Minolta Di251 Service Manual
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Minolta Di251 Service Manual

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Di251 / Di351

SERVICE MANUAL

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GENERAL
4011-7990-11

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  • Page 1: Service Manual

    Di251 / Di351 SERVICE MANUAL GENERAL 4011-7990-11...
  • Page 2 INDEX (GENERAL) GENERAL MECHANICAL/ELECTRICAL...
  • Page 3 GENERAL...

  • Page 4: Table Of Contents

    CONTENTS 1. SAFETY INFORMATION ................. G-1 2. SPECIFICATION ..................... G-6 3. PRECAUTIONS FOR INSTALLATION ............G-9 3-1. Installation Site ..................G-9 3-2. Power Source ..................G-9 3-3. Grounding ....................G-9 4. PRECAUTIONS FOR USE ................G-10 4-1. To ensure that the copier is used in an optimum condition ..... G-10 4-2.

  • Page 5: Safety Information

    CAUTION: The use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. Because of this, Minolta strongly recommends that you operate your copy machine only as described in this documentation.
  • Page 6 CAUTION: Use of controls, adjustments or performance of procedures other than those specified in this manual may result in hazardous radiation exposure. This is a semiconductor laser. The maximum power of the laser diode is 5 mW (Di251) 15 mW (Di351) and the wavelength is 770-795 nm (Di251)/775-795 nm (Di351).

  • Page 7: Laser Safety Label

    Osynlig laserstråining när denna del är öppnad och spärren är urkopplad. Betrakta ej stråien. Det här är en halvledarlaser. Den maximala effekten för laserdioden är 5 mW (Di251) 15 mW (Di351) och våglängden är 770-795 nm (Di251)/775-795 nm (Di351). For Norway ADVERSEL Dersom apparatet brukes på...
  • Page 8 Label inside copy machine The following laser safety label will be attached inside the copy machine as shown below. Please read the following for your own protection. Caution Opening the cover indicated by the Caution label may expose you to harmful laser radiation which could cause damage or loss of eyesight.
  • Page 9 ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany only VORSICHT! Explosinsgefahr bei unsachgemäßen austausch der batterie. Ersatz nur durch denselben oder einen vom hersteller empfohlenen ähnlichen typ.

  • Page 10: Specification

    SPECIFICATION TYPE Console/Desktop Type ORIGINAL SCANNING SYSTEM CCD Line Sensor PHOTOCONDUCTOR Organic Photoconductor COPYING SYSTEM Electrostatic Dry Powdered Image Transfer to Plain Paper with a Laser RESOLUTION 600 dpi PAPER FEEDING SYSTEM 3-way system Manual Feed Tray ...Single 1st Drawer....250 Sheets (Plain paper) 50 Sheets (Special paper) 2nd Drawer .....500 Sheets (Plain paper) 35 CPM/25 CPM: Standard...
  • Page 11 CONTINUOUS COPY SPEED (copies/min) - Metric - - Inch - Size Speed Size Speed 8-1/2 8-1/2 8-1/2 ZOOM RATIOS - Metric - - Inch - Full Size 1.000 1.000 2.000 2.000 1.414 1.545 Enlargement 1.224 1.294 Fixed 1.154 1.214 0.866 0.785 0.816 0.733...
  • Page 12 COPIER DIMENSIONS Metric area 35 CPM: W...632 mm, D...707 mm, H...647 mm 25 CPM: W...594 mm, D...707 mm, H...647 mm Inch area 35 CPM: W...25, D...27-3/4, H...25-1/2 25 CPM: W...23-1/2, D...27-3/4, H...25-1/2 COPIER WEIGHT Metric area 35 CPM: 60.5 kg, 25 CPM: 58.7 kg Inch area 35 CPM: 133-1/2 lb, 25 CPM: 129-1/2 lb...

  • Page 13: Precautions For Installation

    PRECAUTIONS FOR INSTALLATION 3-1. Installation Site To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: • Where it will be subjected to extremely high or low temperature or humidity. • Where it will be subjected to sudden fluctuations in either temperature or humidity. •...

  • Page 14: Precautions For Use

    PRECAUTIONS FOR USE 4-1. To ensure that the copier is used in an optimum condition • Never place a heavy object on the copier or subject the copier to shocks. • Insert the power plug all the way into the outlet. •...

  • Page 15: Handling Of Consumables

    HANDLING OF CONSUMABLES Before using any consumables, always read the label on its container carefully. • Paper can be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded in the drawer, in a sealed plastic bag in a cool, dark place.

  • Page 16: Other Precautions

    OTHER PRECAUTIONS Use the following precautions when performing service jobs for a copier that uses a laser. • When a service job needs to be performed in the laser beam path, such as when working around the printerhead or PC Drum, be sure first to unplug the power cord of the copier from the outlet.

  • Page 17: System Options

    SYSTEM OPTIONS 1166O014AA 1166O008AA 1166O007AA 1145M035AA 4015O218AA 4002O102AA 1166O011AA 4015O025AB 4015O028AB 6, 7 4015O027AA 1166O012AA 14, 15 4015O029AA 4002O099AA 1166O190AA 1166O191AB 1. Duplexing Document Feeder AFR-17 10. Copy Desk 2. Automatic Document Feeder AF-9 11. Printer Controller Pi3502 3. Original Cover Kit OC-3 12.
  • Page 18 MECHANICAL/ ELECTRICAL...
  • Page 19 CONTENTS 1. CROSS-SECTIONAL VIEW ................M-1 2. COPYING PROCESS ..................M-2 3. DRIVE SYSTEM ....................M-4 4. OPERATING SEQUENCE ................M-5 5. CPU OVERRUN MONITOR FUNCTION ............M-6 5-1. Processing Performed during Watchdog Function ........M-6 6. IMAGE STABILIZATION SYSTEM ..............M-7 7.
  • Page 20 Paper Separating Mechanism ............M-33 14-7.Drawer Paper Take-Up Control ............... M-34 Paper Take-Up Roll ................. M-34 Paper Take-Up Retry Control ............M-34 Paper Take-Up Interval Control ............M-34 Double Feed Paper Take-Up Control (35-cpm copier only) .... M-35 15. MANUAL BYPASS TRAY ................M-36 15-1.Manual Bypass Paper Take-Up Control ..........

  • Page 21: Cross-Sectional View

    CROSS-SECTIONAL VIEW 4011M001AA 1. 2nd Mirror 10. Image Transfer Roller 2. 3rd Mirror 11. Synchronizing Roller 3. Exposure Lamp 12. Manual Bypass Tray 4. 1st Mirror 13. Manual Feed Paper Take-Up Roll 5. Lens 14. Paper Separator Pad 6. CCD Unit 15.

  • Page 22: Copying Process

    COPYING PROCESS 14. Paper Exit 13. Fusing 3. Photoelectric Conversion Section 11. Cleaning 12. Erase 2. Drum Charging 10. Paper Separation 4. MFB2 Board 5. Laser Exposure 1. PC Drum 9. Image Transfer 6. Development 8. Manual Bypass 7. Paper Feed 1.
  • Page 23 11. Cleaning • Residual toner is scraped off the surface of the PC Drum. • The toner is then recycled back to the Developing Unit. 12. Erase • The PC Drum is exposed to light, which effectively neutralize any residual charge on the surface of the PC Drum.

  • Page 24: Drive System

    DRIVE SYSTEM 4011M002AA 1. Scanner Motor M10 2. Main Motor M2 3. I/C Motor M1...
  • Page 25 Power Switch ON Start key ON Full speed Full speed Half speed Half speed Power Unit Cooling Fan Motor M4 Full speed Full speed Half speed Half speed Cooling Fan Motor M3 Ozone Fan Motor M8 Predrive Fusing predrive Main Motor M2 Fusing Roller Heater Lamp H1 Manual Feed Paper Take-Up Clutch CL2 Warm-up completed...

  • Page 26: Cpu Overrun Monitor Function

    CPU OVERRUN MONITOR FUNCTION • The CPU overrun monitor function (watchdog function) is a self-monitoring function that determines whether any of the CPUs mounted on the copier overruns. • If this function detects that a CPU overruns, the copier automatically resets the CPU, restarting the logic circuit and mechanism.

  • Page 27: Image Stabilization System

    IMAGE STABILIZATION SYSTEM • The following image stabilization controls are provided to ensure stabilized copy image. Item Purpose Control PC Drum temperature To compensate for any change I/C Thermistor is used to detect correction in ID due to changing PC Drum temperature and, according to temperatures.

  • Page 28: Imaging Cartridge (I/C)

    IMAGING CARTRIDGE (I/C) • This copier employs an Imaging Cartridge (“I/C” in this manual). • The I/C contains a PC Drum, Developing Unit, PC Drum Charge Corona, and a Cleaning Unit as one unit. 1171M002AA 1171M003AA ATDC Sensor UN2 Toner Supply Port...

  • Page 29: I/C Drive Mechanism

    7-1. I/C Drive Mechanism • Drive from the I/C Motor is transmitted via a gear train to the PC Drum and Hopper. PC Drum Drive Gear Hopper Drive Gear I/C Motor M1 4011M021AA Electrical Component Control Signal Wiring Diagram PJ5A-3 7-2.

  • Page 30: Grounding Of The Pc Drum

    PC DRUM • The PC Drum consists of an aluminum base coated with a charge generation layer and a charge transport layer. (PC Drum Cross-Section) PC Drum Charge Transport Layer Charge Generation Layer Aluminum Base 1167M007AA Gear 1139M007AA 8-1. Grounding of the PC Drum •...

  • Page 31: Drum Charging

    DRUM CHARGING • The PC Drum Charge Corona has a grid mesh to deposit a charge evenly across the sur- face of the PC Drum. • The corona unit has a comb electrode that discharges only toward the grid mesh, thus minimizing the amount of ozone produced.

  • Page 32: Ozone Fan

    Ozone Fan • Ozone produced by the PC Drum Charge Corona is absorbed from the air, which is being drawn out of the copier by the Ozone Fan Motor, by the ozone filter located beneath the motor. Ozone Fan Motor M8 Ozone Filter 4011M025AA Electrical Component...

  • Page 33: Ir Section

    10. IR SECTION • The surface of the original is exposed to a light and the light reflected off the original is converted to an electrical signal. • The electrical image signal is then output to the MFB2 Board. 4011M008AA 1.

  • Page 34: Construction Of The Exposure Section

    10-1. Construction of the Exposure Section 1. Auxiliary Reflector 2. Exposure Lamp 3. 1st Mirror 1167M089AA 1. Auxiliary Reflector When a book or other bound original is copied, the paper in the area near the binding generally fails to come flush against the glass, so that the copy of these areas is gener- ally too dark.

  • Page 35: Image Processing Flow

    10-2. Image Processing Flow • Image processing consists of the following blocks. 1. Photoelectric Conversion (CCD Sensor) 2. MFB2 Board 3. PH (Laser Emission) 1. Photoelectric Conversion (CCD Sensor) • Light reflected off the original is received through mirrors and lens by the CCD Sensor which, in turn, outputs the corresponding data to the MFB2 Board.

  • Page 36: Scanner And 2Nd/3Rd Mirrors Carriage Moving Mechanism

    10-3. Scanner and 2nd/3rd Mirrors Carriage Moving Mechanism Scanner Moving Mechanism • The Scanner is driven by the Scanner Motor at a speed according to the set zoom ratio calculated with reference to the speed of the full size mode. •...

  • Page 37: Original Size Detecting System

    11. ORIGINAL SIZE DETECTING SYSTEM • When the copier is in Auto Paper or Auto Size mode, the Original Size Detecting Sensors mounted at the optical section are used to determine the size of the original. Original Size Detecting Sensor 1 UN3 Original Size Detecting Sensor 6 UN8 Original Size Detecting...

  • Page 38: Original Size Detecting Operation

    11-1. Original Size Detecting Operation • The copier determines that there is an original placed on the glass when a photo receiver of the original size detecting sensor receives the light of a given level or higher of inten- sity. 1136M020AA 11-2.

  • Page 39: Original Size Detection Timing

    11-3. Original Size Detection Timing • Takes size readings: When the Original Cover is raised to an angle of 15° or more (Original Cover Detecting Sensor is unblocked). • Affirms size readings: When the Original Cover is lowered to an angle of 15° or less (Original Cover Detecting Sensor is blocked) and the Size Reset Switch is actuated.

  • Page 40: Ph Section

    12. PH SECTION • Image data sent from the memory section is corrected and, based on the corrected data, a laser light is projected onto the surface of the PC Drum to form a corresponding latent image. PH Unit 1167M022AA M-20...

  • Page 41: Laser Emission Timing

    12-1. Laser Emission Timing • The laser diode is forced to turn ON to project the laser beam onto the SOS Sensor Board, which generates an SOS signal. • The SOS signal determines the laser emission timing. Collimator Lens Cylindrical Lens Laser Diode Board SOS Mirror Polygon Motor M5...

  • Page 42: Developing Unit

    13. DEVELOPING UNIT • The Developing Unit agitates and triboelectrically charges toner so that it sticks to the electrostatic latent image formed on the surface of the PC Drum, then changing the image to a visible, developed one. 1171M011AB 1. Spent Toner Recycling Coil 8.

  • Page 43: Sleeve/Magnet Roller

    13-1. Sleeve/Magnet Roller • The Sleeve/Magnet Roller, which consists of an outer sleeve roller and an inner magnet roller, conveys developer to the point of development. • The magnetic force of the magnet roller at the point of development is the strongest so that the developer brush stands straight up to deliver the greatest amount of toner to the point of development.

  • Page 44: Atdc Sensor Automatic Adjustment

    13-3. ATDC Sensor • The ATDC Sensor detects the toner-to-carrier ratio (T/C) of the developer in the Devel- oper Mixing Chamber. 1. An LED emits infrared rays to toner. 2. There is a phototransistor that converts the intensity of the light reflected off the toner to a corresponding voltage value and outputs it.

  • Page 45: Toner Empty Control (T/C Recovery Mode)

    Toner Empty Control (T/C Recovery Mode) • When control is passed onto the T/C recovery mode, the Sub Hopper Toner Replenish- ing Motor is energized to replenish the supply of toner into the Developing Unit. If T/C is not recovered to a level of 13 % or higher (2.50 V or less) within a given period of time, a toner-empty condition results.

  • Page 46: Toner Bottle Home Position Detection Mechanism

    13-4. Toner Bottle Home Position Detection Mechanism • The Toner Bottle Home Position Sensor detects the Toner Bottle at its home position. When the Toner Bottle is at the home position (stationary), its toner supply port should face up. Toner Bottle Home Position Sensor PC10 4011M004AA Electrical Component...

  • Page 47: Main Hopper Toner Replenishing Mechanism

    13-6. Main Hopper Toner Replenishing Mechanism • The Main Hopper Toner Replenishing Motor gives the drive for supplying toner from the Toner Bottle to Sub Hopper. • Toner is replenished each time the Sub Hopper Toner Empty Switch (S4) provided in the Sub Hopper is actuated and deactuated.

  • Page 48: Sub Hopper Toner Replenishing Mechanism

    13-7. Sub Hopper Toner Replenishing Mechanism • The Sub Hopper Toner Replenishing Motor replenishes toner from the Sub Hopper to the Developer Mixing Chamber. • The toner replenishing time is determined according to the T/C reading. Sub Hopper Sub Hopper Toner Replenishing Motor M7 4011M005AA Electrical Component Control Signal...

  • Page 49: Paper Take-Up/Feed Section

    14. PAPER TAKE-UP/FEED SECTION Paper Size Detecting Sensor (CD) S5 Paper Size Detecting Paper Take-Up Roll Board PWB-I 4011M006AC 14-1. 1st Drawer-in-Position Detection • When the 1st Drawer is slid into the copier, the light blocking plate located in the rear of the drawer blocks the 1st Drawer Set Sensor and the copier determines that the drawer has been slid into position.

  • Page 50: St Drawer Paper Empty Detection

    14-2. 1st Drawer Paper Empty Detection • The 1st Drawer Paper Empty Sensor detects a paper-empty condition. • When a paper-empty condition is detected (sensor is blocked), the Paper Level LED lights up. 1st Drawer Paper Empty Sensor PC4 Empty Lever 1167M073AD Electrical Component Control Signal...

  • Page 51: St Drawer Paper Lifting Plate

    14-4. 1st Drawer Paper Lifting Plate • The Paper Lifting Plate installed in the 1st Drawer is spring-loaded to push the paper stack upward. • When the drawer is slid into the copier, the lever that locks down the Paper Lifting Plate is pushed and unlocked, allowing the Paper Lifting Plate to push the paper stack upward.

  • Page 52: Paper Size Table According To Sensor/Switch Conditions

    Paper Size Table According to Sensor/Switch Conditions Paper Size Detecting Board PWB-I Paper Size 11 × 14 L B4C, Folio, Legal L FLS, G. Legal L B5L, Letter L, G. Letter L, Executive L, 8 × 10 L Letter C Invoice L A4C, G.

  • Page 53: Drawer Paper Take-Up Mechanism

    14-6. Drawer Paper Take-Up Mechanism Paper Separating Mechanism • The coefficient of friction between the Paper Take-Up Roll and Separator Pad is effec- tively used to prevent double feed of paper. When one sheet of paper : The coefficient of friction on the front side of the sheet of is taken up paper taken up and fed through the space between the Paper Take-Up Roll and Separator Pad is the same as that...

  • Page 54: Drawer Paper Take-Up Control

    14-7. Drawer Paper Take-Up Control Paper Take-Up Roll • Drive from the Main Motor is transmitted via a gear train to the Paper Take-Up Clutch (spring clutch). The Paper Take-Up Roll is turned when the 1st Drawer Paper Take-Up Solenoid is then energized. Main Motor M2 Paper Take-Up Clutch Paper Take-Up Roll...

  • Page 55: Double Feed Paper Take-Up Control (35-Cpm Copier Only)

    Double Feed Paper Take-Up Control (35-cpm copier only) • The following control is provided to minimize the occurrence of a paper misfeed due to double feed. If the Double Feed Detecting Board detects a sheet of paper, the copier retards the start of paper take-up sequence for the subsequent sheet of paper a period of time equivalent to about 10 mm.

  • Page 56: Manual Bypass Tray

    15. MANUAL BYPASS TRAY Main Motor M2 Manual Feed Paper Take-Up Clutch CL2 Manual Feed Paper Take-Up Roll Manual Feed Paper Take-Up Sensor PC8 Manual Bypass Tray 4011M023AB 15-1. Manual Bypass Paper Take-Up Control • Drive from the Main Motor is transmitted via a gear train to the Manual Feed Paper Take- Up Roll when the Manual Feed Paper Take-Up Clutch is energized.

  • Page 57: Synchronizing Rollers

    16. SYNCHRONIZING ROLLERS • The Synchronizing Rollers synchronize the timing of the exposure section (PH) with that of the paper transport section. Synchronizing Clutch CL1 Synchronizing Roller 4011M018AA 16-1. Paper Dust Remover • Paper dust attracted from the paper to the surface of the Synchronizing Roller is trans- ferred onto the Paper Dust Remover.

  • Page 58: Synchronizing Roller Drive Mechanism

    16-2. Synchronizing Roller Drive Mechanism • Drive for the Synchronizing Rollers is provided by the Main Motor through the Synchro- nizing Clutch. Main Motor M2 Synchronizing Clutch CL1 Synchronizing Roller 1167M064AA Electrical Component Control Signal Energized Deenergized Wiring Diagram PJ3A-2A M-38...

  • Page 59: Image Transfer And Paper Separation

    17. IMAGE TRANSFER AND PAPER SEPARATION Image Transfer • A charge is applied to the Image Transfer Roller to transfer the toner image formed on the surface of the PC Drum onto the paper. • To ensure that image transfer efficiency is stabilized, the image transfer current is auto- matically varied according to the paper size, paper type, and the B/W ratio of the original.

  • Page 60: Pc Drum Cleaning

    18. PC DRUM CLEANING • The Cleaning Blade is used to scrape residual toner off the surface of the PC Drum. • The spent toner is conveyed by Spent Toner Feed Rollers 1 and 2 to the Recycling Duct and eventually back to the Developer Mixing Chamber. •...

  • Page 61: Erase Lamp

    19. ERASE LAMP • Any potential remaining on the surface of the PC Drum is neutralized by both light from the Erase Lamp and a negative voltage applied by the Charge Neutralizing Sheet. • The Charge Neutralizing Sheet applies a negative charge on the surface of the PC Drum which is positively charged by the Image Transfer Roller.

  • Page 62: Fusing Unit

    20. FUSING UNIT • The heat and pressure applied by the Fusing Rollers to the paper fixes the image perma- nently to the paper. 4011M014AB 1. Paper Exit Roller 6. Right Fusing Roller 2. Fusing Unit Pressure Lever 7. Fusing Roller Heater Lamp H1 3.

  • Page 63: Fusing Unit Drive Mechanism

    20-1. Fusing Unit Drive Mechanism • Drive from the Main Motor is transmitted via a gear train to the Left Fusing Roller. Left Fusing Roller Main Motor M2 Paper Exit Roller 4011M017AB Electrical Component Control Signal Energized Deenergized Wiring Diagram PJ5A-1 4 to 5-F M-43...

  • Page 64: Fusing Temperature Control

    20-2. Fusing Temperature Control • The Fusing Roller Heater Lamp is turned ON and OFF so that the surface temperature of the Fusing Roller is maintained at a preset temperature. • The surface temperature of the Fusing Roller is detected by converting the temperature read by the thermistor to a corresponding electrical signal.

  • Page 65: Paper Exit Unit

    21. PAPER EXIT UNIT • The paper exit unit feeds the paper, which has been transported from the Fusing Unit, out of the copier. • The Charge Neutralizing Brush touches the surface of the sheet of paper being fed out to neutralize any static charge left on it.

  • Page 66: Other Units And Mechanisms

    22. OTHER UNITS AND MECHANISMS 22-1. Memory Backup • IC3 mounted on the Master Board (PWB-A) stores the values set and adjusted with the Tech. Rep. Mode and other functions, as well as counter values. When replacing PWB-A, therefore, it is necessary to remount IC3. NOTE •...

  • Page 67: Interior Cooling Mechanism

    22-3. Interior Cooling Mechanism I/C Cooling Mechanism • A fan motor is used to blow outside air against the I/C, thereby preventing low ID and a foggy background from occurring due to an increased temperature of the developer. I/C Cooling Fan Motor M9 1171M032AB Electrical Component Control Signal...

  • Page 68: Fusing Section Cooling Mechanism

    Fusing Section Cooling Mechanism • A fan motor draws air from the area around the Fusing Unit to the outside to prevent the copier interior temperature from running high. Fusing Unit Cooling Fan Motor M3 4011M015AA Electrical Component Control Signal Energized Deenergized Wiring Diagram PJ3A-3A...

  • Page 69: Power Supply Section Cooling Mechanism

    Power Supply Section Cooling Mechanism • A fan motor draws air from the area around the Power Supply Unit to the outside to pre- vent the temperature of the unit from running high. Power Unit Cooling Fan Motor M4 Power Supply Unit PU1 4011M016AA Electrical Component Control Signal...
  • Page 70 Copyright 2001 MINOLTA ME GmbH Printed in Germany Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA ME GmbH 4011-7990-11...
  • Page 71 Di251 / Di351 SERVICE MANUAL FIELD SERVICE 4011-7991-11...

  • Page 72: Safety Precautions For Inspection And Service

    Safety Precautions for Inspection and Service When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety. Depending on the model, some of the precautions given in the following do not apply. WARNING 1. Always observe precautions. •...
  • Page 73 7. Do not touch a high-temperature part. • A part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is energized. Touching them may result in a burn. •...
  • Page 74 CAUTION 1. Precautions for Service Jobs • A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire. • When reassembling parts, make sure that the correct screws (size, type) are used in the correct places.
  • Page 75 5. Precautions for the Laser Beam (Only for Products Employing a Laser) • Removing the cover marked with the following caution label could lead to possi- ble exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover.

  • Page 76: Used Batteries Precautions

    Used Batteries Precautions ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions. Germany VORSICHT! Explosionsgefahr bei unsachgemäßem Austausch der Batterie. Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ.

  • Page 77: Precautions For Service

    Precautions for Service When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply. Precautions Before Service •...
  • Page 78 Precautions for Dis/Reassembly • Be sure to unplug the copier from the outlet before attempting to service the copier. • The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears.
  • Page 79 Handling of PWBs 1. During Transportation/Storage: • During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem- perature.

  • Page 80: Handling Of The Pc Drum

    Handling of the PC Drum Only for Products Not Employing an Imaging Cartridge. 1. During Transportation/Storage: • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. •...
  • Page 81 3. Soak a small amount of either ethyl alcohol or iso- propyl alcohol into a clean, unused Dust-Free Cot- ton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one con- tinuous movement from its rear edge to its front edge and off its surface one to two times.
  • Page 82 INDEX (FIELD SERVICE) INSTALLATION DIS/REASSEMBLY, ADJUSTMENT SWITCHES ON PWBs, TECH. REP. SETTINGS TROUBLESHOOTING...
  • Page 83 NSTALLATION Rev. 1.1.0/03.01 Di251/Di351...
  • Page 84 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28 1.5.4 Reference Gap Adjustment - - - - - - - - - - - - - - - - - - - - - - - 28 Di251/DI351 Rev. 1.1.0/03.01...
  • Page 85 1.7.17 Adjusting the Position of the Single Feed Copy - - - - - - - - - 53 1.7.18 Securing the stoppers - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 Rev. 1.1.0/03.01 Di251/Di351...
  • Page 86 1.10.6 Attaching the paper size label - - - - - - - - - - - - - - - - - - - - - - 79 1.10.7 Registration Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - 80 Di251/DI351 Rev. 1.1.0/03.01...
  • Page 87 1.11.8 Affixing the Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92 1.11.9 Adjust the Paper Reference Position - - - - - - - - - - - - - - - - - 93 Rev. 1.1.0/03.01 Di251/Di351...
  • Page 88 Di251/DI351 Rev. 1.1.0/03.01...

  • Page 89: Installation Imaging Unit

    Always keep the imaging unit in a horizontal position when handling it. 1.1.1 Unpacking Remove the imaging unit from the box and check that it contains the following items. Imaging unit .......1 Installation instructions ....1 1.1.2 Imaging Unit Installation 1. Remove the seal from the imaging unit. Seal Rev. 11..0.0/03.01 Di251/Di351...
  • Page 90 5. Align the green labels on both ends of the new imaging unit with the green labels on the rails of the copier and position the imaging unit. Grasp the handles to position the imaging unit and push it into the copier. Di251/Di351 Rev. 1.1.0.0/03.01...

  • Page 91: When Removing The Imaging Unit

    1.1.3 When removing the imaging unit 1. Grasp the green handles and gently pull out the imaging unit. NOTE Be especially careful when handling the imaging unit. It may be damaged if it is dropped. Rev. 11..0.0/03.01 Di251/Di351...

  • Page 92: Installation The Copy Table/Copy Desk (Ct-2/Cd-2M)

    10. Grounding plate screws ......3 1.2.2 Unpacking the Copy Desk Copy desk..........1 Stabilizers A..........2 Stabilizer B..........1 Stabilizers screws ........1 Adjusters............ 2 Fixing plates..........4 Flat-head screws ........4 Grounding plates (inside)......2 Grounding plate (right-front) ...... 1 Di251/Di351 Rev. 1.1.0.0/03.01...
  • Page 93 10. Grounding plate screws......3 Rev. 11..0.0/03.01 Di251/Di351...

  • Page 94: Installing The Copy Table/Copy Desk

    B to the copy table or copy desk at the positions shown in the illustration below. 3. Attach the two adjusters to the copy table or copy desk at the positions shown in the illustration at the left. Stabilizers A Stabilizer B Adjusters Di251/Di351 Rev. 1.1.0.0/03.01...

  • Page 95: Adjusting The Adjusters

    Attaching the paper feed unit to the copy table 1. Place the paper feed unit on top of the copy table so that the rubber feet on the paper feed unit are correctly aligned on the copy table. Rev. 11..0.0/03.01 Di251/Di351...

  • Page 96: Attaching The Paper Feed Unit To The Copy Desk

    1. Place the paper feed unit on top of the copy desk, ensuring that the two are aligned properly with each other. 2. Using the four enclosed fixing plates and fixing plate screws, secure the paper feed unit to the copy desk as shown. Di251/Di351 Rev. 1.1.0.0/03.01...

  • Page 97: Installation Js-100

    Exit Tray ......1 Front Cover ......1 Rear Cover ......1 Third Tray ......1 Screw (4 x 10 mm) ....2 Remove tape and other fixing brackets. 1.3.2 Installing the Third Tray 1. Open the Finisher Cover. Rev. 11..0.0/03.01 Di251/Di351...
  • Page 98 2. Remove one screw from the Dummy Cover. 3. Secure the Third Tray (using two screws) and connect the Hookup Cord to the Finisher. 4. Install the Front Cover. 5. Install the Rear Cover. Di251/Di351 I-10 Rev. 1.1.0.0/03.01...
  • Page 99 6. Fit the Exit Tray. 7. Close the Finisher Cover. Rev. 11..0.0/03.01 I-11 Di251/Di351...

  • Page 100: Installation Js-201

    2. Verify the following accessories are in the accessory box. Screws (4 mm x 8 mm)....3 Mounting frame....... 1 Decorative cover......1 Copy tray ........1 Auxiliary tray ........1 Spring ..........2 3. Remove the tape from the job tray unit. Di251/Di351 I-12 Rev. 1.1.0.0/03.01...

  • Page 101: Job Tray Installation

    Make sure that the harness does not fall inside the main unit. 3. Cut off the treaded tires from only the two Exit Rolls on both sides of the machine. 4. Use two accessory screws (4 x 8 mm) to secure the mounting frame. Rev. 11..0.0/03.01 I-13 Di251/Di351...
  • Page 102 7. Use an accessory screw (4 x 8 mm) to secure the job tray unit at the front. NOTE Tighten the screw after aligning the hole position. Di251/Di351 I-14 Rev. 1.1.0.0/03.01...

  • Page 103: Copy Tray Set-Up

    2. Attach the accessory auxiliary tray to the copier in alignment with the hole (at two place) in the copier. 3. Attach the accessory copy tray by aligning the three tabs of the tray with the three insertion holes of the main unit. Rev. 11..0.0/03.01 I-15 Di251/Di351...

  • Page 104: Installation Ot-102 (Shift Tray)

    Screw (4 mm x 8 mm) ..... 4 Mounting frame (front) ..... 1 Mounting frame (rear)...... 1 Decorative cover ......1 Copy tray ......... 1 3. Remove the tape and securing materials. Tape Securing material Tape Di251/Di351 I-16 Rev. 1.1.0.0/03.01...

  • Page 105: Shift Tray Installation

    4. Use three screws (4 ¥ 8 mm) to secure the rear end of the mounting frames (front/rear) from the front side of the copier as shown. NOTE Install the mounting frame so the pins pass through the holes at the rear side of the copier. Rev. 11..0.0/03.01 I-17 Di251/Di351...
  • Page 106 7. Use an accessory screw (4 x 8 mm) to secure the shift tray unit at the front. 8. Press on the decorative cover. Di251/Di351 I-18 Rev. 1.1.0.0/03.01...

  • Page 107: Copy Tray Setting-Up

    1.5.3 Copy Tray Setting-up Install the accessory copy tray in the shift tray unit. Rev. 11..0.0/03.01 I-19 Di251/Di351...

  • Page 108: Installation Ad-15

    Automatic Duplex Unit Setting-up 1. Turn off the power and disconnect the power cord and interface cable from the copier. Open the manual feed table. 2. Remove the Duct Cover. (for Di251 only) 3. Peel off the polyester film as shown. Di251/Di351 I-20...
  • Page 109 (Use a Phillips head screw driver.) NOTE Support the duplex unit by hand until it is secured. 8. Plug in the connectors (two) of the duplex unit to the copier. Rev. 11..0.0/03.01 I-21 Di251/Di351...

  • Page 110: Switching The Tension Strength Of The Automatic

    1.6.4 Reference Gap Adjustment 1. Access the service mode screen. (Refer to the service manual.) Level History 2. Press the stop key and then immediately Stop press the start key. The Adjust Mode will be displayed. Di251/Di351 I-22 Rev. 1.1.0.0/03.01...
  • Page 111 Measure margins A and B on the copy. Standard Values: A4C 10.0 mm ± 3.0 mm Letter C 10.0 mm ± 3.0 mm If the measured width is not within the standard values, use the following procedure for adjustment. Main scanning direction Rev. 11..0.0/03.01 I-23 Di251/Di351...
  • Page 112 7. After pressing the Clear key, you can change the value using the key pad. Use the * key to change between + and -. 8. Touch “OK” to complete the setting. 9. Make another test copy and check the image once again. Di251/Di351 I-24 Rev. 1.1.0.0/03.01...

  • Page 113: Installation Af-9

    ADF Kit I shown below must be installed when installing the ADF. Original Glass (for AF-9) ......1 1.7.2 Installing ADF Kit 1. Remove the caps (two). 2. Remove the Upper Front Cover (two screws). 3. Remove the Original Cover brackets (two). Rev. 11..0.0/03.01 I-25 Di251/Di351...
  • Page 114 4. Remove the Upper Left Cover (two screws). 5. Remove the Original Glass. 6. Remove the Right Rear Cover. 7. Remove the Rear Upper Cover (two screws). 8. Press the Original Glass toward the rear of the copier. Di251/Di351 I-26 Rev. 1.1.0.0/03.01...
  • Page 115 Use the screw which has been removed in step 3 for A. Use the screw contained in the ADF for B. (Use the screw furnished with the ADF for B. 12. Reinstall the covers which have been removed. Rev. 11..0.0/03.01 I-27 Di251/Di351...

  • Page 116: Components

    1. Remove the Right Rear Cover. 2. Unplug the connector that is connected to the copier. NOTE Tidy up the connector which has been removed to ensure that it does not interfere with the subsequent steps. Di251/Di351 I-28 Rev. 1.1.0.0/03.01...
  • Page 117 Automatic Document Feeder into the frame of the copier to secure the cable in position. 6. Secure the ADF. Screw 4x8 Silver 7. Cut out the knockout shown in the illustration. 8. Reinstall the cover which has been removed. Rev. 11..0.0/03.01 I-29 Di251/Di351...

  • Page 118: Checking For Zoom Adjust

    Reference Line Registration Specifications: A (CD): 200 ± 2.0 mm B (FD): 300 ± 4.5 mm If the length of the line reproduced on the copy falls outside the specified range, make the “Registration Adjustment.” Di251/Di351 I-30 Rev. 1.1.0.0/03.01...

  • Page 119: Registration Adjustment

    Touch Panel. For details on how to access the menu, see the Service Manual. 2. Touch “Tech. Rep. Choice.” Level History 3. Touch “Scan-through ADF.” 4. Touch “Zoom adjust.” 5. Touch CD “Copier” or FD “Copier.” Rev. 11..0.0/03.01 I-31 Di251/Di351...

  • Page 120: Checking For Registration

    Margin Registration Specifications: Width A: 20 ± 2.0 mm Width B: 20 ± 3.0 mm If the margins reproduced on the copy fall outside the specified range, make the “Registration Adjustment.” Di251/Di351 I-32 Rev. 1.1.0.0/03.01...

  • Page 121: Registration Adjustment

    1. Access the “Tech. Rep. Mode” menu on the Touch Panel. For details on how to access the menu, see the Service Manual. Level History 2. Touch “Tech. Rep. Choice.” 3. Touch “Scan-through ADF.” 4. Touch “Registration.” 5. Touch “CD” or “FD.” Rev. 11..0.0/03.01 I-33 Di251/Di351...
  • Page 122 8. Press the * key to change the sign to select either + or -. 9. Enter the numeric value from the 10-Key Pad. 10. Touch [END] to go back to the initial screen. Make a copy again and check for correct registration. Di251/Di351 I-34 Rev. 1.1.0.0/03.01...

  • Page 123: Installation Afr-17

    NOTE When mounting the Duplexing Document Feeder, be careful to hold it by the top and bottom sides. Rev. 11..0.0/03.01 I-35 Di251/Di351...
  • Page 124 Tighten the Shoulder Screws until there is no clearance between the hinges and the copier body. 5. Remove all the tape from the Duplexing Document Feeder. Remove the plastic bag from the Hookup Cord. Tapes 6. Install the exit tray. 7. Secure the screw from underneath the unit. Di251/Di351 I-36 Rev. 1.1.0.0/03.01...

  • Page 125: Checking And Adjusting The Skewed Feeding

    5. After the paper is fed onto the Original Glass, open the Duplexing Document Feeder gently. NOTE If the Duplexing Document Feeder is opened quickly, the paper may slide out of position. Rev. 11..0.0/03.01 I-37 Di251/Di351...

  • Page 126: Checking And Adjusting The Document Stop Position

    2. Place a sheet of A4 or Letter paper crosswise onto the Document Feed Tray. 3. Press the start key and open the paper guide F1 as soon as the paper is fed into the unit and the scanning starts. Di251/Di351 I-38 Rev. 1.1.0.0/03.01...
  • Page 127 If the distance is out of tolerance, carry out the following procedure. Adjusting the Document Stop Position 1. Access the initial Tech. Rep. Mode screen. (Refer to the Service Manual for the procedure.) 2. Touch “Tech. Rep. Choice”. Level History 3. Touch “ADFR”. Rev. 11..0.0/03.01 I-39 Di251/Di351...
  • Page 128 Use the * key to switch between + and -. +: Adjusts in direction C -: Adjusts in direction D 7. Press the Panel Reset Key to display the Panel Reset Service Mode screen and touch the Stop key. Check the document stop position again. Di251/Di351 I-40 Rev. 1.1.0.0/03.01...

  • Page 129: In The 2-Sided Original Mode

    “c” or “d” direction from the edge of the Original Scale. Recommended: Within 1 mm in the C direction from the edge of the Original Scale. If the distance is out of tolerance, carry out the following procedure. Rev. 11..0.0/03.01 I-41 Di251/Di351...

  • Page 130: Adjusting The Document Stop Position

    Use the * key to switch between + and -. +: Adjusts in direction C -: Adjusts in direction D 3. Press the Panel Reset Key to display the Panel Reset Service Mode screen and touch the Stop key. Check the document stop position again. Di251/Di351 I-42 Rev. 1.1.0.0/03.01...

  • Page 131: Checking And Adjusting The Document Stop Position In The Single Feed Copy Mode

    “c” or “d” direction from the edge of the Original Scale. Recommended: Within 1 mm in the C direction from the edge of the Original Scale. If the distance is out of tolerance, carry out the following procedure. Rev. 11..0.0/03.01 I-43 Di251/Di351...

  • Page 132: Adjusting The Document Stop Position

    5. Select the “Single Feed Set” mode. 6. After pressing the Clear key, use the key pad to enter the adjustment. Use the * key to switch between + and -. +: Adjusts in direction C -: Adjusts in direction D Di251/Di351 I-44 Rev. 1.1.0.0/03.01...

  • Page 133: Checking And Adjusting The Position Of The Rear Guide Plate

    F1 as soon as the scanning starts. 4. After the paper is fed onto the Original Glass, open the Duplexing Document Feeder gently. NOTE When the Duplexing Document Feeder is opened quickly, the paper will be knocked out of position. Rev. 11..0.0/03.01 I-45 Di251/Di351...

  • Page 134: Checking The Position Of The Rear Guide Plate

    F1 immediately. 4. After the paper is fed onto the Original Glass, open the Duplexing Document Feeder gently. NOTE When the Duplexing Document Feeder is opened quickly, the paper will be knocked out of position. Di251/Di351 I-46 Rev. 1.1.0.0/03.01...

  • Page 135: Checking The Position Of The Single Feed Copy

    More than 5.0 mm : To the back 1.8.18 Securing the stoppers Remove the shoulder screws (one each at the right- and left-hand side) in the rear of the copier and tighten these shoulder screws into the corresponding upper holes. Rev. 11..0.0/03.01 I-47 Di251/Di351...

  • Page 136: Installation Fn-109 / Fn-110

    1. Copier + Paper Feed Unit (three drawers) + Copy Table 2. Copier + Paper Feed Unit (one drawer) + Large Capacity Cassette 3. Copier + Paper Feed Unit (one drawer) + Copy Desk Di251/Di351 I-48 Rev. 1.1.0.0/03.01...

  • Page 137: Unpacking The Finisher

    1. Remove the finisher from its box, and then check that the following accessories are also enclosed. Rail guide ..............1 Rail ................1 Stabilizing pin ..............1 Magnet ................1 Horizontal transport unit ..........1 Horizontal transport unit mounting base......1 Tray ................1 Protective guide............1 Labels................2 10. Screws.................3 11. Setup instructions (this manual) ........1 Rev. 11..0.0/03.01 I-49 Di251/Di351...
  • Page 138 2. Remove all tape and packing brackets. On the FN-109 Packing bracket Tape: Packing bracket NOTE: Do not remove these parts. Packing bracket Di251/Di351 I-50 Rev. 1.1.0.0/03.01...
  • Page 139 If it is necessary to move the copier, follow the procedure described under “Removing the rail” on page I-57. After moving the copier, perform the operations described in “Installing the Horizontal Transport Unit” and “Installing the Stabilizing Pin and Rail”. Rev. 11..0.0/03.01 I-51 Di251/Di351...

  • Page 140: Installing The Accessories

    5. Slide the other end of the rail installed in step 3 into the rail guide on the finisher. NOTE Insert the rail until it snaps into place. At this time, the finisher should stay attached to the copier, even if you try to pull it away. Di251/Di351 I-52 Rev. 1.1.0.0/03.01...

  • Page 141: Installing The Horizontal Transport Unit

    Transport Unit and the Finisher are in positive engagement with each other. Then, secure the Horizontal Transport Unit with the lock lever. NOTE Install the Horizontal Transport Unit, making sure that the gears are in positive engagement. Rev. 11..0.0/03.01 I-53 Di251/Di351...

  • Page 142: Adjusting The Height And Tilt Of The Finisher

    Turn the bolt clockwise If the stabilizing pin is too low: Turn the bolt counterclockwise Two front casters If the magnet is too high: Turn the bolt clockwise If the magnet is too low: Turn the bolt counterclockwise Di251/Di351 I-54 Rev. 1.1.0.0/03.01...

  • Page 143: Connecting The Hookup Cord

    1.9.6 Installing the Tray and Protective Guide Install the enclosed tray and protective guide at the positions shown in the illustrations. Rev. 11..0.0/03.01 I-55 Di251/Di351...

  • Page 144: Affixing The Labels

    1.9.7 Affixing the Labels Affix the enclosed operation labels. 1. Label (for the copier) Label (for ADF) AF-9 AFR-17 For Copier For ADF Di251/Di351 I-56 Rev. 1.1.0.0/03.01...

  • Page 145: Checking The Hole-Punching Positions (Fn-109 Only)

    6. Fold the paper that is fed out in half, and check that the punched holes are aligned. Standard position: ±2 mm If the punched holes are not at their standard positions, adjust the hole-punching position. Rev. 11..0.0/03.01 I-57 Di251/Di351...

  • Page 146: Adjusting The Hole-Punching Positions (Fn-109 Only)

    4. Carefully pull the finisher away from the copier. 5. Slide the rail under the copier, and then remove it from the right side of the copier. Di251/Di351 I-58 Rev. 1.1.0.0/03.01...

  • Page 147: Installation Fn-504

    1. Remove the main unit (Finisher), transport unit and accessories from the box. 2. Remove all other plastic wrappings, tape and packing materials. FINISHER (main unit) Tape: Cushion Tape (wait to remove during the installation!) Label Rev. 11..0.0/03.01 I-59 Di251/Di351...
  • Page 148 Finisher and the copier. In this case, first remove the pipe from the Finisher, then remove it from the copier. After the system has been relocated, perform the following steps again: “Installing the transport unit” and “Attaching the pipe” shown on p. 3. Di251/Di351 I-60 Rev. 1.1.0.0/03.01...

  • Page 149: Attaching The Finisher Set Pin

    3. Set the finisher with the main unit by inserting one end of the pipe that was used in STEP 2 into the side of the main unit where the feeder attachment is installed. Rev. 11..0.0/03.01 I-61 Di251/Di351...

  • Page 150: How To Remove The Pipe

    3. Mount the horizontal transport unit on the exit Lock lever section of the copier. 4. Open the cover of the horizontal transport unit and fit the shaft of the horizontal transport unit positively into position as illustrated. Di251/Di351 I-62 Rev. 1.1.0.0/03.01...

  • Page 151: Adjusting The Height Of The Finisher

    If the horizontal transport unit appears lower Wing bolts toward the copier, turn the adjust bolt counterclockwise. 4. After the height has been adjusted, tighten the front and back wing bolts (2) and set the adjust bolts. Rev. 11..0.0/03.01 I-63 Di251/Di351...
  • Page 152 < b turn the adjust bolt counter clockwise Wing bolts 8. After the gap has been adjusted, tighten the front and back wing bolts (2) and set the adjust bolts. Replace the covers onto the casters. Di251/Di351 I-64 Rev. 1.1.0.0/03.01...

  • Page 153: Connecting The Cable

    2. Connect two cables to the copier as shown. 1.10.8 Attaching the labels Attach the labels that came with the Finisher. Label 1 (for the copier) Label 2 (for the ADF) AFR-17 AF-9 for the copier for the ADF Rev. 11..0.0/03.01 I-65 Di251/Di351...

  • Page 154: Adjusting The Placement Of The Punch Hole

    3. Touch the “Hole Punch” key. Memory Free 4. Touch “Select Position”. Select finishing mode. SELECT POSITION Select hole punching positon Memory Free 5. Select the position of the punch hole. Memory Free 6. Press the Start key. Di251/Di351 I-66 Rev. 1.1.0.0/03.01...
  • Page 155 Use the measuring scale above the green lever as a guide to determine the amount of the adjustment. 12. Retighten the screw and output another sample to check the adjusted position of the hole punch. 13. Replace the cover onto the Finisher. Rev. 11..0.0/03.01 I-67 Di251/Di351...

  • Page 156: Attaching The Holder For The Instruction Manual

    Attaching the holder for the instruction manual Place the holder in the position shown in the illustration. NOTE If a holder has already been installed onto the copier, reposition it as shown in the illustration to the left. Di251/Di351 I-68 Rev. 1.1.0.0/03.01...

  • Page 157: Installation Pf-117

    Tape 3. Pull out the tray and remove the packing Tape material. NOTE Cushion Be sure to remove the packing material before setting the copier onto the Cabinet. 4. Return the tray to its original position. Rev. 11..0.0/03.01 I-69 Di251/Di351...

  • Page 158: Stopper Installation

    3. Use the Long thumbscrews to install the L- shaped stopper to the rear side of the cabinet. 1.11.3 Support Adjustment Unscrew the 3 supports on the front and right side of the main unit firmly against the floor. Di251/Di351 I-70 Rev. 1.1.0.0/03.01...

  • Page 159: Cabinet Setup

    4. Use the flat-head screw and fixing plates to secure the optional cassette and the cabinet. Refer to the Optional Cassette Setup Instructions packaged with the cassette for a description of the setup procedures. Rev. 11..0.0/03.01 I-71 Di251/Di351...

  • Page 160: Paper Size Setting

    Remove the rear edge guide plates when adjusting the size to Letter C. NOTE Side edge guide plate Make sure that the bottom part of the side edge guide plate is inserted into the slot securely. Di251/Di351 I-72 Rev. 1.1.0.0/03.01...

  • Page 161: Attaching The Paper Size Label

    6. Reinstall the cover. 1.11.6 Attaching the paper size label Affix the paper size label and cassette number label included in the main unit's package in the locations show in the diagram. Cassette number label Label Rev. 11..0.0/03.01 I-73 Di251/Di351...

  • Page 162: Registration Adjustment

    (Refer to the Service Manual for the procedure.) 3. Press the stop key and then immediately press the start key. 4. Touch “Printer”. 5. Touch the key for the direction to be adjusted. 6. Touch “Test Print”. Di251/Di351 I-74 Rev. 1.1.0.0/03.01...
  • Page 163 10. After pressing the Clear key, you can change the value using the key pad. Use the * key to change between + and -. 11. Touch “OK” to complete the setting. 12. Make another test copy and check the image once again. Rev. 11..0.0/03.01 I-75 Di251/Di351...

  • Page 164: Installation Pf-118 / Pf-119

    Fixing plate............4 Flat-head screw............. 4 Bracket ..............1 Screw ..............2 Harness ..............1 Power supply harness 1 (with core) ...... 1 Power supply harness 2 ........1 Label (PF-118 only)..........1 Di251/Di351 I-76 Rev. 1.1.0.0/03.01...

  • Page 165: Installation To The Copier

    3. Slightly pull out the paper drawers of the copier’s paper feed unit and the optional paper feed unit, and then secure the optional paper feed unit to the copier using the enclosed fixing plates and flat-head screws. Rev. 11..0.0/03.01 I-77 Di251/Di351...

  • Page 166: Connecting The Paper Feed Unit To The Copier

    2. Remove the rear Cover from the Paper Feed Unit. 3. Remove the bracket from the Paper Feed Unit. (for Di251 and Di351) 4. Connect the Harness furnished with the Paper Feed Unit to the copier and the Paper Feed Unit.
  • Page 167 The connector of Power Supply Harness 1 (with a core) may be connected to any one of the receptacles on the copier. 8. Reinstall the rear Cover of each unit. 9. Reinstall the connector cover of the copier. Rev. 11..0.0/03.01 I-79 Di251/Di351...

  • Page 168: Connecting The Paper Feed Unit To The Paper Feed Unit

    Connect the Harness furnished with the Paper Feed Unit to the copier. NOTE Push the Harness into a recess in the rear as illustrated to ensure easy and proper installation of the Bracket in the subsequent step. Di251/Di351 I-80 Rev. 1.1.0.0/03.01...
  • Page 169 Power Supply Harness 1 (with a core) to the connector (black portion) of Power Supply Harness 2 (without core). 8. Connect the connector (black portion) of Power Supply Harness 2 (without core) to the copier. 9. Reinstall the rear Cover of each unit. Rev. 11..0.0/03.01 I-81 Di251/Di351...

  • Page 170: Changing The Paper Size Of The Paper Feed Unit

    1. Pull out the drawer of the Paper Feed Unit and press down the paper lifting plate until it locks. 2. Adjust the front/rear edge-guide-plates and the trailing-edge guide plate to the size of the paper that will be loaded. Di251/Di351 I-82 Rev. 1.1.0.0/03.01...
  • Page 171 If they have been touched, wipe them with a soft, dry cloth. Be sure the paper is not curled when it is loaded. Make sure that the front/rear edge-guide-plates are pressed tightly up against the edges of the paper stack. Rev. 11..0.0/03.01 I-83 Di251/Di351...

  • Page 172: (Fixed Cassette)

    Paper Size Spring Paper Size Spring Black FLST/FOLIOT Silver Silver 11x17 L Black Silver LEGAL L Silver Silver LETTER L Silver 11x14 L Black LETTER C Silver Di251/Di351 I-84 Rev. 1.1.0.0/03.01...

  • Page 173: Paper Size Input For The Fixed Cassette

    1. Access the service mode screen. (Refer to the service manual for the procedure.) 2. Touch “System Input.” Level History 3. Touch “Paper Size Input.” 4. Select the position where the paper feed unit is set. Rev. 11..0.0/03.01 I-85 Di251/Di351...

  • Page 174: Affixing The Labels

    5. Touch the paper size to be set. 6. Touch “END.” 7. Touch “Panel Reset” to display the service mode screen. 1.12.8 Affixing the Labels Affix the enclosed label for the paper size at the position shown. Di251/Di351 I-86 Rev. 1.1.0.0/03.01...

  • Page 175: Adjust The Paper Reference Position

    5. Touch “Test Print.” 6. Touch the key representing the drawer selected as the paper source, and then press the start key. Output the test print. Standard Values: 10.0 ±2.0 mm Letter C 10.0 ±2.0 mm Rev. 11..0.0/03.01 I-87 Di251/Di351...
  • Page 176 Loosen the two screws of the drawer. watching the scale on the adjusting plate inside the drawer, move the guide plate as necessary. After the adjustment has been made, tighten the screws and then produce a test print to check again. Di251/Di351 I-88 Rev. 1.1.0.0/03.01...
  • Page 177 Loosen five screws of the drawer. Then, watching the scale on the adjusting plate, move the guide plate as necessary. After the adjustment has been made, tighten the screws and then produce a test print to check again. Rev. 11..0.0/03.01 I-89 Di251/Di351...
  • Page 178 Di251/Di351 I-90 Rev. 1.1.0.0/03.01...
  • Page 179 DIS/REASSEMBLY, ADJUSTMENT 10230...
  • Page 180 CONTENTS 1. SERVICE INSTRUCTIONS ................D-1 1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS ....D-1 1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ....D-1 1-3. PARTS WHICH MUST NOT BE TOUCHED ........... D-2 Red painted Screws ................ D-2 Variable Resistors on Board ............D-2 Other Screws ...................
  • Page 181 3-3. ADJUSTMENT ITEMS LIST ..............D-33 3-4. ADJUSTMENT OF SCANNER MOTOR TIMING BELT TENSION ..D-34 3-5. ELECTRICAL/IMAGE ADJUSTMENT ............. D-35 Touch Panel Adj................D-35 Original Size Detecting Sensor Adjustment (F7-1) ......D-36 Loop Adjustment ................D-37 Edge Erase ..................D-38 Registration (CD) (Printer) ...............

  • Page 182: Service Instructions

    NOTES • For the Duplex Unit standard on the 35-cpm copier, see Service Manual for AD-15. • For the Fixed Paper Size Cassette standard on the 35-cpm and 25-cpm copiers, see Ser- vice Manual for PF-119. SERVICE INSTRUCTIONS 1-1. IDENTIFICATION OF FUSES AND CIRCUIT BREAKERS Fusing Roll Hearter Lamp Fuse (TF1) 125 V 15 A...

  • Page 183: Parts Which Must Not Be Touched

    1-3. PARTS WHICH MUST NOT BE TOUCHED Red painted Screws Purpose of Application of Red Paint Red painted screws show that the assembly or unit secured can only be adjusted or set at the factory and shall not be readjusted, set, or removed in the field. If it becomes unavoidably necessary to disassemble any of these assemblies and units, disassembly may be done provided that the conditions permitting reassembly are met.
  • Page 184 DISASSEMBLY/REASSEMBLY 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES 4011D113CA 4011D114CA...
  • Page 185 Part Name Removal Procedure Original Glass Remove no. 17. Remove two holding brackets. Right IR Cover Remove two screws that secure the Right IR Cover. Upper Rear Unhook one tab and remove the Upper Rear Inside Cover. Inside Cover Lower Rear Remove no.
  • Page 186 Part Name Removal Procedure Fixed Paper Size Unhook one tab and remove the Fixed Paper Size Cassette Connector Cassette Cover. Connector Cover ( 1) Connector Cover Unhook one tab and remove the Connector Cover. Harness Cover Remove one screw that secures the Harness Cover. Lower Rear Remove no.
  • Page 187 2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER ELECTRICAL COMPOMENTS • When removing a circuit board or other electrical component, refer to “PRECAUTIONS FOR HANDLING THE PWBs” contained in SWITCHES ON PWBs and follow the corre- sponding removal procedures. • The removal procedures given in the following omit the removal of connectors and screws securing the circuit board support or circuit board.
  • Page 188 Symbol Part Name Removal Procedure PWB-A Master Board Remove the Rear Upper Cover. Remove the Upper Rear Cover. Remove the Shield Box. Remove the MFB2 Board Assy. PWB-A For details, see steps 2 through 12 of "(1) Removal of the PH Unit"...

  • Page 189: Maintenance Schedule

    2-3. MAINTENANCE SCHEDULE • To keep the copier in good operating condition and ensure an extended service life of the copier, it is recommended that the maintenance jobs described in this schedule be car- ried out. • Carry out the maintenance jobs according to the PM Counter values. PM Parts Maintenance Part No.
  • Page 190 1: When I/C Life is detected I/C Life is a value of the period of time during which I/C has been energized, converted to the number of copies made in the standard copying mode, which differs from the actual number of copies made. The following table lists the life counter values of different models based on the standard copying mode.
  • Page 191 2-4. PAPER TAKE-UP/TRANSPORT SECTION Removal of the Paper Take-Up Roll 1. Slide out the Multi Purpose Cassette. 4011D007AA 2. Lock the Paper Lifting Plate. 3. Snap off one C-clip of the Paper Take-Up Roll Assy. 4. Slide the Paper Take-Up Roll Assy to the rear so that it can be pulled off the bushing at the front.
  • Page 192 Cleaning of the Paper Dust Remover Assy 1. Remove the Paper Dust Remover Assy. 2. Using a brush, whisk dust and dirt off the Paper Dust Remover Assy. 4011D011AA Removal of the Synchronizing Roller Gear and Synchronizing Roller Bushing 1. Open the Side Cover. 4011D009AA 2.
  • Page 193 4. Remove one spring and the upper and lower Synchronizing Roller bushings. NOTE • When reinstalling the bushings, make sure that the flanges of the bushings are on the outside. 4011D015AA 5. Snap off one retaining ring E type, unplug one connector, and remove the Synchronizing Clutch.

  • Page 194: Optical Section

    2-5. OPTICAL SECTION Removal of the PH Unit NOTES • Do not place the PH Unit upside down or subject it to excessive shock. • Replace the PH Unit as one unit. • NEVER attempt to disassemble or adjust the PH Unit. •...
  • Page 195 8. Unplug one connector. 9. Remove five screws and one PWB support. Then, holding the MFB2 Board Assy at the slit with a finger of your left hand (see the illustration), remove the assy. 4011D028AD NOTES • When reinstalling the MFB2 Board Assy, push the harness inside the frame to ensure that it will not interfere with other parts.
  • Page 196 10. Remove all connectors of PWB-A. 11. Remove the harness from six cord clamps, six wiring saddles, and two edge covers. 12. Remove six screws and the PWB-A Assy. 4011D029AB 13. Remove one screw and the Flexible Harness Guide. 4011D030AB 14.
  • Page 197 17. Remove three screws and the mounting bracket. 18. Remove four screws and the PH Unit. 4011D033AA Removal of the CCD Unit 1. Remove the Original Glass. 2. Unhook the tabs of the cover in order of A, B, C, and D and remove the cover.
  • Page 198 Cleaning of the Mirrors 1. Remove the Original Glass. 2. Wipe clean the Mirrors with a soft cloth. 1167D017AC Cleaning of the Lens 1. Remove the CCD Unit. 2. Wipe clean the Lens with a soft cloth. 1167D018AB Cleaning of the Original Glass 1.
  • Page 199 Removal of the Scanner 1. Remove the Original Glass. 2. Remove the Rear Holding Bracket. 3. Move the Scanner to the location shown in the illustration. 4011D037AA 4. Remove one screw and unplug the connector of the Exposure Lamp. 5. Remove the flat cable of the Exposure Lamp. 4011D038AA 6.
  • Page 200 Removal of the Scanner Drive Cables 1. Remove the Original Glass. 2. Remove the Scanner. 3. Remove the Left Upper Cover and Left IR Cover. 4. Unhook the spring at the end of the cable from the front hook and remove the cable guide. Cable 5.
  • Page 201 Winding of the Scanner Drive Cables Pulley F Pulley H Pulley E Pulley D Pulley C Pulley G Pulley B Pulley A 4011D047AB Front 1. Position the round bead of the cable (silver) at the location shown in the illustration. 1167D051AC 2.
  • Page 202 4. Slide the pulley to the front and fit one retaining ring E type. 5. Pushing the pulley tightly up against the retaining ring E type, secure the pulley with one screw. 4011D048AA 6. Wind the fixed bead end of the cable around pul- ley D and pulley C and fit the fixed bead at a posi- tion about 5.5 mm from the Scanner rail.
  • Page 203 10. Wind the hook end of the cable two turns coun- terclockwise from the front to the rear. Cable on Hook End 1167D054AD 11. Wind the bead end of the cable four turns clock- Cable on wise from the rear to the front. Then, secure the Bead End cable with tape.
  • Page 204 16. Fit the hook end of the cable into the groove in the Cable Guide and hook the spring. Cable Guide 4011D053AA 17. Peel off the tape from the pulleys at the front and rear. 18. Loosen one screw that secures the spring mounting bracket. Using a bar tension gage, pull the mounting bracket with a force of 1,300 100 g.

  • Page 205: Image Transfer Section

    2-6. IMAGE TRANSFER SECTION Removal of the Image Transfer Roller Assy 1. Open the Side Cover. 4011D009AA 2. Raise the Image Transfer Guide Plate. 4011D056AA 3. Remove the Image Transfer Roller Assy. NOTE • Do not touch the surface of the Image Transfer Roller directly with bare hands.
  • Page 206 Cleaning of the Pre-Image Transfer Guide Plate 1. Open the Side Cover. 4011D009AA 2. Using a soft cloth dampened with alcohol, wipe the Pre-Image Transfer Guide Plate. NOTE • Make sure the alcohol does not touch the surface of the Image Transfer Roller. 4011D059AB Removal of the Ozone Filter 1.

  • Page 207: Developing Section

    2-7. DEVELOPING SECTION Removal of the Imaging Cartridge 1. Open the Side Cover. 4011D009AA 2. Holding onto the green handles, slide the Imag- ing Cartridge part of the way out. 3. Then grasp the handle on top of the cartridge and pull the cartridge out.

  • Page 208: Fusing Section

    2-8. FUSING SECTION Removal of the Fusing Unit 1. Open the Side Cover. 4011D009AA 2. Push the lever and open the Exit Cover. 3. Unplug two connectors in the rear. 4011D062AB 4. Close the Exit Cover, remove two screws, and slide out the Fusing Unit.
  • Page 209 Removal of the Fusing Roller Heater Lamp, Right Fusing Roller, and Left Fus- ing Roller 1. Remove the Fusing Unit. 2. Open the Exit Cover. 3. Remove three screws and the Fusing Front Cover. NOTE • After the Fusing Front Cover has been installed, insert a screwdriver through the hole in the Fusing Front Cover and move the ends of the flat spring in the direction of the arrow so that they rest on the...
  • Page 210 6. Remove the harness from the Rear Cover. 7. Remove two screws and the Rear Cover. 8. Remove one screw and the lamp holder in the rear. 4011D068AB 9. Remove one screw and the lamp holder at the front. Then, slide out the Fusing Roller Heater Lamp.
  • Page 211 18. Remove one shoulder screw and the Fusing Guide Assy. 19. 1Remove one screw, one shoulder screw, and the cover. 4011D072AB 20. Snap off one retaining ring E type and remove the Front Pressure Lever Assy and bearing. 4011D073AA 21. Snap off one retaining ring E type and remove the Rear Pressure Lever Assy and bearing.
  • Page 212 24. Remove one shoulder screw and the gear. 25. Snap off one retaining ring E type and remove the gear assy, gear, and spring. 4011D077AB NOTES • Study the illustration for how the spring is installed. • After the spring has been installed, move the gear assy in the direction of the arrow to make sure that it is returned by the tension of the spring.
  • Page 213 ADJUSTMENT 3-1. ADJUSTMENT JIGS AND TOOLS USED Scanner/Mirrors Carriage Positioning Jigs 1167D108AA 3-2. ADJUSTMENT REQUIREMENT LIST Adjustment Item Requirements Adjustment Point Ref. Page Touch Panel Adj. Automatically adjusted Control Panel D-35 Original Size Detecting Sensor D-36 Adjustment (F7-1) Loop Adjustment —...
  • Page 214 3-3. ADJUSTMENT ITEMS LIST Adjustment/ Setting Items Job Item Check Item Automatic Touch Panel Adj. D-35 adjustment Original Size Automatic Detecting Sensor D-36 adjustment Adjustment Loop Adjustment — D-37 Setting range Leading 0 to 5 mm Edge Setting range Trailing D-38 Erase 0 to 5 mm...
  • Page 215 3-4. ADJUSTMENT OF SCANNER MOTOR TIMING BELT TEN- SION 1. Remove the Original Glass. 2. Loosen the two screws that secure the Scanner Motor. Using a bar tension gage, pull the motor to the right with a tension of 1000 g ±50 g and, at the same time, tighten the mounting screws.
  • Page 216 3-5. ELECTRICAL/IMAGE ADJUSTMENT Touch Panel Adj. Make this adjustment after either of the following procedures have been performed: • Memory Clear • Control Panel replacement • ROM/RAM Board replacement Adjustment Procedure 1. Call the Initial mode to the screen. (For details, see SWITCHES ON PWBs, TECH. REP.
  • Page 217 Original Size Detecting Sensor Adjustment (F7-1) Make this adjustment after any of the following procedures have been performed: • Memory Clear • A faulty original size detection occurs • Replacement of the CCD Unit and Scanner parts (including the Exposure Lamp) •...
  • Page 218 Loop Adjustment Requirement Adjust so that a correct loop is formed before the Synchronizing Rollers when paper is fed through Adjust Mode Setting Value Loop Adjustment -5 to +5 NOTE • This adjustment is to be made when any of the following symptoms occurs: variations in the amount of print leading edge void, paper skew, and misfeed.
  • Page 219 Edge Erase <Leading> Requirement Set the erase width on the leading edge of paper (width A) in the range between 0 and 5 mm. Adjust Mode Setting Range Edge Erase/Leading 0 to 5 1171D003AA 1171D003AA NOTE • This adjustment must be made when the PH Unit has been replaced and after Registra- tion (CD/FD) (Printer) has been made.
  • Page 220 <Trailing> Requirement Set the erase width on the trailing edge of paper (width A) in the range between 0 and 5 mm. Adjust Mode Setting Range Edge Erase/Trailing 0 to 5 1171D004AA 1171D004AA NOTE • This adjustment must be made when the PH Unit has been replaced and after Registra- tion (CD/FD) (Printer) has been made.
  • Page 221 <Right/Left> Requirement Set the erase width on the right and left edges of paper (width A) in the range between 0 and 5 mm. Adjust Mode Setting Range Edge Erase/Right/Left 0 to 5 1171D005AA 1171D005AA NOTE • This adjustment must be made when the PH Unit has been replaced and after Registra- tion (CD) (Printer) have been made.
  • Page 222 Registration (CD) (Printer) Adjust so that width A on the test pattern produced falls within the following range. Requirement 1-Side 2-Sided 4658D512AA 4661D501AA Specification Adjust Mode Setting Range 1-Sided: 10 ±2.0 mm Registration (CD) -4.0 to +4.0 2-Sided: 10 ±3.0 mm NOTE •...
  • Page 223 9. Enter the new setting value from the 10-Key Pad. Use the Access Mode key or " " to change the + or - sign. Setting Instructions If width A is wider than specifications, make the setting value smaller than the current one. If width A is narrower than specifications, make the setting value greater than the current one.
  • Page 224 Registration (FD) (Printer) Requirement Adjust so that width A on the test pattern output falls within the following range. 4011D097AA Specification Adjust Mode Setting Range 25-cpm copier: -26 to +26 10 ±2.0 mm Registration (FD) 35-cpm copier: -19 to +19 NOTE •...
  • Page 225 8. Enter the new setting value from the 10-Key Pad. Use the Access Mode key or " " to change the + or - sign. Setting Instructions If width A is wider than specifications, make the setting value smaller than the current one. If width A is narrower than specifications, make the setting value greater than the current one.
  • Page 226 Registration (IR) <CD> Requirement Place the test pattern output after the adjustments of Registration (CD and FD) (Printer) have been com- pleted on the Original Glass and make a copy of it. Adjust so that width A on the test pattern copy falls within the following range.
  • Page 227 7. Enter the new setting value from the 10-Key Pad. Use the Access Mode key or " " to change the + or - sign. Setting Instructions If width A is wider than specifications, make the setting value smaller than the current one. If width A is narrower than specifications, make the setting value greater than the current one.
  • Page 228 <FD> Requirement Place the test pattern output after the adjustments of Registration (CD and FD) (Printer) have been com- pleted on the Original Glass and make a copy of it. Adjust so that width A on the test pattern copy falls within the following range.
  • Page 229 7. Enter the new setting value from the 10-Key Pad. Use the Access Mode key or " " to change the + or - sign. Setting Instructions If width A is wider than specifications, make the setting value smaller than the current one. If width A is narrower than specifications, make the setting value greater than the current one.
  • Page 230 Zoom Adjust (IR) <CD> Requirement • The difference should be within ±1.0 % of the actual length. • Adjust so that the following specifications are satisfied with a scale length of 200 mm. Zoom Ratio Specification Adjust Mode Setting Range Full size (×1.000) 200 ±2.0 mm Zoom Adjust (CD)
  • Page 231 3. Call the Adjust Mode to the screen. 4. Touch "IR" , "Zoom Adjust", and "CD", in that order. 5. Press the Clear key to clear the current setting value. 6. Enter the new setting value from the 10-Key Pad. Setting Instructions If the scale on the copy is longer than the actual scale, decrease the setting value.
  • Page 232 <FD> Requirement • The difference should be within ±1.0 % of the actual length. • Adjust so that the following specifications are satisfied with a scale length of 300 mm. Zoom Ratio Specification Adjust Mode Setting Range Full size (×1.000) 300 ±3.0 mm Zoom Adjust (FD) 0.990 to 1.010...
  • Page 233 3. Call the Adjust Mode to the screen. 4. Touch "IR" , "Zoom Adjust", and "FD", in that order. 5. Press the Clear key to clear the current setting value. 6. Enter the new setting value from the 10-Key Pad. Setting Instructions If the scale on the copy is longer than the actual scale, decrease the setting value.
  • Page 234 IR-Erasure Width Requirement Set the erase width along the four edges of the paper (width A) in the range between 0 and 3 mm. Adjust Mode Setting Range IR-Erasure Width 0 to 3 1171D062AA NOTE • This adjustment must be made when a shadow is produced from the Original Scale. Adjustment Procedure 1.
  • Page 235 (10) Book Center Erase Requirement Set the erase width at the center of the paper (width A) in the range between 2 and 20 mm. Adjust Mode Setting Range Book Center Erase 2 to 20 4011D083AB NOTES • This setting determines the erase width when Book Center Erase is selected. •...
  • Page 236 3-6. FOCUS-POSITIONING OF THE SCANNER AND 2ND/3RD MIRRORS CARRIAGE Make this adjustment after any of the following procedures has been performed: • After the Scanner Drive Cables have been replaced. • When the Scanner has been removed. • When the Scanner Drive Cable comes unwound. Requirement •...
  • Page 237 Front NOTE • If there is any gap between the Scanner and the Scanner/Mirrors Carriage Positioning Jigs or between the 2nd/3rd Mirrors Carriage and the jigs when each is pressed up against the jigs, eliminate the gap by turning the adjusting screws for the front and rear Scanner Drive Cables.
  • Page 238 MISCELLANEOUS 4-1. INSTALLATION OF THE KEY COUNTER SOCKET (OPTION) 1. Remove the Front Cover. 2. Remove the knockout from the Front Upper Cover. 3. Using two screws, secure the Counter Mounting Bracket. 4011D088AB 4. Remove the harness from one cord clamp and route it as shown in the illustration.
  • Page 239 4-2. REMOUNTING THE EEPROM (IC3A) NOTES • When the Master Board is replaced with a new one, be sure to demount EEPROM (IC3A) from the old Master Board and mount it on the new Master Board. • If the Master Board has been replaced, but the EEPROM (IC3A) has not been remounted, be sure to replace the Imaging Cartridge with a new one at the same time.
  • Page 240 4-3. ADJUST DATA INPUT When any of the following procedures has been performed, be sure to re-input the Adjust data: • The MFB2 Board has been replaced. • The ROM/RAM Board has been replaced. NOTES • Be sure to produce a Service Call Report before performing the above procedures. •...
  • Page 241 SWITCHES ON PWBs, TECH. REP. SETTINGS 17196...
  • Page 242 CONTENTS 1. CONTROL PANEL KEYS AND TOUCH PANEL ..........S-1 1-1. Control Panel Keys .................. S-1 1-2. Explanation of the Touch Panel ............... S-2 Basis Screen ................... S-2 Warning Screens ................S-3 2. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs ......S-4 2-1.
  • Page 243 7-4. Data/Conditions Cleared by Reset Switches ........... S-36 8. UTILITY MODE ....................S-37 8-1. Utility Mode selection Screen ..............S-37 8-2. User’s Choice Function Tree ..............S-37 8-3. Settings in the Utility Mode ..............S-38 9. SOFT SWITCH SET ..................S-39 9-1.

  • Page 244: Control Panel Keys

    CONTROL PANEL KEYS AND TOUCH PANEL 1-1. Control Panel Keys 4015O038AA 1. Touch Panel 7. Access Mode Key • Shows various screens and message. • Press to enter the access number when Copy Track of the Administrator mode 2. Utility Key available.
  • Page 245 1-2. Explanation of the Touch Panel Basis Screen The Basic screen is the initial screen that appears when the copier is turned ON. 4011P291CA 1. Supplementary Function Keys • The auxiliary, Density, Orig. Copy, and Basics keys are displayed. 2. Message Display •...
  • Page 246 Warning Screens The Warning screen may be a malfunction display, error display, warning display, or a cau- tion display. <Malfunction Display> <Error Display> Given when a malfunction occurs. Given when an error occurs. E.g.: Malfunctions that can be identified E.g.: Paper misfeed, door open, etc. with a specific code.

  • Page 247: Pwb Location

    FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs 2-1. PWB Location PWB-A PWB-F 4011D095AA 2-2. PWB-A (Master Board) 4011D093AA Symbol Name Description Test Print Switch Produces the test pattern of Function F12. <Procedure> 1. Press S1 to let the copier start the output sequence.
  • Page 248 2-3. PWB-F (Control Panel) 4011D095AA Symbol Name Description SW37 Warm Restart Switch Used to enter the initial mode.

  • Page 249: Utility Mode

    UTILITY MODE • Utility Mode is used to make various settings according to the user’s need. 3-1. Utility Mode selection Screen • Press the Utility key on the control panel. 4011P294CA 3-2. Utility Mode Function Tree User’s Choice 1/6 User’s Choice 2/6 User’s Choice 3/6 User’s Choice User’s Choice 4/6...
  • Page 250 3-3. Settings in the Utility Mode Touch Panel Setting Display User’s Choice User’s Choice is used to make various settings according to the user’s need. Meter Count Displays the counts of various counters. Copy Job Recall Permits programming of various functions, including copying jobs. User Management Permits setting of the various User Management functions.
  • Page 251 2. User's Choice Function Tree Memory Recall User’s Choice 1/6 Mixed Original Detection Language Selected Original Copy Default Auto Paper/Auto Size User’s Choice 2/6 Drawer Priority Special Paper Multiple-in-1 and Booklet Copy Zoom Auto Panel Reset Energy Save Mode User’s Choice Mode User’s Choice 3/6 Plug-In Counter,ID Key Reset Auto Power Off...
  • Page 252 3. Settings in the User's Choice Mode Touch Panel Setting (The default is Highlighted Display Memory Recall Select whether to enable or disable the Memory Recall function. Mixed Original Select the priority Mixed Original Detection mode that is automatically Detection selected when the Power Switch is turned ON or Panel Reset key pressed.
  • Page 253 Touch Panel Setting (The default is Highlighted Display Multiple-in-1 and Select whether to enable or disable recalling a default zoom ratio for Booklet Copy 2in1, 4in1, or Booklet Creation. Zoom Auto Panel Reset Select the time it takes the Auto Panel Reset function, which resets the panel settings when the set period of time elapses after a copy cycle has been completed or the last key operated, to be activated.
  • Page 254 Touch Panel Setting (The default is Highlighted Display 4in1 Copy Order Specify the default copying order in the 4in1 mode. Density Priority Specify the priority exposure mode that is selected automatically when the Power Switch is turned ON or the Panel Reset key pressed. <Density>...
  • Page 255 Touch Panel Setting (The default is Highlighted Display Intelligent Sorting Select whether to enable or disable the function that automatically switches between Sort and Non-Sort according to the number of orig- inals and the number of copy sets to be made. Applicable when the system is equipped with a finishing option and using an ADF or ADFR.
  • Page 256 User Management • Permits setting of the various User Management functions. 1. User Management Function Setting Procedure <Procedure> 1. Press the Utility key. 2. Touch the “User Management” key. 3. Select the appropriate function. 4. After the settings are complete, touch the “Enter” key to validate the settings. <Exiting the Mode>...
  • Page 257 Admin. Management • The entry on the “Administrator # Input ” set using the Tech. Rep. mode permits the set- tings of the following functions. 1. Admin. Management Mode Function Setting Procedure <Procedure> 1. Press the Utility key. 2. Touch the “Admin. Management Mode” key. 3.
  • Page 258 Touch Panel Setting (The default is Highlighted Display 100 Accounts-1 100 Accounts-1 100 Accounts-2 • Copying is authorized only for the accounts, for which Access Codes have been programmed. 100 Accounts-2 • Permits the accounts, for which Access Codes have been pro- grammed, to make copies.
  • Page 259 TECH. REP. MODE • This mode is used by the Tech. Rep. to check, set, adjust, and/or program various ser- vice functions. 4-1. Tech. Rep. Mode Menu Screen 4011P296CA 4-2. Tech. Rep. Mode Function Setting Procedure <Procedure> 1. Press the Utility key. 2.
  • Page 260 4-3. Tech. Rep. Mode Menu Function Tree Auto Paper Configuration FLS Paper System Set Simplex/Duplex Dry Key Set Function Limit Edge Erase Loop Adjustment Printer Image Density ATDC Sensor Gain Tech. Rep. Choice VG Adjust Original Stop Position ADFR Registration Loop Registration Scan-through ADF Zoom Adjust...
  • Page 261 4-4. Setting in the Tech. Rep. Mode Tech. Rep. Mode • This function allows the Tech. Rep. to make various settings and adjustments. 1. System Set • Set the environment for copying operations. Touch Panel Setting (The default is Highlighted Display Auto Paper Select the paper size selection scheme for automatic original size...
  • Page 262 2. Printer • Make the necessary adjustments of the printer (engine). Touch Panel Setting (The default is Highlighted Display Edge Erase Set the erase width on the leading, trailing, right, and left edge of the image. 0 to 5 mm ( 4 mm Loop Adjustment Set the length of the loop to be formed in paper before the Synchro-...
  • Page 263 3. ADFR • Make the necessary adjustments of ADFR. Note: • For details, see Option service manual. Touch Panel Setting (The default is Highlighted Display Original Stop Adjust the document stop position in each of the ADF modes. Position -7..................+7 Smaller Greater...
  • Page 264 5. IR-Erasure Width • Make the adjustment of original erase width on the IR side. Note: • For details, see DIS/REASSEMBLY, ADJUSTMENT Touch Panel Setting (The default is Highlighted Display IR-Erasure Width Set the forced erasure width along the four edges of the paper. 0 mm ........
  • Page 265 Touch Panel Setting (The default is Highlighted Display Machine Displays the machine configuration status. Configuration Technical Memo Enter the serial number and other data. Original Size Select “ON” when the optional Original Size Detecting Sensor is Detecting mounted. Option Administrator # Input •...
  • Page 266 Touch Panel Setting Display Counts the number of misfeeds that have occurred at different loca- tions in the copier. Display Display MCBJ System Manual Feed MCBJ Machine Only Vertical Transport 1st Drawer Separator 2nd Drawer Fusing 3rd Drawer Duplex Entrance 4th Drawer Duplex Feed 5th Drawer...

  • Page 267: Touch Panel Display

    Touch Panel Setting Display Display Description SADF No. of single feeds IR 1 No. of scan motions IR 2 No. of scan motions Job Tray No. of cycles of feeding paper out into Job Tray Toner Pages No. of pages equivalent to the no. of black dots on A4 original with B/W 5% Fusing Unit No.
  • Page 268 Touch Panel Setting Display Device Shows the numbers of prints for different applications. It also allows the Tech. Rep. to clear each counter. Display Description Copier No. of prints made by copier Printer No. of prints made by printer Report Print No.
  • Page 269 I/O Check • Checks the function of sensors. Touch Panel Setting Display Scan-through ADF For details, see Option service manual. Scanner For details, see Option service manual. ADFR For details, see Option service manual. Mail Bin Finisher For details, see DIS/REASSEMBLY, ADJUSTMENT. Printer For details, see DIS/REASSEMBLY, ADJUSTMENT.
  • Page 270 RD Mode • Make the initial settings of the copier for the Data Terminal. 1. RD Mode Menu Function Tree ID Code CT-ID DT Setting DT-ID TEL. # Initial Transmisson RD Mode Maintenance Counter Clear Call Completion RAM Clear Dial Mode Common DT Auto Receive Result Code...
  • Page 271 Touch Panel Setting (The default is Highlighted Display Initial Performs the initial transmission from the PPC to the Center to check Transmission for correct communication after the Data Terminal has been set up. Counter Clear Clears the spare counter. <Procedure> 1.

  • Page 272: Security Mode

    SECURITY MODE • Allows the Tech. Rep. to set the various counters. 5-1. Security Mode Menu Screen 4011P278CA 5-2. Security Mode Setting Procedure <Procedure> 1. Show the Tech. Rep. mode menu screen. 2. Press the following keys in this order: Stop 3.

  • Page 273: Settings In The Security Mode

    5-3. Settings in the Security Mode Touch Panel Setting (The default is Highlighted Display Total Counter Select the condition by which the Counter count is increased. 1 Copy per 1 copy cycle Mode 1 Multiple count-up according to paper size 1/2-sided Mode 2 copying Multiple count-up according to paper size 1/2-sided...
  • Page 274 Touch Panel Setting (The default is Highlighted Display Key Counter Set to “ON” if a Key Counter is plugged in. Note: • If “OFF” is set, copies can be made without having to plugging the Key Counter into the socket. Vender Mode Set the initial screen according to the type of vender mounted on the copier.

  • Page 275: Adjust Mode

    ADJUST MODE • Used at the factory for making adjustments. 6-1. Adjust Mode Menu Screen C1166P002CA 6-2. Adjust Mode Setting Procedure <Procedure> 1. Show the Tech. Rep. mode menu screen. 2. Press the following keys in this order: Stop Start 3.

  • Page 276: Settings In The Adjust Mode

    6-4. Settings in the Adjust Mode Printer • Adjust functions relating to the printer. • Runs a test print sequence. Touch Panel Setting Display Registration (CD) Adjust registration in the CD direction on the engine side. -4.0........... 0...........+4.0 Smaller Greater Registration (FD) Adjust registration in the FD direction on the engine side 35 CPM...

  • Page 277: Initial Mode

    INITIAL MODE • Used to initialize the various service functions. 7-1. Initial Mode Menu Screen 4011P297CA 7-2. Initial Mode Setting Procedure <Procedure> 1. Press the Warm Restart switch. Then “.” appears at the center on the left side of the screen.
  • Page 278 7-3. Settings in the Initial Mode Touch Panel Setting (The default is Highlighted Display Memory Clear Clears all data. Touch Panel Adj. Corrects deviation in the sensitive area of the Touch Panel. <Procedure> • Sequentially touch the four points marked with + on the screen as instructed by the arrow.
  • Page 279 7-4. Data/Conditions Cleared by Reset Switches Clearing Method Side Cover Memory Trouble Reset Total Clear open/close Clear Data Cleared Misfeed display – – Fusing – – Malfunction display Others – Erratic operation/display – – Job/Image – – – User’s Choice –...
  • Page 280 UTILITY MODE • Utility Mode is used to make various settings according to the user’s need. 8-1. Utility Mode selection Screen • Press the Utility key on the control panel. 4011P295CA 8-2. User’s Choice Function Tree User’s Choice Meter Count Copy Job Recall Utility User Management...
  • Page 281 8-3. Settings in the Utility Mode Touch Panel Setting Display User’s Choice Utility Mode S-6 Meter Count Utility Mode S-6 Copy Job Recall Utility Mode S-6 User Management Utility Mode S-6 Admin. Utility Mode S-6 Management Report Protocol Trace For details, see the FAX Service Manual. Service Call Report Touching “Service Call Report”...
  • Page 282 SOFT SWITCH SET 9-1. Soft Switch Initial Value Table • The contents of the soft switches are described mainly for modes related to copying. • The mark indicates a mode containing items that can be set according to the user's choice, for example.
  • Page 283 9-2. Set Contents of Soft Switches NOTES • The contents of the software switches are described mainly for modes related to copying. • The mark indicates a mode containing items that can be set according to the user's choice, for example. •...
  • Page 284 Mode Initial value Bit: HEX: 01 Logic Function Description Simplex/Duplex 1-Sided 2-Sided Original Copy Default Bit6-5: 1-Sided 2-Sided Setting other inhibit Bit4-3: APS: Auto paper mode Auto Paper/Auto Size AMS: Auto magnification mode Setting inhibit Manual Sets the print form for overseas PC printing. Main Application Copy: All PC prints are output together after Copy...
  • Page 285 Mode Initial value Bit: HEX: 01 Logic Function Description Auto Panel Reset Bit7-0: Setting of whether or not auto clear takes place after the speci- 00000000 No Reset fied time from the end of copying or a key operation and also the 00000001 1 min.
  • Page 286 Mode Initial value 25-cpm Copier Bit: 35-cpm Copier HEX: 3C Logic Function Description Auto Power Off Bit7-0: • Setting of whether or not to cut OFF the power to the machine 00000000 after the specified time from 00000001 1 min. the end of copying or a key operation, and also the time setting...
  • Page 287 Mode Initial value Bit: HEX: 00 Logic Function Description Drawer Priority Bit7-4: Setting of paper source selected preferentially in the APS (auto 0000 1st Drawer paper mode) or the manual mode. 0001 2nd Drawer 0010 3rd Drawer 0011 4th Drawer 0100 5th Drawer Manual...
  • Page 288 Mode Initial value Bit: HEX: 44 Logic Function Description Default Copy Output Levels Bit7-6: Darker Selection of level in auto density mode. Normal Setting inhibit Lighter Fixed Setting change inhibit Density (ADF only) Normal: Black Image is read at the specified density. streak Normal Black streak prevention:...
  • Page 289 Mode Initial value Bit: HEX: 08 Logic Function Description Priority Sort Mode Bit7-6: Non Sort Selection of the paper exit mode that has priority when the paper sort exit system option is installed. Setting inhibit Group Can be set simultaneously with a mode other Priority Stapling Mode (copy) than "Non-sort"...
  • Page 290 Mode Initial value Bit: HEX: A0 Logic Function Description Image Compression When Bit7-4: Indicates the memory reserve Reserving Capacity In The Copy capacity per copy converted into 0101 Memory (copy) image compression, and reserves memory capacity before 0110 start of scanning, according to 0111 the set compression correspond- ing to the original used.
  • Page 291 Mode Initial value Bit: HEX: 60 Logic Function Description Sound Volume Setting 3 Monitor Line monitor tone volume setting Bit3-1: (No tone) Tone (copy) Setting Other inhibit Orientation Of Images When Fin- Facing Sets the orientation of the image when a fin- isher Is Connected (copy) facing each...
  • Page 292 Mode Initial value Bit: HEX: 78 Logic Function Description Fixed Setting change inhibit Bit6-5: 0 mm Edge Erase When a BS scan (including ADFR) is performed 1 mm In the APS/AMS mode, exactly the width set from the 2 mm detected original size frame is erased.
  • Page 293 Mode Initial value Bit: HEX: 08 Logic Function Description Total Counter Mode 1 Setting of total counter counting Bit7-6: (standard) method. Mode 2 (ME) Mode 3 Setting inhibit Size Counter Do not Setting of paper size to be Bit5-3: count counted by size counter.
  • Page 294 Mode Initial value Bit: HEX: 48 Logic Function Description Copy Copy Setting of threshold value of copy kit counter, Plug-In Counter Made Cycles and viewing count value. Key Counter Use of key counter or vender. Vender Mode Sets which of the key counter or Bit5-4: counter vender to set when these are...
  • Page 295 Mode Initial value Bit: HEX: 00 Logic Function Description 7 to 4 Fixed Setting change inhibit Image Quality Mode Adjustment Bit3-0: 0000 Setting of image density for print- (copy) ing. Enables setting of special image 1000 quality mode for Original Image Type of MODE 409 Bit4-1.

  • Page 296: Troubleshooting

    TROUBLESHOOTING 14413...
  • Page 297 CONTENTS 1. INTRODUCTION ..................... T-1 1-1. Reading the Text ..................T-1 2. I/O CHECK ...................... T-1 2-1. Electrical Components Check Procedure ..........T-1 2-2. I/O Check List ..................T-2 3. PAPER TRANSPORT FAILURE ..............T-8 3-1. Paper Misfeed ..................T-8 3-2.
  • Page 298 Blank Copy ..................T-48 Black Copy ..................T-49 Low Image Density ................T-50 Foggy Background ................T-51 Black Streaks or Bands ..............T-52 Black Spots ..................T-53 Blank Streaks or Bands ..............T-54 Void Areas ..................T-55 Smear on Back ................T-56 (10) Uneven Image Density ..............

  • Page 299: Introduction

    INTRODUCTION 1-1. Reading the Text 1. The paper transport failure troubleshooting procedures are given according to the symptom. First identify the location where the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward.

  • Page 300: I/O Check List

    2-2. I/O Check List <I/O Check Screens> • The following screen is only typical and it may be different from what is shown on each individual copier. 4011T539CA <I/O Check List> Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board PC13...
  • Page 301 <I/O Check Screens> • The following screen is only typical and it may be different from what is shown on each individual copier. Printer “BackUp” “Next” 4011T540CA 4011T541CA “Next” “BackUp” “Next” “BackUp” 4011T543CA 4011T542CA...
  • Page 302 <I/O Check List> Printer Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board Drawer 1st Drawer Set In position Out of Master IC1A PJ3A-5B Drawer Sensor position Board PWB-A PWB-H Double Double Feed Blocked *2 Unblocked IC1A PJ4A-2 Feed...
  • Page 303 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board Take-up Paper Take-Up Paper Paper not Control IC1A PJ3A-5A Drawer Sensor present present Board PWB-A Paper Paper Near Empty Unblocked Blocked IC1A PJ3A-11A Near Sensor Empty Paper Paper Empty Sen- Paper not Paper...
  • Page 304 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board Lift Level Lift-Up Sensor 1 At upper Not at IC4A P74/ CN4A-6 limit upper limit Control ANI4 Board Lift Level Lift-Up Sensor 2 At upper Not at IC4A P73/ CN4A-9...
  • Page 305 Operation Characteris- Input Port CN/PJ tics/Panel Display Symbol Panel Display Parts/Signal Name Board SIDE Doors/ LCC Side Door Set Sensor When When IC4A P34/ CN3A-12 Toner Cover opened closed Control Board FRONT LCC Front LCC Set Sensor Out of In position IC4A P35/ CN6A-9...

  • Page 306: Paper Transport Failure

    PAPER TRANSPORT FAILURE 3-1. Paper Misfeed • When a paper misfeed occurs, the Touch Panel shows the corresponding message, mis- feed location, and paper location. Misfeed location display display Paper location 15 11 15 11 4011T544CA 4011T545CA Misfeed/Paper Location Ref. Page Display See the relevant option service manual.
  • Page 307 If a communications error occurs between MFB2 Board and Master Board during a copy cycle, it forces a paper misfeed condition ( displayed on the Touch Panel). If that hap- pens, check the circuit between MFB2 Board and Master Board for proper connection and, if it is intact, replace the board.

  • Page 308: Size Error

    3-2. Size Error • The following warning screen appears if the actual size of the paper loaded in a paper source differs from the paper size set for that particular paper source. 1st to 5th Drawer Manual Bypass 4011T546CA 4011T547CA 1st to 5th Drawer: A size error is indicated by a highlighted paper source in the copier overview display.

  • Page 309: Misfeed Detection Sensor Layout

    3-3. Misfeed Detection Sensor Layout Paper Exit Sensor PC3 Duplex Unit Door Set Sensor PC1 Duplex Unit Trans- port Sensor PC2 Synchronizing Roller Sensor PC2 Manual Feed Paper Take-Up Sensor PC8 Paper Take-Up Sensor PC101 4011T548CA The Duplex Unit is standard on the 35-cpm copier. A fixed paper size cassette is standard for the 2nd Drawer of the 25-cpm and 35-cpm copier.

  • Page 310: Types Of Misfeed Detection And Detection Timings

    3-4. Types of Misfeed Detection and Detection Timings • The following lists the types of misfeed detection and detection timings for different mis- feed locations. • The symbol “L” (for the leading edge) and “T” (for the trailing edge) given in ( ) indicate the particular edge of the paper detected by the sensor.
  • Page 311 Duplex Turnover/Take-Up Misfeed Type Detection Start Detection Leading edge detection by Paper Exit Sensor (T) Duplex Unit Transport Sen- Duplex Unit Transport Sen- sor (L) Paper take-up failure detec- Duplex Unit Transport Sen- Synchronizing Roller Sensor tion sor (L) Paper left Power Switch ON / Misfeed Duplex Unit Transport Sen- reset...
  • Page 312 3-5. Misfeed Troubleshooting Procedures 1st Drawer Take-Up Misfeed Relevant Electrical Parts 1st Drawer Paper Take-Up Solenoid SL1 Master Board PWB-A Synchronizing Roller Sensor PC2 PWB-A PJ3A-6A (GND) PJ3A-7A (PC2 ON) PJ3A-8A (DC5 V) CN10 PJ3A-13B (SL1 ON) PJ3A-12B (DC24 V) 4011T513AA T-14...
  • Page 313 1st Drawer Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage. Edge Guide and Trailing Edge Stop are at cor- Set as necessary.
  • Page 314 Manual Bypass Take-Up Misfeed Relevant Electrical Parts Manual Feed Paper Take-Up Clutch CL2 Manual Feed Paper Take-Up Sensor PC8 Synchronizing Roller Sensor PC2 Master Board PWB-A PWB-A CN36 CN14 PJ23 PJ2A-8A (DC24 V) PJ2A-9A (CL2 ON) PJ2A-8B (GND) PJ2A-7B (PC8 ON) PJ40 PJ2A-6B (DC5 V) PJ3A-6A (GND)
  • Page 315 Manual Bypass Take-Up Misfeed Troubleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage. Edge Guides are at the correct position along Set as necessary.

  • Page 316: Separator/Fusing/Exit Misfeed

    Separator/Fusing/Exit Misfeed Relevant Electrical Parts Paper Exit Sensor PC3 Synchronizing Clutch CL1 Synchronizing Roller Sensor PC2 Master Board PWB-A PWB-A CN23 PJ24 PJ3A-1A (DC24 V) PJ3A-2A (CL1 ON) PJ3A-6A (GND) PJ3A-7A (PC2 ON) PJ3A-8A (DC5 V) PJ3A-11A (GND) PJ3A-12A (PC3 ON) PJ3A-13A (DC5 V) 4011T515AA T-18...
  • Page 317 Separator/Fusing/Exit Misfeed Troubleshooting Procedures • Paper is at a stop near the Synchronizing Roller. Step Check Result Action Pre-Image Transfer Guide Plate is dirty or Clean or change. deformed. Synchronizing Rollers are dirty, deformed, or Clean or change. worn. The misfeed is eliminated after the paper loop This completes the proce- length has been adjusted.
  • Page 318 Paper Take-Up/Transport Misfeed (2nd Fixed Paper Size Cassette/PF-118/PF- 119) Relevant Electrical Parts Paper Take-Up Clutch CL1 Power Supply Unit PU1 Paper Take-Up Sensor PC1 Control Board PWB-A Synchronizing Roller Sensor PC2 Master Board PWB-A I/C Motor M1 PWB-A CN83 PJ3A-6A (GND) PJ3A-7A (PC2 ON) PJ3A-8A (DC5 V) CN93...

  • Page 319: Paper Take-Up/Transport Misfeed (2Nd Fixed Paper Size Cassette

    Paper Take-Up/Transport Misfeed (2nd Fixed Paper Size Cassette/PF-118/PF-119) Trou- bleshooting Procedures • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage.
  • Page 320 • Paper is at a stop at the vertical transport section or near the Synchronizing Roller. Step Check Result Action Vertical Transport Roller is dirty, deformed, or Clean or change. worn. Vertical transport guide plate is dirty or Clean or change. deformed.
  • Page 321 Paper Take-Up Misfeed (PF-117) Relevant Electrical Parts LCC Paper Take-Up Sensor PPS0 Separator Clutch BCL Paper Empty Sensor 1 PPS1 Registration Clutch RCL Paper Standby Position Sensor S1 LCC Control Board PWB-A Registration Sensor RSEN Control Board PWB-A Paper Take-Up Clutch 1 P1CL Master Board PWB-A Paper Take-Up Clutch 2 P2CL CN83...

  • Page 322: Paper Take-Up Misfeed

    Paper Take-Up Misfeed (PF-117) Troubleshooting Procedures • Misfeed is detected when the cassette is slid in. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage. Paper Take-Up Roll is dirty, deformed, or worn.
  • Page 323 • Paper is not taken up at all. Step Check Result Action Paper meets product specifications. Change paper. Paper is curled, wavy, or damp. Change paper. Instruct user in correct paper storage. Feed Roll and Separator Roll are dirty, Clean or change. deformed, or worn.

  • Page 324: Duplex Turnover/Take-Up Misfeed

    Duplex Turnover/Take-Up Misfeed (AD-15) Relevant Electrical Parts Paper Exit Sensor PC3 Duplex Unit Turnover Motor M1 Synchronizing Roller Sensor PC2 Duplex Unit Transport Motor M2 Manual Feed Paper Take-Up Clutch CL2 Duplex Unit Control Board PWB-A Duplex Unit Transport Sensor PC2 Master Board PWB-A PWB-A PJ2A-1A (DC24 V)
  • Page 325 Duplex Turnover/Take-Up Misfeed (AD-15) Troubleshooting Procedures • Paper is at a stop near the exit section. Step Check Result Action Paper Exit Roller is dirty, deformed, or worn. Clean or change. Duplex Unit Transport Roller/Roll 1 is dirty, Clean or change. deformed, or worn.
  • Page 326 • Paper is at a stop inside the Duplex unit. Step Check Result Action Duplex Unit Transport Roller/Roll 2 is dirty, Clean or change. deformed, or worn. Manual Feed Paper Take-Up Roll is dirty, Clean or change. deformed, or worn. Duplex Unit Transport Sensor operation check Check step 6.

  • Page 327: Malfunction

    MALFUNCTION The copier’s CPU is equipped with a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. Malfunction Resetting Procedure • For all malfunctions except fusing-related ones, turn OFF, then ON the Power Switch or open and close the Side Cover.

  • Page 328: C0510: Abnormally Low Fusing Temperature

    Code Description Detection Timing C0510 Abnormally low fusing • The fusing temperature remains 105 °C or less for a temperature continuous 0.1-sec. period or more during the standby state or printing. • The fusing temperature remains a level lower than the following temperature for a continuous 2-min.
  • Page 329 Code Description Detection Timing C0B38 Shift Motor drive mal- function C0B48 Exit Roller/Rolls Spacing Motor drive malfunction C0B4A Storage Roller/Rolls Spacing Motor drive mal- function C0B4D Paper Holding Tray Motor drive malfunction C0B4E Finisher Tray Motor drive malfunction C0B50 Stapling Motor 1 drive malfunction / Stapling See the relevant option service manual.
  • Page 330 Code Description Detection Timing C1300 Polygon Motor malfunc- <Faulty start detection> tion • The Lock signal is not detected at any time during a given period of time 1 sec. after the Polygon Motor has been energized. <Faulty Lock signal detection> •...
  • Page 331 4-2. Troubleshooting Procedures by Malfunction Code C0000: Main Motor malfunction C0010: I/C Motor malfunction C0045: Cooling Fan Motor malfunction C004C: Ozone Fan Motor malfunction C004E: Power Unit Cooling Fan Motor malfunction C0070: Main Hopper Toner Replenishing Motor malfunction Relevant Electrical Parts Main Motor M2 Power Unit Cooling Fan Motor M4 I/C Motor M1...
  • Page 332 C0000 Step Check Result Action Main Motor operation check: the voltage Check various parts for across PJ1-3 of the Main Motor and GND possible overload. changes from DC5 V to DC0 V when the Side Change Main Motor. Cover is opened and closed. Change Master Board.
  • Page 333 C0070 Step Check Result Action Main Hopper Toner Replenishing Motor opera- Check step 3. tion check: • Remove the Lower Rear Cover. • Unlock the Toner Bottle Lock Lever. • Block the Toner Bottle Cover Sensor. • Turn the Toner Bottle a half turn by hand. The Toner Bottle turns when the Toner Bottle Cover Sensor is unblocked under the above conditions.
  • Page 334 C0214: Abnormal image transfer voltage Relevant Electrical Parts Power Supply Unit PU1 Master Board PWB-A High Voltage Unit PU2 PJ9PU1-1 (DC5 V) PJ9PU1-2 (GND) CN11 DC24 V CN1PU2-1 (DC24 V) CN1PU2-2 (GND) CN1PU2-3 (GND) CN1PU2-4 (DC5 V) CN17 PWB-A PJ15A-4A (P.C./I.T. REM) CN2PU2-4 (P.C./I.T.
  • Page 335 C0500: Warming-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature Relevant Electrical Parts Fusing Roller Heater Lamp H1 Side Cover Interlock Switch 2 S3 Fusing Roller Thermistor TH1 Power Supply Unit PU1 Fusing Roller Thermostat TS1 Master Board PWB-A Fusing Roller Heater Lamp Fuse TF1 PWB-A CN25...
  • Page 336 C0500,C0510 Step Check Result Action Fusing Roller Heater Lamp turns ON when the Check step 3 and onward. Side Cover is opened and closed. The resistance of Fusing Roller Thermistor Change Fusing Roller (across CN25-2 and 3 on the Fusing Unit end) Thermistor.

  • Page 337: C0650: Faulty Scanner Home Position Sensor

    C0650: Faulty Scanner Home Position Sensor 1 C0651: Faulty Scanner Home Position Sensor 2 Relevant Electrical Parts Scanner Home Position Sensor 1 PC12 BCR Board BCR Scanner Home Position Sensor 2 PC13 MFB2 Board MFB2 Scanner Motor M10 Master Board PWB-A CN33 PC12 CN32...
  • Page 338 C0650,C0651 Step Check Result Action Scanner Motor operation check: Select func- Check step 3 and onward. tions in the following order: Tech. Rep. Mode Movement Check Scanner; set “+1000” in “Relative Position” and touch “Set”; the Scan- ner moves at this time. The Scanner can be moved manually.

  • Page 339: C0991: Lift 1 Ascent Motion Failure

    C0990: LCC Lift-Up Motor failure to turn C0991: Lift 1 ascent motion failure C0995: LCC Transport Motor failure to turn C0999: Lift 2 ascent motion failure C099D: LCC communication error Relevant Electrical Parts LCC Lift-Up Motor EMOT Power Supply Unit PU1 Lift-Up Sensor 1 LS1 LCC Control Board PWB-A Lift-Up Sensor 2 LS2...
  • Page 340 C0990 Step Check Result Action The voltage across CN1A-15 on LCC Control Change LCC Lift-Up Board and GND is DC24 V. Motor. Change LCC Control Board. Change Control Board. Change Master Board. Fuse is conducting. Change Power Supply Unit. Change fuse. C0991 Step Check...
  • Page 341 C0999 Step Check Result Action Lift-Up Sensor 2 operation check through I/O Check step 3 and onward. check Lift-Up Sensor 2 operation check: the voltage Change LCC Control across CN4A-9 on LCC Control Board and Board. GND is DC5 V when the sensor is blocked and Change Control Board.

  • Page 342: C0F32: Faulty Atdc Sensor C0F33: Atdc Adjustment Failure

    C0F32: Faulty ATDC Sensor C0F33: ATDC adjustment failure Relevant Electrical Parts ATDC Sensor UN2 Master Board PWB-A Power Supply Unit PU1 CN11 PWB-A CN50 PJ18 PJ6A-1 (UN2 CONTROL) PJ6A-2 (DC24 V) PJ6A-3 (UN2 ON) PJ6A-4 (GND) PJ6PU1-5 (DC5 V) 4011T512AA C0F32,C0F33 Step Check...

  • Page 343: C10Xx To C13Xx

    C10XX to C13XX • These malfunctions are concerned with faulty symptoms as they mainly relate to soft- ware, hardware, and communications. Code Action C1038 1. Check the connection between Master Board and MFB2 Board. 2. Reset the malfunction and turn OFF and ON the Power Switch. 3.

  • Page 344: The Copier Does Not Turn On

    The Copier Does not Turn ON. Relevant Electrical Parts Power Switch S1 Touch Panel UN1 Power Supply Unit PU1 MFB2 Board MFB2 Panel Board PWB-F Master Board PWB-A Inverter Board 2 PU3 • Touch Panel indicates nothing. Step Check Result Action Power supply voltage check: the voltage across Check the power outlet...

  • Page 345: Image Failure

    IMAGE FAILURE 5-1. Image Failure Troubleshooting • If any image failure has occurred, first make the initial checks, then proceed to the corre- sponding image failure troubleshooting procedure. 5-2. Initial Checks • Determine if the failure is attributable to a basic cause or causes. Section Step Check...

  • Page 346: Troubleshooting Procedures Classified By Image Failure

    5-3. Troubleshooting Procedures Classified by Image Failure Blank Copy <Typical Faulty Images> 4011T516AA Section Step Check Result Action Developing Unit is driven properly. Correct or change drive coupling mechanism. Image transfer current contact terminal YES Clean or change. is dirty or deformed. Developing bias contact terminal is YES Clean or change.

  • Page 347: Black Copy

    Black Copy <Typical Faulty Images> When engine is faulty. When IR is faulty. 4011T517AA 4011T537AA Section Step Check Result Action Comb Electrode contact terminal is YES Clean or change. dirty or deformed. Grid voltage contact terminal is dirty or YES Clean or change. deformed.

  • Page 348: Low Image Density

    Low Image Density <Typical Faulty Images> 4011T518AA Section Step Check Result Action Image transfer current contact terminal YES Clean or change. is dirty or deformed. Developing bias contact terminal is Clean or change. dirty or deformed. Select functions in the following order: YES Make setting again.

  • Page 349: Foggy Background

    Foggy Background <Typical Faulty Images> When engine is faulty. When IR is faulty. 4011T519AA 4011T538AA Section Step Check Result Action Sunlight or any other extraneous light YES Protect the copier from — enters the copier. extraneous light. PC Drum is dirty. YES Clean.

  • Page 350: Black Streaks Or Bands

    Black Streaks or Bands <Typical Faulty Images> 4011T520AA Section Step Check Result Action Paper path is dirty with toner. YES Clean. PC Drum is dirty. YES Clean. Engine Fusing Rollers are dirty or scratchy. YES Clean or change. Change I/C. Change Master Board.

  • Page 351: Black Spots

    Black Spots <Typical Faulty Images> 4011T521AA Section Step Check Result Action Paper path is dirty with toner. YES Clean. PC Drum is dirty. YES Clean. Fusing Rollers are dirty or scratchy. YES Clean or change. Comb Electrode contact terminal is YES Clean or change.

  • Page 352: Blank Streaks Or Bands

    Blank Streaks or Bands <Typical Faulty Images> 4011T522AA Section Step Check Result Action Image Transfer Roller is dented or YES Change. scratchy. PC Drum is dirty. YES Clean. Engine Fusing Rollers are dirty or scratchy. YES Clean or change. PH Assy window glass is dirty. YES Clean.

  • Page 353: Void Areas

    Void Areas <Typical Faulty Images> 4011T523AA Section Step Check Result Action PC Drum is dirty. YES Clean. Image Transfer Roller is dented or Change. scratchy. Engine Fusing Rollers are scratchy or YES Clean or change. deformed. Change I/C. Change Master Board. Original Glass is dirty.

  • Page 354: Smear On Back

    Smear on Back <Typical Faulty Images> 4011T524AA Section Step Check Result Action Paper path is dirty with toner. YES Clean. Engine Image Transfer Roller is dirty. YES Clean. Fusing Rollers are dirty. YES Clean. T-56...

  • Page 355: (10) Uneven Image Density

    (10) Uneven Image Density <Typical Faulty Images> 4011T525AA Section Step Check Result Action Image Transfer Roller is dirty or YES Clean or change. deformed. Engine Change I/C. Change Master Board. Mirror, lens, and/or Original Glass are YES Clean. dirty. Shading sheet is dirty. YES Clean.

  • Page 356: (11) Gradation Reproduction Failure

    (11) Gradation Reproduction Failure <Typical Faulty Images> 4011T526AA Section Step Check Result Action Image Transfer Roller is dirty or YES Clean or change. deformed. Engine Change I/C. Change Master Board. Mirror, lens, and/or Original Glass are YES Clean. dirty. Shading sheet is dirty. YES Clean.

  • Page 357: (12) Rough Image

    (12) Rough Image <Typical Faulty Images> 4011T527AA Section Step Check Result Action Image Transfer Roller is dirty or YES Clean or change. deformed. Image transfer current contact terminal YES Clean or change. is dirty or deformed. Toner has caked or is contaminated YES Remove foreign matter.

  • Page 358: (13) Periodically Uneven Image

    (13) Periodically Uneven Image <Typical Faulty Images> 4011T528AA Section Step Check Result Action Developing Unit is driven properly. Correct or change drive coupling mechanism. PC Drum and Image Transfer Roller Correct or change drive are driven properly. coupling mechanism. Synchronizing Roller is driven properly. Correct or change drive coupling mechanism.

  • Page 359: Abort Codes

    ABORT CODES • The copier displays an abort code on the Touch Panel as it becomes unable to process tasks properly through its software control. Abort Code 4011T536AA 6-1. List of Abort Codes • When the system program is aborted, the copier attempts to restart it automatically. If it fails to restart the program, check the electrical component, unit, option, and connection relating to the specific type of the abort condition.
  • Page 360 Description Code Relevant Electrical Components, Units, and Options Scanner control sys- 0x00c00000 MFB2 Board, BCR Board, Inverter Board 1, AF-9, tem failure to 0x00c0ffff AFR-17 Scanner control sys- 0x00c10000 MFB2 Board, BCR Board, Inverter Board 1, AF-9, tem failure to 0x00c2ffff AFR-17 Scanner control sys- 0x00c30000...
  • Page 361 Description Code Relevant Electrical Components, Units, and Options Function sequence 0x01100400 MFB2 Board system failure to 0x011004ff OS message pro- 0x02000000 cessing system fail- MFB2 Board, FPLAN Board, CEN Board to 0x020fffff Network processing 0x03000000 MFB2 Board, FPLAN Board, CEN Board system failure to 0x030fffff T-63...
  • Page 362 Copyright 2001 MINOLTA ME GmbH Printed in Germany Use of this manual should be strictly supervised to avoid disclosure of confidential information. MINOLTA ME GmbH 4011-7991-11...

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