] Paper Reverse and Exit Control P.GND MAINM CONT MAINM CLK MAINM F/R MAINM EM FIXEXIT PS PS30 S.GND MAINEXIT PS PS37 S.GND IO DTXD IO DCLK ADU LATCH IO UCLK REQ1 IO URXD ACK1 ERR OUT1 2NDM CLK PS42 DECUR PS S.GND PRCB...
  • Page 114 1. Operation quently turns OFF, M8 and M9 start rotating in Reverse/exit selection gate control the opposite direction at a high speed, feeding The reverse/exit selection gate is driven by SD7 the paper in the paper exit direction. (reverse gate). Normally, the reverse/exit selec- When PS45 (ADU paper reverse) detects the tion gate is open to guide paper to the reverse/ trailing edge of paper and consequently turns...
  • Page 115 starts rotating at a low speed to even up the 2. Signals edges of paper in the exit tray. When PS37 Input signals (paper exit) is turned OFF at detection of the trail- (1) FIXEXIT_PS (PS30 to PRCB) ing edge of paper, M7 starts rotating at a high Detection signal of paper passage at fixing unit speed again, proceeding to eject the next sheet exit...

  • Page 116: Adu Paper Conveyance/Feed Control

    [6] ADU Paper Conveyance/Feed Control PGND START/STOP CW/CCW PGND +24V PS41 ADU JAM S.GND ADU REV PS45 S.GND IO DTXD IO DCLK ADU LATCH REV PS IO UCLK PS46 REQ1 S.GND IO URXD ACK1 ERR OUT1 HD PS PS47 2NDM CLK S.GND PRCB PS48...
  • Page 117 1. Operation 2. Signals ADU conveyance control Input signals The paper fed from the ADU paper reversal sec- (1) ADU_JAM (PS41 to ADUSDB) tion is fed to ADU pre-registration rollers at a high Detection signal of paper passage from exit of speed by transmitting the drive force of M5 (con- ADU conveyance roller 1 veyance) to ADU conveyance rollers 1 to 4.

  • Page 118: Fixing Unit

    FIXING UNIT FIXING UNIT [1] Composition Fixing unit cover (upper) 10. Fixing heater lamp/1 (L2) Pressure release lever 11. Fixing heater lamp/2 (L3) Fixing claw unit (upper) 12. Fixing heater lamp/3 (L4) Fixing claw (upper) 13. Fixing roller (lower) Cleaning web wind-up shaft 14.
  • Page 119 FIXING UNIT *1 Fixing heater lamps Decurler Two halogen lamps are used for the fixing upper The paper guided by the reverse/exit selection roller and one halogen lamp is used for the fixing gate is decurled while it passes between the lower roller to reduce the warm-up time and decurler roller and restriction shafts.

  • Page 120: M16 (Web Drive) Control

    FIXING UNIT [3] M16 (Web Drive) Control 2. Signals PRCB input signal (1) FIXEXIT_PS (PS30 to PRCB) 24VDC FIXEXIT_PS PS30 Detection signal of passage of paper at fixing unit PGND S.GND 5VDC exit SGND MC24V_2 DCPS [L]: Detected. WEBSC_DRV [H]: Not detected. PRCB PRCB output signal (1) WEBSC_DRV (PRCB to SD2)

  • Page 121: Fixing Temperature Control

    FIXING UNIT [4] Fixing Temperature Control TRC1 AC(H) FIXHT1_CONT TRC2 FIXHT2_CONT TRC3 FIXHT3_CONT 24VDC S.GND AC(C) MAINRL_CONT DCPS TH1+ TH1- TH2+ TH2- PRCB The fixing roller (upper) is heated by L2 (fixing TS1: Opens at 180°C heater lamp 1) and L3 (fixing heater lamp 2) and TS2: Opens at 110°C the fixing roller (lower) is heated by L4 (fixing heater lamp 3).

  • Page 122: Other Kinds Of Control

    OTHER KINDS OF CONTROL OTHER KINDS OF CONTROL [1] Parts Energized when SW1 (Main Power) is OFF CBR1 AC(L) COIL2 12V1 (Europe DCPS only) COIL1 CBR2 AC(N) (Europe only) TRANSFORMER OPTION 1. Operation If the power cord is plugged in the wall outlet, the following parts are energized regardless of whether SW1 (main power) is ON or OFF: CBR1/2 (circuit breaker/1/2)

  • Page 123: Parts That Operate When Sw1 (Main Power)/Sw2 (Sub Power) Is

    OTHER KINDS OF CONTROL [2] Parts that Operate when SW1 (Main Power)/SW2 (Sub Power) is ON AC(L) 5VDC -5VDC 12VDC DCPS 12V1 AC(N) REM/2 REM/3 AC OFF(IN) 5VDC IP-511 12VDC -12VDC 5VDC 12VDC HD-105 -12VDC 1. Operation (2) AC_OFF (IN) (ICB to DCPS) Operation performed when SW1 (main RL1 (main relay) control signal power) is ON...

  • Page 124: Cooling Fan Control

    OTHER KINDS OF CONTROL [3] Cooling Fan Control MAINFAN EM MAINFAN D MAINFAN HL 20 P.GND WRFAN1 EM WRFAN1 D WRFAN1 HL P.GND CLFAN EM CLNFAN D CLFAN HL P.GND FIXFAN D FIXFAN3 EM P.GND FIXFAN D FIXFAN2 EM P.GND FIXFAN D FIXFAN1 EM P.GND 24V DRV SCANFAN CONT-18...
  • Page 125 OTHER KINDS OF CONTROL (2) OFF timing FM13 (power supply cooling) • During warm-up, stops when M2 (drum) is (1) ON timing turned OFF. Starts rotating at a constant speed when SW1 • After completion of warm-up, not turned OFF (main power) is turned ON. until SW2 (sub power) is turned OFF.
  • Page 126 OTHER KINDS OF CONTROL Fan air flow FRONT FM1: Main body cooling fan 1 FM3: Conveyance suction fan FM9: Scanner cooling fan FM2: Write unit cooling fan Duct FM7: Paper exit fan/R FM4: Developing suction fan 10. FM6: Paper exit fan/F Duct (Lower side of developing unit) 11.
  • Page 127 OTHER KINDS OF CONTROL 2. Signals Output signals Input signals (1) MAINFAN_D (PRCB to FM1) (1) MAINFAN_EM (FM1 to PRCB) FM1 (main body cooling/1) ON/OFF control signal FM1 (main body cooling/1) abnormality detec- [L]: FM1 ON tion signal [H]: FM1 OFF [H]: Abnormality is detected. (2) MAINFAN_HL_20 (PRCB to FM1) (2) WRFAN1_EM (FM2 to PRCB) FM1 (main body cooling/1) rotational speed con-...

  • Page 128: Operation Panel Control

    OTHER KINDS OF CONTROL [L]: FM10 ON (13) SCANFAN_CONT-18 (PRCB to SCDB) [H]: FM10 OFF FM9 (scanner cooling) ON/OFF control signal (12) FAN1 (DCPS to FM13) [L]: FM9 ON [L]: FM13 ON [H]: FM9 OFF [H]: FM13 OFF [4] Operation Panel Control S OUT2 S IN2 /RTS2 /CTS2...
  • Page 129 OTHER KINDS OF CONTROL 2. Signals Input signals (1) S_IN2 (OB1 to ICB) Serial data which informs ICB (image control board) of the operation state of OB1 (operation board/1). (2) /CTS2 (OB1 to ICB) Signal which indicates that data can be sent from OB1 (operation board/1) to ICB (image control board) When this signal is at the high level ([H]), ICB...

  • Page 130: Counter Control

    OTHER KINDS OF CONTROL [5] Counter Control MC24V 3 C(T) TC DRV KEYC DRV S.GND C(K) KEYC SET MC24V 3 MAINEXIT PS PS37 S.GND S OUT2 S IN2 /RTS2 /CTS2 /DTR2 /DSR2 24V1 S.GND P.GND PRCB DCPS 2. Signals This machine has the following counters: C (T): Total counter PRCB input signals C (K): Key counter...

  • Page 131: Option Control

    OTHER KINDS OF CONTROL [6] Option Control (FS-110/FS-210) (LT-402/LT412) IP-511 HD-105 MODEM (COPY VENDOR) 24V1 P.GND S.GND PRCB 12V1 DCPS Options such as LCT and FNS are controlled by the PRCB (printer control board). 1. Operation FNS incorporates CB which exchanges only control data with PRCB (printer control board) of the main body.
  • Page 132 OTHER KINDS OF CONTROL <Functions and output timings of signals for copy vendors> Connector Pin No. Signal name Description Output timing Signal type DV24V Key counter power supply Always 24 V, 300 mA C(K) SIG Key counter connection rec- ognition C(K) GND Signal ground C(K) DRIVE Key counter signal count up 100-ms L-signal output after paper ejection...
  • Page 133 Blank page...
  • Page 134 Service Manual [Field Service] Di551/Di650...
  • Page 135 There are using both Official Options name and Popular Options name in the Di551 / Di650 Service Manual and Option Service Manual. : RADF FN-6, FN-112, FN-113 : FNS C-403, C-404 : LT & LCT Cover Inserter B : PI...
  • Page 136 CONTENTS CONTENTS 1. DISASSEMBLY/ASSEMBLY SAFETY AND IMPORTANT WARNING ITEMS ..S-1 EXTERNAL SECTION........... 1-A-1 IMPORTANT NOTICE ....S-1 Replacing the Ozone Filter .....1-A-1 Replacing the Developing Suction DANGER, WARNING, AND CAUTION Filter ............
  • Page 137 CONTENTS [10] Replacing the Transfer/Separation ADU UNIT.............. 1-N-1 Wires and Transfer/Separation Wire Drawing out and Reinstalling Cleaning Block........1-F-6 the ADU Stand ........1-N-1 [11] Removing and Reinstalling the TSL Cleaning the Paper Dust Unit ............1-F-7 Removing Brush........1-N-1 Cleaning the Paper Mis-centering PS DEVELOPING UNIT ..........
  • Page 138 CONTENTS [12] Removing and Reinstalling the Fixing Removing and Reinstalling the Booklet Temperature Sensors 1 and 2 ....1-O-9 Paper Exit Opening Cover (FN-6 only)...1-R-5 [13] Removing and Reinstalling the CONVEYANCE SECTION........1-R-6 Thermostat (TS1)......... 1-O-11 Replacing the Paper Exit Roller [14] Removing and Reinstalling the (Sponge Roller) ........1-R-6 Replacing the Intermediate Conveyance...
  • Page 139 CONTENTS 2. ADJUSTMENT [15] Recall standard data (Image adjustment) ........2-71 HOW TO USE THIS SECTION ........ 2-1 [16] Running Test Mode ........2-72 Scope and Precautions ......2-1 [17] Test pattern output mode ......2-72 ADJUSTMENTS MADE WHEN REPLACING [18] Test pattern density setting ......2-79 PARTS..............
  • Page 140 CONTENTS [[27] PK Adjusting the tilt of the punch hole PK-2 /PK-5 Connector Layout Drawing ..4-24 position (PK-5 only) ....... 2-134 ZK-2 Connector Layout Drawing ....4-25 [28] PK Adjusting the punch hole vertical JAM CODE LIST............4-26 position (PK-2 only) ....... 2-135 ERROR CODE LIST..........4-38 [29] Sensitivity adjustment for the PK TIMING CHART............4-56...
  • Page 141 Blank page...

  • Page 142: Safety And Important Warning Items

    IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this copier as well as the risk of damage to the copier, Minolta Corporation strongly recommends that all servicing be performed only by Minolta-trained ser- vice technicians. Changes may have been made to this copier to improve its performance after this Service Manual was printed.

  • Page 143: Safety Warnings

    SAFETY WARNINGS MODIFICATIONS NOT AUTHORIZED BY MINOLTA Minolta copiers are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Copier design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
  • Page 144 CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE Minolta copiers are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engineer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
  • Page 145 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Power Plug and Cord • Do not bundle or tie the power cord. Overheating may occur there, leading to a risk of fire. • Check whether dust is collected around the power plug and wall outlet. Using the power plug and wall outlet without removing dust may result in fire.
  • Page 146 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Ground Lead • Pay attention to the point to which the ground lead is connected. Connecting the ground lead to an improper point such as the points listed below results in a risk of explosion and electric shock: a.
  • Page 147 SAFETY AND IMPORTANT WARNING ITEMS CAUTION: Ventilation • The copier generates ozone gas during operation, but it is not sufficient to be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room.
  • Page 148 SAFETY AND IMPORTANT WARNING ITEMS DANGER: Work Performed with the Copier Powered • Take every care when servicing with the external cover detached. High-voltage exists around the drum unit. A risk of electric shock exists. WARNING: Safety Checkpoints • Check the exterior and frame for edges, burrs, and other damages. The user or CE may be injured.
  • Page 149 SAFETY AND IMPORTANT WARNING ITEMS WARNING: Safety Checkpoints • After replacing a part to which AC voltage is applied (e.g., optical lamp and fixing lamp), be sure to check the installation state. A risk of fire exists. • Check the interlock switch and actuator for loosening and check whether the interlock functions properly.

  • Page 150: Safety Information

    SAFETY INFORMATION DANGER: HANDLING OF MATERIALS FOR SERVICING • 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. If the substances get in the eye, rinse with plenty of water immediately.

  • Page 151: Safety Circuits

    SAFETY INFORMATION SAFETY CIRCUITS This machine is provided with the following safety cir- Protection by L2, L3 and L4 (fixing cuits to prevent machine faults from resulting in seri- heater lamps) overheating prevention ous accidents. circuit Overall protection circuit L2 and L3 (fixing heater lamps) overheating DCPS prevention circuit These safety circuits are described below to provide...
  • Page 152 SAFETY INFORMATION Protection by the hardware circuit The output voltages from TH1 and TH2 (fixing temperature sensors) are compared with the abnormality judgment reference value in the comparator circuit. If the output voltage from TH1 or TH2 exceeds the reference value, L2 (fixing heater lamp 1), L3 (fixing heater lamp 2), L4 (fixing heater lamp 3) and RL1 (main relay) are turned OFF in hardware means.

  • Page 153: Indication Of Warning On The Machine

    SAFETY INFORMATION INDICATION OF WARNING 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 DO NOT INSERT your finger into the two...
  • Page 154 SAFETY INFORMATION (Finisher with Cover Inserter B only) CAUTION DO NOT insert your finger into the bottom of the feeder upper part when returning to its original position; otherwise you may be injured. (All trays) CAUTION your hand between the main body and (FN-6/FN-112 Finisher) tray;...
  • Page 155 SAFETY INFORMATION <SCANNER SECTION> <WRITE UNIT> <REAR COVER> CAUTION You may be burned or injured if you touch any area that you are advised by any caution label to keep yourself away from. Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot be read, Contact our Service Office.

  • Page 156: Disassembly/Assembly

    DISASSEMBLY/ASSEMBLY...
  • Page 157 This section explains how to disassemble and reassemble the machine. When disassembling and reassembling the machine, follow the precau- tions given below. 1. Be sure the power cord has been unplugged from the wall outlet. 2. The disassembled parts must be reassembled following the disas- sembly procedure in reverse unless otherwise specified.

  • Page 158: External Section

    EXTERNAL SECTION EXTERNAL SECTION [1] Replacing the Ozone Filter [2] Replacing the Developing Suction Fil- Caution: Be sure the power cord has been Caution: unplugged from the wall outlet. Be sure the power cord has been unplugged from the wall outlet. Caution: When replacing the ozone filter, insert it in the opening in the main body as far Caution: When replacing the developing suc-...

  • Page 159: Removing And Reinstalling The External Covers

    EXTERNAL SECTION [3] Removing and Reinstalling the Exter- (2) Remove seven screws to detach the left side cover. nal Covers Caution: Be sure the power cord has been unplugged from the wall outlet. Procedure (1) Remove fourteen screws to detach the rear cover.
  • Page 160 EXTERNAL SECTION (3) Loosen one screw and remove the developing (14) Remove the top cover (middle front) and top suction filter cover. cover (middle rear). (4) Loosen five screws and detach the right side cover (upper). Caution: The developing suction filter cover detaches together with the right side cover (upper).

  • Page 161: Changing The Operation Panel Attachment Angle And Removing/Reinstalling

    EXTERNAL SECTION (15) Open the front right door and front left door. [4] Changing the Operation Panel (16) Remove two screws to remove the front right Attachment Angle and Removing/ door hinge (lower) and front right door. Reinstalling (17) Remove two screws and remove the front left Caution: door hinge (lower) and the front left door.
  • Page 162 EXTERNAL SECTION (4) When changing the operation panel attachment (5) Remove the relay connectors (CN163, 164). angle, align the operation panel stopper with the Caution: Each relay connector consist of two stopper hole at the front side on the bottom of the male sides and one female side.

  • Page 163: Resetting The Circuit Breaker

    EXTERNAL SECTION [5] Resetting the Circuit Breaker Caution: Be sure the power cord has been unplugged from the wall outlet. Caution: Connection of cables to circuit breaker 1 and 2 (CBR1, 2) must not be changed. Procedure (1) Remove the rear cover. (2) Remove two screws and loosen the circuit breaker assembly.

  • Page 164: Drive Section

    DRIVE SECTION DRIVE SECTION [1] Removing and Reinstalling the Drum (5) Remove five screws at the rear and three screws on the right side and remove all connectors from Motor(M2) the image control board (ICB). Caution: Screws (3) Be sure the power cord has been unplugged from the wall outlet.

  • Page 165: Removing And Reinstalling The Fixing Input Gear

    DRIVE SECTION (8) Remove three screws and remove the two fly- [2] Removing and Reinstalling the Fixing wheels. Input Gear Caution: Flywheels (2) Be sure the power cord has been unplugged from the wall outlet. Procedure (1) Open the image control bard mounting board. (2) Remove six screws and remove the fixing motor Screws (3) cover.

  • Page 166: Scanner Section

    SCANNER SECTION SCANNER SECTION [1] Screws that Must not be Removed [2] Removing and Reinstalling the CCD 14 screws securing the CCD unit Unit Caution: Screws that must not be removed Be sure the power cord has been unplugged from the wall outlet. Caution1: Be sure to adjust the image after installing unit...

  • Page 167: Replacing The Exposure Lamp

    SCANNER SECTION (3) Remove the connector (CN170) from the A/D [3] Replacing the Exposure Lamp converter board (ADB). Caution1: Be sure the power cord has been CCD unit unplugged from the wall outlet. Caution2: Do not touch the exposure lamp with bare hands.

  • Page 168: Removing And Reinstalling The Exposure Unit

    SCANNER SECTION [4] Removing and Reinstalling the Expo- (6) Move the exposure unit to the notch in the main body frame on the paper exit side. sure Unit (7) Remove two screws to detach the cord clamp Caution: (B). Be sure the power cord has been (8) Remove one screw to remove the ground termi- unplugged from the wall outlet.

  • Page 169: Installing The Optics Wire

    SCANNER SECTION Installation procedure [5] Installing the Optics Wire (1) Move the V-mirror unit toward the paper exit side, Caution: then insert the optics positioning jigs from the Be sure the power cord has been front to secure the V-mirror unit. Ensure that the unplugged from the wall outlet.
  • Page 170 SCANNER SECTION Four turns Four turns Rear Front Five turns Five turns Front Metal bead Pulley 3 Wire stopper Spring fixing plate Pulley 1 V-mirror unit Drive pulley 10. Exposure unit mounting piece V-mirror pulley 11. Spring Pulley 2 12. Screws Caution: There are two grooves in the wire (6) Install the other wire following the same proce- stopper.

  • Page 171: Cleaning The Slit Glass And Platen Glass

    SCANNER SECTION [6] Cleaning the Slit Glass and Platen [7] Replacing the Scanner Motor (M11) Glass Caution: Be sure the power cord has been Caution: unplugged from the wall outlet. Be sure the power cord has been (1) Remove the RADF unit, original stopper plates unplugged from the wall outlet.
  • Page 172 SCANNER SECTION (5) Install the scanner motor (M11) and the scanner (7) Pull the spring scale upward, and tighten the belt. Tighten the scanner motor loosely with four scanner motor (M11) tightly with the tension screws. pressure of 2 ± 0.2 kgf. (Use four screws) Caution1: Make sure to install the belt in the Caution: Make sure that the scanner motor middle of two pulleys.
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  • Page 174: Write Section

    WRITE SECTION WRITE SECTION [1] Removing and Reinstalling the Write Unit Warning: (1) Do not energize the write unit when it is not in the correct position. (2) Never remove the write unit cover and the polygon unit cover. (3) Never look directly into the laser beam. It can cause blindness.

  • Page 175: Cleaning The Dust-Proof Glass

    WRITE SECTION [2] Cleaning the Dust-proof Glass Caution: Be sure the power cord has been unplugged from the wall outlet. Procedure (1) Remove the write unit. (2) Clean the dust-proof glass at the bottom of the write unit with cleaning pad and blower brush. Write unit Dust-proof glass (3) Reinstall the above parts following the removal...

  • Page 176: Drum Unit

    DRUM UNIT DRUM UNIT [1] Removing and Reinstalling the Drum (4) Loosen one screw and slide the blade fixing com- ponent in the direction of the arrow until it stops Unit to release the crimp of the cleaning blade. Caution: (5) Loosen the screw of the blade fixing component.
  • Page 177 DRUM UNIT (9) Hold the two sections shown in the figure and pull out the drum unit. Drum unit Toner supply pipe Hold here Drum shaft coupling Drum coupling Screws (10) Reinstall the above parts following the removal steps in reverse. Caution: To install the coupling, see "[2] Install- ing the Coupling."...

  • Page 178: Installing The Coupling

    DRUM UNIT [2] Installing the Coupling (4) Turn the head of the drum coupling clockwise so that the flange section on the drum shaft coupling Caution: is flush. Be sure the power cord has been unplugged from the wall outlet. Procedure (1) Clean the outer surface of the drum coupling and drum shaft coupling with drum cleaner and...

  • Page 179: Removing, Cleaning, And Reinstalling The Drum

    DRUM UNIT [3] Removing, Cleaning, and Reinstall- Procedure (1) Remove the drum unit from the main body. ing the Drum (2) Remove the charging corona unit, developing Caution: unit, cleaning blade, and toner guide roller from Be sure the power cord has been the drum unit.

  • Page 180: Removing And Reinstalling The Separation Claws And Separation Claw Solenoid

    DRUM UNIT [4] Removing and Reinstalling the Sepa- ration Claws and Separation Claw Solenoid Caution: Be sure the power cord has been unplugged from the wall outlet. Caution1: Take care not to damage the drum when removing separation claws. Caution2: Note the orientation and position of the separation claws when reinstall- ing them.
  • Page 181 DRUM UNIT (7) Remove two screws and detach the separation [Reference] claw SD (SD1). When removing the separation claw solenoid (Normally, it should not be removed except when Separation claw SD (SD1) replacing the solenoid). (1) Install the separation claw unit to the drum unit.

  • Page 182: Removing And Reinstalling The Toner Control Sensor Board

    DRUM UNIT [5] Removing and Reinstalling the Toner (7) Reinstall the above parts following the removal steps in reverse. Control Sensor Board Caution: Caution: When installing the toner control sen- Be sure the power cord has been sor board, tighten the screws pulling it unplugged from the wall outlet.
  • Page 183 Blank page...
  • Page 184 DRUM UNIT 1-E-9...
  • Page 185 DRUM UNIT 1-E-10...

  • Page 186: Corona Unit

    CORONA UNIT CORONA UNIT [1] Screws that Must not be Removed [2] Removing and Reinstalling the Five screws securing the transfer entrance Charging Corona Unit guide plate Caution: Be sure the power cord has been Screws that must not be removed unplugged from the wall outlet.

  • Page 187: Removing And Reinstalling The Charge Control Plate

    CORONA UNIT [3] Removing and Reinstalling the [4] Replacing the Charging Wires Charge Control Plate Caution: Be sure the power cord has been Caution: unplugged from the wall outlet. Be sure the power cord has been Procedure unplugged from the wall outlet. (1) Remove the charging corona unit.

  • Page 188: Removing And Reinstalling The Charging Wire Cleaning Unit

    CORONA UNIT (4) Remove the charge control plate cleaner. [5] Removing and Reinstalling the (5) Remove the spring and remove the charging Charging Wire Cleaning Unit wire. Caution: Be sure the power cord has been unplugged from the wall outlet. Procedure (1) Remove the charging wire.

  • Page 189: Removing And Reinstalling The Pcl

    CORONA UNIT [6] Removing and Reinstalling the PCL [7] Cleaning the Charging Corona Unit/ Caution: Be sure the power cord has been Caution: unplugged from the wall outlet. Be sure the power cord has been Procedure unplugged from the wall outlet. (1) Remove the charging corona unit.

  • Page 190: Removing And Reinstalling The Transfer/Separation Corona Unit

    CORONA UNIT [8] Removing and Reinstalling the Trans- [9] Removing and Reinstalling the fer/Separation Corona Unit Plunger Prevention Plate Caution: Caution: Be sure the power cord has been Be sure the power cord has been unplugged from the wall outlet. unplugged from the wall outlet.

  • Page 191: Replacing The Transfer/Separation Wires And Transfer/Separation Wire Cleaning Block

    CORONA UNIT [10] Replacing the Transfer/Separation (6) Release and remove three wires from each cleaning block. Wires and Transfer/Separation Wire Cleaning Block Caution: Be careful not to drop and lose the support rubber when removing the Caution: wire. Be sure the power cord has been unplugged from the wall outlet.

  • Page 192: Removing And Reinstalling The Tsl Unit

    CORONA UNIT (7) Turn the transfer/separation corona unit upside [11] Removing and Reinstalling the TSL down, remove the stop rings, and remove the Unit transfer wire cleaning block and separation wire Caution: cleaning block from the front side. Be sure the power cord has been unplugged from the wall outlet.
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  • Page 194: Developing Unit

    DEVELOPING UNIT DEVELOPING UNIT [1] Screws that must not be Removed [2] Removing and Reinstalling the Devel- Procedure oping Unit (1) Two screws securing the toner transfer regula- Caution: tion plate. Be sure the power cord has been (2) One screw securing the magnet angle adjusting unplugged from the wall outlet.

  • Page 195: Replacing The Developer

    DEVELOPING UNIT [3] Replacing the Developer (4) Tilt the developing unit about 45° and rotate the developing gear counterclockwise to discharge Caution1: When replacing the developer in the all of the developer adhering to the inside of the developing unit, take care not to developing unit and magnet roller.

  • Page 196: Cleaning The Developing Unit Bias Shaft

    DEVELOPING UNIT (8) Rotate the developing gear counterclockwise to [4] Cleaning the Developing Unit Bias check that the developer bristles along the entire shaft length of the developing sleeve. Caution: Be sure the power cord has been Developing unit stopper roller unplugged from the wall outlet.
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  • Page 198: Toner Supply Unit

    TONER SUPPLY UNIT TONER SUPPLY UNIT [1] Replacing and Cleaning the Toner Cartridge Procedure (1) Open the toner supply door and pull the toner supply unit forward. Toner supply door Toner supply unit (2) Remove the toner cartridge. (3) After removing the toner cartridge, clean the area around the toner cartridge insertion hole with a cleaning pad.
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  • Page 200: Cleaning/Toner Recycle Unit

    CLEANING/TONER RECYCLE UNIT CLEANING/TONER RECYCLE UNIT [1] Removing and Reinstalling the Clean- (5) Check that the blade fixing component is released. If it is not, release it referring to"DRUM ing Blade UNIT." Caution: Be sure the power cord has been unplugged from the wall outlet.

  • Page 201: Removing And Reinstalling The Toner Guide Roller (Tgr)

    CLEANING/TONER RECYCLE UNIT [2] Removing and Reinstalling the Toner Guide Roller (TGR) Caution: Be sure the power cord has been unplugged from the wall outlet. Caution1: Be sure to replace the following parts at the same time: • Cleaning blade •...

  • Page 202: Paper Feed Units Of Trays 1 And 2

    PAPER FEED UNITS OF TRAYS 1 AND 2 PAPER FEED UNITS OF TRAYS 1 AND 2 [1] Removing and Reinstalling the Paper [2] Removing and Reinstalling the Paper Feed Unit Feed Trays 1 and 2 Caution: Warning: Be sure the power cord has been When removing the tray, stand in a proper unplugged from the wall outlet.

  • Page 203: Feed Roller And Feed Roller Rubber

    PAPER FEED UNITS OF TRAYS 1 AND 2 [3] Removing and Reinstalling the Paper (6) Reinstall the above parts following the removal steps in reverse. Feed Roller and Feed Roller Rubber Caution1: When reinstalling the rollers, pay Procedure attention to their orientation. (1) Remove the paper feed unit.

  • Page 204: Replacing The Pre-Registration And Feed Clutches (Mcs)

    PAPER FEED UNITS OF TRAYS 1 AND 2 [5] Replacing the Pre-registration and [6] Replacing the Wires Feed Clutches (MCs) Caution1: After replacing or reinstalling the wires, manually rotate the up/down Procedure drive shaft to check that the tray (1) Remove the paper feed unit. moves up and down smoothly.
  • Page 205 PAPER FEED UNITS OF TRAYS 1 AND 2 (3) Remove the front and rear wires according to steps 1 to 7 below. . Remove the E-ring to detach . Remove the E-ring to slide out the wire restraining cover and the drive pulley.
  • Page 206 PAPER FEED UNITS OF TRAYS 1 AND 2 <Installing Wires> Install the wires C and D from . Install the pulley, pass wire . Install the pulley, pass wires inside the drive shaft hole, D through the pulley, and C and D, and install the wire push in the drive pulley, and install the wire restraining restraining cover and retain-...
  • Page 207 PAPER FEED UNITS OF TRAYS 1 AND 2 <Wire Lengths> 182.8±1 mm (Tray 1, 2) Wire A, C 473.1±1 mm (Tray 1, 2) Wire B, D 1-J-6...

  • Page 208: Paper Feed Unit Of Tray 3

    PAPER FEED UNIT OF TRAY 3 PAPER FEED UNIT OF TRAY 3 [1] Removing and Reinstalling the Paper [2] Removing and Reinstalling Paper Feed Unit Feed Tray 3 Caution: Warning: Be sure the power cord has been When removing the tray, stand in a proper unplugged from the wall outlet.

  • Page 209: Removing And Reinstalling The Paper

    PAPER FEED UNIT OF TRAY 3 [3] Removing and Reinstalling the Paper (6) Reinstall the above parts following the removal steps in reverse. Feed Roller and Feed Roller Rubber Caution1: When reinstalling the rollers, pay Procedure attention to their orientation. (1) Remove the paper feed unit.

  • Page 210: Replacing The Pre-Registration And [6] Feed Clutches (Mcs)

    PAPER FEED UNIT OF TRAY 3 [5] Replacing the Pre-registration and [6] Replacing the Wires Feed Clutches (MCs) Caution1: After replacing or reinstalling the wires, manually rotate the up/down Procedure drive shaft to check that the tray (1) Remove the paper feed unit. moves up and down smoothly.
  • Page 211 PAPER FEED UNIT OF TRAY 3 (5) Remove the front and rear wires according to steps 1 to 7 below. . Remove the E-ring to detach . Remove the E-ring to slide out the wire restraining cover and the drive pulley. pulley.
  • Page 212 PAPER FEED UNIT OF TRAY 3 <Installing Wires> Install the wires C and D from . Install the pulley, pass wires . Install the pulley, pass wire inside the drive shaft hole, C and D, and install the wire D through the pulley, and push in the drive pulley, and restraining cover and retain- install the wire restraining...
  • Page 213 PAPER FEED UNIT OF TRAY 3 <Wire Lengths> 182.8±1 mm (Tray 3) Wire A, C 473.1±1 mm (Tray 3) Wire B, D 1-K-6...

  • Page 214: By-Pass Feed Tray

    BY-PASS FEED TRAY BY-PASS FEED TRAY [1] Removing and Reinstalling the by- pass Feed Tray Paint mark Caution: Be sure the power cord has been unplugged from the wall outlet. Procedure (1) Remove the developing suction filter cover and right side cover (upper). (See "EXTERNAL SEC- TION.") (2) Remove connector (CN214).

  • Page 215: Replacing The Double Feed Prevention Roller Rubber

    BY-PASS FEED TRAY [3] Replacing the Double Feed Preven- (4) Remove the double feed prevention roller assembly from the by-pass feed tray unit. tion Roller Rubber (5) Remove the stop ring to pull out the shaft and Procedure remove the double feed prevention roller rubber (1) Remove the by-pass feed tray and place the tray from the double feed prevention roller.

  • Page 216: Vertical Conveyance Section

    VERTICAL CONVEYANCE SECTION VERTICAL CONVEYANCE SECTION [1] Removing and Reinstalling the Verti- [2] Removing and Reinstalling the Verti- cal Conveyance Section cal Conveyance MC (MC11, MC12) Caution: Caution: Be sure the power cord has been Be sure the power cord has been unplugged from the wall outlet.
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  • Page 218: Adu Unit

    ADU UNIT ADU UNIT [1] Drawing out and Reinstalling the ADU [2] Cleaning the Paper Dust Removing Stand Brush Warning: Caution: The interlock which is turned OFF when Be sure the power cord has been the front right or left door opens or closes unplugged from the wall outlet.

  • Page 219: Cleaning The Paper Mis-Centering Ps (Ps70)/Leading Edge Ps (Ps43)

    ADU UNIT [3] Cleaning the Paper Mis-centering PS [4] Removing and Reinstalling the Reg- (PS70)/Leading Edge PS (PS43) istration MC (MC1) Warning: Warning: The interlock which is turned OFF when The interlock which is turned OFF when the front right or left door opens or closes the front right or left door opens or closes should never be turned ON forcibly with should never be turned ON forcibly with...

  • Page 220: Removing And Reinstalling The Second

    ADU UNIT (4) Remove one screw and remove the registration [5] Removing and Reinstalling the Sec- roller rotation knob. ond Paper Feed Unit Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out.

  • Page 221: Cleaning The Registration Ps (Ps44)

    ADU UNIT (4) Remove five screws to remove the second paper [6] Cleaning the Registration PS (PS44) feed unit. Warning: The interlock which is turned OFF when Screws Screws the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out.

  • Page 222: Removing And Reinstalling The Registration Roller

    ADU UNIT [7] Removing and Reinstalling the Reg- (6) Remove the two E-rings (one at the left and the other at the right) and one bearing from the reg- istration Roller istration roller. Warning: The interlock which is turned OFF when Bearing the front right or left door opens or closes should never be turned ON forcibly with...

  • Page 223: Removing And Reinstalling The Pre-Transfer Roller

    ADU UNIT [8] Removing and Reinstalling the Pre- (4) Remove the E-ring to remove the pre-transfer roller from the shaft. transfer Roller Warning: Caution: When reinstalling, pay attention to the The interlock which is turned OFF when position of the E-ring. the front right or left door opens or closes Pre-transfer roller should never be turned ON forcibly with...

  • Page 224: Cleaning The Adu Paper Reverse Ps (Ps45)/Reverse/Exit Ps (Ps46)

    ADU UNIT [9] Cleaning the ADU Paper Reverse PS (7) Remove two screws to remove the ADU reverse guide assembly. (PS45)/Reverse/Exit PS (PS46) Warning: Caution: When reinstalling, align the projection The interlock which is turned OFF when on the rear of the ADU reverse guide the front right or left door opens or closes assembly with the hole on the ADU should never be turned ON forcibly with...
  • Page 225 ADU UNIT (8) Remove the nine screws illustrated from the bot- (10) Lower the ADU bottom plate assembly straight tom of the ADU stand. down and remove the ADU guide cover. Front Screws Screws Paper exit side ADU bottom plate assembly ADU guide cover ADU bottom plate assembly (9) Remove one screw while holding the ADU bot-...

  • Page 226: Removing And Reinstalling The Adu Reverse Roller

    ADU UNIT [10] Removing and Reinstalling the ADU (9) Slide the ADU reverse roller to the upper side and then to the lower side to slide it out. Reverse Roller Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out.

  • Page 227: Removing And Reinstalling The Adu Stand

    ADU UNIT [11] Removing and Reinstalling the ADU (8) Disconnect the three relay connectors (CN445, 446, 447). Stand Warning: Caution: Disconnect each connector on the The interlock which is turned OFF when ADU stand. the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out.

  • Page 228: Removing And Reinstalling The Pre- Registration Roller

    ADU UNIT (9) Remove one screw to release the lock of the han- [12] Removing and Reinstalling the Pre- dle(right). registration Roller (10) Remove the two screws securing the guide rails Warning: on the paper feed side and paper exit side. The interlock which is turned OFF when Caution: Do not mistake the screws securing the front right or left door opens or closes...

  • Page 229: Removing And Reinstalling The Adu Conveyance Roller 3 And 4

    ADU UNIT [13] Removing and Reinstalling the ADU Conveyance Roller 3 and 4 Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out. Warning: Removal and reinstallation of the ADU stand involve carrying a heavy load so it...
  • Page 230 ADU UNIT (7) Remove two screws to release the high voltage (11) Remove two screws to remove the harness supply unit (1). guide plate (front). (8) Disconnect the two connectors (CN460, 461). Caution: Each relay connector consists of two male sides and one female side. Be sure to remove only the male side (shown below) of the connector.
  • Page 231 ADU UNIT (13) Remove the stop rings to remove the ADU decel- (18) Remove the front E-ring and bearing, and eration MC (MC2) and ADU conveyance MC remove the ADU conveyance roller (3) and ADU (MC13). conveyance roller (4) by sliding them back and forth.

  • Page 232: Removing And Reinstalling The Adu Conveyanece Roller 1 And 2

    ADU UNIT [14] Removing and Reinstalling the ADU (11) Disconnect the connector (CN415). (12) Remove three screws to detach the reverse Conveyanece Roller 1 and 2 motor assembly. Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out.
  • Page 233 ADU UNIT (13) Disconnect the two connectors (CN403, 404). (17) Remove the E-ring from ADU conveyance roller (14) Disconnect the connector (CN417). (2) shaft. (18) Remove the front E-ring, two belt holding collars, Caution: Each relay connector consists of two ADU conveyance belt (2), and two ADU convey- male sides and one female side.

  • Page 234: Removing And Reinstalling The Paper Reverse/Exit Roller

    ADU UNIT [15] Removing and Reinstalling the Paper (12) Remove the paper reverse/exit roller by sliding it back and forth. Reverse/Exit Roller Warning: The interlock which is turned OFF when the front right or left door opens or closes should never be turned ON forcibly with the ADU stand drawn out.
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  • Page 236: Fixing Unit

    FIXING UNIT FIXING UNIT [1] Removing and Reinstalling the Fixing [2] Removing and Reinstalling the Fixing Unit Unit (Top) Caution: Warning: Before opening the fixing unit (top), check Do not touch the fixing unit immediately that the pressure release lever is turned after turning OFF the main power switch counterclockwise and the bottom roller because it is very hot and you may suffer...

  • Page 237: Removing And Reinstalling The Web Cover

    FIXING UNIT [3] Removing and Reinstalling the Web [4] Removing and Reinstalling the Clean- Cover ing Web Procedure Procedure (1) Remove the fixing unit. (1) Draw out the ADU stand. (See "ADU UNIT.") (2) Remove the fixing unit front cover. (2) Remove the web cover.

  • Page 238: Replacing The Fixing Heater Lamps (L2, L3)

    FIXING UNIT [5] Replacing the Fixing Heater Lamps (7) Remove the two Faston terminals of the far side lamp. (L2, L3) Caution: When removing the Faston terminals, Caution: be sure to hold the connector. Con- Do not touch the fixing heater lamp with nector cannot be removed by pulling bare hands.

  • Page 239: Replacing The Fixing Heater Lamp(L4)

    FIXING UNIT [6] Replacing the Fixing Heater (4) Remove the rear lamp harness from the two har- ness guide to remove the Faston terminal. Lamp(L4) Caution: Do not touch the fixing heater lamp with Harness guides bare hands. Caution1: Install the heater lamp with the man- ufacturers mark facing the rear.

  • Page 240: Removing And Reinstalling The Fixing Separation Claw (Upper) Unit And Fixing Separation Claws (Upper)

    FIXING UNIT [7] Removing and Reinstalling the Fixing (9) Reinstall the above parts following the removal steps in reverse. Separation Claw (Upper) Unit and Fix- ing Separation Claws (Upper) Caution: After installing the fixing separation Procedure claw (upper), move the upper claws (1) Remove the fixing unit.

  • Page 241: Removing And Reinstalling The Fixing Separation Claw (Lower) Unit And Fixing Separation Claws (Lower)

    FIXING UNIT [8] Removing and Reinstalling the Fixing [9] Removing and Reinstalling the Fixing Separation Claw (Lower) Unit and Fix- Upper Roller ing Separation Claws (Lower) Procedure (1) Remove the fixing unit. Procedure (2) Remove the fixing unit front cover. (1) Remove the fixing unit.

  • Page 242: Removing And Reinstalling The Fixing Lower Roller

    FIXING UNIT [10] Removing and Reinstalling the Fixing Lower Roller Procedure (1) Remove the fixing unit. (2) Remove two screws to remove the fixing entrance guide plate (lower) Fixing entrance guide plate (lower) Screw Screw (3) Remove the fixing separation claw (lower) unit. (4) Remove the fixing lower roller upward.
  • Page 243 FIXING UNIT [11] Removing and Reinstalling the De- (6) From the rear side, remove one E-ring, one washer, one screw, and bearing in this order and curler roller then remove the decurler roller from the frame. Procedure (1) Remove the fixing unit. (2) Open the fixing unit (top).
  • Page 244 FIXING UNIT [12] Removing and Reinstalling the Fixing Reinstallation procedure (1) Secure fixing temperature sensor 2 to the fixing Temperature Sensors 1 and 2 plate with a screw. Caution1: After reinstalling fixing temperature (2) Make sure that fixing temperature sensor 2 sensor 2, make sure that the sensor touches the fixing upper roller.
  • Page 245 FIXING UNIT f) Set the distance "a" between the fixing tem- perature sensor 1 and fixing upper roller so that it is equal to the thickness of the position- ing jig. Fixing temperature sensor 1 Fixing upper roller Standard value of a : 0.75 ± 0.05 mm (4) Apply screw lock agent to the two screws secur- ing fixing temperature sensor 1.
  • Page 246 FIXING UNIT [13] Removing and Reinstalling the Ther- Reinstallation procedure (1) Connect two Faston terminals to the thermostat/ mostat/U (TS1) Caution: (2) Set a thermostat positioning jig (4024-2152-01) This is an important safety part. (P/N: between the thermostat/U and fixing upper roller SP00-0020) Be sure to observe the follow- and secure the thermostat/U with one screw so ing cautions and steps when removing or...
  • Page 247 FIXING UNIT g) When making the adjustment, make sure that [14] Removing and Reinstalling the Ther- the thermostat/U does not ride on the posi- mostat/L (TS2) tioning jig (C). Caution: This is an important safety part. Be sure to observe the following cautions and steps when removing or reinstalling.
  • Page 248 FIXING UNIT Reinstallation procedure f) After setting the distance “b”, remove the (1) Set a part (a) thermostat/L positioning jig (4024- thermostat/L positioning jig, and make sure 2992-01) between the thermostat/L and the fix- that the part (b) thermostat/L positioning jig ing lower roller, and secure the thermostat/L with cannot be inserted in a space between the fix- two screws so that the distance between the...
  • Page 249 Blank page...

  • Page 250: Edh

    EXTERNAL SECTION [1] Removing the RADF (4) Remove four connectors (CN612 to CN615) from the scanner drive board (SCDB) on the Caution: main body. Make sure power cord of the main unit has been unplugged from the wall outlet. Procedure (1) Remove the rear cover.

  • Page 251: Reinstalling The Radf

    (7) Close the RADF. Remove three screws to detach [2] Reinstalling the RADF each of two fixing plates. Caution: Make sure power cord of the main unit has been unplugged from the wall outlet. Procedure (1) Place the RADF on the top of the main unit and loosely secure each of the two fixing plates with four screws.
  • Page 252 (5) Install two RADF positioning jigs in the mounting (11) Close the RADF and check whether both stopper holes of the original stopper plates (left). pieces on the RADF-side touch the slit glass. (6) Close the RADF to mate the reference holes and RADF positioning jigs.

  • Page 253: Original Feed/Conveyance/Exit Section

    ORIGINAL FEED/CONVEYANCE/EXIT SECTION [1] Replacing the Pickup Roller and Con- (8) Remove the original feed roller rubber from the original feed roller. veyance Roller Rubber Caution: Make sure power cord of the main unit has been unplugged from the wall outlet. Procedure (1) Open the Jam access cover.

  • Page 254: Cleaning The Cleaning Pad

    [2] Cleaning the Cleaning Pad [3] Replacing the Double Feed Preven- tion Roller / Double Feed Prevention Caution: Roller Rubber Make sure power cord of the main unit has been unplugged from the wall outlet. Caution: Procedure Make sure power cord of the main unit has (1) Open the Jam access cover.
  • Page 255 Blank page...

  • Page 256: Paper Feed Section

    C-403 / C-404 PAPER FEED SECTION [1] Cleaning the Paper Dust Removing [2] Cleaning the LT feed PS (PS106)/LT Brush first paper feed PS (PS107) Caution:If LT is connected to the main Caution:If LT is connected to the main body, make sure that main body body, make sure that main body power plug is disconnected power plug is disconnected...

  • Page 257: Removing And Reinstalling The Paper Feed Roller Unit

    C-403 / C-404 [3] Removing and Reinstalling the Paper [4] Replacing the Paper Feed Roller Rub- Feed Roller Unit ber/Feed Roller Rubber Caution:If LT is connected to the main Caution:If LT is connected to the main body, make sure that main body body, make sure that main body power plug is disconnected power plug is disconnected...

  • Page 258: Replacing The Double Feed Prevention Roller Rubber

    C-403 / C-404 (5) Remove the bearing from the opposite side of the [5] Replacing the Double Feed Preven- coupling, then remove the paper feed roller from tion Roller Rubber the shaft. Caution:If LT is connected to the main (6) Remove the stop ring to pull the feed roller from body, make sure that main body the shaft.
  • Page 259 C-403 / C-404 (3) Remove two screws to detach the double feed (5) Remove the double feed prevention roller rubber prevention roller unit. from the double feed prevention roller. Caution: When reinstalling the double feed pre- Paint mark vention roller unit, tighten the screws on the rear side first.

  • Page 260: Replacing The Lt Feed Mc (Mc101)/Lt First Paper Feed Mc (Mc102)

    C-403 / C-404 [6] Replacing the LT feed MC (MC101)/LT (5) Disconnect two relay connectors (CN765, CN766) of the clutches. first paper feed MC (MC102) (6) Remove the stop ring to detach each clutch. Procedure (1) Open the top cover. (2) Remove the spring from the paper feed roller unit.

  • Page 261: Replacing The C-403 Up/Down Wires

    C-403 / C-404 [7] Replacing the C-403 Up/Down Wires (5) Remove twelve screws to detach the rear cover. Caution: With the power held on, press the LT Screw tray down switch (SW100) to move the up/down plate down to the bottom in advance.
  • Page 262 C-403 / C-404 (10) Remove three screws to detach the up/down (11) Replace the up/down wire following the instruc- motor assembly. tions in “Removing Up/Down Wires’’ and “Install- ing Up/Down Wires.’’ Caution: Two sets of four up/down wires with different length, one set at the front and the other at the back, are used.
  • Page 263 C-403 / C-404 <Removing the Up/Down Wires> Up/down plate 2.Release the metal Wire B ball to remove wireC. Wire A 18.Release the metal- Wire B ball to remove wire A. Wire A 4.Release the metal ball to remove wire D. 16.Release the metal 14.Release the metal ball to remove wire B.
  • Page 264 C-403 / C-404 <Installing the Up/Down Wires> Up/down plate 20.Insert wire B in the pulleys, then attach a metal ball. Wire B 2.Insert wire A in the pulleys, Wire A then attach a metal ball. Wire B 17.Insert wire D in the pulleys, Wire A then attach a metal ball.

  • Page 265: Replacing The C-404 Up/Down Wires

    C-403 / C-404 (12) After installing the up/down wires, make sure the [8] Replacing the C-404 Up/Down Wires up/down wires are passed in the grooves in the Procedure pulleys properly and wires do not run on the Caution: With the power held on, press the LT sides of the pulleys.
  • Page 266 C-403 / C-404 (9) Remove the bearing behind gear C. (15) Remove the E-ring to remove the bearing. (10) Remove the E-ring to remove the up/down gear. (16) Remove the six screws to remove the up/down (11) Remove the detent pin for up/down gear from the motor mounting assembly.
  • Page 267 C-403 / C-404 <Removing the Up/Down Wires> Up/down plate 2.Release the metal ball to remove wire A. Wire C Wire D 18.Release the metal Wire C ball to remove wire D. Wire D 4.Release the metal ball to remove wire B. 14.Release the metal ball to remove wire D.
  • Page 268 C-403 / C-404 <Installing the Up/Down Wires> Up/down plate 20.Insert wire A in the pulleys, then attach a metal ball. Wire C Wire D 2.Insert wire D in the pulleys, Wire C then attach a metal ball. Wire D 17.Insert wire B in the pulleys, then attach a metal ball.
  • Page 269 C-403 / C-404 (18) After installing the up/down wires, check whether they are engaged with the pulleys properly and whether they do not ride over the pulleys. Next, move the up/down plate manually to check whether it moves up and down smoothly. Caution: If the up/down plate does not move smoothly, remove the up/down wires and install them again.

  • Page 270: External Section

    FN-6 / FN-112 EXTERNAL SECTION [1] Removing and Reinstalling the Book- [2] Removing and Reinstalling the Top let Tray (FN-6 only) Cover/1 (1) Remove two screws to detach the booklet tray. Procedure (1) Remove the two caps. (2) Open the front door, and remove five screws to detach the top cover/1.

  • Page 271: Removing And Reinstalling The Top Cover/2

    FN-6 / FN-112 [3] Removing and Reinstalling the Top [4] Removing and Reinstalling the Side Cover/2 Cover Caution: Caution: Make sure that the power cord of the main Make sure that the power cord of the main body is unplugged from the power outlet. body is unplugged from the power outlet.

  • Page 272: Removing And Reinstalling The Front Door

    FN-6 / FN-112 [5] Removing and Reinstalling the Front [6] Removing and Reinstalling the Rear Door Cover Caution: Caution: Make sure that the power cord of the main Make sure that the power cord of the main body is unplugged from the power outlet. body is unplugged from the power outlet.

  • Page 273: Removing And Reinstalling The Main Tray

    FN-6 / FN-112 [7] Removing and Reinstalling the Main (3) Remove the two mounting screws. (4) Lift the main tray and detach it from the hooks of Tray the up/down stay. Caution: Main tray After you have lowered the main tray, be sure to unplug the power cord of the main body from the power outlet.

  • Page 274: Removing And Reinstalling The Main Paper Exit Opening Cover

    FN-6 / FN-112 [8] Removing and Reinstalling the Main [9] Removing and Reinstalling the Book- Paper Exit Opening Cover let Paper Exit Opening Cover (FN-6 only) Caution: Procedure Make sure that the power cord of the main (1) Remove the booklet tray. body is unplugged from the power outlet.

  • Page 275: Conveyance Section

    FN-6 / FN-112 CONVEYANCE SECTION [1] Replacing the Paper Exit Roller (3) Insert the end of the blade screwdriver into the slot in the sponge roller, and twist the screwdriver (Sponge Roller) to pry apart. Caution: After you have lowered the main tray, be Paper exit roller (sponge roller) sure to unplug the power cord of the main body from the power outlet.

  • Page 276: Replacing The Intermediate Conveyance Roller (Sponge Roller)

    FN-6 / FN-112 [2] Replacing the Intermediate Convey- (4) Place the two components of a new sponge roller around the roller shaft so that the tabs of the ance Roller (Sponge Roller) components are aligned with the dents on the Caution: shaft.

  • Page 277: Removing And Reinstalling The Paper Exit Opening Unit

    FN-6 / FN-112 [3] Removing and Reinstalling the Paper (3) Remove three screws holding the clamps, one screw holding the ground. Also remove the con- Exit Opening Unit nector (CN110) for the paper exit opening SD Caution: (SD704) and the main tray paper exit PS Make sure that the power cord of the main (PS706).

  • Page 278: Main Tray Section

    FN-6 / FN-112 MAIN TRAY SECTION [1] Replacing the Tray Up/down Motor [2] Replacing the Up/Down Wire (M703) Caution: Make sure that the power cord of the main Caution: body is unplugged from the power outlet. Make sure that the power cord of the main body is unplugged from the power outlet.
  • Page 279 FN-6 / FN-112 (3) Remove two screws. Detach the wire bracket on (5) Remove the E-ring and the up/down pulley/L. the rear from the up/down stay. Then remove the up/down wire. CAUTION: When you remove the up/down pul- ley, the pin falls. Be careful not to lose the pin.
  • Page 280 FN-6 / FN-112 (7) Secure the end of a new up/down wire to the wire (9) Insert the pin into the hole in the shaft. Put the end of the up/down pulley/L. Wind the wire tightly gear into the shaft and fix the gear with the E- around the up/down pulley/L approx.
  • Page 281 FN-6 / FN-112 (11) Loosen the two screws securing the front wire bracket. Adjust the height of the front wire bracket to level the up/down stay. Tighten the four mounting screws on the wire brackets (front and rear). CAUTION: Make sure that the up/down stay is level.

  • Page 282: Removing And Reinstalling The Stacker Unit

    FN-6 / FN-112 STACKER SECTION [1] Removing and Reinstalling the [2] Removing and Reinstalling the Stacker Unit Cover Stacker Unit Caution: Caution: Make sure that the power cord of the main We recommend that at least two people body is unplugged from the power outlet. perform this service.
  • Page 283 FN-6 / FN-112 (7) Remove two screws, and further pull stacker unit (8) Remove two screws. Lift the stacker unit to out. detach from the guide rail. CAUTION: Place something under the drawn Caution: stacker unit to prevent the FNS from Take care of your posture when servicing falling due to the weight of the unit.

  • Page 284: Stapler Section

    FN-6 / FN-112 STAPLER SECTION [1] Removing and Reinstalling the Sta- (3) Remove the two screws securing the rail stopper. Further pull the stacker unit out. pler Unit Cover CAUTION: Place something under the drawn Caution: stacker unit to prevent the FNS from Make sure that the power cord of the main falling due to the weight of the unit.

  • Page 285: Removing And Reinstalling The Clincher

    FN-6 / FN-112 [2] Removing and Reinstalling the (5) Remove four mounting screws holding the clincher/R. Clincher Clincher/R Caution: Make sure that the power cord of the main Screw body is unplugged from the power outlet. Caution: Do not use hands to move stapler units to horizontal direction.

  • Page 286: Removing And Reinstalling The Stapler

    FN-6 / FN-112 [3] Removing and Reinstalling the Sta- (5) Remove two screws holding the sensor cover of the stapler/R. Remove the screw securing the pler ground cable. Detach the connector (CN182) of Caution: the stapler rotation HP PS (PS713). Make sure that the power cord of the main body is unplugged from the power outlet.
  • Page 287 FN-6 / FN-112 (6) Remove four screws. Detach the stapler/R and the connector (CN180). CAUTION: Take care not to damage the stapler rotation HP PS (PS713) when removing the stapler/R. Stapler/R Connector (CN180) Stapler rotation HP PS (PS713) Screw (7) Reinstall the above parts following the removal steps in reverse.

  • Page 288: Cover Insertert B

    Cover Inserter B EXTERNAL SECTION [1] Removing / Re-installing the External (5) Remove two screws, disconnect the relay con- nector (CN232), and detach the operation panel covers cover. Caution: Make sure that the power cord of the main Relay connector (CN232) body is unplugged from the power outlet.

  • Page 289: Paper Feed Unit

    Cover Inserter B PAPER FEED UNIT [1] Replacing the Paper Feed Roller and (3) Remove actuator, three stop rings, three bear- ings of the feed roller unit, then slide the roller Feed Roller shaft in the direction of the allow to remove each Caution: roller.

  • Page 290: Replacing The Double Feed Prevention

    Cover Inserter B [2] Replacing the Double Feed Prevent (5) When replacing the double feed prevention roller and the torque limiter for the lower tray, open the Roller and Torque Limiter upper unit and perform the steps 2 and 3. Caution: (6) Reinstall the above parts following the removal Make sure that the power cord of the main...
  • Page 291 Blank page...

  • Page 292: Punch Section

    PK-2 PUNCH SECTION Caution: The following screws should not be [1] Replacing the Punch unit removed. If you do, punching cannot Caution:Be sure to unplug the power be done as designed. cords of the main body and this machine from the wall outlet. Screws that should Procedure not be removed.

  • Page 293: Cleaning The Punch Edges And Punch Scraps Full Ps (Ps802)

    PK-2 (3) Disconnect two connectors (CN65, CN66) con- [2] Cleaning the Punch Edges and Punch necting the punch unit from the PK drive board. Scraps Full PS (PS802) Caution:Be sure to unplug the power cords of the main body and this machine from the wall outlet.
  • Page 294 Other OTHER [1] Installation of the Key Counter Socket 5. Remove dummy connector. Connect the Key Counter Socket connector. (OPTION) 1. Remove the Rear Cover and Right Side Cover. 2. Remove the Key Counter Cover from the Right Side Cover. Key Counter Cover Note: When the Key Counter Socket is mounted, Set to the Software DIP Switches.

  • Page 296: Adjustment

    ADJUSTMENT...
  • Page 297 Blank page...

  • Page 298: How To Use This Section

    ADJUSTMENT HOW TO USE THIS ADJUSTMENTS MADE SECTION WHEN REPLACING PARTS [1] Scope and Precautions Adjustments (including checks) and settings are not This section provides detailed information about only required when a customer complaint about the adjustment items and procedures. Before addressing copy image quality is received, but also after replacing customer complaints, perform the following checks.

  • Page 299: List Of Adjustment Items

    ADJUSTMENT LIST OF ADJUSTMENT ITEMS 1 Process High voltage Charging grid manual 2-50 Adjust- adjustment adjustment ment Drum Blade setting mode 2-51 Peculiarity Auto maximum density Adjustment 2-52 4 2 1 1 adjustment Auto dot diameter adjust- 2-52 5 3 2 2 ment LD1 offset adjustment 2-53...
  • Page 300 ADJUSTMENT 35 Finisher Punch Punch vertical position 2-82 Adjust- Adjustment adjustment ment Punch horizontal position 2-82 O O O adjustment Punch registration loop 2-83 adjustment 38 Tray Centering Adjustment 2-101 39 Adjusting the LCT Paper Feed Roller Pressure 2-104 40 Paper up/down Plate Horizontal Adjustment 2-105 41 Skew Adjustment 2-107...

  • Page 301: Lcd Adjustment

    ADJUSTMENT LCD ADJUSTMENT SETTINGS AND ADJUSTMENTS MADE [1] LCD Control Panel Adjustment WITH THE P FUNCTION Enter the key operator mode and select " Touch panel adjustment" to adjust the LCD touch panel. The P function allows you to perform following numer- *If you cannot select the touch panel adjustment ical value checks using the Utility button: mode pressing any numeric key after entering...

  • Page 302: Mode Changing Menu

    ADJUSTMENT MODE CHANGING MENU [1] Mode Selection You can select a mode from the following [Mode chang- ing menu: [Select mode] without turning OFF and ON the power switch. Basic screen 3-6 mode 2-5 mode Key operation mode 4-7 mode Step Operation Turn on the SW2 (sub power).

  • Page 303: Display Transition Of 36 Modes

    ADJUSTMENT [2] Display transition of 36 modes High voltage adjustment mode menu 1 HV adjustment (Charge) 2 HV adjustment (Transfer) 3 HV adjustment (Separation-AC) x : Factory exclusive use. Service is not used. 4 HV adjustment (Separation-DC) 5 HV adjustment (Charging grid voltage) 6 HV adjustment (Bias of development) x 7 Transfer guide confirm 8 HV adjustment (TGR)

  • Page 304: Display Transition Of 25 Modes

    23 1 Shot indication time 14 Machine management list print 24 Energy save screen 25 Start Key latch function 15 * Not use Minolta! Management list print mode menu 26 Stop Key function 16 Side 2 lens adjustment 1 Program memory list...

  • Page 305: Mode

    ADJUSTMENT 25 MODE [1] Setting the 25 Mode This machine has an adjustment mode called the "25 Mode". Select this mode to rewrite data in the non-vol- atile memory or make various settings. Turn OFF the SW2 (sub power). While pressing the copy quantity setting button 2 and 5, turn ON the SW2 (sub power).

  • Page 306: List Of Adjustment Items For 25 Mode

    ADJUSTMENT [2] List of Adjustment Items for 25 Mode Adjustment Item Menu Remarks Software DIP SW setting See "list of Software DIP Switches". Paper size setting PM count Resetting PM Count Setting PM cycle Data collection Total count of each paper size Copy count of each paper size Print count of each paper size RADF count...

  • Page 307: Setting Software Dip Switches

    ADJUSTMENT [3] Setting Software DIP Switches 1. Procedure Bring up the Software DIP SW Setting screen and set software DIP switches. Step Operation Enter the 25 mode. [Memory setting mode menu Screen] Select " Software DIP SW setting". [Software DIP SW setting screen] Select a DIP switch number.
  • Page 308 ADJUSTMENT < List of Software Switches > DIPSW Initial Value Function Japan Inch Metric 0 Condition for stopping copying after indica- tion of toner supply 2 Method for stopping copying after indica- tion of toner supply DIPSW 1 Inhibition of copying when PM count is Disabled Inhibited reached...
  • Page 309 ADJUSTMENT DIPSW Initial Value Function Japan Inch Metric Toner guide roller current correction * 12 * 12 DIPSW 7 Transfer/separation output for recycled * 13 * 13 paper Fixing roller initial rotation * 14 * 14 DIPSW8 Fixing roller initial rotation time setting * 15 * 15 6 A3(11 ×...
  • Page 310 ADJUSTMENT DIPSW Initial Value Function Japan Inch Metric 0 Size detection 1 5.5 x 8.5 1 Size detection 2 8.5 x 11R 2 Size detection 3 8.5 x 14 DIPSW 13 Size detection 4 * 21 * 21 F4 size detection * 22 * 22 B4 : 11 x 17/...
  • Page 311 ADJUSTMENT DIPSW Initial Value Function Japan Inch Metric Fixing temperature setting switch over * 28 * 28 DIPSW 19 4 PZ-fold faulty part isolation Normal Unavailable 5 PK faulty part isolation Normal Unavailable IP scanner default resolution * 29 * 29 0 Group stapling Disabled Enabled...
  • Page 312 ADJUSTMENT DIPSW Initial Value Function Japan Inch Metric Operation when printer EKC password is Counted and Not output (dis- not matched output to EKC play it on the or other user JOB list that is domain not produced) 2 Image density selection DIPSW23 * 31 * 31...
  • Page 313 ADJUSTMENT DIPSW Initial Value Function Japan Inch Metric Image’s gray background control at power ON Not performed Performed (toner density reduction control) *34 Image’s gray background control at power ON Not performed Performed (toner recycle MC control during printing) *34 2 Toner supply operation (use prohibited) Performed Not performed...
  • Page 314 ADJUSTMENT *1 Condition for stopping copying after indication of *5 Electrode cleaning cycle (after power is turned toner supply request Mode Mode Stops after printing 1,500 copies 10,000 copies Stops after printing 3,000 copies 20,000 copies Stops after printing 4,000 copies 30,000 copies Stops after printing 5,000 copies 40,000 copies...
  • Page 315 ADJUSTMENT *8 Image density selection *10 Transfer/separation output for thick paper These bits set image write laser PWM. Against This bit is used when "Thick" is selected for exessive density of 100% black color, thick letters "Paper type/special size setting" in the key oper- and lines, and excessive toner consumption, the ator mode to change transfer/separation output, setting should be made by selecting “light.”...
  • Page 316 ADJUSTMENT *13 Transfer/separation output for recycled paper Mode These bits are used when "Recycle" is selected Low temperature for "Paper type/special size setting" in the key Low and normal temperature operator mode. When "User paper" is selected with these bits, Low, normal, and high tem- the transfer/separation output for the user paper peratures...
  • Page 317 ADJUSTMENT *17 Copy count limit *20 Transfer/separation out put for high-quality paper These bits are used when “High-quality” is Mode selected for “Paper type/special size setting” in No limit the key operator mode. 1 copy When “No specification” is selected, output data 3 copies by paper size (metric or inch system) (metric: 64 5 copies...
  • Page 318 ADJUSTMENT *25 Selection of area to be erased in non-original *28 Fixing temperature setting switch over area automatic erasure This setting is performed to change fixing tem- These bits are used to make a setting associated perature when fixing is insufficient or paper curl with the non-original automatic erasure mode is excessive.
  • Page 319 ADJUSTMENT *31 Image density selection (toner density selection *34 Image's gray background control at power ON If an image s gray background problem occurs of developer) while making about 100 copies after power ON These bits set the toner density of developer by changing toner supply threshold and developing (the fixing temperature is 50°C or lower), set bits 0, 1, 3, 5, 6, and 7 of DIPSW27 to 1.

  • Page 320: Setting The Paper Size

    ADJUSTMENT [4] Setting the Paper Size 2. Setting the non-standard size When the LCT paper type is changed, it must be stored Step Operation in the main body. This setting is effective when an Enter the 25 mode. optional LCT is added. [Memory setting mode menu Screen] Select a paper size among standard, non-standard Select "...

  • Page 321: Pm Count Resetting

    ADJUSTMENT 3. Setting the wide paper [5] PM Count Resetting Step Operation Care should be taken not to reset the PM count by mis- take. Enter the 25 mode. Step Operation [Memory setting mode menu Screen] Enter the 25 mode. Select "...

  • Page 322: Setting The Pm Cycle

    ADJUSTMENT [6] Setting the PM Cycle [7] Collecting Data This function allows you to change the PM cycle. This function allows you to view various data retained by the machine. Caution: The PM cycle is factory-set. Use this function to change the factory-set PM 1.
  • Page 323 ADJUSTMENT 2. Viewing Collecting Data No.1 to No.6 3. Viewing Collecting Data No.7 to No.12 Step Operation Step Operation Enter the 25 mode. Enter the 25 mode. [Memory setting mode menu Screen] [Memory setting mode menu Screen] Select " Data collection". Select "...
  • Page 324 ADJUSTMENT 4. Details on Display Data (1) Collecting data No.1 to No.3: Total/copy/print counts of each paper size Destination Maximum count Remarks Japan Inch area Metric area 17x22 11x17 8.5x14 B4 (8K) 8.5x11 5.5x8.5 B5 (16K) All counters are 99999999 8-digit counters.
  • Page 325 ADJUSTMENT (2) Collecting data No.4: RADF mode Maximum Items Remarks count Number of originals fed in ADF mode Number of originals fed in RADF mode Number of 1-sided mixed original fed Number of 2-sided mixed original fed Number of 1-sided Z-folded mode original Number of 2-sided Z-folded mode original All counters are 8-digit 99999999...
  • Page 326 ADJUSTMENT (6) Collecting data No.8: JAM count / Collecting data No.11: JAM count of each section (can be reset) Description of JAM Code displayed position when display of display Maximum Counting jam code is Location of jam on oper- count condition selected by ation...
  • Page 327 ADJUSTMENT Description of JAM Code displayed position when display of display Maximum Counting jam code is on oper- Location of jam count condition selected by ation 25DIPSW panel 61-1 61-2 62-1 62-2 62-3 62-4 62-5 62-6 62-7 62-8 62-9 62-10 63-1 63-2 63-3...
  • Page 328 ADJUSTMENT Description of JAM Code displayed position when display of display Maximum Counting jam code is on oper- Location of jam count condition selected by ation 25DIPSW panel 72-49 72-50 72-51 72-81 72-82 All counts are 72-83 999999 72-90 6-digit counters. 72-60 72-61 72-62...
  • Page 329 ADJUSTMENT (7) Collecting Data No.7:Count of each copy mode Maximum Item Counting condition count 1-1 mode 1-2 mode 2-1 mode 2-2 mode ADF1-1 mode ADF1-2 mode Mixed original mode Index original Z-folded original mode 10 LEF/portrait, SEF/landscape normal set 11 LEF/landscape, SEF/portrait normal set 12 LEF/portrait, SEF/landscape reverse set 13 LEF/landscape, SEF/portrait reverse set 14 Auto (text/photo)
  • Page 330 ADJUSTMENT Maximum Item Counting condition count 46 Preset magnification R3 47 Preset magnification R2 48 Preset magnification R1 49 User lens mode 1 50 User lens mode 2 51 User lens mode 3 52 ZOOM 53 Vertical/Horizontal zoom 54 Maximum ZOOM 55 Minimum ZOOM 56 APS 57 AMS...
  • Page 331 ADJUSTMENT Maximum Item Counting condition count Set quantity 11 or more All counters are 8-digit counters. Energized time of power condition 1 Total period of time during which image control board is energized. Total period of time during the opera- tion of CPU.
  • Page 332 ADJUSTMENT Maximum Item Counting condition count N of ADF special error 1 occurred Original size detection error occurrence count N of ADF special error 2 occurred Next original information error occurrence count N of ADF special error 3 occurred Mixed loading prohibited original size error occur- rence count N of Scanner scanned...
  • Page 333 ADJUSTMENT (8) Collecting data No.10: SC count / Collecting data No.12: SC count of each section (can be reset) Trouble Maximum Description Remarks code count Paper feed MT EM LCT conveyance MT EM Tray 1 up MT EM Tray 1 up error Tray 2 up MT EM error Tray 2 up error Tray 3 up MT EM error...
  • Page 334 ADJUSTMENT Trouble Maximum Description Remarks code count Second paper feed MT EM Fixing upper roller high temperature error detection Fixing upper roller high temperature error detection Fixing upper roller low temperature error detection 1 Fixing upper roller low temperature error detection 2 Fixing upper roller low temperature error detection 3...
  • Page 335 ADJUSTMENT Trouble Maximum Description Remarks code count HDD initialization trouble HDD JOB save error HDD periodic cleaning error HDD access failure Tandem communication error Tandem image communication error PWMg curve generation failure Insufficient/broken message queue Invalid message or method parameter Invalid task Invalid event Memory access error...
  • Page 336 ADJUSTMENT Trouble Maximum Description Remarks code count Clincher/F driving error Clincher/F driving error Stopper motor drive error Alignment plate/L drive error Folding knife motor drive error Folding conveyance motor drive error Trimmer conveyance drive error Trimmer conveyance error Trimmer rear end stopper drive error Trimmer rear end release motor driving error Trimmer press motor driving error Trimmer pusher motor driving error...

  • Page 337: Copy Count By Parts To Be Replaced (Fixed Parts)

    ADJUSTMENT [8] Copy Count by Parts to be Replaced (Fixed Parts) This function allows you to display or reset the copy count for a fixed part or data. Step Operation Enter the 25 mode. [Memory setting mode menu Screen] Select “ Parts counter.”...
  • Page 338 ADJUSTMENT Maximum Part name Counting condition count 11 Trans./sep. cleaning assembly 99999999 25DIPSW8-6 =0: Count 1 per ejected paper for single sided, 2 12 Fixing upper roller for double sided 13 Fixing lower roller =1: For A3, 11x17, 8k, count 2 per ejected paper 14 Fixing upper claw for single sided, 4 for double sided 15 Fixing lower claw...
  • Page 339 ADJUSTMENT Maximum Part name Counting condition count 44 Tray 4 feed rubber (Japan only) 99999999 1 is counted each time the paper from tray 4 is ejected. 45 Tray 4 feed conv/rev rubber (Japan only) 46 Tray 4 feed clutch (Japan only) 47 Tray 4 convey clutch (Japan only)
  • Page 340 ADJUSTMENT Maximum Part name Counting condition count 70 FNS stapler/front 99999999 1 is counted each time a copy is ejected in sta- pling front 1-point stapling, stapling 2-point sta- 71 FNS stapler/rear pling, or middle binding mode. 72 FNS shift motor 1 is counted each time even-numbered paper is ejected.
  • Page 341 ADJUSTMENT Maximum Part name Counting condition count ADF pressure roller release solenoid 2 is counted each time one original passes in the double side or the mixed mode 100 Exposure ON time Unit 101 Sub power switch 1 is counted each time sub power is switched off. 102 Door switch 1 is counted each time front door is opened.

  • Page 342: Copy Count By Parts To Be Replaced (Optional Parts)

    ADJUSTMENT [9] Copy Count by Parts to be Replaced Changing the data on the Copy Count by Parts to be Replaced (Optional Parts) (Optional Parts) This function allows you to change the limit This function allows you to make the following settings value, part number, or part name for the desired for an optional part or data: optional copy count by parts to be replaced...

  • Page 343: Setting Passwords

    ADJUSTMENT Reference1: The characters entered in the data [10] Setting Passwords field of each data item will be This function allows you to set the following passwords: shifted to the left one after another. Key operator password (4 digits) This password is required to enter the key oper- Reference2: When the number of entered char- ator mode.

  • Page 344: Setting The Telephone Number And/Or Fax Number Of The Service Center

    ADJUSTMENT Reference1: The digits entered in the data field [11] Setting the Telephone Number and/or of each data item will be shifted to Fax Number of the Service Center the left one after another. This function allows you to set the telephone number and/or fax number of the service center displayed Reference2: When the number of entered digits when a service call occurs.

  • Page 345: Setting The Serial Number

    ADJUSTMENT [12] Setting the Serial Number [13] Displaying the ROM Version This function allows you to display, set, or change the This function allows you to display the versions of the serial number of the main body or option. installed ROMs. Step Operation Step...

  • Page 346: Mode

    ADJUSTMENT 36 MODE [1] Setting Method [2] High Voltage Adjustment This machine is provided with 36 Mode as an adjust- Adjusting the high voltage for charging, transfer, sep- ment mode. aration, and development. This mode is used to perform various adjustments. Select "...

  • Page 347: Changing Grid Voltage Adjustment

    Default setting value must be set under the guid- Turn the SW2 (sub power) OFF. ance of Minolta Technical Support Center. 3. Separation (AC) manual adjustment Standard value: Specified value on the drum Default setting value must be set under the guid- flange ±5 V...

  • Page 348: Drum Peculiarity Adjustment

    ADJUSTMENT [4] Drum Peculiarity Adjustment 1. Blade setting mode In this mode, toner stuck on the drum surface Adjusting the blade set, maximum density (Dmax), dot during replacement of the cleaning blade or diameter, laser offset and gamma. drum is removed to prevent damage to the drum Select "...
  • Page 349 ADJUSTMENT 2. Auto maximum density adjustment 3. Auto dot diameter adjustment (Dmax adjustment) Automatically adjusting the dot diameter. Automatically adjusting the maximum density This adjustment should be performed when the (Dmax). This adjustment should be performed drum, developer, write unit, or dust-proof glass is when the drum, developer, write unit, or dust- replaced.
  • Page 350 ADJUSTMENT 4. LD1 offset adjustment Check the test pattern. This adjusts the place at which LD1 laser starts Specification: Check if two output pat- writing. terns from laser are consis- This adjustment should be performed when the tent and the beginning of drum or developer is replaced.
  • Page 351 ADJUSTMENT 5. LD2 offset adjustment Check the test pattern. This adjusts the place at which LD2 laser starts Specification: Check if two output pat- writing. terns from laser are consis- This adjustment should be performed when the tent and the beginning of drum or developer is replaced.
  • Page 352 ADJUSTMENT 6. LD1 bias adjustment Reference: LD1 bias adjustment is inhibited in the field. If any one of the following error messages appears during auto gamma adjustment, 7. LD1 bias adjustment clean the TSCB (toner control sensor board), LD1 bias adjustment is inhibited in the field. check its installation state, and retry the auto gamma adjustment.
  • Page 353 ADJUSTMENT 9. Auto gamma adjustment (2 dot) 10. Cartridge set mode Performs gamma adjustment (2 dot) automatically. This adjustment should be performed when This adjustment should be performed when the blank dots appears on the copy after the drum drum, developer, write unit, or dust-proof glass is removing and installing.

  • Page 354: Drum Peculiarity Adjustment (Manual)

    This adjustment must be performed under the This setting is applied when "User" is selected for guidance of Minolta Technical Support Center. "Paper type/Special size setting" in the key operator Variable range: 0 to 41 mode or when "User paper" is selected for "Transfer/ separation output for plain paper"...

  • Page 355: Recall Standard Data (Process Adjustment)

    ADJUSTMENT [7] Recall Standard Data (Process [8] Tray Adjustment Adjustment) This adjustment should be performed when the tray or by-pass unit is replaced. Restoring process adjustment settings to standard val- ues (factory setting data). Step Operation Step Operation Enter the 36 mode. Enter the 36 mode.

  • Page 356: Magnification Adjustment

    ADJUSTMENT [9] Magnification Adjustment 1. Printer drum clock magnification adjust- ment Adjusting the printer and copy vertical and horizontal Adjusting the printer vertical magnification. magnifications. Step Operation Select " Image adjustment" in the Adjust- Enter the 36 mode. ment mode menu Screen to display the Image [Adjustment mode menu Screen] adjustment mode menu Screen.
  • Page 357 ADJUSTMENT 2. Printer horizontal magnification adjust- 3. Scanner (platen) drum clock magnifica- ment tion adjustment Adjusting the horizontal magnification. Adjusting the vertical magnification for the scan- ner. Step Operation Step Operation Enter the 36 mode. Enter the 36 mode. [Adjustment mode menu Screen] [Adjustment mode menu Screen] Press "...

  • Page 358: Timing Adjustment

    ADJUSTMENT 4. Scanner (RADF) drum clock magnifica- [10] Timing Adjustment tion adjustment Adjusting the leading edge timing (paper feed restart Adjusting the vertical magnification during RADF timing), registration loop amount, and leading edge copy. erasure amount. Step Operation Select Image adjustment in the Adjustment Enter the 36 mode.
  • Page 359 ADJUSTMENT 1. Printer restart timing adjustment 2. Printer registration loop adjustment This adjusts the printer restart timing (paper feed Adjusting the printer registration loop amount for timing). The adjustment is performed at line trays (tray 1, 2 and 3), by-pass tray, and ADU. speed of 320, 280 and 185 respectively.
  • Page 360 ADJUSTMENT 3. Printer pre-registration amount adjust- 4. Printer leading edge timing adjustment ment Adjusting the printer leading edge timing (image Adjusting the pre-registration loop amount for erasure amount). trays 1, 2, 3, LCT and ADU. Step Operation Step Operation Enter the 36 mode. Enter the 36 mode.
  • Page 361 ADJUSTMENT 5. Scanner (platen) restart timing adjustment 6. RADF restart timing adjustment Adjusting the scanner restart timing during platen Adjusting the scanner leading edge timing during copy. RADF copy. Caution: Printer restart timing adjustment must Caution: Printer restart timing adjustment must be completed before performing this be completed before performing this adjustment.

  • Page 362: Radf Adjustment

    ADJUSTMENT 7. RADF registration loop amount adjust- [11] RADF Adjustment ment Performing RADF density adjustment, RADF original Adjusting the registration loop amount during size adjustment and RADF skew offset adjustment. RADF copy. Select Image adjustment in the Adjustment Caution: Printer restart timing adjustment must mode menu Screen to display the Image adjust- be completed before performing this ment mode menu Screen.
  • Page 363 ADJUSTMENT 1. RADF density adjustment 2. RADF original size adjustment When the original reader slit glass is replaced, Perform this adjustment when the RADF original the density when reading originals with the size detection does not operate properly. RADF must be adjusted. Caution: RADF original size adjustment con- Preparation: Wipe the original reader slit glass sists of A4 and B6R.

  • Page 364: Centring Adjustment

    ADJUSTMENT 3. RADF incline offset adjustment [12] Centring Adjustment Adjusting the standard value of the distortion Perform this adjustment to centre the image in a direc- adjustment (Copier). tion perpendicular to the paper feed direction. Step Operation Select “ Image adjustment” in the Adjust- Enter the 36 mode.
  • Page 365 ADJUSTMENT 1. Printer Centring Adjustment 2. Scanner (platen) centring adjustment Adjusting the printer centring. Adjusting the scanner (platen) centring. Step Operation Preparation: Printer centring adjustment must Enter the 36 mode. be completed before performing this adjustment. [Adjustment mode menu Screen] Step Operation Press "...
  • Page 366 ADJUSTMENT 3. RADF centring adjustment Press the key to return to the RETURN This adjusts centring for the RADF copy. Centring adjustment mode menu Screen. There are six adjustment items as follows: • Single sided small size • Double sided (front) small size •...

  • Page 367: Distortion Adjustment (Copier)

    ADJUSTMENT [13] Distortion adjustment (Copier) [14] Non-image area erase check This is to correct distortion during platen/RADF copy- When this machine is installed in a place or is moved ing. There are four adjustment items as follows: to another location, research should be conducted on •...

  • Page 368: Recall Standard Data (Image Adjustment)

    ADJUSTMENT <Error message2> [15] Recall standard data (Image adjust- A datum with potentioal not to function non- ment) image-area-erase is found. Restoring image adjustment settings to standard val- Please confirm "adjustment" - "36 mode" colums ues (factory setting data). of the Service Hand book. Step Operation <Countermeasure2>...

  • Page 369: Running Test Mode

    ADJUSTMENT [16] Running Test Mode [17] Test pattern output mode Testing continuous copy operation. Output test pattern. Select “ Running test mode” in the Adjustment Select “ Test pattern output mode” in the Adjust- mode menu Screen. ment mode menu Screen to display the Test pattern This adjustment consists of the following items: output mode screen.
  • Page 370 ADJUSTMENT Overall halftone No.1 Check item When density is set to 70 (halftone) If there are white stripes, black stripes, or uneven density, determine whether the fault is with the scanner or the printer. When density is set to 0 (white) If the test pattern is gray background, determine whether the fault is with the scanner or the printer.
  • Page 371 ADJUSTMENT Gradation pattern No.2 Check item If the test pattern is gray background or the density is light, determine whether the fault is with the processing system or with γ correction. If the copy image is abnormal despite this test pattern being normal, either the image processing system or the scanner system is abnormal.
  • Page 372 ADJUSTMENT Gradation pattern No.3 Check item If the test pattern is abnormal, check whether the two lasers are emitting light normally. Test patterns 2-75...
  • Page 373 ADJUSTMENT Gradation pattern No.5 Check item If the test pattern is abnormal, check whether the two laser outputs are uniform. Test patterns LD-1 LD-2 2-76...
  • Page 374 ADJUSTMENT Beam misalignment check No.11 Check item If the test pattern is abnormal, check to see if position correction of the two laser beams is normal. Test patterns 2-77...
  • Page 375 ADJUSTMENT Linearity evaluation pattern No.16 Check item Use this check pattern to determine whether the fault is with the scanner or the printer. The printer horizontal magnification, vertical magnification, tilt, and leading edge timing and etc, can be checked. If the copy image is defective despite no abnormality in the test pattern, the scanner is at fault.

  • Page 376: Test Pattern Density Setting

    ADJUSTMENT [18] Test pattern density setting [19] Finisher adjustment Setting the test pattern density. Adjusting the finisher, cover sheet tray, and puncher. Select “ Test pattern density setting” in the Select “ Finisher adjustment” on the Adjust- Adjustment mode menu Screen to display the Test pattern density setting Screen.
  • Page 377 ADJUSTMENT 1. Stitch and fold stopper adjustment (FN-6 2. Folding stopper adjustment (FN-6 only) only) Adjusting the folding position when stitch and Adjusting the stapling position when stitch and fold or folding mode. fold mode. Step Operation Step Operation Enter the 36 mode. Enter the 36 mode.
  • Page 378 ADJUSTMENT 3. Cover sheet tray size adjustment 4. Punch adjustment (PK-2, PK-5, ZK-2) (Cover Inserter B only) This performs the punch horizontal positions and This adjustment should be performed when the adjusts punch registration loop amount. cover sheet tray size cannot be detected properly Select “...
  • Page 379 ADJUSTMENT (1) Punch vertical position adjustment (PK-5, (2) Punch horizontal position adjustment (PK-2, ZK-2) PK-5, ZK-2) Adjusting the punch horizontal position. Adjusting the punch horizontal position. Step Operation Step Operation Enter the 36 mode. Enter the 36 mode. [Adjustment mode menu Screen] [Adjustment mode menu Screen] Press "...
  • Page 380 ADJUSTMENT (3) Punch registration loop adjustment (PK-2, 4. Z-folding position adjustment (ZK-2) PK-5, ZK-2) Adjusting the positions for the Z-foldingis per- Adjusting the registration loop amount for the formed. reversed paper exit, the ADU paper exit (straight Step Operation exit) and cover sheet upper/lower.. Set to 36 mode.
  • Page 381 ADJUSTMENT Use the numeric keys to enter a numerical value, then press the key. Setting range: -128 to +127 1 step = 0.1 mm Press the key to return to COPY SCREEN the Copy screen, and make a copy. Confirm the position of the 2nd fold. If the 2nd folding position is not properly set, press the C button while holding down the Utility key to return to the adjustment...
  • Page 382 ADJUSTMENT 5. Three-folding adjustment (FN-6 only) 6. 2 positions staple pitch adjustment Adjusting the folding positions during the three- Adjusting the pitch of the 2 positions staple. folded copy. Step Operation Step Operation Enter the 36 mode. Enter the 36 mode. [Adjustment mode menu Screen] Press "...

  • Page 383: List Output Mode

    ADJUSTMENT [20] List Output Mode Outputting various data. Select " List output mode" in the Adjustment mode menu Screen to display the List output mode menu Screen. List output mode menu consists of the following: Machine management list 1 Adjustment data list Pixel ratio data list Machine management list 2 Parameter list...

  • Page 384: Mode

    ADJUSTMENT 47 MODE [1] 47 Mode / Multi Mode Setting Method (4) Ending 47 mode Press the stop button to cancel the operation. 1. 47 Mode Turn off the main switch to exit the 47 mode. This mode provides self-diagnostic functions Step Operation (input/output check function) to check and adjust...
  • Page 385 ADJUSTMENT 3. Multi mode Step Operation This machine features Multi modes amongst the Enter the 47 mode. 47 Mode functions. [I/O check Screen] This enables multiple I/O checks using a single I/ Use the copy quantity button and enter the O check code.

  • Page 386: Adjustment Data Display

    ADJUSTMENT [2] Adjustment Data Display (1) When the total capacity of the hard disk is checked: Displaying a list of machine adjustment values The total capacity of the hard disk is (factory-set values and current values). displayed after "OUT:" in the message No adjustment (data value change) can be made display field.

  • Page 387: Input Checklist

    ADJUSTMENT [4] Input Checklist Display and Signal Classifi- Multi Source Code Symbol Name mode cation Remaining toner detection signal Empty VR301 ADF original size VR signal 0 to 255 Fixer upper roller temperature detection signal °C Fixer upper roller temperature Humidity sensor signal Dmax MONI signal Dmax signal...
  • Page 388 ADJUSTMENT Display and Signal Classifi- Multi Source Code Symbol Name cation mode Tray 1 upper limit detection signal Tray 2 upper limit detection signal PS14 Tray 3 upper limit detection signal PS34 By-pass feed tray upper limit detection signal By-pass feed tray lower limit detection signal PS35 LCT upper limit detection signal PS109...
  • Page 389 ADJUSTMENT Display and Signal Classifi- Multi Source Code Symbol Name cation mode PS310 Original size detection signal 1 Original size detection signal 2 PS309 PS304 Original registration detection signal 1 Original registration detection signal 2 PS305 PS306 Original conveyance detection signal Original ejection detection signal PS303 Last original detection signal...
  • Page 390 ADJUSTMENT Display and Signal Classifi- Multi Source Code Symbol Name cation mode PS718 Shift HP detection signal Stacker no paper detection signal PS720 SW702 Staple/R SW detection signal Stapler HP/R detection signal PS730 SW701 Cartridge/R detection signal Other than Clincher /R detection signal M710 Start start...
  • Page 391 ADJUSTMENT Display and Signal Classifi- Multi Source Code Symbol Name cation mode 1st stopper HP Paper scraps full detection Punch HP Other than Fan motor locking detection Lock lock Gate HP detection signal PS716 Paper edge PS (side edge sensor 5) With No Paper Passage PS...

  • Page 392: Output Checklist

    ADJUSTMENT [5] Output checklist Classi- Multi Cannot be set or Code Symbol Name fication mode changed in field *1 Exposure lamp Toner bottle motor × Charger × Transfer × Separation (AC+DC) × D max LED γ LED × × Jam detection LED ×...
  • Page 393 ADJUSTMENT Classi- Multi Cannot be set or Code Symbol Name fication mode changed in field Loop roller motor Loop motor H(470 mm/s), forward Loop motor L(320 mm/s), forward Loop motor L(280 mm/s), forward Loop motor L(185 mm/s), forward Loop motor H(470 mm/s), backward Loop motor L(320 mm/s), backward Loop motor L(280 mm/s), backward Loop motor L(185 mm/s), backward...
  • Page 394 ADJUSTMENT Cannot be set or Classifi- Multi Code Symbol Name cation mode changed in field Fixing motor Fixing motor (320 mm/s) Fixing motor (280 mm/s) Fixing motor (185 mm/s) Drum motor Drum motor / Developing motor (320 mm/s) M2/M3 Drum motor / Developing motor (280 mm/s) Drum motor / Developing motor (185 mm/s) Fan motor Scanner cooling fan...
  • Page 395 ADJUSTMENT Cannot be set or Classifi- Multi Code Symbol Name cation mode changed in field Original feed motor (forward) M301 Original feed motor (backward) Original conveyance motor (forward) M302 Original conveyance motor (backward) RADF MC301 Paper feed MC SD303 Pressure roller release SD SD301 Reverse gate SD SD302...
  • Page 396 ADJUSTMENT Cannot be set or Classifi- Multi Code Symbol Name cation mode changed in field FN-6/ FN-112 MC202 Conveyance MC /L Tray up/down motor /L (move to the lower limit) M202 Tray up/down motor /L (HP research) SD202 Sheet feed SD /L Registration motor/Conveyance motor M1/M6 1st stopper motor...
  • Page 397 ADJUSTMENT Cannot be set or Classifi- Multi Code Symbol Name cation mode changed in field Reverse gate SD ADU lock SD MC13 ADU conveyance MC ADU conveyance MC Second paper feed motor ADU reverse motor Forward(320 mm/s) Forward(280 mm/s) Forward(185 mm/s) Forward(600 mm/s) Forward(700 mm/s) Backward(660 mm/s)

  • Page 398: Other Adjustment

    ADJUSTMENT OTHER ADJUSTMENT [1] Centring Adjustment Adjustment method Step Operation Caution: Centring adjustment need not be per- Draw out the tray. formed normally because paper incli- nation is detected in the second paper Loosen the two screws at the centre of the tray.

  • Page 399: Centring Adjustment

    ADJUSTMENT LCT tray centring adjustment Adjustment method Step Operation Raise the up/down plate. Open the top cover. Remove five screws to detach the side cover (right). Screws Right side cover C-403 C-404 Screws Loosen two screws on the upper part of LCT to slide the guide plates (front/rear) the same amount in the same direction.
  • Page 400 ADJUSTMENT Setting the LCT Rear Guide (C-404 only) Standard value of mis-centring: within 3mm Rear guide Screws Centre of image Within 3 mm Centre of paper Rear guide Screws Adjustment method Step Operation Open the top cover. Press SW100 (LT tray down switch) to lower the up/down plate to the bottom.

  • Page 401: Skew Adjustment (Main Body)

    ADJUSTMENT [2] Skew adjustment (Main body) [3] Adjusting the LCT Paper Feed Roller Pressure (C-404 only) Tool • Screwdriver (Phillips) Caution: This adjustment is required when no Adjustment method paper feed occurs. Tool • Screwdriver (Phillips) Adjustment method Screws Spring Piled plate Step Operation...

  • Page 402: Paper Up/Down Plate Horizontal Adjustment (Lct Only)

    ADJUSTMENT [4] Paper up/down plate horizontal Adjustment method adjustment (LCT only) Step Operation Raise the up/down plate. Caution: Up/down plate horizontal adjustment Open the top cover. must be carried out when a paper feed jam occurs frequently or after replace- Remove five screws to detach the side ment of the up/down wires of a tray.
  • Page 403 ADJUSTMENT LCT up/down plate horizontal adjustment of C- Step Operation Remove three screws to detach the clutch replacement cover. Clutch replacement cover Screws Remove twelve screws to detach the rear cover. Screws Adjusting screws Mark Up/down plate Screws Adjustment method Screws Step Operation...

  • Page 404: Skew Adjustment (Lct Only)

    ADJUSTMENT [5] Skew adjustment (LCT only) Adjustment method (when some printed sheets are skewed irregularly) Caution: Skew adjustment is required when the Step Operation paper supplied from the current tray is Print a test pattern (No.16) in the continu- different from the paper supplied from ous copy mode to check for skew.

  • Page 405: Tray Spring Pressure Adjustment

    ADJUSTMENT [6] Tray spring pressure adjustment Change the spring hooking position at the bottom of paper feed unit. Caution: Tray spring pressure adjustment must Weak: Double feed is prevented. be performed when no feed or double Strong: No feed is prevented. feed of paper occurs.
  • Page 406 ADJUSTMENT Adjustment method PI spring pressure adjustment Step Operation Remove the by-pass tray. Weak (standard) Strong Remove two screws and detach the bottom plate assembly. Change the spring hooking position. Weak: Double feed is prevented. Strong: No feed is prevented. Reference: The spring load changes about 15 % each time the spring is hooked in the next...

  • Page 407: Paper Feed Height (Upper Limit) Adjustment (Lct Only)

    ADJUSTMENT [7] Paper feed height (upper limit) adjust- Adjustment method ment (LCT only) Step Operation Move the up/down plate up. Caution1: Paper feed height (upper limit) adjustment must be performed when Open the top cover. no paper feed occurs, when the lead- Measure the distance between the top sur- ing edge of the fed paper is folded or faces of the paper feed guide and paper up/...

  • Page 408: Pick-Up Release Amount Adjustment (Lct Only)

    ADJUSTMENT [8] Pick-up release amount adjustment Remove two screws securing the sensor (LCT only) mounting bracket and install them in the outside mounting holes (oblong holes) Caution: Pick-up release amount adjustment temporarily. must be performed when a no-feed <When the heights are not within specifi- jam occurs frequently.

  • Page 409: Radf Mounting Position Adjustment

    ADJUSTMENT Adjustment method [9] RADF mounting position adjustment Step Operation Tool • Screwdriver (Phillips) Move the paper up/down plate up. • Open-end wrench or flat-nose pliers. Open the top cover. Adjustment method Remove the paper feed pick-up cover/B. Remove the spring from the paper feed Adjusting screw B Adjusting screw A roller unit.

  • Page 410: Radf Skew Adjustment

    ADJUSTMENT [10] RADF Skew adjustment Remove two screws for each of the two stoppers. Tool • Hexagonal wrench • Open-end wrench or flat-nose pliers Adjustment method Screws Screws Stopper 1 Stopper 2 Loosen the three screws illustrated. Skew adjustment screw Skew pattern A Skew pattern B Step...

  • Page 411: Radf Paper Skew Adjustment

    ADJUSTMENT [11] RADF paper skew adjustment Open the RADF and loosen the six screws illustrated. Face side of original paper skew adjustment Note: Perform this adjustment after completing the RADF skew adjustment described in the previous page. Screws Screws Close the RADF and loosen the nut of skew adjustment screw.
  • Page 412 ADJUSTMENT Move the registration roller bracket one cal- Step Operation ibration in the direction below according to Make a copy in the double sided - single the paper skew pattern. sided copy mode, then check the skew of For skew in pattern A: the original.

  • Page 413: Fns Adjusting The Magnets On The By-Pass Conveyance Guide Plate

    ADJUSTMENT [12] FNS Adjusting the magnets on the by- Adjustment pass conveyance guide plate Step Operation Loosen the two screws securing the mag- Tool net. • Screwdriver (Phillips) Adjustment method Adjust the by-pass conveyance guide plate Preparation to the direction indicated by the arrow, and press it against the conveyance guide plate Step Operation...

  • Page 414: Fns Adjusting The By-Pass Gate

    ADJUSTMENT [13] FNS adjusting the by-pass gate Step Operation Tool When the by-pass gate (SD705) is OFF, check the gap between the by-pass gate • Screwdriver (Phillips) and the by-pass conveyance plate is within • Scale the standard value. Adjustment method Specifications: A=3.2 ±...
  • Page 415 ADJUSTMENT Adjustment Step Operation Step Operation Loosen two screws securing the by-pass gate SD (SD705) and adjust the position of Take off the rear cover. SD705 so that the gap between the by- Remove all cable assembly from the con- pass gate and by-pass conveyance plate nectors and clamps connecting to FNS CB becomes within the standard value.

  • Page 416: Fns Adjusting The Shift Position

    ADJUSTMENT [14] FNS Adjusting the Shift Position Adjustment Step Operation Tool • Screwdriver (Phillips) Loosen the screw fastening the bracket for the roller shift HP PS (PS718), and shift the Adjustment method bracket to adjust the amount of discrep- Preparation ancy using the mark as a guide.

  • Page 417: Fns Adjusting The Paper Exit Solenoid

    ADJUSTMENT [15] FNS Adjusting the paper exit solenoid Adjustment Step Operation Tool • Screwdriver (Phillips) Remove two screws securing the solenoid bracket and remove the solenoid together • Scale with the bracket. Adjustment method Preparation Step Operation Remove the following parts. Screws •...

  • Page 418: Fns Adjusting The Mount Location Of The Paper Exit Arm

    ADJUSTMENT [16] FNS Adjusting the mount location of Step Operation the paper exit arm Place the solenoid to its original position, and tighten the screw securing the sole- Tool noid bracket at the position where the • Screwdriver (Phillips) paper exit guide makes contact with the Adjustment method cushioning rubber of the paper exit guide Preparation...

  • Page 419: Fns Adjusting The Mount Location Of The Alignment Plates / U

    ADJUSTMENT Adjustment [17] FNS Adjusting the mount location of the alignment plates / U Step Operation Remove the two screws securing the rail Tool stopper and pull out the stacker unit even • Screwdriver (Phillips) further. • Scale To prevent the Finisher from toppling over, Adjustment method place a board or the like to support the Preparation...

  • Page 420: Fns Adjusting The Mount Location Of The Alignment Plates / L (Fn-6 Only)

    ADJUSTMENT Adjustment [18] FNS Adjusting the mount location of the alignment plates / L (FN-6 only) Step Operation After loosening two screws to position the Tool rear side of the alignment plate/U to the • Screwdriver (Phillips) center or marking lines, adjust the location •...
  • Page 421 ADJUSTMENT Adjustment Step Operation Step Operation Load paper sized A4R or larger, put the paper against the alignment plate /U (rear) Loosen the two screws and perform the and the alignment plate /L (rear) and check adjustment so that the mount location of whether the paper is plumb.

  • Page 422: Fns Adjusting The Stapling Position (Flat Stapling)

    ADJUSTMENT [19] FNS Adjusting the stapling position Adjustment (Flat stapling) Step Operation Open the front door and pull out the stacker Caution: Do not use hands to move stapler unit unit. to horizontal direction. Take off the stapler unit cover. (Otherwise the belt and the gear teeth skipping may occur.

  • Page 423: Fns Adjusting The Stapler Vertical Positioning

    ADJUSTMENT [20] FNS Adjusting the stapler vertical Step Operation positioning Remove the cartridge, open the cover, and then slide the staple sheet out. Caution: Do not use hands to move stapler unit Staple sheet to horizontal direction. (Otherwise the belt and the gear teeth skipping may occur.
  • Page 424 ADJUSTMENT Step Operation Step Operation Loosen the four screws for each clincher. Rotate the stapler gears downward. Adjust the clincher position so that the plate on the cartridge fits smoothly into the groove on the jig. Rotate the stapler gear further to fit the plate in the groove in the jig and the jig in the clincher unit completely.

  • Page 425: Fns Adjusting The Stapling Position (Stapling-And-Folding) (Fn-6 Only)

    ADJUSTMENT [21] FNS Adjusting the stapling position Adjustment (stitch-and-fold) (FN-6 only) Step Operation Make sure that the "Adjusting the mount Caution: Do not use hands to move stapler unit location of the alignment plates / U" and to horizontal direction. "Adjusting the mount location of the align- (Otherwise the belt and the gear teeth ment plates / L"...

  • Page 426: Fns Adjusting The Angle Of The Folding Stopper (Fn-6 Only)

    ADJUSTMENT [22] FNS Adjusting the angle of the folding Adjustment stopper (FN-6 only) Step Operation Open the front door and pull out the stacker Caution: Do not use hands to move stapler unit unit. to horizontal direction. Take off the stapler unit cover. (Otherwise the belt and the gear teeth skipping may occur.

  • Page 427: Fns Adjusting The Folding Force (Fn-6 Only)

    ADJUSTMENT [23] FNS Adjusting the folding force (FN-6 Step Operation only) Install the rear cover and stacker unit cover, put the stacker unit away, and close the Tool front cover. • Flat-nose pliers Adjustment method Preparation Step Operation If necessary, change the force and pres- sure of the folding rollers.

  • Page 428: Fns Adjusting The Three-Holding Positions (Fn-6 Only)

    ADJUSTMENT [24] FNS Adjusting the three-holding Adjustment positions (FN-6 only) Step Operation Power on the main body. Use "7: Three- Tool hold positions adjustment" from "6: Fin- • Screwdriver (Phillips) isher adjustment" on the 36 Mode, adjust Adjustment method the first folded line (reference value a), and Preparation perform three-holding.

  • Page 429: Fns Stapler Driver Belt Position Adjustment

    ADJUSTMENT [25] FNS Stapler Driver Belt Position Step Operation Adjustment Move the stapler/clincher to the center at the same time until it stops at the bearing. Caution: Stapler drive belt position adjustment Caution: Make sure to move them at the is only performed when the positions same time, otherwise, the flat- of drive belt and gear are misaligned...

  • Page 430: Pk Adjusting The Tilt Of The Punch Hole Position (Pk-2 Only)

    ADJUSTMENT [26] PK Adjusting the tilt of the punch hole Adjustment position (PK-2 only) Step Operation Measure the position of the sampled punch Tool holes to check the tilt of the position. • Screwdriver (Phillips) • Scale Adjustment method Preparation Step Operation Check the following items:...

  • Page 431: Pk Adjusting The Tilt Of The Punch Hole Position (Pk-5 Only)

    ADJUSTMENT [27] PK Adjusting the tilt of the punch hole Step Operation position (PK-5 only) Remove the punch unit cover by removing three screws Tool • Screwdriver (Phillips) Punch unit cover • Scale Adjustment method Preparation Step Operation Check the following items: •...

  • Page 432: Pk Adjusting The Punch Hole Vertical Position (Pk-2 Only)

    ADJUSTMENT [28] PK Adjusting the punch hole vertical Adjustment position (PK-2 only) Step Operation Fold the sample at the middle of the paper, Caution1: Perform this adjustment after finish- check the position of each punch hole, and ing the adjustment for the tilt of the calculate the dimension to be adjusted.

  • Page 433: Sensitivity Adjustment For The Pk Paper Edge Sensor (Pk-5 Only)

    ADJUSTMENT [29] Sensitivity adjustment for the PK Step Operation paper edge sensor (PK-5 only) Using the mark scale as a guide, move the punch unit vertically to 1/2 the distance of Tool the above dimension. • Screwdriver (Phillips) • Clock driver (Phillips) Adjustment method Preparation Volumes...

  • Page 434: Pi Centering Adjustment

    ADJUSTMENT [30] PI Centering Adjustment Step Operation Caution1: PI Centering adjustement must be When adjusting for the lower tray, remove two screws and slide rightward to remove performed on the upper tray first, the side guide plate (rear). then on the lower tray. When it is necessary to slide the side guide plate (rear) a lot, perform step 11 before step 3 and subsequent...

  • Page 435: Adjusting The Tilt Of Pi (When Pk Punch Is Used)

    ADJUSTMENT [31] Adjusting the tilt of PI (when PK Step Operation punch is used) Using the mark as a guide, move the guide plate laterally by the amount of tilt in the Tool position of punch holes. • Screwdriver (Phillips) •...

  • Page 436: Adjusting The Paper-Path Switching Solenoid (Zk-2 Only)

    ADJUSTMENT [32] Adjusting the Paper-Path Switching Step Operation Solenoid (ZK-2 only) Open the front door of FNS, remove the front cover of ZK-2 (three screws), and 1. Tools remove ZK-2 from the main body. • Screwdriver (Phillips) Remove the AC cord and the rear cover (four screws).

  • Page 437: Adjusting The Tension Of The Punch Shift Timing Belt (Zk-2 Only)

    ADJUSTMENT [33] Adjusting the Tension of the Punch Make sure that the gate solenoid/L (SD1) is Shift Timing Belt (ZK-2 only) ON, and adjust the position of the solenoid bracket so that the gap between the gate tip 1. Tools and the registration guide plate is within the •...

  • Page 438: Adjusting The 1St Folding Skew (Zk-2 Only)

    ADJUSTMENT [34] Adjusting the 1st Folding Skew (ZK- Step Operation 2 only) Remove the ZK from the main body. Remove the four screws to remove the rear 1. Tools cover. • Screwdriver (Phillips) Loosen the two screws holding the punch 2.
  • Page 439 ADJUSTMENT Pull out the z-folding/conveyance unit. Reassemble in the opposite sequence to Remove two screws from the rail and further removal. draw out the conveyance unit. Note: The conveyance unit must be Screws inserted so that the plate on the con- veyance unit (see the figure below) is positioned in side the rail on the enclosure.

  • Page 440: Adjusting The Position Of The 2Nd Folding Stopper (Zk-2 Only)

    ADJUSTMENT [35] Adjusting the Position of the 2nd Step Operation Folding Stopper (ZK-2 only) Set paper into the tray and make a copy Note: This adjustment affects the 2nd folding (required to place the paper stopper at its skew. Therefore, first complete this HP position).

  • Page 441: Adjusting The 2Nd Folding Skew 2Nd Stopper Assembly (Zk-2 Only)

    ADJUSTMENT [36] Adjusting the 2nd Folding Skew 2nd Open the front door of the FNS and draw out Stopper Assembly (ZK-2 only) the conveyance unit. Loosen the four screws holding the 2nd Note: Before beginning this operation, complete the stopper assembly. adjustment described in the [14] Adjusting the Position of the 2nd folding Stopper section.

  • Page 442: Sensitivity Adjustment For The Pz Paper Edge Sensor (Zk-2 Only)

    ADJUSTMENT [37] Sensitivity adjustment for the PZ Step Operation paper edge sensor (ZK-2 only) Using the mark scale as a guide, move the punch unit vertically to 1/2 the distance of Tool the above dimension. • Screwdriver (Phillips) • Precision driver (Phillips) Adjustment method Preparation Step...
  • Page 443 Blank page...

  • Page 444: Service

    SERVICE...
  • Page 445 Main Precautions for Maintenance 1. Points to be confirmed before mainte- 4. When replacing the drum and devel- nance oper, must perform neccessary adjust- Before starting maintenance, ask a ment by refering to the List of user and collect information about trou- Adjustment Items.

  • Page 446: Service Schedule

    SERVICE SERVICE SCHEDULE [1] Service Schedule Guarantee period (5 years or 5,000,000 copies) Service ×10,000 copies count Service item Numbe of copies 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! Main Maintenance...

  • Page 447: Maintenance Items

    SERVICE [2] Maintenance Items 1. Main body (Every 250,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace- replaced ning ction ation ment 1 Preparation (1) Image check 2 Drum unit (1) Charging control plate 4024-1006-xx (2) Charging wire 4024-1020-xx...
  • Page 448 SERVICE Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace- replaced ning ction ation ment 6 Conveyance (1) Conveyance section upper sur- unit face (2) Conveyance belt (3) TSL cover member 7 Registration (1) Paper dust removing brush (2) 2nd paper feed roller 8 Drive section (1) Ozone filter K...
  • Page 449 SERVICE Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace- replaced ning ction ation ment 14 Writing section (1) Dust-proof glass (external) 15 Fixing unit (1) Fixing upper roller (2) Fixing lower roller (3) Fixing claw (L) (4) Paper exit roller (5) Paper exit conveyance roller (right) and guide rib...
  • Page 450 SERVICE 2. RADF [EDH](Every 250,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Preparation (1) Paper through check 2 Paper feed (1) Size detection sensor/1 section (2) Size detection sensor/2 (3) Registration sensor (4) Feed roller (5) Paper feed roller rubber...
  • Page 451 SERVICE 3. FNS [FN-112] (Every 250,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Preparation (1) Paper through check 2 Conveyance (1) Conveyance roller section (2) Paper exit roller/A (sponge roller) 4594-2074-xx (3) Conveyance roller/4...
  • Page 452 SERVICE 5. LCT [C-403/404](Every 250,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Preparation (1) Paper through check 2 Inside of (1) Sensors machine (2) Gears (3) Conveyance roller/driven roller (4) Feed roller (5) Paper feed conveyance roller (6) Double feed prevention roller...
  • Page 453 SERVICE 7. PK-2 / PK-5 (Every 250,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Punch section (1) Punch die 2 Conveyance (1) Punch dust box (for punch dust section dump) (2) Punch dust detection sensor...

  • Page 454: Main Body Periodic Inspection Items

    SERVICE [3] Main Body Periodic Inspection Items 1. Periodic check (I) (Every 500,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Fixing unit (1) Fixing roller (U) 4024-2002-xx (2) Heat insulating sleeve (U) Apply Tri flow oil...
  • Page 455 SERVICE 2. Periodic check (II) (Every 1,000,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Paper feed unit (1) Paper feed oscillate roller Actual assembly replacement 55 cpm 4026-1011-xx count: 800 K feeds 65 cpm...
  • Page 456 SERVICE 4. Periodic check (IV) (Every 2,500,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Drum unit (1) Toner control board unit 4024-1017-xx 2 Charging (1) Charging corona unit (includ- ing PCL) 4024-1022-xx corona unit...

  • Page 457: Radf [Edh]

    SERVICE [4] RADF [EDH] 1. Periodic check (I) (Every 500,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Paper feed (1) Feed roller rubber Actual 4594-1009-xx replacement section count: 200 K feeds (2) Paper feed roller rubber...

  • Page 458: Lct [C-403/C-404]

    SERVICE [6] LCT [C-403 / C-404] 1. Periodic check (I) (Every 1,000,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Inside of (1) Feed roller Actual replace- 4014-3029-xx ment count: machine...

  • Page 459: Pi [Cover Inserter B]

    SERVICE [7] PI [Cover Inserter B] 1. Periodic check (I) (Every 500,000 copies) Implementation classification Number NO Classification Service item Note of parts Clea- Inspe- Lubric- Replace replaced ning ction ation -ment 1 Paper feed (1) Feed roller assembly/B Actual 4014-3153-xx replacement section...

  • Page 460: Replacement Parts List

    SERVICE [9] Replacement parts list 1. Main body Classification Parts name Parts No. Qty Total count Actual count Parts count No. 1 Maintenance Charging control plate 4024-1006-xx 250,000 (Every 250,000 Charging wire 4024-1020-xx 250,000 copies) Charger cleaning base 4024-2486-xx 250,000 Charger slide block 4024-2485-xx 250,000...
  • Page 461 SERVICE Classification Parts name Parts No. Qty Total count Actual count Parts count No. 2 Periodic check (I) Fixing roller /U 4026-2002-xx 500,000 (Every 500,000 Insulating sleeve /U 4014-3007-xx 500,000 copies) Upper roller bearing 4014-1747-xx 500,000 Fixing roller /L 4024-1013-xx 500,000 Fixing claw /L 4024-1015-xx...
  • Page 462 SERVICE Classification Parts name Parts No. Qty Total count Actual count Parts count No. 5 Periodic check Toner control board unit 4024-1017-xx 2,500,000 (IV) Charging unit (including PCL) 4024-1022-xx 2,500,000 (Every 2,500,000 4024-2093-xx 2,500,000 copies) Drum drive bearing 4024-2190-xx 2,500,000 Registration roller /U 4024-2627-xx 2,500,000...
  • Page 463 SERVICE 4. C-403/C-404 Classification Parts name Parts No. Qty Total count Actual count Parts count No. 1 Periodic check (I) Feed roller 4014-3029-xx 500,000 (Every 1,000,000 Paper feed conveyance roller 4014-3028-xx 500,000 copies) Double feed prevention roller 4014-3029-xx 500,000 2 Periodic check (II) Paper feed clutch 4024-1028-xx 2,000,000 (Every 4,000,000...

  • Page 464: Copy Materials

    SERVICE COPY MATERIALS [1] Single unit supply Name Durability/copies Toner cartridge 43,000 Developer 250,000 Drum 500,000 3-19...

  • Page 465: Service Material List

    SERVICE SERVICE MATERIAL LIST Tool No. Tool Name Appearance Quantity Remarks Thermostat PS jig 4024-2152-01 (for upper roller) Thermostat PS jig 4024-2992-01 (for lower roller) 4024-2990-01 Temp. detection jig 4014-5005-01 Optics PS jig 4014-5006-01 Door switch jig 2set 2PCS/set 4014-5007-01 Setting powder 25 g 3-20...
  • Page 466 SERVICE Tool No. Tool Name Appearance Quantity Remarks For EDH 4014-5008-01* PS shaft 2pc/set positioning For EDH 4014-5010-01* ADJ chart adjustment For EDH 4014-5011-01* White chart adjustment For FN-6/ 4014-5009-01 Stapler PS jig FN-112 adjustment 3-21...
  • Page 467 Blank page...

  • Page 468: Electric Parts List

    ELECTRIC PARTS LIST...
  • Page 469 Blank page...

  • Page 470: Parts Layout Drawing

    ELECTRIC PARTS LIST PARTS LAYOUT DRAWING [1] Parts Layout Drawing 1. Read Section FM9 : Scanner cooling fan PS64 : APS sensor/2 PS61 : Scanner HP PS ADB : A/D converter board PS51 : APS timing PS L1 INVB : L1 converter PS65 : APS sensor/3 L1 : Exposure lamp PS63 : APS sensor/1...
  • Page 471 ELECTRIC PARTS LIST 3. Charging corona Section M14 : Charger cleaning motor PCL : Pre-charging exposure lamp 4. Drum Stand Section MC14 : Toner recycle MC SD1 : Separation claw SD TCSB : Toner control sensor board...
  • Page 472 ELECTRIC PARTS LIST 5. Tray 1, 2, 3 MC3/5/7 : Paper feed MC /1, /2, /3 PS4/10/16 : Remaining paper PS/1, /2, /3 MC4/6/8 : Pre-registration MC/1, /2, /3 VR1/2/3 : Paper size VR/1, /2, /3 PS2/8/14 : Tray upper limit PS/1, /2, /3 PS5/11/17 : Paper size PS/1-1, /1-2, /1-3 PS3/9/15 : No paper PS/1, /2, /3 PS6/12/18 : Paper size PS/2-1, /2-2, /2-3...
  • Page 473 ELECTRIC PARTS LIST 7. By-pass Feed Section PS33 : No paper size /BP VR5 : Paper size VR/BP PS34 : Tray upper limit PS/BP PS36 : Loop PS PS32 : Paper size PS/2-BP PS35 : Tray lower limit PS/BP PS31 : Paper size PS/1-BP M20 : Up/down motor/BP 8.
  • Page 474 ELECTRIC PARTS LIST 9. ADU Stand Section M8 : Reverse/exit motor3 14. MC2 : ADU deceleration MC M9 : ADU reverse motor 15. ADU DB : ADU drive board PS46 : Reverse/exit PS 16. MC13 : ADU conveyance MC FM3 : Conveyance suction fan 17.
  • Page 475 ELECTRIC PARTS LIST 10. Fixing Section TH2 : Fixing temperature/2 L3 : Fixing heater lamp/2 TH1 : Fixing temperature/1 TS2 : Thermostat/L TS1 : Thermostat/U PS30 : Fixing exit PS L2 : Fixing heater lamp/1 L4 : Fixing heater lamp/3 11.
  • Page 476 ELECTRIC PARTS LIST 12. Write Section LDB : Laser driver board PMDB : Polygon driver board INDXSB : Index sensor board M15 : Polygon motor 13. Left Side of the Main Body FM2 : Write section cooling fan FM13 : Power supply cooling fan PS37 : Paper exit PS M7 : Paper exit motor FM6 : Paper exit fan/F...
  • Page 477 ELECTRIC PARTS LIST 14. Rear Side of the Main Body M3 : Developing motor 14. DCPS : DC power supply unit MB : Memory board 15. HTR1 : Heater/1 M11 : Scanner motor 16. HTR2 : Heater/2 SCDB : Scanner drive board 17.

  • Page 478: Radf Parts Layout Drawing

    ELECTRIC PARTS LIST [2] RADF Parts Layout Drawing FRONT M302 : Original conveyance motor 11. MS301 : Cover open/close MS MC301 : Original feed MC 12. SD303 : Pressure roller release SD PS302 : Original size PS/2 13. SD302 : Exit gate SD M301 : Original feed motor 14.

  • Page 479: C-403/C-404 Parts Layout Drawing

    ELECTRIC PARTS LIST [3] C-403 / C-404 Parts Layout Drawing PS107 : LT first paper feed PS 12. HTR101 : LT heater PS108 : LT no paper detection PS 13. PS101 : LT lower limit detection PS SW100 : LT tray down switch 14.

  • Page 480: Fn-6/Fn-112 Parts Layout Drawing

    ELECTRIC PARTS LIST [4] FN-6 / FN-112 Parts Layout Drawing FRONT PS706 : Main tray paper exit PS 16. M718 : Folding stopper motor (Only for FN-6) PS719 : Sub-tray full PS 17. PS726 : Folding passage PS (Only for FN-6) SD704 : Paper exit opening SD 18.
  • Page 481 ELECTRIC PARTS LIST PS725 : Folding exit PS SD706 : Three-folding gate SD LED729 : Folding full LED M706 : Stapler rotation motor PS729 : Folding full PS PS711 : Stapler movement HP PS PS713 : Stapler rotation HP PS M705 : Alignment motor/U Stapler/R/F PS730 : Stapler HP PS/R...
  • Page 482 ELECTRIC PARTS LIST M721 : Sub-tray paper exit motor M703 : Tray up/down motor M708 : Paper exit motor 10. M720 : Folding conveyance motor M707 : Paper exit roller motor (Only for FN-6) PS707 : Stapler paper exit upper limit PS 11.

  • Page 483: Cover Inserter B Parts Layout Drawing

    ELECTRIC PARTS LIST [5] Cover Inserter B Parts Layout Drawing FRONT MC201 : Conveyance MC/U 13. SD201 : Sheet feed SD/U PIDB : PI driver board 14. MS201 : PI interlock MS M203 : PI conveyance motor 15. PS209 : Tray upper limit PS/L MC202 : Conveyance MC/L 16.

  • Page 484: Pk-5 Parts Layout Drawing

    ELECTRIC PARTS LIST [6] PK-2 /PK-5 Parts Layout Drawing FRONT M801 : Punch motor PKDB : Punch drive board (PK-5 only) PAPER EDGE SENSOR : Paper edge sensor PKDB : Punch drive board (PK-2 only) (PK-5 only) PS804 : Punch scraps box set PS PS802 : Punch scraps full PS (PK-2 only) PS801 : Punch HP PS...

  • Page 485: Parts Layout Drawing

    ELECTRIC PARTS LIST [7] ZK-2 Parts Layout Drawing FRONT FRONT MC1 : Punch clutch 17. M7 : Punch scraps conveyance motor M10 : Conveyance motor cooling fan 18. Paper edge PS M4 : Punch motor 19. PS5 : Punch HP PS M5 : Punch shift motor 20.

  • Page 486: Connector Layout Drawing

    ELECTRIC PARTS LIST CONNECTOR LAYOUT DRAWING [1] Connector Layout Drawing 1. Printer control board 206 (W : 20 pin) 211 (W : 7 pin) 35 (W : 5 pin) 202 (W : 22 pin) 208 (GY : 16 pin) 212 (W : 24 pin) 205 (W : 6 pin) 234 (W : 40 pin) 201 (W : 2 pin)
  • Page 487 ELECTRIC PARTS LIST 2. Image control board 132 (GY : 5 pin) 128 (W : 20 pin) 130 (W : 22 pin) 103 (W : 4 pin) 6 (N.C.) 110 (W : 40 pin) 129 (W : 40 pin) 100 (W : 4 pin) 118 (N.C.) 104 (W : 3 pin) 105 (W : 3 pin)
  • Page 488 ELECTRIC PARTS LIST 3. ADU drive board 401 (W : 2 pin) 400 (W : 7 pin) 407 (W : 2 pin) 402 (W : 40 pin) 404 (GY : 6 pin) 406 (GY : 9 pin) 403 (W : 12 pin) 410 (GY : 13 pin) 110 (W : 40 pin) 414 (N.C.)
  • Page 489 ELECTRIC PARTS LIST 5. Scanner drive board 620 (W : 3 pin) 615 (W : 2 pin) 624 (GY : 15 pin) 614 (W : 22 pin) 625 (GY : 7 pin) 612 (W : 30 pin) 610 (GY : 16 pin) 613 (W : 7 pin) 600 (W : 10 pin) 623 (W : 6 pin)
  • Page 490 ELECTRIC PARTS LIST 9. Operation board/1 13. Laser driver board 153 (W : 3 pin) 152 (W : 4 pin) 151 (W : 14 pin) 180 (W : 22 pin) 150 (W : 11 pin) 158 (W : 2 pin) 156 (W : 2 pin) 14.

  • Page 491: C-403/C-404 Connector Layout Drawing

    ELECTRIC PARTS LIST [2] C-403/C-404 Connector Layout Drawing 1. LT drive board 721 (W : 17 pin) 720 (W : 11 pin) 700 (W : 4 pin) 729 (W : 6 pin) 728 (W : 8 pin) 710 (GY : 10 pin) 723 (W : 2 pin) 722 (GY : 15 pin) 4-22...

  • Page 492: Fn-6/Fn-112 Connector Layout Drawing

    ELECTRIC PARTS LIST [3] FN-6 / FN-112 Connector Layout Drawing 1. FNS control board 51 (W : 32 pin) 51 (W : 32 pin) 52 (W : 6 pin) 51 (W : 32 pin) 33 (NC) 51 (W : 32 pin) 12 (W : 24 pin) 71 (NC) 1 (W : 18 pin)

  • Page 493: Cover Inserter B Connector Layout Drawing

    ELECTRIC PARTS LIST [4] Cover Inserter B Connector Layout Drawing 1. PI drive board 53 (W : 30 pin) 56 (W : 6 pin) 58 (GY : 12 pin) 52 (W : 38 pin) 54 (W : 6 pin) 57 (W : 11 pin) 55 (W : 24 pin) 2.

  • Page 494: Connector Layout Drawing

    ELECTRIC PARTS LIST 2. Punch drive board (PK-5) 70 (W : 15 pin) 68 (W : 8 pin) 69 (W : 6 pin) 63 (GY : 38 pin) 65 (W : 5 pin) 64 (W : 2 pin) 67 (W : 3 pin) 66 (GY : 9 pin) 3.

  • Page 495: Jam Code List

    ELECTRIC PARTS LIST JAM CODE LIST Classification Cause Machine response Countermeasure Code By-pass J10-1 PS44 (registration) does not turn ON The machine stops Pull the paper out of within the predefined time after M6 (loop immediately after the by-pass feed tray roller) has turned ON.
  • Page 496 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code J15-1 PS107 (LT first paper feed) does not turn The machine stops Open the upper cover ON within the predefined time after immediately after of the LCT and remove MC102 (LT first paper feed MC) has turned paper ejection has the jammed paper.
  • Page 497 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code Paper feed/ J17-9 PS43 (leading edge) is turned ON while in Open the vertical con- conveyance the idling status. veyance door and/or the front door on the J17-10 PS44 (registration) is turned ON while in main body and remove the idling status.
  • Page 498 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code Second paper J31-1 PS43 (leading edge) does not turn ON The machine stops Open the front door feed convey- within the predefined time after MC1 (reg- immediately after and pull out the ADU ance istration MC) has turned ON.
  • Page 499 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code J62-2 PS304 (original registration /1) does not RADF stops imme- Open the open/close turn OFF within the predefined time after diately. The cover and the paper feeding of the double-side original has machine stops after feed unit to remove the started.
  • Page 500 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code J63-2 PS306 (original conveyance) does not turn RADF stops imme- Open the open/close OFF within the predefined time since it has diately. The cover and the paper turned ON when processing the reverse machine stops after feed unit to remove the paper feed for copying the back side of the...
  • Page 501 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code FN-113 J72-17 The Upper Entrance Sensor (PC4) is not Machine stops Remove the jammed blocked even after the lapse of a given immediately. paper from the FNS or period of time after the paper has the main body.
  • Page 502 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code FN-6 / J71-1 Front door of FNS or the top cover of PI has Machine stops Remove the jammed FN-112 opened while a job is being processed. immediately. paper from the FNS or the main body.
  • Page 503 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code FN-6 / J72-28 PS705 (stacker entrance) does not turn Machine stops Remove the jammed FN-112 OFF within the predefined time since it has immediately. paper from the FNS or turned ON. the main body.
  • Page 504 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code ZK-2 J72-44 PS8 (exit) does not turn ON within the pre- Machine stops Remove any jammed defined time since leading/trailing/side immediately. paper in the PZ / main edge PS on paper edge PS has turned ON. body.
  • Page 505 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code FN-6 / J72-81 PS730 (stapler HP /R) and PS732 Machine stops Remove the jammed FN-112 (clincher HP /R) do not turn ON within the immediately. paper from the FNS or predefined time after M709 (stapler /R) the main body.
  • Page 506 ELECTRIC PARTS LIST Classification Cause Machine response Countermeasure Code FN-113 J73-01 Storage Sensor PC3 Remove the jammed paper from the FNS or J73-02 Upper Entrance Sensor PC4 the main body. J73-03 Lower Entrance Sensor PC2 J73-04 1st Tray Exit Sensor PC1 J73-05 Transport Unit Acceleration Sensor PC20 J73-06...

  • Page 507: Error Code List

    ELECTRIC PARTS LIST ERROR CODE LIST Warning Estimated Classification Cause Machine response Code abnormal parts Drive F13-01 Error detection signal is detected The machine stops M1 (paper feed) continuously for one second when immediately and turns PRCB (printer control board) two seconds have passed since M1 OFF RL1 (main).
  • Page 508 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts By-pass feed F18-60 PS34 (tray upper limit/BP) or PS35 No error code is dis- M20 (up/down/BP) (tray lower limit/BP) does not turn ON played on the opera- PRCB (printer control board) within 10 seconds since the upward tion panel.
  • Page 509 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Fan abnor- F22-01 An error for SFAN_EM signal is The machine stops FM4 (developing suction) mality detected when 2 seconds have immediately and turns PRCB (printer control board) passed since FM4 (developing suc- OFF RL1 (main).
  • Page 510 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Process F29-01 Dirt correction failure of the Dmax The machine stops TSCB (toner control sensor abnormality sensor during maximum density immediately and turns board) adjustment. If this error is detected OFF RL1 (main).
  • Page 511 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Fan abnor- F32-02 An error for FIXFAN1_EM signal is The machine body FM8 (main cooling /2) mality detected when 2 seconds have stops immediately and PRCB (printer control board) passed since FM8 (main unit cooling turns OFF RL1 (main).
  • Page 512 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Fixing sensor F36-01 TH1 (fixing temperature /1) has not The machine body PRCB (printer control board) abnormality reached 50°C when the specified stops immediately and DCPS (DC power supply unit) time has passed since the fixing ON turns OFF RL1 (main).
  • Page 513 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Image con- E46-01 During image write, APC cannot be If copy operation is Write section trol abnor- performed for sub-scanning beam being performed, the ICB (image control board) mality correction.
  • Page 514 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Image con- E46-14 During image read, image data If copy operation is PRCB (printer control board) trol abnor- decompression from the memory to being performed, the ICB (image control board) mality the printer is not completed within the machine stops after...
  • Page 515 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Image con- E46-25 AOC/AGC error If copy operation is ADB (A/D conversion board) trol abnor- • The light blocking cover and lens being performed, the L1 (exposure lamp) mality cover are removed from the machine stops after...
  • Page 516 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Image con- F46-43 Hard disk access failure The machine stops ICB (image control board) trol abnor- Hard disk failure or poor connection immediately and RL1 ICB program mality of connectors (main) turns OFF.
  • Page 517 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Image con- E46-91 The header read address is illegal. If copy operation is ICB (image control board) trol abnor- being performed, the Expansion memory E46-99 E-RDH memory initialization error mality machine stops after E-RDH memory may not be con-...
  • Page 518 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Fan abnor- F52-01 FM13 (power supply cooling) EM sig- The machine stops FM13 (power supply cooling) mality nal was abnormal 2 seconds after immediately. RL1 DCPS (DC power supply unit) turning ON FM13.
  • Page 519 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts FN-113 SC77-03 The CD Aligning Home Position Sen- The machine stops PC9 (CD Aligning Home Posi- abnormality sor (PC9) does not go HIGH even immediately and RL1 tion Sensor) after the lapse of a given period of (main) is turned OFF.
  • Page 520 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts FN-113 SC77-81 The Transport Unit Entrance Switch- The machine stops PC23 (Transport Unit abnormality ing Sensor (PC23) does not go from immediately and RL1 Entrance Switching Sensor) LOW to HIGH even after the lapse of (main) is turned OFF.
  • Page 521 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts FN-6 / F77-11 After M714 (stapler /F) starts opera- The machine stops FNSCB (FNS control board) FN-112 tion, PS731 (stapler HP/F) does not immediately and RL1 RB (relay board) abnormality turn ON within the specified time.
  • Page 522 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts PK-5 F77-44 PS803 (punch shift HP) does not turn The machine stops FNSCB (FNS control board) abnormality ON within the specified time after immediately and RL1 PKDB (PK drive board) M802 (punch shift) operation has (main) is turned OFF.
  • Page 523 ELECTRIC PARTS LIST Warning Estimated Classification Cause Machine response Code abnormal parts Communica- E80-01 No response from PRCB (printer The machine stops PRCB (printer control board) tion abnor- control board) for 5 seconds after immediately and RL1 mality SW2 (sub power) is turned ON. (main) is turned OFF.
  • Page 524 ELECTRIC PARTS LIST For the following abnormalities, the user can disconnect the faulty unit temporarily to continue using the machine. When an abnormality occurs, press the reset button following the LCD message, and turn the SW2 (sub power) OFF/ON. This allows temporary use of machine until the SW2 (sub power) is turned OFF/ON next time.

  • Page 525: Timing Chart

    ELECTRIC PARTS LIST TIMING CHART [1] Timing Chart (1) A4, life size, 1-1 mode, Tray 1, reversed paper exit, non AE, 2 sets 4-56...

  • Page 526: Timing Chart (2)

    ELECTRIC PARTS LIST [2] Timing Chart (2) A4, life size, 1-2 mode, Tray 1, 2 sets 4-57...

  • Page 527: Radf Timing Chart (1)

    ELECTRIC PARTS LIST [3] RADF Timing Chart (1) [4] RADF Timing Chart (2) A4, 3 originals (single side) A4, 3 originals (double side) 4-58...
  • Page 528 ELECTRIC PARTS LIST [5] C-403 / C-404 Timing Chart A4, life size, 1-1 mode, non AE, 2 sets 4-59...
  • Page 529 ELECTRIC PARTS LIST [6] FN-6 / FN-112 TIming Chart (1) Sort, A4, 2 originals (single side), 3 sets 4-60...
  • Page 530 ELECTRIC PARTS LIST [7] FN-6 / FN-112 Timing Chart (2) 2 staples (flat), A4, 2 originals (single side), 6 sheets (single side) 4-61...
  • Page 531 ELECTRIC PARTS LIST [8] FN-6 / FN-112 Timing Chart (3) Stitch and fold, A4, 2 originals (single side), 6 sheets (single side) 4-62...
  • Page 532 ELECTRIC PARTS LIST [9] FN-6 / FN-112 Timing Chart (4) Three-folding/A4R/3 sheets of originals/2 sets setting/single side 4-63...

  • Page 533: Cover Inserter B Timing Chart (3)

    ELECTRIC PARTS LIST [10] Cover Inserter B Timing Chart PI automatic paper feed (bottom) /2 staples (flat) /A4/2 sheets of original/2 sets setting/single side 4-64...

  • Page 534: Timing Chart

    ELECTRIC PARTS LIST [11] PK-2 Timing Chart Punch/2 staples (flat) /A4/2 sheets of original/3 sets setting/single side 4-65...

  • Page 535: Timing Chart

    ELECTRIC PARTS LIST [12] PK-5 Timing Chart Punch/2 staples (flat) /A4/2 sheets of original/3 sets setting/single side 4-66...

  • Page 536: Timing Chart

    ELECTRIC PARTS LIST [13] ZK-2 Timing Chart Z-folding/ Punch mode/A3/ 3 sheets of original/ single side 4-67...
  • Page 537 Blank page...
  • Page 539 Blank page...

  • Page 540: What's Isw

    ISW (In-System Writer) is a process of updating the control programs stored in flash ROM mounted on var- ious control boards in a Minolta digital copier without isolating the boards from the copier. Running ISW enables you to upgrade control programs without replacing the boards and maintain the boards during their replacement.

  • Page 541: Setup

    SETUP [1] ISW-compatible boards This machine allows ROM data residing on the following boards to be updated via ISW: • Image control board • Printer control board • Finisher control board [2] Data flow Image control board Printer control board Finisher control board Important Note: The availability of the image control program is prerequisite to updating on other boards.

  • Page 542: Preparing The Copier To Transfer

    ROM data. Energy Saver [ISW mode Screen] Timer key appears, indicating the Start Interrupt copiers readiness to launch an ISW transfer. Follow operating instructions in Minolta ISW (In-System Writer) Service Hand book. Energy Timer LED Processing Saver LED (orange) (green)

  • Page 543: Rewriting Procedure After An Error Interruption

    [6] Rewriting procedure after an error [8] Connecting to the ISW connector interruption The ISW connector is at the right side of the copier. If errors occur while writing ROM data, it is writ- Procedure ten the same way as explained in "Writing ROM (1) Connect the PC parallel port and the copier ISW data newly"...

  • Page 544: Error Code Table For Isw Setup

    [9] Error code table for ISW Setup Error Code Description Action No. There is an error in the command to ISW processing unit. A program error is detected. Input data format error. Invalid machine name input data. Invalid board name input data. Input device error such as input timeout.

  • Page 545: Updating With Isw Trns

    UPDATING WITH ISW TRNS [1] ISW Trns Specifications ISW Trns disk organization Setup disk : 2 disks Update disk : Dependent on the copier 2. Software environment : Windows 95/98 : Pentium 75 MHz or faster : 16 MB or more Hard disk space : 100 MB or more Others...

  • Page 546: Setting Up Isw Trns

    ISW Trns program has installed Click OK as instructed by on-screen guid- (C:\Program_File\Minolta\ISWTrns ance. for Minolta) has been set up as a Note: This procedure will add an ISW Trns storage folder (data folder). icon to the Start menu. Note2: To change the storage folder, click...
  • Page 547 Step Procedure Note3: Clicking Make Folder will create the following hierarchy folders branching off from the new storage folder: Note: Pctrl and Vit Indications can not be function. [Option window] Click OK. Note: This procedure will save the data folders created in Step 4 to the INI file for the ISW Trns program.
  • Page 548 3. ISW Trns Main Window Overview The ISW Trns program, when run, comes up with the ISW Trns main window. The ISW Trns main window lets you select, verify, and transfer a transfer file (update data) and display information in it. A detailed description of its functions follows: ⑩...
  • Page 549 Data sources appearing in the detailed file information list Display title ORIGINAL (Batch data) DIVIDE (Divided data) File Name File name of the version selection file File name of the version selection file File Date Date of the version selection file Date of the version selection file File Time Time of the version selection file...
  • Page 550 File Check button Step Procedure Click this button when send files are listed in the Boot the PC. Send File Info list in , and a file checksum of Open the System icon in the Control Panel the transfer files displayed (file checksum) is cal- and click the Device Manager tab.

  • Page 551: Copying Transfer Data (Update Data)

    [3] Copying Transfer Data (Update Data) Step Procedure Run the ISW Trns program to copy transfer data (update data) to the PC. Click Copy to copy the selected transfer files (update data) to the folder created at ISW Trns setup. Step Procedure Note1: To copy all the files (update data)

  • Page 552: Connecting

    [4] Connecting [5] Updating Connect a parallel interface cable to the copier. Prerequisites to cabling are: 1. Update operation overview • A PC to which transfer files (update data) have Follow the steps below to update the ROM data been copied. on each control board using ISW Trns.
  • Page 553 2. Checking the ROM version of the copier Selecting transfer file (update data) con- (before updating) ditions Before updating ROM data, check the ROM ver- Select various conditions for selecting the trans- sion of the existing control program in the 25 fer files (update data) in the ISW Trns main win- mode.
  • Page 554 6. Selecting a version of transfer files Step Procedure (update data) When a transfer file (update data) has been cho- In the ISW Trns main window, click in the sen to meet a given set of conditions, it may be [Divide] field in [Select Type] and select a method of dividing the transfer files (update available in multiple versions.
  • Page 555 7. Verifying transfer files (update data) 8. Transmitting transfer files (update data) Once a particular version of a transfer file When transfer files (update data) are estab- (update data) is selected, the transfer files lished, run a data transfer to the copier. (update data) that are transmitted actually are Step Procedure...
  • Page 556 9. Exiting ISW Trns. When the update of the ROM data on the control boards completes, exit the ISW Trns program. Step Procedure Exit the ISW Trns program. Turn OFF the PC. Turn OFF the copier main switch. Disconnect the parallel interface cable from the PC and the copier.

  • Page 557: Isw Trns Messages

    ISW TRNS MESSAGES The ISW Trns program displays dialog messages when errors occur and when processing ends. Definitions of these messages are listed below, along with the associated display status. Message Display status Cannot open a checksum file Opening of a checksum file failed. Possible causes include a corrupted file and a file in use.
  • Page 558 Message Display status File copying end File copying completed. Send file not found, or invalid file name in the The number of divisions of a send file recorded in the folder. Check. folder. Check. checksum file and the number of files actu- ally existing do not match.

  • Page 559: Troubleshooting Isw Trns

    TROUBLESHOOTING ISW Trns If errors occur while running the ISW Trns program, 5. Unsuccessful file transfer take the actions suggested below to correct them. 5.1 “Cannot open a file” error • The file is used by any other program or by the system.

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