Page 1: Service Manual
SERVICE MANUAL FIELD SERVICE 2005.03 2005.03 Ver. 1.0 Ver. 1.0...
Page 2: Safety And Important Warning Items
IMPORTANT NOTICE Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the product, KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. (hereafter called the KMBT) strongly recommends that all servicing be performed only by KMBT-trained service technicians.
Page 3: Safety Warnings
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. KONICA MINOLTA brand products are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Product design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors.
Page 4 SAFETY AND IMPORTANT WARNING ITEMS [2] POWER PLUG SELECTION In some countries or areas, the power plug provided with the product may not fit wall outlet used in the area. In that case, it is obligation of customer engineer (hereafter called the CE) to attach appropriate power plug or power cord set in order to connect the product to the supply.
Page 5: Connection To Power Supply
SAFETY AND IMPORTANT WARNING ITEMS [3] CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE KONICA MINOLTA brand products are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engi- neer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure.
Page 6 SAFETY AND IMPORTANT WARNING ITEMS Power Plug and Cord WARNING • When using the power cord set (inlet type) that came with this product, make sure the connector is securely inserted in the inlet of the product. When securing measure is provided, secure the cord with the fixture properly.
Page 7 SAFETY AND IMPORTANT WARNING ITEMS Wiring WARNING • Never use multi-plug adapters to plug multiple power cords in the same outlet. If used, the risk of fire exists. • When an extension cord is required, use a specified one. Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire.
Page 8 SAFETY AND IMPORTANT WARNING ITEMS Ventilation CAUTION • The product generates ozone gas during operation, but it will not be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a.
Page 9 SAFETY AND IMPORTANT WARNING ITEMS Work Performed with the Product Powered On WARNING • Take every care when making adjustments or performing an operation check with the product powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.
Page 10 SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Check electrode units such as a charging corona unit for deterioration and sign of leakage. Current can leak, leading to a risk of trouble or fire. • Before disassembling or adjusting the write unit (P/H unit) incorporating a laser, make sure that the power cord has been disconnected.
Page 11: Handling Of Consumables
SAFETY AND IMPORTANT WARNING ITEMS Safety Checkpoints WARNING • Make sure that all screws, components, wiring, connec- tors, etc. that were removed for safety check and mainte- nance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of product trouble, electric shock, and fire exists.
Page 12 SAFETY AND IMPORTANT WARNING ITEMS Handling of Service Materials CAUTION • Use only a small amount of cleaner at a time and take care not to spill any liquid. If this happens, immediately wipe it off. A risk of fire exists. •...
Page 13 SAFETY AND IMPORTANT WARNING ITEMS [4] 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.
Page 14 SAFETY AND IMPORTANT WARNING ITEMS [5] FUSE CAUTION Double pole / neutral fusing ATTENTION Double pôle / fusible sur le neutre. [6] LED Radiation Safety • This product is a copier which operates by means of a LED (light emitting diodes) expo- sure system.
Page 15: Warning Indications On The Machine
SAFETY AND IMPORTANT WARNING ITEMS WARNING INDICATIONS ON THE MACHINE Caution labels shown are attached in some areas on/in the machine. When accessing these areas for maintenance, repair, or adjustment, special care should be taken to avoid burns and electric shock. High temperature High voltage High voltage...
Page 16 SAFETY AND IMPORTANT WARNING ITEMS High voltage High voltage High voltage 4037P0C502DA S-15...
Page 17 SAFETY AND IMPORTANT WARNING ITEMS High voltage 4037P0C503DA CAUTION: • You may be burned or injured if you touch any area that you are advised not to touch by any caution label. Do not remove caution labels. If any caution label has come off or soiled and therefore the caution cannot be read, contact our Service Office.
Page 18: Main Unit
SERVICE MANUAL FIELD SERVICE Main Unit 2005.03 Ver. 1.0...
Page 20 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 22: Table Of Contents
Field Service Ver. 1.0 Mar. 2005 CONTENTS General System configuration....................1 Product specifications ..................... 3 Type ........................3 Functions ......................3 Types of Paper ...................... 4 Maintenance ......................4 Machine Specifications ..................4 Operating Environment ..................5 Built-in Controllers ....................5 Maintenance Periodical check ......................
Page 23 Field Service Ver. 1.0 Mar. 2005 3.5.12 Replacing the Waste Toner Box..............24 3.5.13 Cleaning of the Area around the Waste Toner Collecting Port ....25 3.5.14 Replacing Ozone Filter ................25 3.5.15 Cleaning of the Comb Electrode..............26 3.5.16 Cleaning LPH Assy..................
Page 24 Field Service Ver. 1.0 Mar. 2005 6.3.4 Lower Rear Cover/Tray 2 Rear Cover/Rear Cover/Rear Right Cover/ Tray 2 Rear Right Cover/Wiring Cover ............52 6.3.5 IR Upper Front Cover/IR Upper Right Cover/IR Upper Rear Cover .... 53 6.3.6 Original Glass/IR Front Cover ..............54 6.3.7 Control Panel (UN201)................
Page 25 Field Service Ver. 1.0 Mar. 2005 6.3.41 Toner Supply Motor Y/M (M4) ..............98 6.3.42 Tray 2 Lift-Up Motor (M101) ................ 98 6.3.43 Tray 2 Paper Feed Motor (M102) ..............99 6.3.44 Tray 2 Vertical Transport Motor (M103)............. 100 6.3.45 Color PC Drum Motor (M5)...............
Page 26 Field Service Ver. 1.0 Mar. 2005 Utility Mode function tree .................. 135 Utility Mode function setting procedure............. 149 8.3.1 Procedure ....................149 8.3.2 Exiting ....................... 149 8.3.3 Changing the setting value in Utility Mode functions......... 149 One-Touch Registration ..................150 8.4.1 Scan......................
Page 27 Field Service Ver. 1.0 Mar. 2005 10.4.5 Printer Area....................226 10.4.6 Scan Area ....................230 10.4.7 Printer Resist Loop ................... 233 10.4.8 Color Registration Adjustment ..............234 10.4.9 LPH Rank ....................236 10.4.10 LPH Chip Adjust ..................237 10.4.11 Manual Bypass Tray Adjustment............... 238 10.4.12 Lead Edge Erase Adjustment ..............
Page 28 Field Service Ver. 1.0 Mar. 2005 10.8.1 Marketing Area..................260 10.8.2 Tel/Fax Number..................260 10.8.3 Serial Number ................... 260 10.8.4 No Sleep ....................260 10.8.5 Original Size Detection ................261 10.8.6 Foolscap Size Setting ................261 10.8.7 Initialization ....................261 10.8.8 Install Date ....................
Page 29 Field Service Ver. 1.0 Mar. 2005 10.11.6 Fax Setting List ..................272 10.12 State Confirmation.................... 273 10.12.1 Sensor Check ................... 273 10.12.2 Table Number ................... 282 10.12.3 Level History1 ................... 283 10.12.4 Level History2 ................... 283 10.12.5 Temp. & Humidity..................283 10.12.6 CCD Check ....................
Page 30 Field Service Ver. 1.0 Mar. 2005 11.3.5 IU Life Stop Setting ................... 294 Billing Setting ...................... 295 12.1 Billing Setting Function Setting Procedure ............295 12.1.1 Procedure ....................295 12.1.2 Exiting ....................... 295 12.2 Billing Setting Function Tree ................295 12.3 Settings in the Billing Setting ................
Page 31 Field Service Ver. 1.0 Mar. 2005 16.2 Alert code ......................318 16.2.1 Alert list ..................... 319 16.3 Solution ......................320 16.3.1 S-1: CCD clamp/gain adjustment failure........... 320 16.3.2 P-5: IDC Sensor (Front) failure ..............320 16.3.3 P-28 IDC Sensor (Back) failure..............320 16.3.4 P-6: Cyan Imaging Unit failure ..............
Page 32 Field Service Ver. 1.0 Mar. 2005 16.6.18 C2257: Cleaning Brush Motor's failure to turn .......... 350 16.6.19 C2258: Cleaning Brush Motor Turning at abnormal timing ....... 350 16.6.20 C2351: Toner Suction Fan Motor/K's failure to turn ........350 16.6.21 C2352: Toner Suction Fan Motor’s failure to turn........351 16.6.22 C2451: New Transfer Cleaner Unit resetting failure ........
Page 33 Field Service Ver. 1.0 Mar. 2005 16.6.55 C4705: Printer Time Out................359 16.6.56 C4761: Compression hardware timeout ........... 359 16.6.57 C4765: Extraction hardware timeout ............359 16.6.58 C4770: JBIG0 Error .................. 359 16.6.59 C4771: JBIG1 Error .................. 359 16.6.60 C4772: JBIG2 Error .................. 359 16.6.61 C4773: JBIG3 Error ..................
Page 34 Field Service Ver. 1.0 Mar. 2005 16.6.92 CD005: Hard Disk Error 1 ................. 367 16.6.93 CD006: Hard Disk Error 2 ................. 367 16.6.94 CD007: Hard Disk Error 3 ................. 367 16.6.95 CD008: Hard Disk Error 4 ................. 367 16.6.96 CD009: Hard Disk Error 5 ................. 367 16.6.97 CD00A: Hard Disk Error 6.................
Page 35 Field Service Ver. 1.0 Mar. 2005 18.2 How to identify problematic part ............... 377 18.2.1 Initial Check Items ..................377 18.3 Solution ......................379 18.3.1 IR System: white lines in Sub Scan Direction, white bands in Sub Scan Direction, colored lines in Sub Scan Direction, and colored bands in Sub Scan Direction ..................
Page 36 Field Service Ver. 1.0 Mar. 2005 18.3.28 Printer 4-Color: white lines in main scan direction, white bands in main scan direction, colored lines in main scan direction, and colored bands in main scan direction.................... 409 18.3.29 Printer 4-Color: uneven density in sub scan direction....... 410 18.3.30 Printer 4-Color: uneven density in main scan direction......
Page 37: Field Service Ver. 1.0 Mar
Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 38: System Configuration
Field Service Ver. 1.0 Mar. 2005 1. System configuration General System configuration 1/2 System Front View [10] 4037F1C501DA Machine Paper Feed Cabinet PC-402 Working Table WT-501 Finisher FS-507 Paper Feed Cabinet PC-202 Job Separator JS-601 Paper Feed Cabinet PC-102 Finisher FS-603 Desk DK-501 [10] Punch Kit PK-501...
Page 39 1. System configuration Field Service Ver. 1.0 Mar. 2005 2/2 System Rear View [10] PC-102 PC-202 DK-501 PC-402 4037F1E503DA Machine Image Controller IC-402 Fax Kit FK-502 Video Interface Kit VI-502 Mount Kit MK-703 Local Interface Kit EK-702 Mount Kit MK-704 Mechanical Counter MC-501 Dehumidifier Heater 1C [10] Key Counter Kit KIT-1...
Page 40: Product Specifications
Field Service Ver. 1.0 Mar. 2005 2. Product specifications Product specifications Type Type Desktop-type printer integrated with scanner Copying System Electrostatic dry-powdered image transfer to plain paper Printing Process Tandem-type indirect electrostatic recording system PC Drum Type OPC (organic photo conductor) Scanning Density Equivalent to 600 dpi Exposure Lamp...
Page 41: Types Of Paper
2. Product specifications Field Service Ver. 1.0 Mar. 2005 Types of Paper Paper Source Tray 1 Tray 2 Multiple Bypass Plain paper ❍ ❍ ❍ (60 to 90 g/m / 16 to 24 lb Translucent paper – – – OHP transparencies (crosswise –...
Page 42: Operating Environment
Field Service Ver. 1.0 Mar. 2005 2. Product specifications Operating Environment Temperature 10 to 30 °C / 50 to 86° F (with a fluctuation of 10° C / 18° F or less per hour) Humidity 15 to 85 % (with a fluctuation of 20 %/h) Built-in Controllers Type Built-in type controller...
Page 43 2. Product specifications Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 44: Maintenance
Field Service Ver. 1.0 Mar. 2005 3. Periodical check Maintenance Periodical check Service schedule Guarantee period (5-year or 1,000,000 prints) × 10,000-print Per cycle Number × print of times 6 12 15 18 20 24 30 36 40 42 45 48 54 60 66 72 75 78 80 84 90 96 number Upon ●...
Page 45: Maintenance Call (Per 60,000-Print)
3. Periodical check Field Service Ver. 1.0 Mar. 2005 3.2.2 Maintenance call (per 60,000-print) Number of Lubrica- Descrip- Class Parts to be replaced Check Clean Replace personnel tion tions Paper take-up and ● image conditions Overall ● ● Appearance ● Registration Roller ●...
Page 46: Periodical Parts Replacement 3 (Per 300,000-Print)
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 3.2.5 Periodical parts replacement 3 (per 300,000-print) Number of Lubri- Class Parts to be replaced Check Clean Replace Descriptions personnel cation Paper take-up and ● image conditions Overall ● ● Appearance ●...
Page 47: Maintenance Parts
3. Periodical check Field Service Ver. 1.0 Mar. 2005 Maintenance parts • To ensure that the machine produces good copies and to extend its service life, it is rec- ommended that the maintenance jobs described in this schedule be carried out as instructed.
Page 48: Cleaning Parts
Field Service Ver. 1.0 Mar. 2005 3. Periodical check B. Option Actual Ref.Page Classifi- Parts name durable Parts No. Descriptions in this cation ntity cycle *1 manual Pick-up Roller 300 K 4030-3005-XX Replace those PC-102 PC-202 Paper Take-up Roller 300 K 4030-3005-XX three parts at the PC-402...
Page 49: Concept Of Parts Life
3. Periodical check Field Service Ver. 1.0 Mar. 2005 Concept of parts life Life value Max. number of Description (Specification printed pages value) A waste toner full condition is detected when about Waste Toner 8,000 printed pages have been produced after a –...
Page 50 Field Service Ver. 1.0 Mar. 2005 3. Periodical check A. Conditions for Life Specifications Values • The life specification values represent the number of copies made or figures equivalent to it when given conditions (see the Table given below) are met. They can be more or less depending on the machine operating conditions of each individual user.
Page 51: Maintenance Procedure (Periodical Check Parts)
3. Periodical check Field Service Ver. 1.0 Mar. 2005 Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol. 3.5.1 Replacing the Tray 1 Paper Take-up Roller 1. Slide out the Tray 1. 2.
Page 52: Replacing The Bypass Tray Paper Take-Up Roller
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 3. Take off the rubber stopper [3], shaft [4], spring [5], and guide plate [6] to remove the Paper Separation Roller fixing bracket Assy [7]. 4037F2C508DA 4. Snap off the E-ring [8] and the Tray 1 Paper Separation Roller Assy [9].
Page 53 3. Periodical check Field Service Ver. 1.0 Mar. 2005 4. Remove five screws [5], and remove the Frame [6] under the Bypass Unit. 4037F2C518DA 5. Snap off the C-clip [7], and remove the Bypass Paper Feed Clutch [8]. 6. Snap off the C-clip [9] for the Paper Take-up roller, and remove the shaft [10].
Page 54: Replacing The Bypass Tray Separation Roller Assy
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 3.5.4 Replacing the Bypass Tray Separation Roller Assy 1. Remove the Multi Bypass Unit. ☞ 76 2. Remove two screws [1], and remove Bypass Paper Separation Roller fix- ing bracket Assy [2]. 4037F2C515DA 3.
Page 55 3. Periodical check Field Service Ver. 1.0 Mar. 2005 6. Remove two Screws [5], and remove the Jam processing cover [6]. 4037F2C004DA 7. Remove two Screws [7] and the Tray 2 Separation Roller installation plate Assy [8]. 4036fs2021c1 8. Remove two C-rings [9] and the Shaft [10], and remove the Separa- [11] tion Roller fixing plate Assy [11].
Page 56: Replacing The Tray 2 Paper Take-Up Roller
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 3.5.6 Replacing the Tray 2 Paper Take-up Roller 1. Remove the Tray 2 Separation Roller installation plate Assy. ☞ See the procedures 1 to 7 in page 17 “Tray 2 Separation Roller.” 2.
Page 57 3. Periodical check Field Service Ver. 1.0 Mar. 2005 6. Remove the C-ring [10] and Bushing [11] [11]. [10] 4036fs2027c0 7. Remove the C-ring [13] and Gear [14] while sliding out the Shaft Assy [12] in the direction indicated in left figure.
Page 58: Replacing The Tray 2 Pick-Up Roller
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 10. Remove the C-ring [21] and Tray 2 [21] Paper Take-up Roller [22]. 11. Select “Service Mode” → “Counter” → “Life” and clear the count of “2nd.” [22] 4036fs2596c0 3.5.7 Replacing the Tray 2 Pick-up Roller 1.
Page 59: Cleaning Of Registration Roller
3. Periodical check Field Service Ver. 1.0 Mar. 2005 5. Remove two Screws [8] and Tray 2 Paper Take-up Roller cover [9]. 4037F2C006DB 6. Remove two C-rings [10] and two [10] Bushings [11], and remove the Tray [12] 2 Pick-up Roller Assy [12]. [11] [11] 4036fs2597c1...
Page 60: Paper Dust Remover
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 3.5.9 Paper Dust Remover A. Cleaning Procedure 1. Open the Right Door. 2. Pushing the hook [1] with a blue label inward, remove the Paper Dust Remover [2]. 4036fs2501c0 3. Using a brush, whisk dust off the Paper Dust Remover [3].
Page 61: Cleaning Of 2Nd Image Transfer Entrance Upper Guide
3. Periodical check Field Service Ver. 1.0 Mar. 2005 3.5.11 Cleaning of 2nd Image Transfer Entrance Upper Guide 1. Open the Right Door. 2. Open the Left Door. 3. Remove the Waste Toner Box. ☞ 36 4. Remove two screws and slide the Transfer Belt Unit out halfway.
Page 62: Cleaning Of The Area Around The Waste Toner Collecting Port
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 5. Clean the surface around the waste toner collecting port. 6. Remove the waste toner box from its box, and remove the packing mate- rial. 7. Grasp the handle, and set the waste toner box in place.
Page 63: Cleaning Of The Comb Electrode
3. Periodical check Field Service Ver. 1.0 Mar. 2005 3.5.15 Cleaning of the Comb Electrode 1. Open the Front Door. 2. Clean the Comb Electrode by mov- ing the Comb Electrode Cleaning Lever [1] In and Out several times. NOTE •...
Page 64: Replacement Of The Deodorant Filter
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 3.5.17 Replacement of the Deodorant Filter 1. Holding onto the hook, take out the Deodorant Filter [1]. NOTE • The Deodorant Filter is supplied with the toner cartridge (black). Replace it when replacing the toner cartridge (black).
Page 65: Image Transfer Belt Unit
3. Periodical check Field Service Ver. 1.0 Mar. 2005 B. Reinstallation Procedure 1. Holding onto the blue lock levers [1] (at two places), mount the 2nd Image Transfer Roller Unit [2]. 2. Lock the blue lock levers [1](at two places). 3.
Page 66 Field Service Ver. 1.0 Mar. 2005 3. Periodical check B. Replacing Procedure NOTE • If a Finishing Option is installed, remove if from the main unit before trying to replace the Transfer Belt Assembly. • When removing the Finishing Option, support the horizontal transport unit with your hand to prevent if from dropping.
Page 67 3. Periodical check Field Service Ver. 1.0 Mar. 2005 7. Pull out the Image Transfer Belt Unit [4]. 4037F2C527DA C. Reinstallation Procedure 1. Insert the Transfer Belt Unit [1]. NOTE • Insert the Transfer Belt Unit with care not to allow its docking gear to be damaged by hitting it against the rail or associated part.
Page 68: Replacing The Imaging Unit (C, M, Y, K)
Field Service Ver. 1.0 Mar. 2005 3. Periodical check 3. Hold the handle and install the Waste Toner Box [3] in position. 4. Close the Left Door. 5. Close the Right Door. NOTE • Make sure that the door is locked in position both at front and rear.
Page 69 3. Periodical check Field Service Ver. 1.0 Mar. 2005 B. Reinstallation Procedure 1. Remove the Imaging Unit from its plastic bag. 2. Tilt the Imaging Unit [1] to the left and shake it a small stroke in the tilt direction twice. Then, tilt it to the right and shake it a small stroke in the tilt direction twice.
Page 70 Field Service Ver. 1.0 Mar. 2005 3. Periodical check 4. Pull out the PC Drum protective sheet [3] while pressing the IU. NOTE • Pull out the PC Drum protective sheet half way, and pull it down slantwise. 4036fs2582c0 5. Close the Imaging Unit Locking Lever [4] while pressing the IU.
Page 71: Replacing The Fusing Unit
3. Periodical check Field Service Ver. 1.0 Mar. 2005 3.6.4 Replacing the Fusing Unit NOTE • Before replacing the Fusing Unit, ensure that it has had time to cool down. 1. Turn OFF the main power switch and unplug the power cord from the power outlet, then wait for about 20 minutes.
Page 72: Service Tool
Field Service Ver. 1.0 Mar. 2005 4. Service tool Service tool CE Tool list Tool name Shape Parts No. Personnel Remarks Scanner Drive Cable 4581-7901-XX Holding Jig 4036fs2001c0 LED Cleaning Jig 4004-7502-XX 4036fs2002c0 LED Cleaning Jig Pad 4004-7503-XX 4036fs2003c0 LPH Assy Mounting Jigs 4025-7901-XX 4036fs2004c0 ⎯...
Page 73: Copy Materials
4. Service tool Field Service Ver. 1.0 Mar. 2005 Copy materials 4.2.1 Imaging Unit Single Parts (IU) Also replace the Dust filter packed in the Imaging Unit Black at the same time. Parts name Replacing period IU Black 100,000 copies IU Yellow 50,000 copies IU Magenta...
Page 74: Firmware Upgrade
Field Service Ver. 1.0 Mar. 2005 5. Firmware upgrade Firmware upgrade Preparations for Firmware rewriting 5.1.1 Service environment • OS: Windows 2000 • Drive which enables writing/reading of Compact flash • Compact flash (with 128MB or more) 5.1.2 Application to be used •...
Page 75 5. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 4. Specify the folder for installation. Check to make sure that “Root Directory” is in default setting, [C:\cygwin]. NOTE • Make sure to check that “Root Directory” is in default setting, [C:\cygwin]. •...
Page 76 Field Service Ver. 1.0 Mar. 2005 5. Firmware upgrade 8. Click [Next (N)]. 4037F2E549DA 9. Click [Complete] to start installing. 4037F2E550DA 10. After installing, open the Property of “My Computer”, and click the “Environmental Vari- able” of “Advanced” tab. 11. Click the “New” in System Variable Setting. 4036fs2620e0...
Page 77 5. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 12. Set the following two values as the Windows Environmental Variable. Variable name Variable value CYGWIN ntsec HOME /home/username 4036fs2621e0...
Page 78: Writing Into The Compact Flash
Field Service Ver. 1.0 Mar. 2005 5. Firmware upgrade 5.1.4 Writing into the Compact flash 1. Put the data of Firmware in the optional directory. (C:\C450 in the below figure) 4037F2E541DA NOTE • The file name of Firmware data consists of the “Release Date_Version_CHECKSUM-****.exe.”...
Page 79 5. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 3. Mount the Compact flash on the PC, and check the Drive name, which was recognized in the Windows. (F-drive in the following figure) 4036fs2623e0 → → → 4. Click “Start” “Program”...
Page 80 Field Service Ver. 1.0 Mar. 2005 5. Firmware upgrade 7. Once the “mkcf.bat” is executed, data writing into the Compact flash is started. 8. Upon completion of writing, CHECKSUM is executed. If CHECKSUM value is precisely matched, “VERIFY OK” appears. 4037F2E544DA 9.
Page 81: Firmware Rewriting
5. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 Firmware rewriting • The F/W is updated using the Compact flash. 5.2.1 Updating method NOTE • NEVER remove or insert the Compact Flash card with the machine power turned 1. With the main power switch in the OFF position, unplug the power cord from the power outlet.
Page 82: Action When Data Transfer Fails
Field Service Ver. 1.0 Mar. 2005 5. Firmware upgrade 7. Press the Start key. (At this time, the Start key starts blinking red.) 8. Check that the Touch Panel shows the message indicating that the data has been rewritten correctly (“Downloading Completed”). Check also the Check Sum value (“Check Sum XXXX”) shown on the Touch Panel.
Page 83: Other
6. Other Field Service Ver. 1.0 Mar. 2005 Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
Page 84: Disassembly/Assembly/Cleaning List (Other Parts)
Field Service Ver. 1.0 Mar. 2005 6. Other Disassembly/Assembly/Cleaning list (Other parts) 6.2.1 Disassembly/Assembly parts list Section Part name Ref.Page ☞ Original Glass ☞ IR Upper Right Cover ☞ Control Panel ☞ IR Front Cover ☞ IR Upper Front Cover ☞...
Page 85 6. Other Field Service Ver. 1.0 Mar. 2005 Section Part name Ref.Page ☞ Scanner Motor Drive Board ☞ CCD Unit ☞ Image Processing Board ☞ Copier Board ☞ LAN Board ☞ Standard Memory ☞ Hard Disk Drive ☞ Board and etc. Electronic Sorting Board ☞...
Page 86: Cleaning Parts List
Field Service Ver. 1.0 Mar. 2005 6. Other Section Part name Ref.Page ☞ PWB Unit ☞ PWB Box ☞ Main Motor ☞ Fusing Drive Motor ☞ Toner Supply Motor C/K ☞ Toner Supply Motor Y/M ☞ Tray 2 Lift-Up Motor ☞...
Page 87: Disassembly/Assembly Procedure
6. Other Field Service Ver. 1.0 Mar. 2005 Disassembly/Assembly procedure 6.3.1 IR Right Cover/Front Right Cover/Bypass Right & Left Cover 4037F2C018DB 1. Remove four Screws [1], and remove the IR Right Cover [2]. 2. Remove the Panel Cover. ☞ 52 3.
Page 88: Exit Tray/Ir Left Cover/Rear Left Cover/Left Front Cover
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.2 Exit Tray/IR Left Cover/Rear Left Cover/Left Front Cover 4037F2C019DB 1. Open the Front Door [1]. 2. Remove two Screws [2], and remove the Exit Tray [3]. 3. Remove four Screws [4], and remove the IR Left Cover [5]. 4.
Page 89: Front Door/Panel Cover/Tray 1 Front Right Cover
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.3 Front Door/Panel Cover/Tray 1 Front Right Cover 4037F2C022DB 1. Open the Front Door [1]. 2. Remove the Screw [2], and remove the Panel Cover [3]. 3. Pick up the Front Door [1] and remove it. 4.
Page 90: Ir Upper Front Cover/Ir Upper Right Cover/Ir Upper Rear Cover
Field Service Ver. 1.0 Mar. 2005 6. Other [12] [10] [11] [13] [11] 4037F2C024DB 5. Remove four Screws [9], and remove the Rear Cover [10]. 6. Remove four Screws [11]. 7. Open the Right Door [12], and remove the Rear Right Cover [13]. 6.3.5 IR Upper Front Cover/IR Upper Right Cover/IR Upper Rear Cover 4037F2C025DB...
Page 91: Original Glass/Ir Front Cover
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.6 Original Glass/IR Front Cover 4037F2C026DB 1. Remove the IR Upper Right Cover. ☞ 53 2. Remove each Screw [1], and remove the Original Glass fixing bracket (near side/ inmost side) [2]. 3.
Page 92: Control Panel (Un201)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.7 Control Panel (UN201) 1. Remove four caps [1] at both ends of Control Panel. 4037F2C027DB 2. Remove four Screws [2]. 4037F2C028DB...
Page 93: Tray 1
6. Other Field Service Ver. 1.0 Mar. 2005 3. Remove the Flat Cable [3]. 4. Remove the Control Panel [4]. 4037F2C029DA 6.3.8 Tray 1 1. Slide out the Tray 1 [1]. 4036fs163c0 2. Slide out the Tray 1 [3] while press- ing the Slide Locks [2] at both ends.
Page 94: Tray 2
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.9 Tray 2 1. Slide out the Tray 2 [1]. 4036fs165c0 2. Remove one Screw [2], and remove the Stopper [3]. 3. Slide out the Tray 2 while pressing the Slide Locks [4]. 4037F2C031DB 6.3.10 Scanner Motor Drive Board (PWB-IC)
Page 95: Ccd Unit
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.11 CCD Unit A. Removal Procedure 1. Remove the Original Glass. ☞ 54 2. Remove seven Screws [1], and remove the CCD Unit Cover [2]. 4037F2C009DA 3. Remove four Screws [3] and Flat Cable [4], and remove the CCD Unit [5].
Page 96: Image Processing Board (Pwb-C)
Field Service Ver. 1.0 Mar. 2005 6. Other 4. Carry out the Cross Direction Adjustment. If the specifications are not met, loosen the CCD Unit mounting screws and move the CCD Unit in the sub scan direction as neces- sary. ☞...
Page 97 6. Other Field Service Ver. 1.0 Mar. 2005 6. Remove two connectors [7]. 4037F2C037DA 7. Remove all the Connectors and Flat Cables on the Image Processing Board [8]. 4037F2C038DA 8. Remove six Screws [9] and two Bolts [10], and remove the Image Process- ing Board [11].
Page 98: Copier Board (Pwb-Cf)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.13 Copier Board (PWB-CF) 1. Remove the right rear cover ☞ 52 2. Remove the connector [1]. 4037F2C040DA 3. Loosen two screws [2], and pull out the Copier Board Assy [3]. 4037F2C041DA 4.
Page 99: Lan Board (Pwb-Lan)
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.14 LAN Board (PWB-LAN) 1. Remove the PWB Unit. ☞ 92 2. Pull out the Copier Board. 3. Remove four screws [1] and two hex- head screws [2]. Remove the Inter- face Cover [3]. 4037F2C043DA 4.
Page 100: Standard Memory (D_File0)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.15 Standard Memory (D_FILE0) 1. Remove the PWB Unit. ☞ 92 2. Remove two Standard memories [1]. 4037F2C538DA 6.3.16 Hard Disk Drive (HDD) 1. Remove the PWB Unit. ☞ 92 2. Remove four screws [1]. 4037F2C539DA 3.
Page 101: Electronic Sorting Board (Pwb-Es)
6. Other Field Service Ver. 1.0 Mar. 2005 4. Remove four screws [4] and the Flat cable [5]. Remove the Hard Disk Drive [6]. NOTE • When the Hard Disk is replaced, select “State Confirmation” → “Memory/HDD Adj.” → “HDD For- mat”...
Page 102: Mfp Control Board (Pwb-Mfpc)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.18 MFP Control Board (PWB-MFPC) 1. Remove the PWB Unit. ☞ 92 2. Remove the Electronic sorting Board. ☞ 64 3. Remove the work memory [1] on the MFP Control Board. 4037F2C049DA 4.
Page 103: Control Board (Pwb-Mc)
6. Other Field Service Ver. 1.0 Mar. 2005 6. Remove three Interface connectors [5] and the MFP Control Board [6]. Note on replacing the MFP Control Board • When the MFP Control Board is replaced, mount the removed Backup RAM to the new MFP Con- trol Board.
Page 104: Slide Interface Board (Pwb-Sif)
Field Service Ver. 1.0 Mar. 2005 6. Other Cautions in replacing the Control Board: • When Control Board (PWB-MC) is replaced, relocate the Parameter Chip (IC40). Mount the Parameter Chip (IC40) of old Control Board onto the new Control Board. 4037F2C053DB NOTE •...
Page 105 6. Other Field Service Ver. 1.0 Mar. 2005 3. Remove four screws [3] and the cover [4]. 4037F2C055DA 4. Remove fifteen screws [5] and the Control Board Assy [6]. 4037F2C056DA 5. Remove seven screws [7] and the Flat cable [8]. Remove the Slide Interface Board [9].
Page 106: High Voltage Unit/1 (Hv1)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.21 High Voltage Unit/1 (HV1) 1. Remove the PWB Box. ☞ 93 2. Remove four Screws [1] and eight Connectors [2], and remove two Har- ness Holder [3]. 4037F2C058DA 3. Remove all the Connectors on the High Voltage Unit/1 [4].
Page 107: High Voltage Unit/2 (Hv2)
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.22 High Voltage Unit/2 (HV2) 1. Remove the PWB Box. ☞ 93 2. Remove all the Connectors on the High Voltage Unit/2 [1]. 4037F2C059DA 3. Remove two Screws [2], and remove the High Voltage Unit/2 Assy [3]. 4037F2C060DA 4.
Page 108: Tray 1 Paper Size Board (Pwb-I1)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.23 Tray 1 Paper Size Board (PWB-I1) 1. Slide out the Tray 1. 2. Remove the PWB Box. ☞ 93 3. Remove the Connector [1] on the High Voltage Unit/2. 4. Remove two Screws [2] and Connec- tor [3], and remove the Tray 1 Paper Size Board Assy [4].
Page 109 6. Other Field Service Ver. 1.0 Mar. 2005 3. Remove the Harness from thirteen wire saddles. 4. Unplug all connectors from the DC Power Supply. 4036fs2074c1 5. Remove seven Screws [3], and remove the DC Power Supply Assy [4]. 4036fs2075c1 6.
Page 110: Led Drive Board (Pwb-Led)
Field Service Ver. 1.0 Mar. 2005 6. Other 7. Remove 12 Screws [7], and remove the DC power Supply [8]. 4036fs2077c1 6.3.25 LED Drive Board (PWB-LED) 1. Remove the LPH Unit. ☞ 79 2. Remove two screws [1], unplug the connector [2] each, and remove each guide Assy.
Page 111: Tray 2 Board (Pwb-Z)
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.26 Tray 2 Board (PWB-Z) 1. Remove the Tray 2 Rear Cover. ☞ 52 2. Remove all the Connectors on the Tray 2 Board. 4037F2C061DA 3. Remove four Screws [1], and remove the Tray 2 Board [2].
Page 112: Inverter Board (Pu201)
Field Service Ver. 1.0 Mar. 2005 6. Other 5. Remove two Claws [5] and Connec- tor [6], and remove the Tray 2 Paper Size Board Assy [7]. 4037F2C063DA 6. Remove the Lever [8], and remove the Tray 2 Paper Size Board [9]. 4037F2C533DA 6.3.28 Inverter Board (PU201)
Page 113: Multi Bypass Unit
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.29 Multi Bypass Unit 1. Remove two Screws [1], and remove the Tray 2 Rear Right Cover [2]. 4036fs2078c1 2. Remove three Connectors [3]. 4036fs2079c1 3. Remove the Screw [4], and remove the Bypass Left Cover [5].
Page 114: Toner Hopper Unit
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.30 Toner Hopper Unit 1. Open the Front Door. 2. Remove the Toner Cartridge (C, M, Y, K). 3. Remove the IU (C, M, Y, K). NOTE • After the Imaging Unit has been removed from the main unit wrap it in the light shielding cloth and store it in a dark place.
Page 115 6. Other Field Service Ver. 1.0 Mar. 2005 8. Disconnect five connectors [6]. 4037F2C066DA 9. Remove five screws [7] and the Toner Hopper Unit [8]. 4036fs2086c2...
Page 116: Lph Unit
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.31 LPH Unit 1. Open the Front Door. 2. Slide out the IU (C, M, Y, K). NOTE • After the IU has been pulled out, place the IU lock lever back into the locked posi- tion.
Page 117 6. Other Field Service Ver. 1.0 Mar. 2005 8. Remove five Connectors [5] on the Control Board. 4037F2C069DB 9. Remove the harness from three wire saddles [6]. 4037F2C070DA 10. Remove the Screw [7] and Connec- tor [8]. 4037F2C071DA...
Page 118 Field Service Ver. 1.0 Mar. 2005 6. Other 11. Remove the Connector [9]. 4037F2C072DA 12. Turning the IU (C, M, Y, K) drive hub [10], push it into the locked position (at four places). NOTE [10] • During the locking procedure, use care not to touch the LED surface.
Page 119: Scanner Motor (M201)
6. Other Field Service Ver. 1.0 Mar. 2005 NOTE • After replacing the LPH Unit, be sure to turn four Drive Hubs [13] to release locking. Proceeding with [13] job while still being locked may unintentionally release the locking condition, thus damaging the Drive hub.
Page 120 Field Service Ver. 1.0 Mar. 2005 6. Other 6. Remove three screws [4] and the Scanner Motor Assy [5]. 4036fs2523c0 7. Remove two screws [6], set screw [7], damper [8] and the Scanner Motor [9]. 4036fs2524c1 B. Reinstallation Procedure 1. Temporarily secure the Scanner Motor Assy [2] using three screws [1].
Page 121: Scanner Assy
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.33 Scanner Assy 1. Remove the Original Glass. ☞ 54 2. Move the Scanner Assy [1] to the location shown and remove one mounting screw each at the front and rear end. 4037F2C077DA NOTE •...
Page 122: Scanner Drive Cables
Field Service Ver. 1.0 Mar. 2005 6. Other 4. Remove the screw [4] and the holder [5]. 5. Remove the flat cable [6]. 6. Remove the Scanner Assy [7]. 4037F2C078DA 6.3.34 Scanner Drive Cables A. Removal Procedure 1. Remove the Rear Cover. ☞...
Page 123 6. Other Field Service Ver. 1.0 Mar. 2005 9. Remove the Scanner Motor Assy. ☞ 82 10. Remove the screw [4] and then slide the front pulley [5] toward the front. 4036fs2548c0 11. Remove the Screw [6], and slide the Wire Pulley [7] (Rear side) in the direction of front side.
Page 124: Winding Of The Scanner Drive Cables
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.35 Winding of the Scanner Drive Cables <Overall figure> 4036fs2553c0 A. Reinstallation Procedure <Front> 1. Position the round bead [1] of the Scanner Drive Cable in the pulley [2] as shown. NOTE •...
Page 125 6. Other Field Service Ver. 1.0 Mar. 2005 3. Wind the hook end of the cable around the pulley five turns counter- clockwise, from the front toward the rear side. NOTE • Make sure that no part of the cable rides on the other.
Page 126 Field Service Ver. 1.0 Mar. 2005 6. Other 8. Slip the Cable Holding Jig [6] onto the pulley to secure the cable in posi- tion. 4036fs2561c0 9. Install the front and rear pulleys [7] and bushings [8] onto the shaft [9] and fit the C-clip [10].
Page 127 6. Other Field Service Ver. 1.0 Mar. 2005 NOTE [17] [18] • Mount the Screw [16] in the direc- tion that is opposite against the direction for which Scanner Drive Gear [17] and Screw [18] are screwed together as shown in the left figure.
Page 128 Field Service Ver. 1.0 Mar. 2005 6. Other <Rear> [29] 17. Wind the bead end of the cable [29] around pulley F [30] and pulley E [32] [31] [31], then hook the bead [32] onto the Adjustable Anchor [33]. [30] [33] 4036fs2568c0 18.
Page 129: Pwb Unit
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.36 PWB Unit 1. Remove the Right Rear Cover. ☞ 52 2. Disconnect the connector [1]. 4037F2C040DA 3. Remove eight screws [2]. 4037F2C079DB 4. Remove the PWB Unit [3]. 4037F2C080DA...
Page 130: Pwb Box
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.37 PWB Box 1. Remove the Ozone filter. ☞ 25 2. Remove the Rear Cover, Lower Rear Cover, Right Rear Cover, Left Rear Cover, and IR Left Cover. ☞ 50 3. Remove two screws [1] and the lat- tice connector fixing bracket [2].
Page 131 6. Other Field Service Ver. 1.0 Mar. 2005 7. Remove the Harness from fourteen wire saddles [7]. 4037F2C082DB 8. Remove two connectors [8]. 4037F2C083DB 9. Remove the connector set screw [9]. 4037F2C084DA...
Page 132 Field Service Ver. 1.0 Mar. 2005 6. Other 10. Remove six connectors [11] con- nected to the Slide Interface Board [10]. [11] [10] 4037F2C085DA 11. Remove the connector [12]. [12] 4037F2C086DA 12. Remove eleven screws [13]. [13] [13] [13] 4037F2C087DC...
Page 133: Main Motor (M1)
6. Other Field Service Ver. 1.0 Mar. 2005 13. Remove two claws [14] and the Board Box [15]. [15] [14] [14] 4037F2C088DB 6.3.38 Main Motor (M1) 1. Remove the PWB Box. ☞ 93 2. Remove the Connector [1] and three Screws [2], and remove the Main Motor [3].
Page 134: Toner Supply Motor C/K (M3)
Field Service Ver. 1.0 Mar. 2005 6. Other 4. Remove two connectors [5], and remove the Harness from three wire saddles [6]. 5. Remove two shoulder screws [7] and the Fan Motor Assy[8]. 4037F2C091DA 6. Remove four Screws [9] and Con- nector [10], and remove the Fusing Drive Motor [11].
Page 135: Toner Supply Motor Y/M (M4)
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.41 Toner Supply Motor Y/M (M4) 1. Remove the Toner Hopper. ☞ 77 2. Remove the screw [1] and the gear [2]. 4036fs2529c1 3. Remove the Connector [3]. 4036fs2105c0 4. Remove two screws [4]. Then, turn the Toner Replenishing Motor Y/M [5] counterclockwise and take it off the machine.
Page 136: Tray 2 Paper Feed Motor (M102)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.43 Tray 2 Paper Feed Motor (M102) 1. Pull out the Tray 2. 2. Remove the Tray 2 Rear Cover. ☞ 52 3. Remove the Harness for the Motor Assy [2] from four wire saddles [1]. 4.
Page 137: Tray 2 Vertical Transport Motor (M103)
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.44 Tray 2 Vertical Transport Motor (M103) 1. Pull out the Tray 2. 2. Remove the Tray 2 Rear Cover. ☞ 52 3. Remove the Harness Assy [2] from four wire saddles [1]. 4.
Page 138: Color Pc Drum Motor (M5)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.45 Color PC Drum Motor (M5) 1. Remove the PWB Box. ☞ 93 2. Remove four Connectors [1] on the High Voltage Unit/1. 3. Remove two Screws [2], and remove the Harness Holder [3]. 4037F2C089DA 4.
Page 139 6. Other Field Service Ver. 1.0 Mar. 2005 Cautions when mounting the Color PC Drum Motor: • Before mounting the Color PC Drum Motor, be sure to check the assembled posi- tion of PC Gear. If its position is improper, make positioning adjustment. A.
Page 140: Color Developing Motor (M6)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.46 Color Developing Motor (M6) 1. Remove the PWB Box. ☞ 93 2. Remove eight Connectors [1] on the High Voltage Unit/1. 3. Remove two Screws [2], and remove the Harness Holder [3]. 4037F2C099DA 4.
Page 141: K Pc Motor (M7)
6. Other Field Service Ver. 1.0 Mar. 2005 B. Adjusting method 1. Remove seven Screws and the Upper Frame Assy. 2. Turn the PC Gear/3 [1], and fit the hole C [2] with the PC Gear/3 [1] hole while visually checking. 3.
Page 142: 1St Image Transfer Pressure/Retraction Motor (M11)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.48 1st Image Transfer Pressure/Retraction Motor (M11) 1. Remove the PWB Box. ☞ 93 2. Remove two connectors [1], and remove the Harness from two wire saddles [2]. 3. Remove three screws [3] and the Fan Motor Assy/1 [4].
Page 143: 2Nd Image Transfer Pressure/Retraction Motor (M13)
6. Other Field Service Ver. 1.0 Mar. 2005 6.3.49 2nd Image Transfer Pressure/Retraction Motor (M13) 1. Open the Right Door. 2. Unlock the tab and remove the Transport Unit Assy [1]. 4037F2C510DA 3. Remove four screws [2], unplug the connector [3], and remove the gear Assy [4] and motor Assy [5].
Page 144: Intermediate Transport Motor (M14)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.50 Intermediate Transport Motor (M14) 1. Open the Right Door. 2. Remove the Lock claw to make free conditions of Transport section Assy [1]. 4037F2C510DA 3. Remove six Connectors [3] and Earth [4], and remove the Transport section Assy [5].
Page 145 6. Other Field Service Ver. 1.0 Mar. 2005 6. Remove the C-ring [10], and remove the Gear 2 [11]. [10] [11] 4036fs2116c0 7. Remove the C-ring [12], and remove the Gear 3 [13]. [13] [12] 4036fs2117c0 8. Remove two Screws [14], and remove the Mounting plate [15].
Page 146: Fusing Pressure Roller Pressure/Retraction Motor (M19)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.3.51 Fusing Pressure Roller Pressure/Retraction Motor (M19) 1. Remove the PWB Box. ☞ 93 2. Remove two connectors [1], and remove the Harness from two wire saddles [2]. 3. Remove three screws [3] and the Fan Motor Assy/1 [4].
Page 147 6. Other Field Service Ver. 1.0 Mar. 2005 11. Remove four Screws [10]. [10] [10] 4036fs2124c1 12. Remove six Connectors [11]. [11] [11] [11] 4036fs2123c1 13. Remove the Gear [12]. [12] 4036fs2125c1...
Page 148 Field Service Ver. 1.0 Mar. 2005 6. Other 14. Remove the E-ring [13], and remove the Gear [14]. [14] NOTE • Use care not to miss the Shaft. [13] 4036fs2126c1 15. Remove the Screw [15], and remove the Wire Rail [16]. [15] NOTE •...
Page 149: Cleaning Brush Motor (M22)
6. Other Field Service Ver. 1.0 Mar. 2005 19. Remove two E-rings [22], and remove the Cover [23]. [23] [22] 4036fs2131c1 20. Remove the E-ring [24], and remove the Gear [25]. [24] [25] 4036fs2132c1 21. Remove the two Screws [26], and remove the Fusing Pressure Roller [27] Pressure/Retraction Motor [27].
Page 150 Field Service Ver. 1.0 Mar. 2005 6. Other 3. Remove four screws [3] and the wir- ing guide plate [4]. 4037F2C104DA 4. Remove the connector [5]. 4037F2C105DA 5. Remove two Screws [6], and remove the Harness Holder [7]. 4037F2C106DA...
Page 151: Idc/Registration Sensor/1,2 (Pc8/Pc9)
6. Other Field Service Ver. 1.0 Mar. 2005 6. Remove four Screws [8], and remove the Cleaning Brush Motor [9]. 4037F2C107DA 6.3.53 IDC/Registration Sensor/1,2 (PC8/PC9) 1. Open the Front Door. 2. Remove the Panel Cover. ☞ 52 3. Remove two Screws [1], and remove the Front Right Cover [2].
Page 152: Lph
Field Service Ver. 1.0 Mar. 2005 6. Other 7. Remove three Screws [6] and Con- nector [7], and remove the IDC/Reg- istration Sensor/1 [8]. 4037F2C110DA 8. Remove two Screws [9] and Connec- tor [10], and remove the IDC/Regis- tration Sensor/2 [11]. NOTE [10] •...
Page 153 6. Other Field Service Ver. 1.0 Mar. 2005 3. Remove the three LPH mounting screws [3]. 4036fs2628c0 4. Peel off the seal [4], unlock [5] the LPH Assy, and remove the flat cable [6]. 5. Remove the LPH [7]. 6. Perform the same procedure for each of different colors of LPH.
Page 154 Field Service Ver. 1.0 Mar. 2005 6. Other 1. Insert the flat cable [2] into the LPH [1] and lock the LPH [1]. 2. Affix the seal [3] that comes with the LPH Assy to the location shown on the left. NOTE •...
Page 155 6. Other Field Service Ver. 1.0 Mar. 2005 5. Align the markings [9] on the flat <LPH C/Bk> cable with the positions shown in the photo. 6. Install the Guide. NOTE • Make sure that no part of the flat cable is wedged in mechanisms or bent.
Page 156: Tcr Sensor Y/M/C (Pwb-N1/-N2/-N3)
Field Service Ver. 1.0 Mar. 2005 6. Other 11. Press the LPH Assy [16] down into the locked position. NOTE → • Select “Service Mode” → “Machine” “LPH Rank” and change the value of “LPH Rank” to [16] “1”. • When the LPH Unit has been rein- stalled, be sure to run “Stabilizer”...
Page 157: Cleaning Procedure
6. Other Field Service Ver. 1.0 Mar. 2005 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 6.4.1 Tray 1 Paper Take-up Roller 1. Slide out the Tray 1. 2. Using a soft cloth dampened with alcohol, wipe the Tray 1 Paper Take- Up Roller [1] clean of dirt.
Page 158: Bypass Tray Paper Take-Up Roller
Field Service Ver. 1.0 Mar. 2005 6. Other 6.4.3 Bypass Tray Paper Take-up Roller 1. Remove the Multi Bypass Unit. ☞ 76 2. Remove two screws [1], and remove the Bypass Paper Separation Roller fixing bracket Assy [2]. 4037F2C515DA 3. Using a soft cloth dampened with alcohol, wipe the Bypass Paper Take-up Roller [3].
Page 159: Tray 2 Paper Take-Up Roller
6. Other Field Service Ver. 1.0 Mar. 2005 3. Using the soft cloth dampened with alcohol, wipe the Bypass Paper Sep- aration Roller [3]. 4037F2C521DA 6.4.5 Tray 2 Paper Take-up Roller 1. Remove the Tray 2 Separation Roller installation plate Assy. ☞...
Page 160 Field Service Ver. 1.0 Mar. 2005 6. Other 4. Open the Vertical transport door. 5. Remove two Claws [3] and the Verti- cal transport door [4]. 4036fs2019c0 6. Remove two Screws [5], and remove the Jam processing cover [6]. 4037F2C004DA 7.
Page 161: Tray 2 Transport Roller
6. Other Field Service Ver. 1.0 Mar. 2005 6.4.8 Tray 2 Transport Roller 1. Open the Vertical transport door. 2. Using a soft cloth dampened with alcohol, wipe the Tray 2 Transport Roller [1]. 4036fs2033c1 6.4.9 Scanner Rail 1. Remove three screws [1] and the IR Upper Right Cover [2].
Page 162: Mirrors (1St/2Nd/3Rd)
Field Service Ver. 1.0 Mar. 2005 6. Other 6.4.10 Mirrors (1st/2nd/3rd) 1. Remove the Original Glass. ☞ 54 2. Using a soft cloth dampened with alcohol, wipe the Mirror 1 [1] and Mirror 2/3 [2]. 4036fs2507c0 6.4.11 Lens 1. Remove the Original Glass. ☞...
Page 163: Original Glass
6. Other Field Service Ver. 1.0 Mar. 2005 6.4.12 Original Glass 1. Using a soft cloth dampened with alcohol, wipe the Original Glass [1] clean of dirt. 4036fs2508c0 6.4.13 CCD Sensor 1. Remove the Original Glass. ☞ 54 2. Remove seven Screws [1] and CCD Unit protective cover [2].
Page 164: Mount The Original Size Detecting Sensor Fd2 (Pc204)
Field Service Ver. 1.0 Mar. 2005 6. Other Mount the original size detecting sensor FD2 (PC204) 1. Remove the Original glass. 2. Using the screw [2], mount the Origi- nal Size Detection Sensor FD2 (PC204) [1] and fix it. 4037F2C113DB <How to set the Harness>...
Page 165 6. Other Field Service Ver. 1.0 Mar. 2005 3. Select Service Mode -> System 1 -> Original Size Detection, and set the Original Glass to “Table2.” 4037F2E530DA 4. Select “Service Mode” → “Machine” → “Org. Size Detecting Sensor Adj.” ☞ 225 5.
Page 166: Option Counter
Field Service Ver. 1.0 Mar. 2005 6. Other Option counter 6.6.1 Installation of The Counter/K 1. Open the Front Door. 2. Remove the Panel Cover. ☞ 52 3. Remove the Screw [1], and remove the Front Right Cover [2]. 4036fs2571c0 4.
Page 167: Installation Method For The Key Counter
6. Other Field Service Ver. 1.0 Mar. 2005 7. Secure the Counter/K [11] with the screw [10]. [11] [10] 4036fs2575c0 8. Mount the Connector [12] of [12] [13] Counter/K on the Relay Connector [13] at main body side. 4036fs2576c0 6.6.2 Installation method for the Key Counter 1.
Page 168 Field Service Ver. 1.0 Mar. 2005 6. Other 7. Using four screws [9], secure the Counter Mounting Bracket [8]. NOTE • Secure the Counter Mounting Bracket passing the connector into the bracket. • Use the four long screws (9646- 0418-14: M4x18) in the Key Counter 4036fs2587c1 Kit to secure the Counter Mounting Bracket.
Page 169 6. Other Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 170: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 7. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting,” the default settings are indicated by “ ”. A.
Page 171: Utility Mode
8. Utility Mode Field Service Ver. 1.0 Mar. 2005 Utility Mode Touch Panel Adj. Functions • To adjust the position of the Touch Panel display • Make this adjustment if the Touch Panel is slow to respond to a pressing action. •...
Page 172: Utility Mode Function Tree
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Utility Mode function tree * The function tree is shown to comply with the format displayed on the screen. NOTE • Keys displayed on screens are different depending on the setting. •...
Page 173 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 No Matching System Paper Tray User Setting Paper in Tray Setting Setting Setting Print Lists Reset System Auto Setting Reset Auto Reset When Job Reset Account is changed Auto Color When Origi- Level Adjust- nal is set on ment...
Page 174 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Scan Basic Display Address Book User Setting Screen Default Setting Default Index Seeing Address Type Symbol Dis- play Fax Basic Screen Default Tab Default Setting Default Pro- gram Address Book Default Index Address Type Symbol Dis- play...
Page 175 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 Auto Magnifi- Copier User Setting cation Selec- Setting tion (ADF)* Specify Default Tray when APS Off* Select Tray for Insert Sheet* Print Jobs During Copy Operation** Scanner JPEG Com- pression Level Setting Black Com- pression Level...
Page 176 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Printer Paper User Setting Hole-Punch Setting Setting PCL Setting Typeface Symbol Set Font Size Line/Page CR/LF Mapping PS Setting PS Error Print Configuration Print Reports Page Demo Page PCL Font List PS Font List Administrator System...
Page 177 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 Administrator System Weekly Weekly Timer ON/OFF Setting Setting Setting Timer Setting Time Setting Date Setting Select Time for Power Save Password for Non-Busi- ness Hours Restrict User Restrict Access to Access Saved Program Jobs Delete Saved Program Jobs...
Page 178 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Administrator System Expert Finisher Half-Fold Adjustment Setting Setting Adjustment Position Thick Paper Density Image Den- Adjustment sity–Yellow Thick Paper Image Den- sity–Magenta Thick Paper Image Den- sity–Cyan Thick Paper Image Image Den- Stabilization sity–Black Thin Paper...
Page 179 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 Administrator System Expert Scanner Vertical Setting Setting Adjustment Adjustment *** Adjustment *** ADF Adjust- Centering*** ment *** Original Stop Position*** Centering Auto Adjustment*** Auto Adj. of Stop Posi- tion*** Management Job Settings List/Counter List List...
Page 180 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Administrator One-Touch Program User Box Setting Registration Subject/Text Subject (for E-mail) Public/Per- User Box Text sonal User Box Bulletin Board User Box One-Touch Address Book Registration List List Group List Program List E-Mail Sub- ject/Text List User Authenti-...
Page 181 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 Administrator Network FTP Setting Setting Setting SMB Setting AppleTalk Setting LDAP Enabling Setting LDAP Setting Up LDAP E-Mail E-Mail TX Setting (SMTP) E-Mail RX (POP) Detail Device Setting Setting Time Adjust- ment Setting Notification Status Notifi-...
Page 182 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Select Tray Administrator Copier when APS Setting Setting Select Tray for Insert Sheet Print Jobs During Copy Operation Printer Local I/F Setting Timeout Parallel I/F IEEE 1284/ Header Infor- Fax Setting mation Header Header/Footer...
Page 183 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 Administrator TX/RX Print Paper Fax Setting Setting Setting Size Incorrect User Box No. Entry Tray Selection for RX Print Min. Reduction for RX Print Print Separate Fax Pages File After Poll- ing TX Function Function ON/...
Page 184 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Administrator Report Bulletin TX Fax Setting Setting Settings Report Broadcast Result Report Paper Tray for Reports Job Settings TX Result Report Check List System IS OpenAPI Access Set- Connection Setting ting Security Set- Administra- Port No.
Page 185 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 Toner Cover- Meter Count Details Copy Print Scan/Fax Other...
Page 186: Utility Mode Function Setting Procedure
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Utility Mode function setting procedure 8.3.1 Procedure 1. Press the Utility/Counter key. 2. The Utility mode screen will appear. 4037F3E522DA 8.3.2 Exiting • Touch the “Close” key. 8.3.3 Changing the setting value in Utility Mode functions •...
Page 187: One-Touch Registration
8. Utility Mode Field Service Ver. 1.0 Mar. 2005 One-Touch Registration 8.4.1 Scan A. Address Book (1) E-Mail Functions • To register/change e-mail address to send scanned data. Setting/ • A new address can be registered by touching “New” key. Procedure •...
Page 188: Fax
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode D. Subject/Text (for E-mail) (1) Subject Functions • To register the e-mail subject when transmitting the scanned data. Setting/ • A new address can be registered by touching “New” key. Procedure •...
Page 189 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 C. Program Functions • To register/change the Fax program. Setting/ • Select any program No. to register, check, change or delete the setting. Procedure D. Subject/Text (for E-mail) (1) Subject Functions •...
Page 190: User Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode User Setting 8.5.1 System Setting A. Language Selection Functions • To select the language on the LCD display • To change the language on the control panel to another language. Setting/ •...
Page 191 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (4) Print Lists Functions • To set the Paper Take-up Tray for output the list for the Meter count or the Unit check. Setting/ • The default setting is “Tray 1.” Procedure D.
Page 192: Display Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode <When NEXT JOB is selected: Staple Setting> Functions • To set whether to cancel the staple setting when the Staple setting job started and the next job setting has become available. Setting/ •...
Page 193 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 B. Scan Basic Screen Default Seeing (1) Default Tab Functions • To set the Basic Screen display in Scanner mode. • To change the Basic Screen display in Scanner mode. Setting/ •...
Page 194 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (3) Address Book Default Index Functions • To set the default display for abbreviation/address screen during Fax mode. • To keep the default display instead of abbreviations/address search string which fre- quently changes during Fax mode.
Page 195: Initial Setting
8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (2) RX Display Functions • To set the screen display on the control panel when receiving Fax. • To display “Receiving” on the screen when receiving the Fax. Setting/ • The default setting is OFF. Procedure “OFF”...
Page 196 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode B. Auto Booklet ON when Fold & Staple Functions • To set whether to set the Auto Booklet when Fold & Staple is selected. • To cancel setting the Auto Booklet when Fold & Staple is selected. Setting/ •...
Page 197: Scanner Setting
8. Utility Mode Field Service Ver. 1.0 Mar. 2005 H. Select Tray for Insert Sheet Functions • To select the default setting of the Tray for Cover sheet paper. Setting/ • The default setting is Tray 2. Procedure Print Jobs During Copy Operation Functions •...
Page 198: Printer Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode 8.5.6 Printer Setting A. Basic Setting (1) PDL Setting Functions • To set the PDL (Page Description Laguage) for PC printing. • To fix the PDL as necessary. It usually switches automatically. Setting/ •...
Page 199 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 B. Paper Setting (1) Paper Tray Functions • To set the Paper Take-up Tray when not specified by the printer driver during PC printing. • To use when Paper Take-up Tray cannot be specified by the printer driver when print- ing from Windows DOS, etc.
Page 200 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (6) Hole-Punch Functions • To select whether to make punch-holes or not when not specified by the printer driver during PC printing. • To use when the printer driver cannot specify punching during printing from Windows DOS, etc.
Page 201 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (5) CR/LF Mapping Functions • To set the mode for replacing data when printing the text data. • To change the mode for replacing data when printing the text data. Mode 1 : Replacing CR with CR-LF Mode 2 : Replacing LF with CR-LF Mode 3 : Replacing with CR-LF : Does not replace...
Page 202: Administrator Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode Administrator Setting • The Administrator setting will be available by entering the administrator password (8 dig- its) set by the administrator setting. (The administrator password is initially set to “12345678.”) 8.6.1 System Setting A.
Page 203 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 B. Output Setting (1) Print/Fax Output Settings Functions • To set the timing for printing for the PC print job or Fax received. Batch Print : Starts printing when all data are received Page Print : Starts printing every time data for each page are received Setting/ <Printer>...
Page 204 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (2) Time Setting Functions • To set the time to turn ON/OFF the Weekly Timer for each day of the week. Setting/ 1. Touch the key of the day to be set. Procedure 2.
Page 205 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (2) Delete Saved Program Jobs Functions • To delete the registered Program Job. • To delete the registered Program Job. Setting/ 1. Touch the appropriate Program Job. Procedure 2. Touch “Delete” key. 3.
Page 206 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (2) Printer Adjustment <Leading Edge Adjustment> Functions • To vary the print start position in the sub scan direction for each of different paper types in Tray 1. • The LPH Unit has been replaced. •...
Page 207 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Centering> Functions • To vary the print start position in the main scan direction for each paper source. • The LPH Unit has been replaced. • A paper feed unit has been added. •...
Page 208 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode <Centering (Duplex 2nd Side)> Functions • To vary the print start position in the main scan direction for each paper source in the 2-Sided mode. • The image on the backside of the 2-sided copy deviates in the main scan direction. Adjustment Width A •Width A on the test pattern produced should...
Page 209 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Vertical Adjustment> Functions • To synchronize the paper transport speed with the image writing speed. • The l adjustment becomes necessary. • The image on the copy distorts (stretched, shrunk). • When the image on the copy is stretched in the sub scan direction. Adjustment Width A and width B on the test pattern pro- Specification...
Page 210 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (3) Finisher Adjustment <Center Staple Position> Functions • To adjust the positions of center staple for the Finisher. • Use when the center staple positions deviate from the correct ones in the copies made using the Staple function.
Page 211 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (5) Image Stabilization <Image Stabilization Only> Functions • The image stabilization sequence is carried out without clearing the historical data of image stabilization control. • Use if an image problem persists even after Gradation Adjustment has been exe- cuted.
Page 212 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (7) Color Registration Adjust <Color Registration Adjust (Yellow, Magenta, Cyan)> Functions • To adjust color shift if there is any when comparing the original with copy of the plain or thick paper. •...
Page 213 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Color Registration Adjust (Black)> Functions • To correct black color shift, if it occurs with plain or thick paper. • Make Color Registration Adjust (cyan, magenta, and yellow) after this adjustment has been made.
Page 214 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (8) Gradation Adjustment Functions • To make an automatic adjustment of gradation based on the test pattern produced and the readings taken by the Scanner • Color reproduction performance becomes poor. •...
Page 215 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (9) Scanner Adjustment • Use the following Color Chart for the adjustment of the Scanner Section. • If the Color Chart is not available, a scale may be used instead. • A: Centering •...
Page 216 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode <Centering> Functions • To adjust part-to-part variations in accuracy of IR parts and their mounting accuracy by varying the scan start position in the main scan direction. • When the CCD Unit is replaced. •...
Page 217 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Horizontal Adjustment> Functions • To adjust the zoom ratio in the main scan direction for the Scanner Section • The CCD Unit has been replaced. Adjustment •Measure C width on the color chart and on Specification the sample copy, and adjust the gap to be within the following specification.
Page 218 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode <Vertical Adjustment> Functions • To adjust the zoom ratio in the sub scan direction for the Scanner Section • The Scanner Assy has been replaced. • The Scanner Motor has been replaced. •...
Page 219 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Centering Auto Adjustment> Functions • Adjust the start position for image scanning • Upon setup of the ADF Setting/ ☞ See Automatic Document Feeder Service Manual. Procedure <Auto Adj. of Stop Position: Front> Functions •...
Page 220: Administrator/Machine Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (2) Foolscap Size Setting Functions • To set the size for Foolscap paper. • Upon setup. • To change the size for Foolscap paper. Setting/ • Select the size from among the following four. Procedure 220 x 330 mm 81/2 x 13...
Page 221 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <User Box> Functions • To register or change the Box address for storing the scanned data to the Box in the hard disk of the Machine. Setting/ • Touch “New” key to register the new address. Procedure •...
Page 222 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode <E-Mail> Functions • To register or change the e-mail address for transmitting the Fax original by e-mail. Setting/ • Touch “New” key to register the new address. Procedure • Select any displayed address to check, change, or delete the setting. <User Box>...
Page 223 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 C. User Box (1) Public/Personal User Box Functions • To register or change the Box for storing the text data in the hard disk of the machine. • To register the shared or personal box for any purpose. Setting/ •...
Page 224: User Authentication/Account Track
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode 8.6.4 User Authentication/Account Track A. General Settings (1) User Authentication Functions • To set the User Authentication method. • To select whether to authenticate the user by the External Server or MFP. Setting/ •...
Page 225 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (6) Synchronize User Authentication & Account Track Functions • To set whether to synchronize the User Authentication and Account Track. • To be used when not to synchronize the User Authentication and Account Track. Setting/ •...
Page 226: Network Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (3) User Counter Functions • To display the status of use of the copier, printer, scanner, and Fax for each user. • To check the status of use of the copier, printer, scanner, and Fax for each user. Setting/ 1.
Page 227 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (2) IP Address Functions • To set the IP address of the device used in the network. • To enter the IP address of the machine. Setting/ • IP address Version 4 format Procedure [0 to 255] .
Page 228 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (8) IP Filtering Functions • To set the IP Filtering. • To set whether to receive IP address within the specified range of the value. Setting/ <Permit Access> Procedure 1. Select Enable or Disable on “Permit Access.” 2.
Page 229 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (2) Ethernet Frame Type Functions • To set the Ethernet Frame Type. • To specify the Frame type for transmission. Setting/ • The default setting is Auto Detect. Procedure “Auto Detect” 802.2 802.3 Ethernet II...
Page 230 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (8) File Server Name Functions • To set the File server name. • To set the Full server name for the print server to logon. Setting/ 1. Touch “File Server Name” key. Procedure 2.
Page 231 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (2) Accept IPP job Functions • To set whether to allow or restrict the IPP job. • To restrict the IPP job Setting/ • The default setting is ON. Procedure “ON” (3) Support Operation Functions •...
Page 232 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (4) Connection Timeout Functions • To set the timeout period for connecting to FTP server. • To change the timeout period for connecting. Setting/ 1. Touch “Input” key. Procedure 2. Press the Clear key. 3.
Page 233 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (4) Print Service Name Functions • To set the Print service name. • To set the Print service name. Setting/ 1. Touch “Print Service Name” key. Procedure 2. Enter the Print Service name (up to 31 characters) on the on-screen keyboard, and touch “OK”...
Page 234 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode G. LDAP Setting (1) Enabling LDAP <LDAP Function> Functions • To set whether to enable or disable the LDAP function. • To use LDAP function. Setting/ • The default setting is OFF. Procedure “OFF”...
Page 235 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Enable SSL> Functions • To set whether to use SSL (data encryption) for connecting to LDAP server. • To use SSL (data encryption) for connecting to LDAP server. Setting/ • The default setting is OFF. Procedure “OFF”...
Page 236 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode <Domain Name> Functions • To set the Domain Name for connecting to LDAP server. • To set the Domain Name for connecting to LDAP server. Setting/ 1. Touch “Domain Name” key. Procedure 2.
Page 237 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Divided Mail Size> Functions • To set the dividing size when carrying out the Binary division for data to be transmit- ted. • To change the dividing size of the data. Setting/ 1.
Page 238 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (2) E-Mail RX (POP) <E-Mail RX Setting> Functions • To set whether to enable or disable the e-mail reception setting. • To disable the e-mail reception setting. Setting/ • The default setting is ON. Procedure “ON”...
Page 239 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 <Network Speed> Functions • To set the Network speed. • To set the specific network speed. Setting/ • The default setting is Auto. Procedure “Auto” 10Mbps Full Duplex 10Mbps Half Duplex 100Mbps Full Duplex 100Mbps Half Duplex NOTE...
Page 240 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode <Notification Item Setting> Functions • To set the item for notifying the machine condition with e-mail. • To set the item for notifying the machine condition with e-mail. Setting/ 1. Select the item to be notified and touch “ON” key. Procedure 2.
Page 241: Copier Setting
8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (8) SNMP Setting Functions • To set whether to use SNMP or not. • Not to use SNMP. Setting/ • The default setting is ON. Procedure “ON” Read Community name: Enter the Read Community name. Write Community Name: Enter the Write Community Name.
Page 242: Printer Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode C. Select Tray when APS OFF Functions • To set the Tray to be used when APS is cancelled. • To set the Tray for the default setting when canceling APS. Setting/ •...
Page 243: Fax Setting
8. Utility Mode Field Service Ver. 1.0 Mar. 2005 8.6.8 Fax Setting • Settings are available only when the Optional FAX kit (FK-502) is mounted. A. Header Information Functions • To register the name of the sender and Fax ID which will be printed when transmitting Fax.
Page 244 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (3) Number of RX Call Rings Functions • To set the number of times to receive call rings. • To change the number of times of the fake RingBack tone after it starts calling until it starts receiving.
Page 245 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (2) Print Paper Selection Functions • To set the priority for Paper Take-up Tray when receiving Fax. • To change the priority for Paper Take-up Tray when receiving Fax. Auto select : Selected automatically Priority Size : Printed on size with priority.
Page 246 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (6) Min. Reduction for RX Print Functions • To set the print magnification for received text. • To change the print magnification for received text. Setting/ • The default setting is 96. Procedure “96”...
Page 247 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (3) Closed Network RX Functions • To set whether to use the closed network function. • To receive data only from the device which password matches. Setting/ • The default setting is OFF. Procedure “OFF”...
Page 248 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode F. PBX CN Set Functions • To set whether to use PBX connection setting or not. • This will be used when the machine is connected to PBX line. Setting/ • The default setting is OFF. Procedure “OFF”...
Page 249: System Connection
8. Utility Mode Field Service Ver. 1.0 Mar. 2005 (6) Bulletin TX Report Functions • To set whether to print out the Bulletin TX Report or not. • To print out the Bulletin TX Report. Setting/ • The default setting is OFF. Procedure “OFF”...
Page 250: Security Setting
Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (2) Port No. Functions • To set the access port for other systems with IS OpenAPI when using Page Scope Data Administrator. • To change the access port number for other systems with IS OpenAPI. Setting/ 1.
Page 251 8. Utility Mode Field Service Ver. 1.0 Mar. 2005 B. User Box Admin. Setting Functions • To set whether to allow or restrict the Box Administrator to use the system. • To allow the Box Administrator to use the system. Setting/ •...
Page 252 Field Service Ver. 1.0 Mar. 2005 8. Utility Mode (3) Print Data Capture Functions • To set whether to allow or restrict capturing the Print Job Data. • To be used when carrying out Service Mode → System 2 → Data capture. Setting/ •...
Page 253: Adjustment Item List
9. Adjustment item list Field Service Ver. 1.0 Mar. 2005 Adjustment item list Replacement Part/Service Job Adjustment/Setting Items ❍ Print Positioning: Leading Edge ❍ Print Positioning: Side Edge Printer Area Dup Print Positioning: Side Paper Feed Direction Adj. (3) (3) LPH Chip Adjust Machine LPH Rank (Changes to 1)
Page 254 Field Service Ver. 1.0 Mar. 2005 9. Adjustment item list ✽ This table shows the adjustment items that are required when a part of the machine has been replaced. Priority order, if applicable, during the adjustment procedures is indicated by the corresponding number in the parentheses. (3) (3) (4) (4) (4) (2) (2)
Page 255: 10. Service Mode
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.1 Service Mode function setting procedure NOTE • Ensure appropriate security for Service mode function setting procedures. They should NEVER be shown to any unauthorized person not involved with service jobs.
Page 256: 10.2 Service Mode Function Tree
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.2 Service Mode function tree ✽ The function tree is shown to comply with the format displayed on the screen. Service Mode Print Positioning: Leading Edge Print Positioning: Side Edge Dup Print Positioning: Side Edge Paper Feed Direction Adj.
Page 257 10. Service Mode Field Service Ver. 1.0 Mar. 2005 Service Mode Marketing Area Tel/Fax Number Serial Number No Sleep System 1 Foolscap Size Setting Original Size Detection Install date Initialization Image Controller Setting Option Board Status Consumable Life Rminder Unit Change System 2 Software Switch Setting Scan Calibration...
Page 258 Field Service Ver. 1.0 Mar. 2005 10. Service Mode Service Mode Gradation Pattern Halftone Pattern Lattice Pattern Solid Pattern Test Mode Color Sample 8 Color Solid Pattern LPH Pattern Running Mode Fax Test Original Stop Position Registration Loop Adj. Auto Stop Position Adjustment Paper Passage Sensor Check Original Tray Width...
Page 259: 10.3 Date/Time Input Mode
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.3 Date/Time Input mode • This mode is used to set time-of-day and date. 10.3.1 Date/Time Input mode screen 4037F3E504DA A. Date/Time input mode setting procedure <Procedure> 1. Call the Service Mode to the screen. 2.
Page 260: 10.4 Machine
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.4 Machine 10.4.1 Fusing Nip Functions • To check the Fusing Roller nip width. • When a fusing failure occurs. • When a blurred image or brush effect occurs. Check Range A: 9 ±...
Page 261: Fusing Temperature
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.4.2 Fusing Temperature Functions • To adjust individually the temperature of the Heating Roller and the Fusing Pressure Roller for each type of paper, thereby coping with varying fusing performance under changing environmental conditions.
Page 262: Fusing Transport Speed
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.4.3 Fusing Transport Speed Functions • To adjust the speed of the Fusing Drive Motor so as to match the fusing speed with transport speed. • Brush effect or blurred image is evident as a result of changes in environmental con- ditions or degraded durability.
Page 263: Printer Area
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.4.5 Printer Area A. Print Positioning: Leading Edge Functions • To vary the print start position in the sub scan direction for each of different paper types in Tray 1. • The LPH Unit has been replaced. •...
Page 264 Field Service Ver. 1.0 Mar. 2005 10. Service Mode B. Print Positioning: Side Edge Functions • To vary the print start position in the main scan direction for each paper source. • The LPH Unit has been replaced. • A paper feed unit has been added. •...
Page 265 10. Service Mode Field Service Ver. 1.0 Mar. 2005 C. Dup Print Positioning: Side Edge Functions • To vary the print start position in the main scan direction for each paper source in the 2-Sided mode. • The image on the backside of the 2-sided copy deviates in the main scan direction. Adjustment Width A •Width A on the test pattern produced should...
Page 266 Field Service Ver. 1.0 Mar. 2005 10. Service Mode D. Paper Feed Direction Adj. Functions • To synchronize the paper transport speed with the image writing speed. • Feed Direction Adjustment becomes necessary. • The image on the copy distorts (stretched, shrunk). •...
Page 267: Scan Area
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.4.6 Scan Area • Use the following Color Chart for the adjustment of the Scanner Section. • If the Color Chart is not available, a scale may be used instead. • A: Image Position: Side Edge •...
Page 268 Field Service Ver. 1.0 Mar. 2005 10. Service Mode B. Image Position: Side Edge Functions • To adjust part-to-part variations in accuracy of IR parts and their mounting accuracy by varying the scan start position in the main scan direction. •...
Page 269 10. Service Mode Field Service Ver. 1.0 Mar. 2005 C. Cross Direction Adjustment Functions • To adjust the zoom ratio in the main scan direction for the Scanner Section • The CCD Unit has been replaced. Adjustment •Measure C width on the color chart and on Specification the sample copy, and adjust the gap to be within the following specification.
Page 270: Printer Resist Loop
Field Service Ver. 1.0 Mar. 2005 10. Service Mode D. Feed Direction Adjustment Functions • To adjust the zoom ratio in the sub scan direction for the Scanner Section • The Scanner Assy has been replaced. • The Scanner Motor has been replaced. •...
Page 271: Color Registration Adjustment
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.4.8 Color Registration Adjustment A. Black Functions • To correct black color shift, if it occurs with plain or thick paper. • Make Color Registration Adjustment (cyan, magenta, and yellow) after this adjust- ment has been made.
Page 272 Field Service Ver. 1.0 Mar. 2005 10. Service Mode B. Cyan, Magenta, Yellow Functions • To adjust color shift if there is any when comparing the original with copy of the plain or thick paper. • Before making this adjustment, be sure to perform Color Registration Adjustment (Black).
Page 273: Lph Rank
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.4.9 LPH Rank Functions • To correct uneven LPH image by producing an output of the LPH Pattern of Test Print • When an uneven image occurs and is not eliminated even after other troubleshooting procedures have been carried out.
Page 274: Lph Chip Adjust
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.4.10 LPH Chip Adjust Functions • To correct chips of locations where sub scan direction white lines or black lines occur in the LPH Pattern produced using “Test Print.” • White line or color line or black line occurs in the sub scan direction. •...
Page 275: Manual Bypass Tray Adjustment
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.4.11 Manual Bypass Tray Adjustment Functions • To set the maximum width and the minimum width for the Manual Bypass Paper Size Unit of the Manual Bypass Guide • Use when the Manual Bypass Paper Size Unit of the Manual Bypass Guide has been changed.
Page 276: 10.6 Imaging Process Adjustment
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.6 Imaging Process Adjustment 10.6.1 Gradation Adjust Functions • To make an automatic adjustment of gradation based on the test pattern produced and the readings taken by the Scanner • Color reproduction performance becomes poor. •...
Page 277: Transfer Belt
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.6.2 Transfer Belt A. Refresh Functions • To turn the Transfer Belt idly • To refresh the surface of the Transfer Belt when filming occurs on the Transfer Belt. Filming 4036fs3100c0 Setting/ 1.
Page 278: Cleaning Bias
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.6.3 Cleaning Bias Functions • To set the strength of the Transfer Belt cleaning bias • When the image pattern is not completely removed, it strengthen the Transfer Belt cleaning bias in order to make the cleaner more effective. Print : To set the cleaning bias value for printing.
Page 279: D Max Density
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.6.6 D Max Density Functions • To adjust gradation, color, and image density to target reproduction levels by varying the maximum amount of toner sticking to paper through auxiliary manual fine-adjust- ment of gamma of each color after Gradation Adjust.
Page 280: Background Voltage Margin
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.6.8 Background Voltage Margin Functions • To adjust the highlight portion (fog level) to the target reproduction level by making an auxiliary manual fine-adjustment of γ of each color after Gradation Adjust. •...
Page 281: Stabilizer
10. Service Mode Field Service Ver. 1.0 Mar. 2005 B. 1st Transfer Adjust Functions • Adjust the output value for the 1st image transfer voltage. • To use when white spots appeared. Adjustment “0” (-5 to +5) Range Adjustment Adjust the output value for the 1st image transfer voltage by; Instructions Increasing it: Increase the setting value (white spots will decrease) Decreasing it: Decrease the setting value...
Page 282: Thick Paper Density Adjustment
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.6.11 Thick Paper Density Adjustment Functions • To fine-adjust density of printed images of each color for thick paper and OHP trans- parencies. • To change the density of the printed image for each color with thick paper and OHP transparencies Adjustment •...
Page 283: Monochrome Density Adjustment
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.6.14 Monochrome Density Adjustment Functions • To fine-adjust the density of the printed image for a black copy • To vary the density of the printed image of a black copy Adjustment Lighter (2 steps), “Std”, Darker (2 steps) Range...
Page 284: 10.7 Cs Remote Care
RAM for CS Remote Care before resetting. ☞ For clearing the RAM, see 256. • When using the telephone line for connection, use the recommended modem. (For recommended modem, contact responsible person of KONICA MINOLTA.) Step Procedure Register the device ID to the application at CS Remote Care Center.
Page 285 10. Service Mode Field Service Ver. 1.0 Mar. 2005 Step Procedure Setting the Device ID 1. Select Service Mode → CS Remote Care, and touch “Detail Setting” key. 2. Touch Machine Setting → Device ID, and input Device ID (nine digits). ☞...
Page 286: Software Sw Setting For Cs Remote Care
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.7.3 Software SW setting for CS Remote Care NOTE • SW bits data are written into the NVRAM every time a change is made. In case you changed bit data by accident, be sure to restore the previous state. A.
Page 287 10. Service Mode Field Service Ver. 1.0 Mar. 2005 SW No. Functions Default SW 05 Modem redial interval 4 to 7 Reservation — — SW 06 Modem redial times Reservation — — SW 07 Redial for response time out Do not redial Redial 1 to 7 Reserved —...
Page 288 Field Service Ver. 1.0 Mar. 2005 10. Service Mode SW No. Functions Default SW 12 Timer 2 Dial request completed → CONNECT reception SW 13 0 to 7 Reservation — — SW 14 Timer 4 Line connection → Start request telegram delivery SW 15 Timer 5...
Page 289 10. Service Mode Field Service Ver. 1.0 Mar. 2005 *1: Baud rate Mode 01-7 01-6 01-5 01-4 9600 bps 19200 bps “38400 bps” *2: Modem redial interval Mode 05-3 05-2 05-1 05-0 1 minute 2 minutes “3 minutes” 4 minutes 5 minutes 6 minutes 7 minutes...
Page 290 Field Service Ver. 1.0 Mar. 2005 10. Service Mode *5: Retransmission times on E-Mail delivery error Mode 09-6 09-5 09-4 09-3 09-2 09-1 09-0 0 to 9 times 000 0000 to 000 1001 “10 times” 11 to 99 times 000 1011 to 110 0011 *6: Timer 1 (RING reception →...
Page 291: Setup Confirmation
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.7.4 Setup confirmation • Follow the steps below to make sure that CS Remote Care has been properly set 1. Call the Service Mode to the screen. 2. Touch “CS Remote Care” key. 3.
Page 292: Calling The Center From The Administrator
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.7.6 Calling the Center from the Administrator • When the CS Remote Care setup is complete, the administrator can call the CS Remote Care center. 1. Select “Administrator Setting”, and touch “System Connection” key. 2.
Page 293 10. Service Mode Field Service Ver. 1.0 Mar. 2005 C. Detail Setting (1) Machine Setting Functions • Execute the primary setting. • Use to change the set contents. • Use to register the machine to the CS Remote Care Center. Setting/ 1.
Page 294 Field Service Ver. 1.0 Mar. 2005 10. Service Mode (4) Communication Log Print Functions • To print out the Communication Log. • Use to output and use the Communication Log. Setting/ 1. Call the Service Mode on the screen. Procedure 2.
Page 295: List Of The Cs Remote Care Error Code
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.7.9 List of the CS Remote Care error code NOTE • Error codes in the shaded region may occur when transmitting from the machine to the center. Error code Error Solution Connection NG (Cannot connect from the K00_00 Redial and wait for re-reception.
Page 296: Troubleshooting For Cs Remote Care
Field Service Ver. 1.0 Mar. 2005 10. Service Mode Error code Error Solution Center call evacuation buffer is full. Cannot evac- K03_00 uate any more. Because of memory shortage, unable to secure K05_90 enough area for sending a mail. In the manual transmission, retry when the controller is idling.
Page 297: System 1
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.8 System 1 10.8.1 Marketing Area Functions • To make the various settings (language, paper size, fixed zoom ratios, etc.) according to the applicable marketing area. • Upon setup. Setting/ <Marketing Area> Procedure •...
Page 298: Original Size Detection
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.8.5 Original Size Detection Functions • To change the document size detection table. • Use to change the setting for the document size detection table. Copy Glass : To change the size detection table for the document glass. : To set whether or not to detect 18k/16k while using ADF (only when marketing area is Europe) Setting/...
Page 299: Install Date
10. Service Mode Field Service Ver. 1.0 Mar. 2005 B. System Error Clear Functions • To reset the trouble data. • Use to clear the “Jam”, “Trouble”, “Error” displays, and other improper displays. ☞ For details on items to be cleared, see page 299 “Contents to be cleared by Reset function.”...
Page 300: Image Controller Setting
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.9.2 Image Controller Setting Functions • To set the type of the controller. • “Peripheral Mode” appears when “Others” is selected. • When setting up the controller. Setting/ Image Controller Setting Procedure •...
Page 301: Consumable Life Reminder
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.9.4 Consumable Life Reminder Functions • To select whether or not to give the display of PM parts lifetime PM parts lifetime display: An entire screen warning is given when the service life of a specific unit has been reached, prompting the user to replace the part.
Page 302: Lct Paper Size Setting
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.9.8 LCT Paper Size Setting Functions • To set the paper size for the LCT • Use to change the paper size for the LCT. Setting/ The default setting depends on the setting made for the applicable marketing area. Procedure 81/2 x 11 10.9.9...
Page 303: Data Capture
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.9.10 Data Capture Functions • When an error occurs, it acquires the print job data in order to analyze the cause of the error. • When an error occurs, this will be used to analyze the cause of the error according to the print job data.
Page 304 Field Service Ver. 1.0 Mar. 2005 10. Service Mode 6. Using the “ls” command, display the list of the file available for capture. 4037F3E540DA 7. Using the “binary” command, set the File transfer mode to the binary transfer. 4037F3E541DA...
Page 305 10. Service Mode Field Service Ver. 1.0 Mar. 2005 8. Using the “get” command, transfer the data for capture to PC. 4037F3E542DA 9. Finish the command prompt. NOTE • When the data capture is set to “ON”, all print job data will be stored in the hard disk.
Page 306: 10.10 Counter
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.10 Counter • The Counter displays the counts of various counters to allow the Technical Representa- tive to check or set as necessary. 10.10.1 Procedure 1. Touch “Counter” to show the Counter menu. 2.
Page 307: Jam
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.10.3 Functions • To check the number of misfeeds that have occurred at different locations in the machine. • To clear the count of each counter. • To check the number of paper misfeeds that have occurred Setting/ •...
Page 308: Service Total
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.10.7 Service Total Functions • To display the count value for the service total counter. • Use to check the total No. of printed pages including the ones printed by the Ser- vice Mode.
Page 309: 10.11 List Output
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.11 List Output 10.11.1 Machine Management List Functions • To produce an output of a list of setting values, adjustment values, Total Counter val- ues, and others. • At the end of setup or when a malfunction occurs. Setting/ •...
Page 310: 10.12 State Confirmation
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.12 State Confirmation 10.12.1 Sensor Check Functions • To display the states of the input ports of sensors and switches when the machine remains stationary. • Used for troubleshooting when a malfunction or a misfeed occurs. Setting/ •...
Page 311 10. Service Mode Field Service Ver. 1.0 Mar. 2005 B. Sensor Check Screens • These are only typical screens which may be different from what are shown on each indi- vidual machine. 4037F3E506DA...
Page 312 Field Service Ver. 1.0 Mar. 2005 10. Service Mode C. Sensor Check List (1) Sensors 1 (Main Unit, PC-102, PC-202) Symbol Panel Display Part/Signal Name Operation Characteristics/ Panel Display PC14 Tray 1 Device Tray 1 Set Sensor In position Out of Detection position Paper Empty...
Page 313 10. Service Mode Field Service Ver. 1.0 Mar. 2005 Symbol Panel Display Part/Signal Name Operation Characteristics/ Panel Display PC111 Manual Multi FD Size1 Bypass FD Paper Size Sensor/1 PC112 Multi FD Size2 Bypass FD Paper Size Sensor/2 PC113 Multi FD Size3 Bypass FD Paper Size Sensor/3 PC114 Multi FD Size4...
Page 314 Field Service Ver. 1.0 Mar. 2005 10. Service Mode D. Sensors 2 (Main Unit, PC-402) Symbol Panel Display Part/Signal Name Operation Characteristics/ Panel Display PC4-LCT Lift-Up Upper Tray Upper Limit Sensor At raised Not at raised position position PC13-LCT Lift-Up Lower Tray Lower Position Sensor At lower limit Not at lower limit...
Page 315 10. Service Mode Field Service Ver. 1.0 Mar. 2005 Symbol Panel Display Part/Signal Name Operation Characteristics/ Panel Display PC17 Devel- C Toner Empty Toner Near-Empty Sensor PQ/C Toner not Toner oping present present PC16 M Toner Empty Toner Near-Empty Sensor PQ/M Toner not Toner present...
Page 316 Field Service Ver. 1.0 Mar. 2005 10. Service Mode E. Sensors 3 (FS-507, JS-601) Operation Characteris- tics/Panel Display Symbol Panel Display Part/Signal Name PC1-FN Multi Exit (Non-sort1) 1st Tray Exit Sensor Paper Paper not Staple present present Finisher PC19-FN Exit (Non-sort3) Job Tray Exit Sensor Paper Paper not...
Page 317 10. Service Mode Field Service Ver. 1.0 Mar. 2005 F. Sensors 4 (FS-603, PK-501) Operation Characteris- tics/Panel Display Symbol Panel Display Part/Signal Name PI1-FN Sad- Entrance Entrance Sensor Paper Paper not present present Stitch PI2-FN Paddle Home Paddle Home Position Sensor Fin- PI3-FN Bundle Roller...
Page 318 Field Service Ver. 1.0 Mar. 2005 10. Service Mode Operation Characteris- tics/Panel Display Symbol Panel Display Part/Signal Name MS1-FN Sad- Front Door SW Front Door Open Sensor Open — Remain in — Paper Stitch Reverse Section horiz. side Fin- MS2-FN Joint SW Joint Open Sensor Open...
Page 319: Table Number
10. Service Mode Field Service Ver. 1.0 Mar. 2005 G. Sensors 5 (Main Unit) Symbol Operation Characteris- tics/Panel Display Panel Display Part/Signal Name PC201 Scan- Home Sensor Scanner Home Sensor At home Out of home SW201 Org. Original Cover Size Reset Switch Lowered Raised Detecti...
Page 320: Level History1
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.12.3 Level History1 Functions • To display TCR (T/C ratio), IDC/Regist Sensor output values, and fusing temperature. • Used for troubleshooting of image problems. Setting/ • TCR-C/-M/-Y/-K: Shows the T/C output reading taken last. Procedure •...
Page 321: Memory / Hdd Adj
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.12.7 Memory / HDD Adj. A. Memory Check Functions • To check correspondence of data written to and that read from memory through write/read check. Rough Check • A check is made to see if the image data reading and writing are correctly made in a very limited area.
Page 322 Field Service Ver. 1.0 Mar. 2005 10. Service Mode D. Work Memory In/Out Check Functions • To check to see if input and output of image data of work memory are correctly per- formed. • If the print image is faulty. Adjustment 1.
Page 323: Memory/Hdd State
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.12.8 Memory/HDD State Functions • To display the condition and amount of the memory and Hard disk. • Use to check the condition and amount of the memory and Hard disk. Setting/ •...
Page 324: 10.13 Test Mode
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.13 Test Mode • To check the image on the printer side by letting the machine produce various types of test pattern. It also tests the printing operation in running mode, as well as the Fax trans- mission.
Page 325: Halftone Pattern
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.13.3 Halftone Pattern Functions • To produce a solid halftone pattern. • Used for checking uneven density and pitch noise. Pattern SINGLE HYPER Gradation Cyan Density: 255 4036fs3043c0 Setting/ • # of Print (“1” to 999) Procedure •...
Page 326: Solid Pattern
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.13.5 Solid Pattern Functions • To produce each of the C, M, Y, and K solid patterns. • Used for checking reproducibility of image density. Pattern SINGLE HYPER Gradation Density: 255 4036fs3045c0 Setting/ •...
Page 327: Color Solid Pattern
10. Service Mode Field Service Ver. 1.0 Mar. 2005 10.13.7 8 Color Solid Pattern Functions • To produce an 8-color solid pattern. • Used for checking color reproducibility and uneven density of each color. Pattern SINGLE HYPER Gradation Density: 255 4036fs3047c0 Setting/ •...
Page 328: 10.13.10 Fax Test
Field Service Ver. 1.0 Mar. 2005 10. Service Mode 10.13.10 Fax Test ☞ For details, see FK-502 Service Manual. 10.14 ADF ☞ For details, see DF-601 Service Manual. 10.15 FAX ☞ For details, see FK-502 Service Manual. 10.16 Finisher ☞ For details on adjustment, see the Service Manual for Option FS-603. Functions •...
Page 329: 11. Enhanced Security
11. Enhanced Security Field Service Ver. 1.0 Mar. 2005 11. Enhanced Security 11.1 Enhanced Security Function Setting Procedure 11.1.1 Procedure 1. Call the Service Mode to the screen. 2. Press the following keys in this order. → → Stop Clear 3.
Page 330: 11.3 Settings In The Enhanced Security
“Administrator Setting” → “Security Setting” • NEVER forget the CE password. When forgetting the CE password, call responsible person of KONICA MINOLTA. 11.3.2 Administrator Password Functions •...
Page 331: Administrator Feature Level
11. Enhanced Security Field Service Ver. 1.0 Mar. 2005 11.3.3 Administrator Feature Level Functions • To set which Modes to be allowed for the Administrator to use in Service Mode. • Use when allowing the Administrator to use some Modes in Service Mode. •...
Page 332: 12. Billing Setting
Field Service Ver. 1.0 Mar. 2005 12. Billing Setting 12. Billing Setting 12.1 Billing Setting Function Setting Procedure 12.1.1 Procedure 1. Call the Service Mode to the screen. 2. Press the following keys in this order. → Stop 3. Billing Setting menu will appear. 4037F3E510DA 12.1.2 Exiting...
Page 333: 12.3 Settings In The Billing Setting
12. Billing Setting Field Service Ver. 1.0 Mar. 2005 12.3 Settings in the Billing Setting 12.3.1 Counter Setting Functions • To set the counting method for the Total Counter and Size Counter. • Use to change the counting method for the counters. Setting/ Total Counter Procedure...
Page 334: Management Function Choice
Field Service Ver. 1.0 Mar. 2005 12. Billing Setting 12.3.2 Management Function Choice Functions • To set whether or not the Key Counter, Data Controller, and Vendor are installed. • Use to change the counting method for the administrative units. Setting/ Key Counter Procedure...
Page 335: Coverage Rate Clear
12. Billing Setting Field Service Ver. 1.0 Mar. 2005 12.3.3 Coverage Rate Clear Functions • To clear the coverage rate • Use to clear the coverage rate Setting/ • The default setting is Unset. Procedure “Unset” • Touching “END” key will clear the coverage rate.
Page 336: 13. Procedure For Resetting
Field Service Ver. 1.0 Mar. 2005 13. Procedure for Resetting 13. Procedure for Resetting 13.1 Trouble resetting Functions • If the trouble occurs and the status would not be cleared by turning main power switch OFF and ON again, or opening and closing the front door, clear the status of the machine.
Page 337: 14. Mechanical Adjustment
14. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 14. Mechanical adjustment 14.1 Mechanical adjustment of the scanner section 14.1.1 Adjustment of the Scanner Motor Belt This adjustment must be made in the following case: • The Scanner Motor Assy has been removed. •...
Page 338: Focus Positioning Of The Scanner And Mirrors Unit
Field Service Ver. 1.0 Mar. 2005 14. Mechanical adjustment 14.1.2 Focus Positioning of the Scanner and Mirrors Unit This adjustment must be made in the following case: • The Scanner Drive Cables have been rewound 1. Slide the Mirrors Unit [1] to the cen- ter until it is pressed up against the cutouts in the rails [2].
Page 339: Mechanical Adjustment Of The Bypass Tray Section
14. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 2. Secure the Scanner [2] in the posi- tion shown on the left using the two Scanner positioning screws [3]. 3. Make the Feed Direction Adjustment. ☞ 233 30 mm 4036fs3040c0 14.3 Mechanical adjustment of the bypass tray section 14.3.1 Adjustment of the Bypass Paper Size Unit...
Page 340 Field Service Ver. 1.0 Mar. 2005 14. Mechanical adjustment 2. Install the Bypass Unit Cover so that part A (edge) [2] of the Rack Gear [1] for the Bypass Paper Size Unit and part B [3] of the Bypass Unit Cover are aligned in a straight line.
Page 341 14. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 342: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 15. Jam Display Troubleshooting 15. Jam Display 15.1 Misfeed Display • When a paper misfeed occurs, the misfeed message, misfeed location, and paper loca- tion are displayed on the Touch Panel of the machine. [11] [10] [10]...
Page 343: Misfeed Display Resetting Procedure
15. Jam Display Field Service Ver. 1.0 Mar. 2005 Display Code Misfeed Location misfeed processing location Action 1101 Tray 1 take-up ☞ Right Door 3001 2nd Image Transfer 1201 Tray 2 take-up Tray 2 Right Door ☞ 2001 Vertical Transport 1001 Manual Bypass take-up Manual Bypass Slide Board...
Page 344: 15.2 Sensor Layout
Field Service Ver. 1.0 Mar. 2005 15. Jam Display 15.2 Sensor layout 15.2.1 System Mounted with PC-402. 4037F4C506DA Exit Sensor PC30 [5] Tray 2 Vertical Transport Sensor PC108 Duplex Unit Transport Sensor 1 PI1-DU [6] Tray 1 Double Feed Sensor [3]*1 Registration Roller Sensor PC28...
Page 345: System Mounted With Pc-202
15. Jam Display Field Service Ver. 1.0 Mar. 2005 15.2.2 System Mounted with PC-202. [10] [11] 4037F4C507DA Exit Sensor PC30 Tray 1 Double Feed Sensor Duplex Unit Transport Sensor 1 PI1-DU Tray 2 Paper Take-Up Sensor PC107 [3]*1 Registration Roller Sensor PC28 Tray 3 Vertical Transport Sensor PC117-PF [3]*1 OHP Sensor...
Page 346: 15.3 Solution
Field Service Ver. 1.0 Mar. 2005 15. Jam Display 15.3 Solution 15.3.1 Initial Check Items • When a paper misfeed occurs, first make checks of the following initial check items Check Item Action Does paper meet product specifications? Change paper. Change paper.
Page 347: Tray 1 Take-Up, 2Nd Image Transfer, Fusing Misfeed
15. Jam Display Field Service Ver. 1.0 Mar. 2005 15.3.2 Tray 1 take-up, 2nd Image Transfer, Fusing Misfeed A. Detection Timing Type Description The leading edge of the paper does not block the Exit Sensor (PC30) even after the lapse of a given period of time after the Registration Roller Clutch has been 2nd Image Transfer, energized.
Page 348: Tray 2 Take-Up, Vertical Transport, Multiple Bypass Take-Up
Field Service Ver. 1.0 Mar. 2005 15. Jam Display 15.3.3 Tray 2 take-up, Vertical Transport, Multiple Bypass take-up A. Detection Timing Type Description The leading edge of the paper does not block the Tray 2 Vertical Transport Sensor (PC108) even after the lapse of a given period of time after the Tray 2 Paper Feed Tray 2 take-up, Ver- Motor has been energized.
Page 349 15. Jam Display Field Service Ver. 1.0 Mar. 2005 Manual Bypass take-up Relevant Electrical Parts Tray 2 Vertical Transport Sensor (PC108) Tray 2 Board (PWB-Z) Bypass Paper Feed Clutch (CL101) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Initial check items —...
Page 350: Lct Take-Up And Vertical Transport Misfeed (Pc-402)
Field Service Ver. 1.0 Mar. 2005 15. Jam Display 15.3.4 LCT Take-up and Vertical Transport Misfeed (PC-402) A. Detection Timing Type Description The leading edge of the paper does not block the LCT Transport Roller Motor (PC2- LCT) even after the lapse of a given period of time after the Paper Feed Motor has Misfeed detected been energized.
Page 351: Tray 3 Take-Up And Vertical Transport Misfeed (Pc-102/Pc202)
15. Jam Display Field Service Ver. 1.0 Mar. 2005 15.3.5 Tray 3 Take-up and Vertical Transport Misfeed (PC-102/PC202) A. Detection Timing Type Description The leading edge of the paper does not block the Tray 3 Vertical Transport Sensor (PC117-PF) even after the lapse of a given period of time after the Tray 3 Paper Misfeed detected at Feed Motor has been energized.
Page 352: Tray 4 Take-Up And Vertical Transport Misfeed (Pc202)
Field Service Ver. 1.0 Mar. 2005 15. Jam Display 15.3.6 Tray 4 Take-up and Vertical Transport Misfeed (PC202) A. Detection Timing Type Description The leading edge of the paper does not block the Tray 4 Vertical Transport Sensor (PC126-PF) even after the lapse of a given period of time after the Tray 4 Paper Misfeed detected at Feed Motor has been energized.
Page 353: Duplex Transport Misfeed
15. Jam Display Field Service Ver. 1.0 Mar. 2005 15.3.7 Duplex Transport Misfeed A. Detection Timing Type Description The Registration Roller Sensor (PC28) is not blocked even after the lapse of a given period of time after a Duplex paper take-up sequence has been started. The Duplex Unit Transport Sensor 2 (PC1-DU) is not blocked even after the lapse of a given period of time after the paper has blocked the Duplex Unit Transport Misfeed detected at...
Page 354: Fusing/Exit Misfeed
Field Service Ver. 1.0 Mar. 2005 15. Jam Display 15.3.8 Fusing/Exit Misfeed A. Detection Timing Type Description PC30 is not unblocked even after the lapse of a given period of time after the paper has blocked the Exit Sensor (PC30). Misfeed detected at The Duplex Unit Transport Sensor 1 (PI1-DU) is not blocked even after the lapse Fusing/Exit Section...
Page 355: 16. Malfunction Code
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.1 Restarting • This machine automatically performs a restarting sequence if a minor fault that would not damage the machine occurs during operation. • No screen information is given for the restarting sequence. •...
Page 356: Alert List
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.2.1 Alert list • If an image stabilization or Scanner fault occurs, the corresponding warning code appears. Code Item Description • It is detected that the CCD clamp gain adjustment CCD clamp gain adjustment failure value is faulty.
Page 357: 16.3 Solution
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.3 Solution 16.3.1 S-1: CCD clamp/gain adjustment failure Relevant Electrical Parts Scanner Assy CCD Sensor Board (PWB-A) Image Processing Board (PWB-C) Step Action Correct the harness connection between PWB-A and PWB-C if faulty. Check for possible extraneous light and correct as necessary.
Page 358: P-6: Cyan Imaging Unit Failure
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.3.4 P-6: Cyan Imaging Unit failure 16.3.5 P-7: Magenta Imaging Unit failure 16.3.6 P-8: Yellow Imaging Unit failure 16.3.7 P-9: Black Imaging Unit failure Relevant Electrical Parts Imaging Unit C Image Transfer Belt Unit Imaging Unit M Imaging Unit Y Imaging Unit K...
Page 359: P-26: 1St Image Transfer Atvc (Black) Failure
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.3.10 P-26: 1st image transfer ATVC (Black) failure 16.3.11 P-27: 2nd image transfer ATVC failure 16.3.12 P-29: 1st image transfer ATVC (Color) failure Relevant Electrical Parts High Voltage Unit/2 (HV2) Image Transfer Belt Unit Control Board (PWB-MC) Step Action...
Page 360: 16.4 Trouble Code
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.4 Trouble code • The machine’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel. 4037F4E505DA 16.4.1 Trouble code list * For the details of the malfunction codes of the options, see the Service Manual for the cor- responding option.
Page 361 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Description Rank C0301 Suction Fan Motor's failure to • The Fan Lock signal remains HIGH for a predeter- turn mined continuous period of time while the Motor remains stationary. C0351 Paper Cooling Fan Motor's •...
Page 362 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Description Rank ☞ C1401 Finishing option Backup RAM See FS-507or FS-603 Service Manual. failure C2151 2nd Image Transfer Roller • The 2nd Image Transfer Pressure Position Sensor pressure/retraction failure is not activated (retracted position) within 2 sec.
Page 363 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Description Rank C2257 Cleaning Brush Motor failure to • The Motor Lock signal remains HIGH for a prede- turn termined continuous period of time while the Motor is turning. C2258 Cleaning Brush Motor's turning •...
Page 364 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Description Rank C2559 Cyan TCR Sensor adjustment • TCR Sensor automatic adjustment does not func- failure tion properly, failing to adjust to an appropriate value. C255A Magenta TCR Sensor adjustment failure C255B Yellow TCR Sensor adjustment failure...
Page 365 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Description Rank C3302 Fusing Cooling Fan Motor/1 or • The Fan Lock signal remains HIGH for a predeter- Fusing Cooling Fan Motor/2 mined continuous period of time while the Motor failure to turn remains stationary.
Page 366 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Description Rank C4705 Printer Time Out • No image data is output from the MFP Control Board (PWB-MFPC). C4761 Compression hardware timeout • The hardware involved with the compression function offered by the MFP Control Board (PWB- MFPC) does not respond.
Page 367 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Description Rank C6102 Scanner Home Sensor • The Scanner Home Sensor is unable to detect the malfunction Scanner located at its home position. • The Scanner Home Sensor is unable to detect a Scanner even when the Scanner Motor has been driven to move the Scanner over the maximum traveling distance.
Page 368 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Description Rank ☞ CB113 FAX Driver Error: Sequence See FK-502 Service Manual. Error among Main Body Tasks CB114 FAX Driver Error: Message Queue Control Error CB115 FAX Driver Error: Main Body - Sequence Error among FAX Boards CB116 FAX Driver Error: FAX Board...
Page 369 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Description Rank ☞ CB137 MIF Driver Error: DPRAM See FK-502 Service Manual. RESET Reception CB140 MSG I/F Error with JC CB141 I/F Error with Main: I/F Error with Driver CB142 I/F Error with Main: Undefined Command Reception CB143 I/F Error with Main: Command...
Page 370 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Description Rank ☞ CB170 Page Control: Internal Que Table See FK-502 Service Manual. Control Error (create/enque/ deque) CB171 Page Control: Instance Genera- tion Error CB172 Page Control: Timeout Error CB173 Page Control: Interface Error CB174 Page Control: Semaphore Acquisition Release Error...
Page 371 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Description Rank CD005 Hard Disk Error 1 • Hard disk is faulty. CD006 Hard Disk Error 2 CD007 Hard Disk Error 3 CD008 Hard Disk Error 4 CD009 Hard Disk Error 5 CD00A Hard Disk Error 6 CD00B Hard Disk Error 7 CD00C Hard Disk Error 8...
Page 372 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code • The machine displays an abort code (CFXXX) on the Touch Panel as it becomes unable to process tasks properly through its software control. • When the system program is aborted, check the electrical component, unit, option, and connection relating to the specific type of the abort condition.
Page 373 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CF202 startWorkSave()Sequence • MFP Control Board/Electronic sorting Board Abnormal CF203 convAPItoIJCParameter()page • MFP Control Board/Electronic sorting Board Abnormal CF204 calcCompresserUse()CmpEx- • MFP Control Board/Electronic sorting Board pID Abnormal CF211 setParameterBandColorPlane() •...
Page 374 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CF600 Report receiving of print start • MFP Control Board/Engine that is out of sequence CF601 Report receiving of paper feed- • MFP Control Board/Engine ing that is out of sequence CF604 Outside IF/Command Queue •...
Page 375 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CF9ED SIO Receiving Port...EPNet • MFP Control Board CFA01 getOneImgTransInfoFromTh() • MFP Control Board/Electronic sorting Board No applied thread CFA02 chkEnableAllocExec() default •...
Page 376 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CFA36 Thread Service malfunction • MFP Control Board/Electronic sorting Board CFA37 Input image height 0 • MFP Control Board/Electronic sorting Board CFA38 Output image width 0 •...
Page 377 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CFB6F Underrun at DMA_D 1 image • MFP Control Board/Electronic sorting Board output interface 1 CFB70 Underrun at DMA_D 2 image • MFP Control Board/Electronic sorting Board output interface 1 CFB71 Underrun at DMA_D 3 image •...
Page 378 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CFD04 ASIC10 Timeout Number of • MFP Control Board/Copier Board DMA under operation and trans- fer completion line=0: DMA_B1 CFD05 ASIC10 Timeout Number of •...
Page 379 16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CFE00 ASIC10 Timeout Number of • MFP Control Board/Copier Board DMA under operation and trans- fer completion line=0: DMA_A0 CFE01 ASIC10 Timeout Number of •...
Page 380 Field Service Ver. 1.0 Mar. 2005 16. Malfunction code Code Item Relevant Electrical Components, Units, and Options Rank CFE10 ASIC10 Timeout Number of • MFP Control Board DMA under operation and trans- fer completion line≠0: DMAPCI Bridge CFE11 ASIC10 Timeout Number of •...
Page 381: 16.5 How To Reset
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 Code Item Relevant Electrical Components, Units, and Options Rank CFF0C ASIC10 Timeout Waiting state of • MFP Control Board/Electronic sorting Board DMA band preparation register setting:DMA_H1 CFF0D ASIC10 Timeout Waiting state of •...
Page 382: 16.6 Solution
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6 Solution 16.6.1 C0204: Tray 2 Elevator failure Relevant Electrical Parts Tray 2 Lift-Up Sensor (PC105) Tray 2 Board (PWB-Z) Tray 2 Lift-Up Motor (M101) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M101 connector for proper connec-...
Page 383: C0301: Suction Fan Motor's Failure To Turn
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.3 C0301: Suction Fan Motor’s failure to turn Relevant Electrical Parts Suction Fan Motor (M12) Control Board (PWB-MC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the connector of motor for proper connection —...
Page 384: C2152: Image Transfer Belt Pressure/Retraction Failure
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.6 C2152: Image Transfer Belt pressure/retraction failure Relevant Electrical Parts 1st Image Transfer Retraction Position Sensor (PC12) Control Board (PWB-MC) 1st Image Transfer Pressure/Retraction Motor (M11) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component)
Page 385: C2251: K Pc Motor Failure To Turn
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.12 C2251: K PC Motor failure to turn Relevant Electrical Parts K PC Motor (M7) Control Board (PWB-MC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the connector of motor for proper connec- —...
Page 386: C2254: Color Pc Motor Turning At Abnormal Timing
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.15 C2254: Color PC Motor turning at abnormal timing Relevant Electrical Parts Color PC Drum Motor (M5) Control Board (PWB-MC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) PWB-MC PJ33MC-10 (REM) C to D- M5 operation check PWB-MC PJ33MC-13 (LOCK)
Page 387: C2257: Cleaning Brush Motor's Failure To Turn
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.18 C2257: Cleaning Brush Motor's failure to turn Relevant Electrical Parts Cleaning Brush Motor (M22) Control Board (PWB-MC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M22 connector for proper connec- —...
Page 388: C2352: Toner Suction Fan Motor's Failure To Turn
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.21 C2352: Toner Suction Fan Motor’s failure to turn Relevant Electrical Parts Toner Suction Fan Motor (M20) Control Board (PWB-MC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M20 connector for proper connec- —...
Page 389: C2551: Abnormally Low Toner Density Detected Cyan Tcr Sensor
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.24 C2551: Abnormally low toner density detected Cyan TCR Sensor 16.6.25 C2553: Abnormally low toner density detected Magenta TCR Sensor 16.6.26 C2555: Abnormally low toner density detected Yellow TCR Sensor Relevant Electrical Parts TCR Sensor/C (PWB-N3) Control Board (PWB-MC) TCR Sensor/M (PWB-N2)
Page 390: C2552: Abnormally High Toner Density Detected Cyan Tcr Sensor
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.27 C2552: Abnormally high toner density detected Cyan TCR Sensor 16.6.28 C2554: Abnormally high toner density detected Magenta TCR Sensor 16.6.29 C2556: Abnormally high toner density detected Yellow TCR Sensor Relevant Electrical Parts TCR Sensor/C (PWB-N3) Control Board (PWB-MC) TCR Sensor/M (PWB-N2)
Page 391: C2558: Abnormally High Toner Density Detected Black Tcr Sensor
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.31 C2558: Abnormally high toner density detected Black TCR Sensor Relevant Electrical Parts Imaging Unit /K Control Board (PWB-MC) TCR Sensor/K (PWB-N4) MFP Control Board (PWB-MFPC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component)
Page 392: C255C: Black Tcr Sensor Adjustment Failure
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.35 C255C: Black TCR Sensor adjustment failure Relevant Electrical Parts Imaging Unit /K Control Board (PWB-MC) MFP Control Board (PWB-MFPC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Correct the TCR connection on the underside of —...
Page 393: C2655: Cyan Lph Correction Data Download Failure
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.40 C2655: Cyan LPH correction data download failure 16.6.41 C2656: Yellow LPH correction data download failure 16.6.42 C2657: Magenta LPH correction data download failure 16.6.43 C2658: Black LPH correction data download failure Relevant Electrical Parts LPH Assy/C LED Drive Board (PWB-LED)
Page 394: C3201: Fusing Drive Motor's Failure To Turn
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.45 C3201: Fusing Drive Motor’s failure to turn Relevant Electrical Parts Fusing Drive Motor (M2) Control Board (PWB-MC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M2 connector for proper connection —...
Page 395: C3302: Fusing Cooling Fan Motor /2, /3'S Failure To Turn
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.48 C3302: Fusing Cooling Fan Motor /2, /3’s failure to turn Relevant Electrical Parts Fusing Cooling Fan Motor/2 (M15) Control Board (PWB-MC) Fusing Cooling Fan Motor/3 (M16) WIRING DIAGRAM Location Step Action Control Signal (Electrical...
Page 396: C4705: Printer Time Out
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.55 C4705: Printer Time Out Relevant Electrical Parts MFP Control Board (PWB-MFPC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Select “Service Mode” → “State Confirmation” → “Memory/HDD Adj.” → “Memory Bus Check” → —...
Page 397: C5102: Main Motor's Failure To Turn
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.68 C5102: Main Motor's failure to turn Relevant Electrical Parts Main Motor (M1) Control Board (PWB-MC) DC Power Supply (PU1) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the M1 connector for proper connection —...
Page 398: C5351: Power Supply Cooling Fan Motor's Failure To Turn
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.70 C5351: Power Supply Cooling Fan Motor’s failure to turn Relevant Electrical Parts Power Supply Cooling Fan Motor (M21) DC Power Supply (PU1) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the connector of motor for proper connec- —...
Page 399: C5355: Cooling Fan Motor/3'S Failure To Turn
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.73 C5355: Cooling Fan Motor/3’s failure to turn Relevant Electrical Parts Cooling Fan Motor/3 (M25) Control Board (PWB-MC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the connector of motor for proper connec- —...
Page 400: C6102: Scanner Home Sensor Malfunction
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.76 C6102: Scanner Home Sensor malfunction 16.6.77 C6103: Scanner overrun failure Relevant Electrical Parts Scanner Home Sensor (PC201) Scanner Motor Drive Board (PWB-IC) Scanner Motor (M201) Image Processing Board (PWB-C) WIRING DIAGRAM Location Step Action...
Page 401: C6704: Scanner Time Out
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.79 C6704: Scanner Time Out Relevant Electrical Parts MFP Control Board (PWB-MFPC) Image Processing Board (PWB-C) Copier Board (PWB-CF) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Select “Service Mode” → “State Confirmation” → “Memory/HDD Adj.”...
Page 402: C9401: Exposure Lamp's Failure To Turn On
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.81 C9401: Exposure Lamp’s failure to turn ON 16.6.82 C9402: Exposure Lamp turning ON at abnormal timing Relevant Electrical Parts Scanner Assy Image Processing Board (PWB-C) Flat Cable WIRING DIAGRAM Location Step Action Control Signal...
Page 403: Cc151: Rom Contents Error Upon Startup (Msc)
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.85 CC151: ROM contents error upon startup (MSC) 16.6.86 CC152: ROM contents error upon startup (Scanner) 16.6.87 CC153: ROM contents error upon startup (PRT) 16.6.88 CC154: ROM contents error upon startup (LPH) WIRING DIAGRAM Location Step...
Page 404: Cd004: Hard Disk Access Error
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.91 CD004: Hard disk access error 16.6.92 CD005: Hard Disk Error 1 16.6.93 CD006: Hard Disk Error 2 16.6.94 CD007: Hard Disk Error 3 16.6.95 CD008: Hard Disk Error 4 16.6.96 CD009: Hard Disk Error 5 16.6.97 CD00A: Hard Disk Error 6...
Page 405: Cd010: Hard Disk Unformat
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.103 CD010: Hard disk unformat Relevant Electrical Parts MFP Control Board (PWB-MFPC) Hard Disk WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Select “Service Mode” → “State Confirmation” → — —...
Page 406: Cd201: File Memory Mounting Failure
Field Service Ver. 1.0 Mar. 2005 16. Malfunction code 16.6.107 CD201: File Memory mounting failure 16.6.108 CD202: Memory capacity discrepancy Relevant Electrical Parts Electronic Sorting Board (PWB-ES) Standard Memory (D_FILE0) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check to see if the standard memory (D_FILE0) on the Electronic Sorting Board (PWB-ES) is —...
Page 407: Ceee1: Msc Undefined Malfunction Occurring
16. Malfunction code Field Service Ver. 1.0 Mar. 2005 16.6.113 CEEE1: MSC undefined malfunction occurring Relevant Electrical Parts MFP Control Board (PWB-MFPC) WIRING DIAGRAM Location Step Action Control Signal (Electrical Component) Check the connectors on PWB-MFPC for proper — — connection and correct as necessary.
Page 408: Power Supply Trouble
Field Service Ver. 1.0 Mar. 2005 17. Power supply trouble 17. Power supply trouble 17.1 Machine is not Energized at All (PU1 Operation Check) Relevant Electrical Parts Main Power Switch (SW1) DC Power Supply (PU1) Control Board (PWB-MC) WIRING Step Check Item DIAGRAM Result...
Page 409: Fusing Heaters Do Not Operate
17. Power supply trouble Field Service Ver. 1.0 Mar. 2005 17.3 Fusing Heaters do not Operate Relevant Electrical Parts Upper Right Door Switch (SW5) DC Power Supply (PU1) Fusing Unit WIRING Step Check Item DIAGRAM Result Action (Location) Is the power source voltage applied across Check wiring from PJ4PU1-1 and 3 on PU1? power outlet to SW5 to...
Page 410: Power Is Not Supplied To Option
Field Service Ver. 1.0 Mar. 2005 17. Power supply trouble 17.6 Power is not Supplied to Option 17.6.1 Optional Paper Feed Cabinet WIRING Step Check Item DIAGRAM Result Action (Location) Is DC24 V being applied to hookup connector Malfunction in Paper O-27 CN28-1? Feed Cabinet...
Page 411: Image Quality Problem
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.1 How to read Element date • As part of troubleshooting procedures, the numeric values set for “State Confirmation” available from “Service Mode” can be used to isolate the cause of the image problem. 4037F4E509DA 18.1.1 Table Number...
Page 412: Level History 1
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.1.2 Level History 1 4037F4E513DA TCR-C • Shows the T/C ratio (in 0.01 % increments). TCR-M • Standard value: 7 ± 3 % TCR-Y • Relevant Components: LPH Unit, TCR Sensor K TCR-K IDC1 •...
Page 413: Level History 2
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.1.3 Level History 2 4037F4E515DA IDC Sensor Adjust 1 • Shows the IDC intensity adjustment value. IDC Sensor Adjust 2 • It should normally be around 40 and can range from 0 to 255. •...
Page 414: How To Identify Problematic Part
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.2 How to identify problematic part • This chapter is divided into two parts: “Initial Check Items” and “Troubleshooting Proce- dure by a Particular Image Quality Problem.” • When an image quality problem occurs, first go through the “Initial Check Items” and, if the cause is yet to be identified, go to “Troubleshooting Procedure by a Particular Image Quality Problem.”...
Page 415 18. Image quality problem Field Service Ver. 1.0 Mar. 2005 C. Initial Check Items 3 • If the printer is responsible for the image problem, let the machine produce a test print and determine whether the image problem occurs in a specific single color or four colors 4 Color Mono Color 4037F4C517DA...
Page 416: Solution
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3 Solution 18.3.1 IR System: white lines in Sub Scan Direction, white bands in Sub Scan Direction, colored lines in Sub Scan Direction, and colored bands in Sub Scan Direction A.
Page 417: Scan Direction, Colored Lines In Main Scan Direction, And Colored Bands In Main Scan Direction
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.2 Scanner System: white lines in Main Scan Direction, white bands in Main Scan Direction, colored lines in Main Scan Direction, and colored bands in Main Scan Direction A. Typical Faulty Images White lines in Main White bands in Main Color lines in Main...
Page 418: Scanner System: Color Spots
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.3 Scanner System: color spots A. Typical Faulty Images 4036fs4029c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original is damaged or dirty. YES Change original. Original Cover Original Pad is dirty.
Page 419: Scanner System: Fog
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.4 Scanner System: fog A. Typical Faulty Images ABCD ABCD ABCD ABCD ABCD 4036fs4030c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original is damaged or dirty. YES Change original. Original Cover Original Pad is dirty.
Page 420: Scanner System: Blurred Image, Blotchy Image
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.5 Scanner System: blurred image, blotchy image A. Typical Faulty Images 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original does not lie flat. YES Change original. Original Cover Original Cover does not lie flat.
Page 421: Scanner System: Incorrect Color Image Registration, Sync Shift (Lines In Main Scan Direction)
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.6 Scanner System: incorrect color image registration, sync shift (lines in main scan direction) A. Typical Faulty Images 4036fs4032c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original does not lie flat. YES Change original.
Page 422: Scanner System: Moire
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.7 Scanner System: moire A. Typical Faulty Images 4036fs4033c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Moire distortions recur even after Change the original mode the orientation of original has been (select one other than that changed.
Page 423: Scanner System: Skewed Image
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.8 Scanner System: skewed image A. Typical Faulty Images 4036fs4034c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original is skew. YES Reposition original. Original Glass Original Glass is in positive contact Reinstall the glass.
Page 424: Scanner System: Distorted Image
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.9 Scanner System: distorted image A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4035c0 B. Troubleshooting Procedure Step Section Check Item Result Action Installation Machine is installed on a level sur- Reinstall.
Page 425: Scanner System: Low Image Density, Rough Image
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.10 Scanner System: low image density, rough image A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4036c0 B. Troubleshooting Procedure Step Section Check Item Result Action Original Original sticks to Original Glass. YES Reposition original.
Page 426: Scanner System: Defective Acs
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.11 Scanner System: defective ACS A. Typical Faulty Images Colored Area of Original ABCDE ABCDE ABCDE Black-and-White Area of Original ABCDE ABCDE 4036fs4037c0 B. Troubleshooting Procedure Step Section Check Item Result Action Auto Color Level...
Page 427: Scanner System: Blank Copy, Black Copy
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.12 Scanner System: blank copy, black copy A. Typical Faulty Images Blank copy Black copy 4036fs4038c0 4036fs4039c0 B. Troubleshooting Procedure Step Section Check Item Result Action Cable connecting Connector is connected properly Reconnect.
Page 428: Scanner System: Abnormal Image
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.13 Scanner System: abnormal image A. Typical Faulty Images ABCDE ABCDE Data on previous page ABCDE ABCDE ABCDE ABCDE ABCDE Data on current page ABCDE 4036fs4040c0 4036fs4042c0 4036fs4041c0 B. Troubleshooting Procedure Step Section Check Item...
Page 429: Scan Direction, Colored Lines Colored Bands In Sub Scan Direction, White Lines In Main Scan Direction, White Bands In Main Scan Direction, Colored Lines In Main Scan Direction, Colored Bands In Main Scan Direction
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.14 Printer Monocolor: white lines in Sub Scan Direction, white bands in Sub Scan Direction, colored lines colored bands in Sub Scan Direction, white lines in Main Scan Direction, white bands in Main Scan Direction, colored lines in Main Scan Direction, colored bands in Main Scan Direction A.
Page 430: Printer Monocolor: Uneven Density In Sub Scan Direction
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.15 Printer Monocolor: uneven density in sub scan direction A. Typical Faulty Images 4036fs4043c0 4036fs4044c0 4036fs4045c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image check Uneven density of void area occurs. YES Check LPH Unit connector for proper connection.
Page 431: Printer Monocolor: Uneven Density In Main Scan Direction
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.16 Printer Monocolor: uneven density in main scan direction A. Typical Faulty Images 4036fs4046c0 4036fs4047c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit The surface of the PC Drum is YES Change Imaging Unit.
Page 432: Printer Monocolor: Low Image Density
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.17 Printer Monocolor: low image density A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4036c0 B. Troubleshooting Procedure Step Section Check Item Result Action State Confirm → Check data for Vg and Vdc. Go to next step.
Page 433 18. Image quality problem Field Service Ver. 1.0 Mar. 2005 Step Section Check Item Result Action Image Process Toner is properly supplied when Go to next step. Adjustment → TCR Toner Supply is run. TCR Toner Supply (Service Mode) Image Process The problem has been eliminated Go to next step.
Page 434: Printer Monocolor: Gradation Reproduction Failure
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.18 Printer Monocolor: gradation reproduction failure A. Typical Faulty Images 4036fs4048c0 4036fs4049c0 B. Troubleshooting Procedure Step Section Check Item Result Action Photo/Density Original type and screen pattern are Change screen pattern. selected properly.
Page 435 18. Image quality problem Field Service Ver. 1.0 Mar. 2005 Step Section Check Item Result Action The problem has been eliminated Change Imaging Unit. → Change Image Transfer Belt through the checks of steps up to 9. Unit. → Change LPH Assy. →...
Page 436: Printer Monocolor: Foggy Background
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.19 Printer Monocolor: foggy background A. Typical Faulty Images ABCD ABCD ABCD ABCD ABCD 4036fs4030c0 B. Troubleshooting Procedure Step Section Check Item Result Action State Confirma- Check data for Vg and Vb. Go to next step.
Page 437 18. Image quality problem Field Service Ver. 1.0 Mar. 2005 Step Section Check Item Result Action Image Process The problem has been eliminated Go to next step. Adjustment through the adjust of D Max. → D Max Density (Service Mode) Image Process After the Reset + Stabilizer Go to next step.
Page 438: Printer Monocolor: Void Areas, White Spots
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.20 Printer Monocolor: void areas, white spots A. Typical Faulty Images Void areas White spots 4036fs4051c0 4036fs4050c0 B. Troubleshooting Procedure Step Section Check Item Result Action ☞ 395 Image Check There are void areas at the front side or high density section.
Page 439: Printer Monocolor: Colored Spots
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.21 Printer Monocolor: colored spots A. Typical Faulty Images Colored spots 4036fs4052c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit Developing bias contact terminal Clean contact terminal and makes good connection.
Page 440: Printer Monocolor: Blurred Image
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.22 Printer Monocolor: blurred image A. Typical Faulty Images blurred image 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action YES Select “Service Mode” → Image Check Image is distorted (stretched or “Machine”...
Page 441: Printer Monocolor: Blank Copy, Black Copy
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.23 Printer Monocolor: blank copy, black copy A. Typical Faulty Images Blank copy Black copy 4036fs4038c0 4036fs4039c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image Check A blank copy occurs. YES Check LPH Unit connector for proper connection.
Page 442: Printer Monocolor: 0.5-Mm-Pitch Uneven Image
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.24 Printer Monocolor: 0.5-mm-pitch uneven image A. Typical Faulty Images 0.5mm 4036fs4053c0 B. Troubleshooting Procedure Step Section Check Item Result Action LPH Assy LED retracting lever is locked in Slide out the IU and reinstall. position.
Page 443: Printer Monocolor: 2-Mm-Pitch Uneven Image
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.25 Printer Monocolor: 2-mm-pitch uneven image A. Typical Faulty Images 2 mm 4036fs4054c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit The drive mechanisms for spent YES Clean. toner conveying and IU are dirty.
Page 444: Printer Monocolor: 94-Mm-Pitch Uneven Image
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.26 Printer Monocolor: 94-mm-pitch uneven image A. Typical Faulty Images 94 mm 94 mm 94 mm 4036fs4057c0 4036fs4056c0 4036fs4055c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit The surface of the PC Drum is YES Change Imaging Unit.
Page 445: Direction, Colored Lines In Sub Scan Direction, And Colored Bands In Sub Scan Direction
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.27 Printer 4-Color: white lines in sub scan direction, white bands in sub scan direction, colored lines in sub scan direction, and colored bands in sub scan direction A. Typical Faulty Images White lines in Sub White bands in Sub Colored lines in Sub...
Page 446: Direction, Colored Lines In Main Scan Direction, And Colored Bands In Main Scan Direction
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.28 Printer 4-Color: white lines in main scan direction, white bands in main scan direction, colored lines in main scan direction, and colored bands in main scan direction A. Typical Faulty Images White lines in Main White bands in Colored lines in Main...
Page 447: Printer 4-Color: Uneven Density In Sub Scan Direction
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.29 Printer 4-Color: uneven density in sub scan direction A. Typical Faulty Images 4036fs4043c0 4036fs4044c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image Transfer Fingerprints, oil, or other foreign YES Clean with specified solvent.
Page 448: Printer 4-Color: Uneven Density In Main Scan Direction
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.30 Printer 4-Color: uneven density in main scan direction A. Typical Faulty Images 4036fs4046c0 4036fs4047c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image Transfer Fingerprints, oil, or other foreign YES Clean with specified solvent.
Page 449: Printer 4-Color: Low Image Density
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.31 Printer 4-Color: low image density A. Typical Faulty Images ABCDE ABCDE ABCDE ABCDE ABCDE 4036fs4036c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper is damp. YES Change paper to one just unwrapped from its package.
Page 450: Printer 4-Color: Poor Color Reproduction
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.32 Printer 4-Color: poor color reproduction A. Typical Faulty Images 4036fs4058c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper is damp. YES Change paper to one just unwrapped from its package.
Page 451: Printer 4-Color: Incorrect Color Image Registration
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.33 Printer 4-Color: incorrect color image registration A. Typical Faulty Images 4036fs4032c0 B. Troubleshooting Procedure Step Section Check Item Result Action Warning display The maintenance call mark is dis- YES Take action according to the played on the panel.
Page 452: Printer 4-Color: Void Areas, White Spots
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.34 Printer 4-Color: void areas, white spots A. Typical Faulty Images Void areas White spots 4036fs4051c0 4036fs4050c0 B. Troubleshooting Procedure Step Section Check Item Result Action ☞ Image Check There are void areas at the front side or high density section.
Page 453: Printer 4-Color: Colored Spots
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.35 Printer 4-Color: colored spots A. Typical Faulty Images 4036fs4052c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit The surface of the PC Drum is YES Change Imaging Unit. scratched.
Page 454: Printer 4-Color: Poor Fusing Performance, Offset
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.36 Printer 4-Color: poor fusing performance, offset A. Typical Faulty Images Poor fusing performance Offset 4036fs4059c0 4036fs4060c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper type does not match. YES Change the setting.
Page 455: Printer 4-Color: Brush Effect, Blurred Image
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.37 Printer 4-Color: brush effect, blurred image A. Typical Faulty Images Brush effect Blurred image 4036fs4061c0 4036fs4031c0 B. Troubleshooting Procedure Step Section Check Item Result Action Paper Paper is damp. YES Change paper to one just unwrapped from its package.
Page 456: Printer 4-Color: Back Marking
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.38 Printer 4-Color: back marking A. Typical Faulty Images 4036fs4062c0 4036fs4063c0 B. Troubleshooting Procedure Step Section Check Item Result Action Image Transfer Image Transfer Roller is scratched YES Change Image Transfer Roller Roller Unit or dirty.
Page 457: Printer 4-Color: 204-Mm-Pitch Uneven Image
18. Image quality problem Field Service Ver. 1.0 Mar. 2005 18.3.39 Printer 4-Color: 204-mm-pitch uneven image A. Typical Faulty Images 204-mm-pitch uneven image 204 mm 4036fs4064c0 B. Troubleshooting Procedure Step Section Check Item Result Action Fusing Unit The Fusing Belt is scratchy. YES Change Fusing Unit.
Page 458: Printer 4-Color: 94-Mm-Pitch Uneven Image
Field Service Ver. 1.0 Mar. 2005 18. Image quality problem 18.3.40 Printer 4-Color: 94-mm-pitch uneven image A. Typical Faulty Images 94 mm 94 mm 94 mm 4036fs4057c0 4036fs4056c0 4036fs4055c0 B. Troubleshooting Procedure Step Section Check Item Result Action Imaging Unit The surface of the PC Drum is YES Change Imaging Unit.
Page 459 18. Image quality problem Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 460: Parts Layout Drawing
Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing Appendix 19. Parts layout drawing 19.1 Main unit 19.1.1 ADF section [17] [16] [15] [14] [13] [12] [11] [10] 4037F5C519DA Exit Motor (M3-DF) [10] Empty Sensor (PC4-DF) Exit Cover Sensor (PC7-DF) [11] Pick-up Sensor (PC2-DF) Exit Sensor (PC6-DF) [12] Registration Sensor (PC1-DF)
Page 461: Ir Section
19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 19.1.2 IR section [12] [11] [10] 4037F5E502DA Scanner Motor (M201) Scanner Home Sensor (PC201) Image Processing Board (PWB-C) Original Cover Angle Sensor (PC202) CCD Sensor Board (PWB-A) Original Size Sensor FD1 (PC203) Size Reset Switch (SW201) [10] Scanner Cooling Fan Motor (M202) Inverter Board (PU201)
Page 462: Engine Section
Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing 19.1.3 Engine section [18] [17] [16] [15] [14] [13] [12] [11] [10] 4037F5C503DA Fusing Cooling Fan Motor/1 (M9) [10] Standard Memory (D_FILE0) Fusing Cooling Fan Motor/2 (M15) [11] Standard Memory (D_FILE0) Fusing Cooling Fan Motor/3 (M16) [12] Hard Disk Drive (HDD) Suction Fan Motor (M12)
Page 463 19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 [11] [10] 4037F5C504DA LAN Board (PWB-LAN) Left Door Switch (SW3) Copier Board (PWB-CF) Slide Interface Board (PWB-SIF) IDC/Registration Sensor/2 (PC9) Work Memory (D_WORK0) Fusing Pressure/Retraction Sensor (PC33) [10] NVRAM Board (PWB-NVR) IDC/Registration Sensor/1 (PC8) [11] MFP Control Board (PWB-MFPC) Temperature/humidity Sensor (PC7)
Page 464 Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing [14] [13] [12] [11] [10] 4037F5C505DA LPH Assy/K (LPH K) Main Erase Lamp/Y (LA1) LED Drive Board (PWB-LED) ATDC Sensor/Y (PWB-N1) Main Erase Lamp/K (LA4) [10] Waste Toner Bottle Set Sensor (PC32) Main Erase Lamp/C (LA3) [11] Waste Toner Full Sensor (PC31) ATDC Sensor/C (PWB-N3)
Page 465 19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 [27] [26] [25] [24] [23] [22] [21] [11] [20] [12] [10] [19] [17] [15] [14] [13] [18] [16] 4037F5C506DA Fusing Drive Motor (M2) [15] Toner Near-Empty Sensor PQ/M (PC16) Registration Roller Clutch (CL3) [16] Toner Set Sensor/Y (PC25) Intermediate Transport Motor (M14) [17] Toner Near-Empty Sensor LED/Y (PC21)
Page 466 Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing [14] [13] [12] [11] [10] 4037F5E534DA Right Door Switch (SW2) Bypass Paper Size Unit (VR1) Fusing Paper Loop Control Solenoid (SL1) Bypass Paper Pick-Up Solenoid (SL101) Control Panel (UN201) [10] Front Door Switch (SW4) Fusing Paper Loop Sensor (PC4) [11] DC Power Supply (PU1) Upper Right Door Switch (SW5)
Page 467 19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 [15] [14] [13] [12] [10] [11] 4037F5C508DA Fusing Retraction Position Sensor (PC34) Bypass FD Paper Size Sensor/2 (PC112) Registration Roller Sensor (PC28) [10] Bypass Paper Empty Sensor (PC110) 2nd Image Transfer Pressure /Retraction [11] K PC Drum Main Sensor (PC11) Sensor (PC29) OHP Sensor (PC27)
Page 468: Tray 1
Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing 19.1.4 Tray 1 4037F5C509DA Tray 1 Paper Feed Clutch (CL1) Tray 1 Paper Size Board (PWB-I1) Tray 1 Double Feed Sensor (PC1) Tray 1 Paper Near-Empty Sensor (PC13) Tray 1 Paper Empty Sensor (PC2) Tray 1 Set Sensor (PC14) Tray 1 CD Paper size Sensor (PC3)
Page 469: Tray 2
19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 19.1.5 Tray 2 [12] [13] [14] [10] [15] [11] 4037F5C510DA Tray 2 Vertical Transport Sensor (PC108) Tray 2 CD Paper Size Sensor/S (PC101) Tray 2 Paper Take-Up Sensor (PC107) [10] Tray 2 Lift-Up Motor (M101) Tray 2 Paper Empty Sensor (PC106) [11] Tray 2 Paper Near-Empty Sensor (PC104) Tray 2 Lift-Up Sensor(PC105)
Page 470: Duplex Section
Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing 19.1.6 Duplex section 4037F5C520DA Switchback Motor (M1-DU) Duplex Unit Transport Sensor 2 (PC1-DU) Duplex Unit Door Set Sensor (in PWB-A) Duplex Unit Transport Motor (M2-DU) (Pl2-DU) Duplex Unit Transport Sensor 1 Duplex Control Board (PWB-A DU) (in PWB-A) (PI1-DU)
Page 471: Pc102/Pc202 (Option)
19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 19.2 PC102/PC202 (Option) [26] [25] [23] [24] [22] [21] [20] [19] [18] [17] [16] [15] [10] [13] [11] [14] [12] 4037F5C511DA Tray 4 Paper Near-Empty Sensor Tray 3 Transport Roller Motor (M120-PF) [14] (PC122-PF) Tray 4 CD Paper Size Sensor 2...
Page 472: Pc-402 (Option)
Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing 19.3 PC-402 (Option) [24] [23] [22] [21] [20] [19] [10] [11] [18] [12] [13] [17] [14] [15] [16] 4037F5C512DA Transport Roller Motor (M2-LCT) [13] Paper Descent Key (UN1-LCT) Shifter Return Position Sensor Right Lower Door Sensor (PC5-LCT) [14] (PC11-LCT)
Page 473: Fs-507 (Option)
19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 19.4 FS-507 (Option) [22] [21] [20] [19] [18] [17] [10] [16] [11] [15] [14] [13] [12] 4037F5C514DA CD Aligning Home Position Sensor Upper Cover Sensor (PC18-FN) [12] (PC9-FN) 1st Tray Full Sensor (PC6-FN) [13] Shift Home Position Sensor (PC10-FN) 1st Tray Exit Sensor (PC1-FN) [14] Shift Motor Pulse Sensor (PC11-FN)
Page 474 Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing [18] [17] [16] [15] [14] [13] [12] [11] [10] 4037F5C515DA Upper Entrance Motor (M4-FN) [10] Control Board (PWB-A FN) Punch Motor (M11-FN) [11] Exit Motor (M3-FN) Storage Roller Home Position Sensor Pinch Speed Sensor (PC15-FN) [12] (PC12-FN)
Page 475: Js-601 (Option)
19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 19.5 JS-601 (Option) 4037F5C513DA Job Tray Cover Sensor (PC21-FN) Job Tray Full Sensor (PC20-FN) Job Tray Exit Sensor (PC19-FN) 3rd Entrance Switching Solenoid (SL-4)
Page 476: Fs-603 (Option)
Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing 19.6 FS-603 (Option) [17] [16] [15] [14] [13] [12] [11] [10] 4037F5C516DA Transport Motor (M1-FN) [10] Shift Motor (M6-FN) Entrance Motor (M9-FN) [11] Slide Motor (M8-FN) Saddle Clutch (CL1-FN) [12] Exit Motor (M3-FN) Joint Open Switch (MS2-FN) [13] Rear Aligning Motor (M5-FN) Front Door Open Switch (MS1-FN)
Page 477 19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 [19] [20] [18] [17] [16] [15] [14] [13] [12] [11] [10] 4037F5C521DA Entrance Sensor (PI1-FN) [11] Saddle Tray Sensor (PI13-FN) Folding Roller Home Position Sensor [12] Shift Motor Clock Sensor (PI17-FN) (PI12-FN) Folding Home Position Sensor (PI11-FN) [13] Stack Full Sensor (PI24-FN)
Page 478: Pk-501 (Option)
Field Service Ver. 1.0 Mar. 2005 19. Parts layout drawing 19.7 PK-501 (Option) [10] 4037F5C517DA Punch Motor (M1P-PK) Side Registration Motor (M2P-PK) Side Registration Home Sensor (PI2P-PK) Punch Trash Full LED Board (PWB-F PK) Punch Trash Full Photo Sensor Board Punch Motor Clock Board (PI3P-PK) (PWB-E PK) Photo Sensor Board (PWB-C PK)
Page 479: Horizontal Transport Unit
19. Parts layout drawing Field Service Ver. 1.0 Mar. 2005 19.8 Horizontal Transport Unit 4037F5C518DA Entrance Switching Solenoid (SL1-HO) Paper Sensor (PC1-HO) Turnover Empty Sensor (PC6-HO) Horizontal Unit Door Sensor (PC4-HO)
Page 480: Connector Layout Drawing
Field Service Ver. 1.0 Mar. 2005 20. Connector layout drawing 20. Connector layout drawing Description ➀ Number of Pin Possible to confirm by removing external cover. Not possible to confirm by removing external cover. [17] 14 14 [16] [10] [15] [11] [12] [13]...
Page 481 20. Connector layout drawing Field Service Ver. 1.0 Mar. 2005 [21] [20] [19] [18] [17] [16] [11] [10] [12] [15] [13] [14] 4037F5C535DA CN No. Location CN No. Location CN38 [12] CN101 S-22 CN69 D-21 [13] CN103 R-22 CN11 D-20 [14] CN108 S-25...
Page 482 Field Service Ver. 1.0 Mar. 2005 20. Connector layout drawing [19] [18] [17] [16] [15] [14] [13] [10] [11] [12] 4037F5C536DA CN No. Location CN No. Location CN72 [11] CN105 R-25 [12] CN104 R-23 to 24 CN15 D-19 [13] CN34 S-24 CN12 [14]...
Page 483: Timing Chart
21. Timing chart Field Service Ver. 1.0 Mar. 2005 21. Timing chart 21.1 Main unit Print request received Main Motor (M1) Cleaning Brush Motor (M22) Color PC Drum Motor (M5) K PC Motor (M7) Color Developing Motor (M6) 2nd Image Transfer Pressure/Retraction Motor (M13) Fusing Drive Motor (M2)
Page 484: Automatic Document Feeder
Field Service Ver. 1.0 Mar. 2005 21. Timing chart 21.2 Automatic Document Feeder 21.2.1 1-sided mode...
Page 485 21. Timing chart Field Service Ver. 1.0 Mar. 2005...
Page 486 Field Service Ver. 1.0 Mar. 2005 21. Timing chart...
Page 487 21. Timing chart Field Service Ver. 1.0 Mar. 2005...
Page 488: Mixed Original Detection Mode
Field Service Ver. 1.0 Mar. 2005 21. Timing chart 21.2.2 Mixed original detection mode...
Page 489 21. Timing chart Field Service Ver. 1.0 Mar. 2005...
Page 490 Field Service Ver. 1.0 Mar. 2005 21. Timing chart...
Page 491 21. Timing chart Field Service Ver. 1.0 Mar. 2005...
Page 492 Field Service Ver. 1.0 Mar. 2005 21. Timing chart...
Page 493 21. Timing chart Field Service Ver. 1.0 Mar. 2005...
Page 494 Field Service Ver. 1.0 Mar. 2005 21. Timing chart...
Page 495 21. Timing chart Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 496 SERVICE MANUAL FIELD SERVICE Standard Controller 2005.03 Ver. 1.0...
Page 498 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 500 Field Service Ver. 1.0 Mar. 2005 CONTENTS General Controller specifications ..................1 Type ........................1 Supporting client specifications ................2 Maintenance Checking the controller firmware version ..............3 Firmware upgrade ....................3 Preparations for Firmware rewriting..............3 3.1.1 Service environment ..................3 3.1.2 Application to be used...................
Page 501 Field Service Ver. 1.0 Mar. 200X Blank Page...
Page 502: Controller Specifications
Field Service Ver. 1.0 Mar. 2005 1. Controller specifications General Controller specifications Type Type Built-in type controller B&W :45 ppm (A4 paper, and simplex or duplex) Print Speed :44 ppm (8-1/2 x 11 paper, and simplex or duplex) Color :35 ppm (A4 or 8-1/2 x 11 paper, and simplex or duplex) PCL5e/c Emulation Printer Language PCL6 (XL 2.1) Emulation...
Page 503: Supporting Client Specifications
1. Controller specifications Field Service Ver. 1.0 Mar. 2005 Supporting client specifications IBM PC and its compatible 64 MB or more (128MB or more for XP) Windows 98/98SE, Windows Me, Windows 2000, Windows XP, Windows NT 4.0, Windows Server 2003 Connection Ethernet 10Base-T/100Base-TX method...
Page 504: Maintenance
Field Service Ver. 1.0 Mar. 2005 2. Checking the controller firmware version Maintenance Checking the controller firmware version • The version of the controller firmware can be checked on the control panel of the machine. 1. Call the Service Mode to the screen. 2.
Page 505 3. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 3. Select “Install from Local Directory”, and click [Next (N)]. 4037F2E546DA 4. Specify the folder for installation. Check to make sure that “Root Directory” is in default setting, [C:\cygwin]. NOTE • Make sure to check that “Root Directory” is in default setting, [C:\cygwin]. •...
Page 506 Field Service Ver. 1.0 Mar. 2005 3. Firmware upgrade 6. Specify the place of the data to be installed. For installing from CD-ROM, select the [cygwin] folder in CD-ROM drive. (Described below is the sample procedure when CD-ROM drive is E-drive.) 7.
Page 507 3. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 10. After installing, open the Property of “My Computer”, and click the “Environmental Vari- able” of “Advanced” tab. 11. Click the “New” in System Variable Setting. 4036fs2620e0 12. Set the following two values as the Windows Environmental Variable. Variable name Variable value CYGWIN...
Page 508: Writing Into The Compact Flash
Field Service Ver. 1.0 Mar. 2005 3. Firmware upgrade 3.1.4 Writing into the Compact flash 1. Put the data of Firmware in the optional directory. (C:\C450 in the below figure) 4037F2E541DA NOTE • The file name of Firmware data consists of the “Release Date_Version_CHECKSUM-****.exe.”...
Page 509 3. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 3. Mount the Compact flash on the PC, and check the Drive name, which was recognized in the Windows. (F-drive in the following figure) 4036fs2623e0 → → → 4. Click “Start” “Program”...
Page 510 Field Service Ver. 1.0 Mar. 2005 3. Firmware upgrade 7. Once the “mkcf.bat” is executed, data writing into the Compact flash is started. 8. Upon completion of writing, CHECKSUM is executed. If CHECKSUM value is precisely matched, “VERIFY OK” appears. 4037F2E544DA 9.
Page 511: Firmware Rewriting
3. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 Firmware rewriting • The F/W is updated using the Compact flash. 3.2.1 Updating method NOTE • NEVER remove or insert the Compact Flash card with the machine power turned 1. With the main power switch in the OFF position, unplug the power cord from the power outlet.
Page 512: Action When Data Transfer Fails
Field Service Ver. 1.0 Mar. 2005 3. Firmware upgrade 7. Press the Start key. (At this time, the Start key starts blinking red.) 8. Check that the Touch Panel shows the message indicating that the data has been rewritten correctly (“Downloading Completed”). Check also the Check Sum value (“Check Sum XXXX”) shown on the Touch Panel.
Page 513 3. Firmware upgrade Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 514: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 4. Checking the Image Controller Setting Adjustment/Setting Checking the Image Controller Setting • Whenever the controller is mounted, it is necessary to select “Controller 0” in “Image Controller Setting.” 1. Call the Service Mode to the screen. 2.
Page 515 4. Checking the Image Controller Setting Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 516: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 5. Checking the system configuration Troubleshooting Checking the system configuration • When a malfunction occurs, let the printer print a Configuration Page to check for system configuration. 1. Press the Utility/Counter key. 2. Touch “User Setting” → “Printer Setting” → “Print Reports.” 3.
Page 517 7. Troubleshooting procedures Field Service Ver. 1.0 Mar. 2005 Check Possible Cause Action Remark The print destination Set the correct See “User’s Guide port setting is wrong. port. [Print Operations].” PC operates errati- Restart the PC. cally temporarily. Uninstall the printer Printer driver incor- driver through the See “User’s Guide...
Page 518: Unable To Transmit Data Through Scan To Ftp
Field Service Ver. 1.0 Mar. 2005 7. Troubleshooting procedures Unable to transmit data through Scan to FTP. Check Possible Cause Action Remark The FTP server is not in Check with the network service. administrator. Check with the network IP address of the FTP administrator and enter server is wrong.
Page 519: Unable To Transmit Data Through Scan To E-Mail/Internet Fax
7. Troubleshooting procedures Field Service Ver. 1.0 Mar. 2005 Unable to transmit data through Scan to E-Mail/Internet FAX. Check Possible Cause Action Remark The SMTP server is not in Check with the network service. administrator. Check with the network IP address of the SMTP administrator and enter the server is wrong.
Page 520: E-Mail Does Not Reach The Destination When Transmission Through Scan To E-Mail/Scan To Internet Fax Is Completed
Field Service Ver. 1.0 Mar. 2005 7. Troubleshooting procedures E-mail does not reach the destination when transmission through Scan to E-Mail/Scan to Internet FAX is completed. Check Possible Cause Action Remark See “User’s Guide The destination mail Enter the correct mail [Network Scanner address is wrong.
Page 521 7. Troubleshooting procedures Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 522 SERVICE MANUAL FIELD SERVICE Automatic Document Feeder 2005.03 Ver. 1.0...
Page 524 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 526 Field Service Ver. 1.0 Mar. 2005 CONTENTS General Product specification ....................1 Type ........................1 Functions ......................1 Paper type ......................1 Paper feed prohibited originals ................2 Paper feed not guaranteed originals..............2 Mixed original feed chart..................3 Machine specifications..................3 Operating environment ..................
Page 527 Field Service Ver. 1.0 Mar. 2005 5.2.3 Auto Stop Position Adjustment ..............16 5.2.4 Paper Passage ................... 17 5.2.5 Sensor Check .................... 17 Sensor check list ....................18 5.3.1 Sensor check screen .................. 18 5.3.2 Original Tray Width..................19 5.3.3 Sensor Auto Adjust ..................
Page 528: Product Specification
Field Service Ver. 1.0 Mar. 2005 1. Product specification General Product specification Type Name Duplexing Document Feeder Paper Take-Up Paper Take-Up from top of stack Transport Endless Belt Transport Mode Type Turnover Loop Turnover Mode U-turn Turnover + Switchback U-Turn Turnover Paper Exit Mode (only in 1-Sided Mode) Installation...
Page 529: Paper Feed Prohibited Originals
1. Product specification Field Service Ver. 1.0 Mar. 2005 Paper feed prohibited originals • If fed, trouble occurrence will be highly possible. Type of Original Possible Trouble Sheets stapled or clipped together Take-up failure, damaged sheet, defective drive mechanism due to jammed staples or clips Sheets glued together Take-up failure, damaged sheet Take-up failure, Sheets misfed...
Page 530: Mixed Original Feed Chart
Field Service Ver. 1.0 Mar. 2005 1. Product specification Mixed original feed chart For Metric Max. Original 297 mm 257 mm 210 mm 182 mm 148 mm Size Mixed Original Size 297 mm 257 mm 210 mm 182 mm 148 mm For Inch Max.
Page 531: Operating Environment
1. Product specification Field Service Ver. 1.0 Mar. 2005 Operating environment Conforms to the operating environment of the main unit. NOTE • These specifications are subject to change without notice.
Page 532: Maintenance
Field Service Ver. 1.0 Mar. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol. 2.1.1 Transport Belt A. Replacing procedure 1. Remove two C-clips [1]. 4582s2501c0 2.
Page 533: Pick-Up Roller / Paper Take-Up Roller
2. Periodical check Field Service Ver. 1.0 Mar. 2005 5. Remove the Transport Belt [7]. 6. To reinstall, reverse the order of removal. 4582fs2505c0 2.1.2 Pick-up Roller / Paper Take-up Roller A. Replacing procedure 1. Open the Paper Take-up Section Cover [1], press inward and unlock the locking claws [2] at both ends of the Paper Take-up Section Guide...
Page 534: Separation Roller
Field Service Ver. 1.0 Mar. 2005 2. Periodical check 5. Remove C-clip (black) of the Paper Take-up Roller, and remove the Paper Take-up Roller [12]. NOTE • Be careful not to lose the Pick-Up/ Take-Up Roller fixing pin. 6. To reinstall, reverse the order of [12] removal.
Page 535: Pick-Up Roller / Paper Take-Up Roller / Separation Roller
2. Periodical check Field Service Ver. 1.0 Mar. 2005 2.1.4 Pick-up Roller / Paper Take-up Roller / Separation Roller A. Cleaning procedure 1. Open the Paper Take-up Section Cover [1]. 2. Wet a cloth with alcohol, and use it to wipe up the Pick-up Roller [2], Paper Take-up Roller [3] and Separation Roller [4].
Page 536: Exit Roller / Roll
Field Service Ver. 1.0 Mar. 2005 2. Periodical check 2.1.6 Exit Roller / Roll A. Cleaning procedure 1. Open the Paper Exit Section Cover [1]. 2. Wet a cloth with alcohol, and use it to wipe up the Exit Roller [2]/Roll [3]. 4582fs2515c0 2.1.7 Turnover Roller...
Page 537 2. Periodical check Field Service Ver. 1.0 Mar. 2005 3. Remove the Registration Roller Cover. ☞ 8 4. Clean the Paper Empty Sensor [3] with a brush or the like. 4582fs2519c0 5. Open the Paper Exit Section Cover. 6. Clean the Paper Exit Sensor [4] with a brush or the like.
Page 538: Other
Field Service Ver. 1.0 Mar. 2005 3. Other Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
Page 539: Disassembly/Assembly List (Other Parts)
3. Other Field Service Ver. 1.0 Mar. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Front Cover Exterior Parts ☞ Rear Cover ☞ Unit Disassembly/Assembly procedure 3.3.1 Front Cover/Rear Cover 4582fs2521c0 1. Open the Paper Take-up Section Cover [1] and the Paper Exit Section Cover [2]. 2.
Page 540 Field Service Ver. 1.0 Mar. 2005 3. Other 2. Open the ADF. 3. Remove two screws [2]. 4037F2C513DA 4. Remove the ADF [3]. 4037F2C514DA...
Page 541 3. Other Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 542: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 543: Service Mode
5. Service Mode Field Service Ver. 1.0 Mar. 2005 Service Mode Service Mode setting procedure ☞ For details of how to display the Service Mode screen, see the Adjustment/Setting of the main unit service manual. ADF setting procedure 5.2.1 Original Stop Position Functions •...
Page 544: Paper Passage
Field Service Ver. 1.0 Mar. 2005 5. Service Mode 5.2.4 Paper Passage Functions • To check for paper passage through the ADF in each of the ADF modes. • Used for checking the document path for any abnormal condition when a document misfeed occurs.
Page 545: Sensor Check List
5. Service Mode Field Service Ver. 1.0 Mar. 2005 Sensor check list 5.3.1 Sensor check screen • This is only typical screen which may be different from what are shown on each individ- ual main unit. 4037F3E515DA • Note with care that the Take-up (Feed) Section Open / Close Sensor, the Transport (Con- vey) Section Open / Close Sensor, the Exit Section Open / Close Sensor and the Middle Tray Open / Close Sensor are displayed as Faulty Set Detected when they are opened.
Page 546: Original Tray Width
Field Service Ver. 1.0 Mar. 2005 5. Service Mode 5.3.2 Original Tray Width Functions • To set the maximum and the minimum width for the width sensor. • When a document misfeed occurs. • When an original size is erroneously detected Setting/ ☞...
Page 547: Mechanical Adjustment
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Mechanical adjustment Adjustment of the tray volume • Read out the value of maximum width and minimum width of the document width detec- tion volume interlocked with the Document Take-up Tray Edge Guide. 1.
Page 548: Adjustment Of The Document Edge Guide Reference Position
Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment 5. Touch “Min. Width.” 6. Press the “Start” key. Confirm that the Result is “OK.” 7. Touch “END.” 8. Touch “Exit” on the Service Mode screen. 4582F3E502DA If the Result is “NG”: •...
Page 549: Adjustment Of The Document Skew
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Adjustment of the document skew Adjustment standard: Skew should be ± 1.0 % or less with respect to the document length; within 3.0 mm for document of A4 size. 1. Place the chart furnished with the Document Feeder in the document feeding tray [1] (with the side having an arrow facing up).
Page 550: Adjustment Of The Document Stop Position
Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment Adjustment of the document stop position • Adjustment of the document stop position is made automatically and manually (by enter- ing numbers). The following adjustment is made in the Service Mode. 4037F3E525DA 6.4.1 Auto adjust: Sub Scanning Direction 1-Side...
Page 551: Auto Adjust: Sub Scanning Direction 2-Side
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 7. Make sure that Result is “OK.” Then, touch “SET.” 8. Touch “END.” 9. Touch “Exit” on the Service Mode screen. If the Result is “NG”: • Check and correct the skew of the document. •...
Page 552: Auto Adjust: Main Scanning Direction
Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment 6.4.3 Auto adjust: Main Scanning Direction A. Adjustment procedure 1. Call the Service Mode to the screen. 2. Touch “ADF.” 3. Touch “Auto Stop Position Adjustment.” 4. Touch “Main Scanning Direction.” 4037F3E531DA 5.
Page 553: Manual Adjust: 1-Sided Set/ 2-Sided Set
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 6.4.4 Manual adjust: 1-Sided Set/ 2-Sided Set Adjusted range: -7 mm to + 7 mm A. Adjustment procedure 1. Call the Service Mode to the screen. 2. Touch “ADF.” 3. Touch “Original Stop Position.” 4037F3E533DA 4.
Page 554: Manual Adjust: Main Scanning Direction
Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment 6.4.5 Manual adjust: Main Scanning Direction Adjusted range: -3 mm to + 3 mm A. Adjustment procedure 1. Call the Service Mode to the screen. 2. Touch “ADF.” 3. Touch “Original Stop Position.” 4037F3E533DA 4.
Page 555: Adjustment Of The Registration Loop Value
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Adjustment of the registration loop value Adjusted range: -5 mm to + 5 mm Default value: 0 (Loop value: 5 mm) • The loop value is increased by the entered + value and decreased by the entered - value. •...
Page 556: Sensor Auto Adjustment
Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment Sensor auto adjustment • The detection level of the document through path sensor is automatically adjusted. • The adjustment has two modes: “Initialize And Sensor Auto Adj.” and “ADF Sensor Auto Adj.”...
Page 557 6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 558: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. Code Misfeed location Misfeed access location Action ☞...
Page 559: Solution
7. Jam Display Field Service Ver. 1.0 Mar. 2005 Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.
Page 560: Transport Section Misfeed
Field Service Ver. 1.0 Mar. 2005 7. Jam Display 7.3.3 Transport section misfeed A. Detection timing Type Description Misfeed due to Misfeed is detected if the Pick-up Sensor (PC2-DF) is not turned OFF within a paper remaining at preset time after the Take-up Motor (M1-DF) started reverse rotation. the Pick-Up Sensor Misfeed due to paper not reached...
Page 561: Paper Exit / Turnover Section Misfeed
7. Jam Display Field Service Ver. 1.0 Mar. 2005 7.3.4 Paper Exit / Turnover section misfeed A. Detection timing Type Description Misfeed due to paper remaining at Misfeed is detected if the Turnover Sensor (PC5-DF) is not turned OFF within a the Turnover Sen- preset time after the Turnover Sensor (PC5-DF) was tuned ON.
Page 562: Transport Tray Section Misfeed
Field Service Ver. 1.0 Mar. 2005 7. Jam Display 7.3.5 Transport Tray section misfeed A. Detection timing Type Description Misfeed due to paper not reached Misfeed is detected if the Exit Sensor (PC6-DF) is not turned ON within a preset the Exit Sensor time after exit operation started in the 1-Sided Mode.
Page 563: Set Error Detection
8. Set error detection Field Service Ver. 1.0 Mar. 2005 Set error detection • When the ADF or cover set error for some reason is detected, the Panel of the main unit will have the following display. 4582F4E502DA <Panel display and detection timing for each> Panel dis- Description of error Detection start...
Page 564: Automatic Duplex Unit
SERVICE MANUAL FIELD SERVICE Automatic Duplex Unit 2005.03 Ver. 1.0...
Page 566 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 568 Field Service Ver. 1.0 Mar. 2005 CONTENTS General Product specifications ..................... 1 Type ........................1 Paper type ......................1 Machine specifications..................1 Operating environment ..................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Transport Roller / Roll 1 ................3 2.1.2 Transport Roller / Roll 2, 3 ................
Page 569 Field Service Ver. 1.0 Mar. 2005 7.3.2 Duplex Unit transport section misfeed ............13...
Page 570: Product Specifications
Field Service Ver. 1.0 Mar. 2005 1. Product specifications General Product specifications Type Name Duplex Unit Type Switchback and Circulating Duplex Unit Installation Mounted on the right side door of main unit Document Alignment Center Paper type Paper Type Plain paper 60 to 256 g/m (16 to 68 lb) Paper Size...
Page 571 1. Product specifications Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 572: Periodical Check
Field Service Ver. 1.0 Mar. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol. 2.1.1 Transport Roller / Roll 1 A. Cleaning procedure 1.
Page 573: Ventilation Section
2. Periodical check Field Service Ver. 1.0 Mar. 2005 2.1.3 Ventilation Section A. Cleaning procedure 1. Using a soft cloth dampened with alcohol, wipe the outside of the Ventilation Section [1] clean of dirt. 4535fs2503c0 2. Open the Duplex Unit Door [2]. 3.
Page 574: Other
Field Service Ver. 1.0 Mar. 2005 3. Other Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
Page 575: Disassembly/Assembly List (Other Parts)
3. Other Field Service Ver. 1.0 Mar. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Unit Duplex Unit Disassembly/Assembly procedure 3.3.1 Duplex Unit 1. Remove the wiring cover. ☞ For details of how to remove the wir- ing cover, see the Maintenance of the main unit service manual.
Page 576: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 577: Sensor Check
5. Sensor check Field Service Ver. 1.0 Mar. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
Page 578: Mechanical Adjustment
Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment Mechanical adjustment Adjusting the paper reference position 1. Call the Service Mode to the screen. ☞ For details of how to display the Ser- vice Mode screen, see the Adjust- ment/Setting of the main unit service manual.
Page 579 6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 580: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. Code Misfeed location Misfeed access location Action 9201...
Page 581: Solution
7. Jam Display Field Service Ver. 1.0 Mar. 2005 Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.
Page 582 Field Service Ver. 1.0 Mar. 2005 7. Jam Display 7.3.2 Duplex Unit transport section misfeed A. Detection timing Type Description The Synchronizing Roller Sensor(PC28) is not blocked even after the lapse of a given period of time after the Duplex Paper Take-up sequence started. The Duplex Unit Transport Sensor 2 (PC1-DU) is not blocked even after the set period of time has elapsed after the Duplex Unit Transport Sensor 1 (PI1-DU) is blocked by the paper.
Page 583 7. Jam Display Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 584 SERVICE MANUAL FIELD SERVICE PC-102/PC-202 2005.03 Ver. 1.0...
Page 586 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 588 Field Service Ver. 1.0 Mar. 2005 CONTENTS General Product specifications ..................... 1 Type ........................1 Paper type ......................1 Machine specifications..................1 Operating environment ..................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Replacing the Separation Roller Assy............3 2.1.2 Replacing the Paper Take-up Roller..............
Page 589 Field Service Ver. 1.0 Mar. 2005 6.1.1 Print Positioning: Side Edge ............... 16 6.1.2 Dup Print Positioning: Side Edge..............17 Troubleshooting Jam Display......................19 Misfeed display....................19 7.1.1 Misfeed display resetting procedure ............19 Sensor layout...................... 20 Solution ......................21 7.3.1 Initial check items ..................
Page 590: Product Specifications
Field Service Ver. 1.0 Mar. 2005 1. Product specifications General Product specifications Type Name 2 way Paper Take-Up Cabinet Type Front loading type 2 way paper take-up device Installation Desk type Document Alignment Center Paper type Paper Type Plain paper 56 to 256 g/m (15 to 68 lb) Recycled paper...
Page 591 1. Product specifications Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 592: Periodical Check
Field Service Ver. 1.0 Mar. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) 2.1.1 Replacing the Separation Roller Assy 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Jam Access Cover [2]. 4348fs2611c0 3.
Page 593: Replacing The Paper Take-Up Roller
2. Periodical check Field Service Ver. 1.0 Mar. 2005 NOTES • Install the Separation Roller Assy while pressing the holder down so that it aligns to the metal bracket of the machine. • Make sure that the Separation Roller Assy is not tilted to the right or left when installed.
Page 594 Field Service Ver. 1.0 Mar. 2005 2. Periodical check 7. Remove two screws [6] and remove the Paper Take-up Cover [7]. 4348fs2605c0 8. Remove the C-ring [8] and remove the bushing [9]. 4348fs2606c0 [10] 9. Shift the Shaft Assy [10] in the orien- tation as shown on the left, and remove the C-ring [11] and the gear [12].
Page 595: Replacing The Pick-Up Roller
2. Periodical check Field Service Ver. 1.0 Mar. 2005 [18] 11. Remove two E-rings [16] and the [16] [16] bushing [17], and remove the Pick- up Roller Fixing Bracket Assy [18]. [17] 4348fs2609c0 12. Remove the C-ring [19] and remove the Paper Take-up Roller [20].
Page 596 Field Service Ver. 1.0 Mar. 2005 2. Periodical check 6. Remove two screws [4] and remove the Paper Separation Roller Mount- ing Bracket Assy [5] together with frame. 4348fs2617c0 7. Remove two screws [6] and remove the Paper Take-up Cover [7]. 4348fs2605c0 8.
Page 597: Other
3. Other Field Service Ver. 1.0 Mar. 2005 Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
Page 598: Disassembly/Assembly/Cleaning List (Other Parts)
Field Service Ver. 1.0 Mar. 2005 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page ☞ Right Door ☞ Rear Right Cover ☞ Exterior parts Lower Right Cover ☞ Front Right Cover ☞ Rear Cover 3.2.2 Cleaning parts list Section...
Page 599: Disassembly/Assembly Procedure
3. Other Field Service Ver. 1.0 Mar. 2005 Disassembly/Assembly procedure 3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover 4348fs2621c0 1. Open the Right Door [1]. 2. Remove the Right Door [1]. 3. Remove two screws [2] and remove the Rear Right Cover [3]. 4.
Page 600: Cleaning Procedure
Field Service Ver. 1.0 Mar. 2005 3. Other Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Separation Roller 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Jam Access Cover [2].
Page 601: Pick-Up Roller
3. Other Field Service Ver. 1.0 Mar. 2005 3.4.3 Pick-up Roller 1. Remove the Tray3.(Remove the Tray4 from 4th row.) 2. Remove the Paper Separation Roller Mounting Bracket Assy. ☞ 3 3. Using a soft cloth dampened with alcohol, wipe the Pick-up Roller [1] clean of dirt.
Page 602: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 603: Sensor Check
5. Sensor check Field Service Ver. 1.0 Mar. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
Page 604: Sensor Check List
Field Service Ver. 1.0 Mar. 2005 5. Sensor check 5.2.2 Sensor check list A. Sensor monitor 1 (PC-102/PC-202) Operation characteris- tics/Panel display Symbol Panel display Part/Signal name PC112-PF Device Detection Tray3 Set Sensor Out of position PC115-PF Paper Empty Tray3 Paper Empty Sensor Paper not Paper present...
Page 605: Mechanical Adjustment
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Mechanical adjustment Adjusting the paper reference position NOTE • Make this adjustment after any of the following procedures has been performed. When the LPH Unit has been replaced. When the image on the print is offset in the sub scan direction. When a faint image occurs on the leading edge of the image.
Page 606: Dup Print Positioning: Side Edge
Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment 8. Slide out the drawer [1] and unload paper from it. 9. Loosen three screws [2] at the center of the Paper Lifting Plate. 4348fs3601c0 10. Watching the graduations [3] pro- vided in the drawer, move the Edge Guide [4] in the rear.
Page 607 6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 5. Measure the width of printed refer- ence line A. ± Specification: 3.0 mm 1.0 mm 6. If the measured width A falls outside the specified range, enter the correc- tion value. 7.
Page 608: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. 4061F4C501DA Code Misfeed location Misfeed access location Action 1301...
Page 609: Sensor Layout
7. Jam Display Field Service Ver. 1.0 Mar. 2005 Sensor layout 4061F4C502DB [1] Tray2 Vertical Transport Sensor PC108 [4] Tray4 Vertical Transport Sensor PC126-PF [2] Tray3 Vertical Transport Sensor PC117-PF [5] Tray4 Paper Take-Up Sensor PC125-PF [3] Tray3 Paper Take-Up Sensor PC116-PF...
Page 610: Solution
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.
Page 611: Tray3 Paper Take-Up Section/Vertical Transport Section Misfeed (Pc-102/Pc-202)
7. Jam Display Field Service Ver. 1.0 Mar. 2005 7.3.2 Tray3 Paper Take-Up section/Vertical Transport section misfeed (PC-102/PC-202) A. Detection timing Type Description The leading edge of the paper does not block the Tray3 Vertical Transport Sensor (PC117-PF) even after the set period of time has elapsed after the Tray3 Paper Feed Motor (M122-PF) is energized.
Page 612: Tray4 Paper Take-Up Section/Vertical Transport Section Misfeed (Pc-202)
Field Service Ver. 1.0 Mar. 2005 7. Jam Display 7.3.3 Tray4 Paper Take-Up section/Vertical Transport section misfeed (PC-202) A. Detection timing Type Description The leading edge of the paper does not block the Tray4 Vertical Transport Sensor (PC126-PF) even after the set period of time has elapsed after the Tray4 Paper Feed Motor (M123-PF) is energized.
Page 613: Trouble Code
8. Trouble code Field Service Ver. 1.0 Mar. 2005 Trouble code Trouble code display • The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4061F4E504DA Trouble code list Code Item Description...
Page 614: Solution
Field Service Ver. 1.0 Mar. 2005 8. Trouble code Solution 8.4.1 C0206: Tray3 Lift-Up Failure C0208: Tray4 Lift-Up Failure Relevant electrical parts Lift-Up Motor 1 (M124-PF) Main Control Board (PWB-C2 PF) Tray4 Lift-Up Motor (M125-PF) main unit Control Board (PWB-MC) Tray3 Lift-Up Upper Limit Sensor (PC114-PF) main unit DC Power Supply (PU1) Tray4 Lift-Up Sensor (PC123-PF)
Page 615 8. Trouble code Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 616 SERVICE MANUAL FIELD SERVICE PC-402 2005.03 Ver. 1.0...
Page 618 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 620 Field Service Ver. 1.0 Mar. 2005 CONTENTS General Product specification ....................1 Type ........................1 Paper type ......................1 Machine specifications..................1 Operating environment ..................1 Maintenance Periodical check ...................... 3 Maintenance procedure (Periodical check parts) ..........3 2.1.1 Replacing the Separation Roller Assy............3 2.1.2 Replacing the Paper Take-up Roller..............
Page 621 Field Service Ver. 1.0 Mar. 2005 Mechanical adjustment ..................20 Adjusting the paper reference position ............... 20 6.1.1 Print Positioning: Side Edge ............... 20 6.1.2 Dup Print Positioning: Side Edge..............22 Shifter movement timing belt adjustment ............22 Troubleshooting Jam Display......................25 Misfeed display....................
Page 622: Product Specification
Field Service Ver. 1.0 Mar. 2005 1. Product specification General Product specification Type Name Large Capacity Cabinet Type Front loading type LCC Installation Desk type Document Alignment Center Paper type Paper Type Plain paper 56 to 256 g/m (15 to 68 lb) Recycled paper 60 to 90 g/m (16 to 24 lb)
Page 623 1. Product specification Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 624: Periodical Check
Field Service Ver. 1.0 Mar. 2005 2. Periodical check Maintenance Periodical check Maintenance procedure (Periodical check parts) 2.1.1 Replacing the Separation Roller Assy 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Paper Separation Roller Mount- ing Bracket Assy [2].
Page 625: Replacing The Paper Take-Up Roller
2. Periodical check Field Service Ver. 1.0 Mar. 2005 NOTE • Install the Separation Roller Assy while pressing the holder down so that it aligns to the metal bracket of the machine. • Make sure that the Separation Roller Assy is not tilted to the right or left when installed.
Page 626 Field Service Ver. 1.0 Mar. 2005 2. Periodical check 7. Remove two screws [6] and remove the Paper Take-up Cover [7]. 4348fs2504c0 8. Remove two C-rings [8] and remove the bushing [9]. 4348fs2505c0 9. Shift the Shaft Assy [10] in the orien- [10] tation as shown on the left, and remove the C-ring [11] and the gear...
Page 627: Replacing The Pick-Up Roller
2. Periodical check Field Service Ver. 1.0 Mar. 2005 11. Remove two E-rings [13] and the [15] [13] [13] bushing [14], and remove the Pick- up Roller Fixing Bracket Assy [15]. [14] 4348fs2507c0 12. Remove the C-ring [16] and remove the Paper Take-up Roller [17].
Page 628 Field Service Ver. 1.0 Mar. 2005 2. Periodical check 6. Remove two screws [4] and remove the Paper Separation Roller Mount- ing Bracket Assy [5] together with frame. 4348fs2516c0 7. Remove two screws [6] and remove the Paper Take-up Cover [7]. 4348fs2515c0 8.
Page 629: Other
3. Other Field Service Ver. 1.0 Mar. 2005 Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
Page 630: Disassembly/Assembly/Cleaning List (Other Parts)
Field Service Ver. 1.0 Mar. 2005 3. Other Disassembly/Assembly/Cleaning list (Other parts) 3.2.1 Disassembly/Assembly parts list Section Part name Ref. page ☞ Right Door ☞ Rear Right Cover ☞ Exterior Parts Lower Right Cover ☞ Front Right Cover ☞ Rear Cover ☞...
Page 631: Disassembly/Assembly Procedure
3. Other Field Service Ver. 1.0 Mar. 2005 Disassembly/Assembly procedure 3.3.1 Right Door/Rear Right Cover/Lower Right Cover/Front Right Cover 4348fs2520c0 1. Open the Right Door [1]. 2. Remove the Right Door [1]. 3. Remove two screws [2] and remove the Rear Right Cover [3]. 4.
Page 632: Drawer
Field Service Ver. 1.0 Mar. 2005 3. Other 3.3.3 Drawer 1. Press the Drawer Eject Button [1] and slide out the drawer [2]. 2. Remove the paper. 3. Remove four screws [3] and slide out the drawer [2]. 4348fs2522c0 4. Remove two screws [4], the connec- tor [5], and remove the Connector Board [6].
Page 633 3. Other Field Service Ver. 1.0 Mar. 2005 5. Remove two screws [6] and remove the Driver Cover [7]. 4348fs2527c0 6. Remove three screws [8] and remove the Driver Mounting Plate Assy [9]. 4348fs2528c0 NOTE [10] • When assembling, be sure to engage rib of gear 1 [10] with con- vex section of gear 2 [11].
Page 634 Field Service Ver. 1.0 Mar. 2005 3. Other 11. Remove the Ground Plate [17]. [18] 12. Remove four Cable Holding Jigs [18] [19] [18] and remove the Main Drawer [19]. NOTE [18] • Use care not to bend the wires. [18] [17] 4348fs2532c0...
Page 635: Cleaning Procedure
3. Other Field Service Ver. 1.0 Mar. 2005 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 3.4.1 Separation Roller 1. Remove the Right Door. ☞ 10 2. Remove two screws [1] and remove the Paper Separation Roller Mount- ing Bracket Assy [2].
Page 636: Vertical Transport Roller
Field Service Ver. 1.0 Mar. 2005 3. Other 3.4.4 Vertical Transport Roller 1. Open the Right Door. 2. Using a soft cloth dampened with alcohol, wipe the Vertical Transport Roller [1] clean of dirt. 4348fs2519c0...
Page 637 3. Other Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 638: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 4. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 639: Sensor Check
5. Sensor check Field Service Ver. 1.0 Mar. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
Page 640: Sensor Check List
Field Service Ver. 1.0 Mar. 2005 5. Sensor check 5.2.2 Sensor check list A. Sensor monitor 2 Operation characteris- tics/Panel display Symbol Panel display Part/Signal name PC4-LCT Lift-Up Upper Tray Upper Limit Sensor Raised Not raised Position PC13- Lift-Up Lower Tray Lower Position Sensor Lowered Not low-...
Page 641: Mechanical Adjustment
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Mechanical adjustment Adjusting the paper reference position NOTE • Make this adjustment after any of the following procedures has been performed. When the LPH Unit has been replaced. When the image on the print is offset in the sub scan direction. When a faint image occurs on the leading edge of the image.
Page 642 Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment 8. Press the Drawer Release button [1] and then slide out the drawer [2] from the Paper Feed Cabinet. 4348fs3510c0 9. Open the Right Door. 10. Loosen the adjustment screw [3] and turn screw D [4] to make the adjust- ment.
Page 643: Dup Print Positioning: Side Edge
6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 6.1.2 Dup Print Positioning: Side Edge 1. Call the Service Mode to the screen. ☞ For details of how to display the Service Mode screen, see the Adjustment/Setting of the main unit service manual. 2.
Page 644 Field Service Ver. 1.0 Mar. 2005 6. Mechanical adjustment 3. Remove two screws [3] and remove the Shifter [4]. 4348fs3502c0 4. Push the tab [6] of the Shift Tray [5] as shown on the left and release the lock. 5. Remove the Shift Tray [5]. 4348fs3503c0 6.
Page 645 6. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 646: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. 4061F4C701DA Code Misfeed location Misfeed access location Action 1501...
Page 647: Sensor Layout
7. Jam Display Field Service Ver. 1.0 Mar. 2005 Sensor layout 4061F4C702DB [1] Tray2 Vertical Transport Sensor PC108 [3] Paper Feed Sensor PC1-LCT [2] LCT Vertical Transport Sensor PC2-LCT...
Page 648: Solution
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.
Page 649: Lct Paper Take-Up Section/Vertical Transport Section Misfeed
7. Jam Display Field Service Ver. 1.0 Mar. 2005 7.3.2 LCT Paper Take-Up section/Vertical Transport section misfeed A. Detection timing Type Description The leading edge of the paper does not block the Paper Feed Sensor (PC1-LCT) or the LCT Vertical Transport Sensor (PC2-LCT) even after the set period of time has elapsed after the Paper Feed Motor (M1-LCT) is energized.
Page 650: Trouble Code
Field Service Ver. 1.0 Mar. 2005 8. Trouble code Trouble code Trouble code display • The main unit's CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4061F4E704DA...
Page 651: Trouble Code List
8. Trouble code Field Service Ver. 1.0 Mar. 2005 Trouble code list Code Item Description C0001 LCT communication error • Due to a software malfunction, etc., the time on the watchdog timer has run out and a reset is performed. C0209 LCT Elevator Motor Failure •...
Page 652: How To Reset
Field Service Ver. 1.0 Mar. 2005 8. Trouble code Code Item Description C0214 LCT Shift Failure • The Shifter Return Position Sensor (PC11-LCT) is not blocked even after the set period of time has elapsed after the shift operation began (shift to the right). •...
Page 653: Solution
8. Trouble code Field Service Ver. 1.0 Mar. 2005 Solution 8.3.1 C0001: LCT communication error Relevant electrical parts Main Control Board (PWB-C1 LCT) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Turn the main unit off, then on again. —...
Page 654: C0210: Lct Lift Failure
Field Service Ver. 1.0 Mar. 2005 8. Trouble code 8.3.3 C0210: LCT Lift Failure Relevant electrical parts Tray Upper Limit Sensor (PC4-LCT) Main Control Board (PWB-C1 LCT) Tray Lower Position Sensor (PC13-LCT) Elevator Motor Pulse Sensor (PC10-LCT) Lower Limit Sensor (PC7-LCT) WIRING DIAGRAM Location Step...
Page 655: C0213: Lct Shift Gate Operation Failure
8. Trouble code Field Service Ver. 1.0 Mar. 2005 8.3.5 C0213: LCT Shift Gate Operation Failure Relevant electrical parts Shift Gate Home Position Sensor (PC14-LCT) Main Control Board (PWB-C1 LCT) Shift Gate Motor (M3-LCT) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the motor and sensor connectors...
Page 656: C0215: Lct Shift Motor Failure
Field Service Ver. 1.0 Mar. 2005 8. Trouble code 8.3.7 C0215: LCT Shift Motor Failure Relevant electrical parts Shift Motor (M4-LCT) Main Control Board (PWB-C1 LCT) Shift Motor Pulse Sensor (PC8-LCT) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the motor and sensor connectors for proper connection, and correct as...
Page 657 8. Trouble code Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 658 SERVICE MANUAL FIELD SERVICE FS-507 2005.03 Ver. 1.0...
Page 660 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 662 Field Service Ver. 1.0 Mar. 2005 CONTENTS General Product specification ....................1 Type ........................1 Functions ......................1 Paper type ......................1 1.3.1 Group, Group offset ..................1 1.3.2 Sort, Sort offset..................... 2 1.3.3 Sort staple/Group staple ................2 Stapling......................... 2 Sort and staple capacity ..................
Page 663 Field Service Ver. 1.0 Mar. 2005 5.2.1 Adjustment of the Upper / Lower Entrance Switching Solenoid (SL1-FN).. 15 5.2.2 Adjustment of the 1st Tray Entrance Selecting Solenoid (SL2-FN) .... 15 5.2.3 Adjustment of the 3rd Entrance Switching Solenoid (SL4) ......15 Timing belt tension adjustment................
Page 664 Field Service Ver. 1.0 Mar. 2005 8.3.6 Paper Stack Exit section misfeed..............30 8.3.7 Stapler section misfeed................31 8.3.8 Horizontal Transport section misfeed ............31 Trouble code......................32 Trouble code display ................... 32 Trouble code list....................32 9.2.1 How to reset ....................33 Solution.......................
Page 665 Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 666: Product Specification
Field Service Ver. 1.0 Mar. 2005 1. Product specification General Product specification Type Type Multi Staple Finisher Installation Freestanding Document Alignment Center Supplies Staple Cartridge Option Job separator (JS-601), Sweden Punch Kit (PK-506) Functions No. of Holes Metric: 4holes, Inch: 2holes / 3holes, Modes Normal Group, Sort, Group Offset, Sort Offset, Sort Staple,...
Page 667: Sort, Sort Offset
1. Product specification Field Service Ver. 1.0 Mar. 2005 1.3.2 Sort, Sort offset Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets to be Stapled Plain paper B5R/B5 to 60 to 209 3,000 sheets 2nd paper A3 Wide (A4R, 8.5 ×...
Page 668: Sort And Staple Capacity
Field Service Ver. 1.0 Mar. 2005 1. Product specification Sort and staple capacity • (Reference: Actual value) Determined by number of Sets or number of Sheets based on number of bindings. A. Number of stacked paper No. of Sheets to be Stapled No.
Page 669 1. Product specification Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 670: Other
Field Service Ver. 1.0 Mar. 2005 2. Other Maintenance Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
Page 671: Disassembly/Assembly List (Other Parts)
2. Other Field Service Ver. 1.0 Mar. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Upper Cover ☞ Upper Front Cover Exterior Parts ☞ Lower Front Cover ☞ Rear Cover ☞ Punch Unit Unit ☞ Stapling Unit ☞...
Page 672: Punch Unit
Field Service Ver. 1.0 Mar. 2005 2. Other 2.3.2 Punch Unit A. Removal Procedure 1. Remove the upper cover. ☞ 6 2. Remove the connector [1]. 4683F2C501DA 3. Remove two screws [2], and remove the Punch Unit [3]. 4683F2C502DA NOTE •...
Page 673: Stapling Unit
2. Other Field Service Ver. 1.0 Mar. 2005 2.3.3 Stapling Unit 1. Holding both sides of the cover [1], lift the cover up and take it off. 4684fs2501c0 2. Remove two screws [2], unplug the connector [3], and remove the Sta- pling Unit [4] from the moving cradle.
Page 674 Field Service Ver. 1.0 Mar. 2005 2. Other 3. Remove two screws [5] and the con- nector [6], and remove the Job Sepa- rator [7]. 4683F2C506DA...
Page 675 2. Other Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 676: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 3. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by boldface. A.
Page 677: Sensor Check
4. Sensor check Field Service Ver. 1.0 Mar. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
Page 678 Field Service Ver. 1.0 Mar. 2005 4. Sensor check Operation characteris- tics/Panel display Symbol Panel display Part/Signal name PC6-FN Full 1st Tray Full Sensor Blocked Unblocked (Non-sort1) PC20-FN Full job Tray Full Sensor Paper Paper not (Non-sort3) present present PC7-FN Full (Elev.
Page 679: Mechanical Adjustment
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Mechanical adjustment Check/Adjustment of the Punch Hole positions 5.1.1 Checking the punch hole position 1. Load the Tray 1 with A4 paper. 2. Touch “Finishing” on Basic Screen. Select Punch “2-Hole.” 4683F3E507DA 4.
Page 680: Adjustment Of The Solenoids
Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment Adjustment of the solenoids 5.2.1 Adjustment of the Upper / Lower Entrance Switching Solenoid (SL1-FN) 1. Loosen the screw [1] that secures the solenoid in position. 2. Move the solenoid [2] up and down and lower the lever [3] downward.
Page 681: Adjustment Of The Lower Entrance Motor (M2-Fn) Timing Belt
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 5.3.2 Adjustment of the Lower Entrance Motor (M2-FN) Timing Belt 1. Loosen two screws [1]. 2. Move the mounting bracket [2] and, when the belt deflects 2 mm at C, tighten two screws [1]. 4684fs2506c0 5.3.3 Adjustment of the Exit Motor (M3-FN) Timing Belt...
Page 682: Adjustment Of The Elevator Tray Upper Limit Sensor
Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment Adjustment of the Elevator Tray Upper Limit Sensor 4684fs2509c0 1. Set up the sensor test mode. 2. Turn VR1 on PWB-A FN fully counterclockwise. 3. Using a sheet of paper, block the Elevator Tray Upper Limit Sensor LED (PWB-C FN). 4.
Page 683: Board Switch
6. Board switch Field Service Ver. 1.0 Mar. 2005 Board switch 4684fs4503c0 Symbol Description Used to run the Test Mode operation. Used to run the Test Mode operation. DIP switch used to set the Test Mode operation. Turn ON or OFF, or blink to indicate a specific condition during Test Mode LED1 to 4 operations.
Page 684: Test Mode
Field Service Ver. 1.0 Mar. 2005 7. Test mode Test mode Test mode setting procedure <Setting Procedure> 1. Turn OFF the Main Power Switch of the main unit. 2. Flip keys of the DIP switch into the ON or OFF position as necessary. (See Table below.) 3.
Page 685: Operation In Each Test Mode Operation
7. Test mode Field Service Ver. 1.0 Mar. 2005 Operation in each test mode operation 7.3.1 Primary paper output tray Exit S1-FN:ON Motors and solenoids: Energized Entrance Motor (M1-FN), Upper Entrance Motor (M4-FN), Upper/ Lower Entrance Switching Solenoid (SL1-FN), 1st Tray Entrance Switching Solenoid (SL2-FN) S2-FN:ON Motors and solenoids: Deenergized...
Page 686: Shifting Operation
Field Service Ver. 1.0 Mar. 2005 7. Test mode 7.3.5 Shifting Operation S1-FN:ON The Elevator Tray shifts to the front. S2-FN:ON The Elevator Tray shifts to the rear. 7.3.6 Aligning Plate Operation S1-FN:ON At the home position S1-FN:ON At a position to align A4 paper S1-FN:ON At a position to align Letter paper S1-FN:ON...
Page 687: Exit Roller/Rolls Spacing
7. Test mode Field Service Ver. 1.0 Mar. 2005 7.3.8 Exit Roller/Rolls Spacing S1-FN:ON Pressed S2-FN:ON Separated 7.3.9 Storage Roller/Rolls Spacing S1-FN:ON Pressed S2-FN:ON Separated 7.3.10 Elevator Tray Operation S1-FN:ON Goes up until the Elevator Tray Upper Limit Sensor PQ (PWB-D FN) is blocked.
Page 688: Punch Hole 2/3 Switching
Field Service Ver. 1.0 Mar. 2005 7. Test mode 7.3.12 Punch Hole 2/3 Switching S1-FN:ON Switch to 2 holes S2-FN:ON Switch to 3 holes 7.3.13 Sensor Test Sensor State ❍ ❍ ❍ ● Elevator Tray Upper Limit Sensor PQ (PWB-D FN) Unblocked ❍...
Page 689 7. Test mode Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 690: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 8. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. [2]~[6] 4683F4C501DA Code Misfeed location Misfeed access location Action...
Page 691: Sensor Layout
8. Jam Display Field Service Ver. 1.0 Mar. 2005 Sensor layout 4684fs4502c0 [1] Job Tray Exit Sensor PC19-FN [6] Paper Sensor PC1-HO [2] 1st Tray Exit Sensor PC1-FN [7] Storage Sensor PC3-FN [3] Upper Entrance Sensor PC4-FN [8] Finisher Tray Paper Sensor PC5-FN [4] Lower Entrance Sensor PC2-FN...
Page 692: Solution
Field Service Ver. 1.0 Mar. 2005 8. Jam Display Solution 8.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.
Page 693: Transport Section Misfeed
8. Jam Display Field Service Ver. 1.0 Mar. 2005 8.3.2 Transport section misfeed A. Detection timing Type Description The 1st Tray Exit Sensor (PC1-FN) is not blocked even after the lapse of a given period of time after the leading edge of the paper has blocked the Paper Sensor (PC1-HO) of the Horizontal Transport Unit.
Page 694: Primary Paper Output Tray Exit Section Misfeed
Field Service Ver. 1.0 Mar. 2005 8. Jam Display 8.3.3 Primary Paper Output Tray Exit section misfeed A. Detection timing Type Description Primary paper out- The 1st Tray Exit Sensor (PC1-FN) is not unblocked even after the lapse of a put tray exit section given period of time after it has been blocked.
Page 695: Secondary Paper Output Tray Exit Section Misfeed
8. Jam Display Field Service Ver. 1.0 Mar. 2005 8.3.5 Secondary Paper Output Tray Exit section misfeed A. Detection timing Type Description Secondary paper output tray exit sec- The Storage Sensor (PC3-FN) is not unblocked even after the lapse of a given tion misfeed detec- period of time after it has been blocked.
Page 696: Stapler Section Misfeed
Field Service Ver. 1.0 Mar. 2005 8. Jam Display 8.3.7 Stapler section misfeed A. Detection timing Type Description Stapler section mis- The Stapler does not return to its home position within a given period of time after feed detection the forward drive of the Stapler has been started. B.
Page 697: Trouble Code
9. Trouble code Field Service Ver. 1.0 Mar. 2005 Trouble code Trouble code display • The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4683F4E504DA Trouble code list Code Item Description...
Page 698: How To Reset
Field Service Ver. 1.0 Mar. 2005 9. Trouble code Code Item Description C11B0 Stapling Unit Moving Motor drive • The Staple Home Position Sensor (PC14-FN) does not malfunction go HIGH even after the lapse of a given period of time after M6-FN has been energized (to return the Stapling Unit to its home position).
Page 699: Solution
9. Trouble code Field Service Ver. 1.0 Mar. 2005 Solution 9.3.1 C1182: Shift Motor drive malfunctions Relevant electrical parts Shift Home Position Sensor (PC10-FN) Control Board (PWB-A FN) Shift Motor Pulse Sensor (PC11-FN) Shift Motor (M8-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo-...
Page 700: C1190: Cd Aligning Motor Drive Malfunction
Field Service Ver. 1.0 Mar. 2005 9. Trouble code 9.3.3 C1190: CD Aligning Motor drive malfunction Relevant electrical parts CD Aligning Home Position Sensor (PC9-FN) Control Board (PWB-A FN) CD Aligning Motor (M5-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the motor and sensor connectors...
Page 701: C11A2: Storage Roller/Rolls Spacing Motor Drive Malfunction
9. Trouble code Field Service Ver. 1.0 Mar. 2005 9.3.5 C11A2: Storage Roller/Rolls Spacing Motor drive malfunction Relevant electrical parts Storage Roller Home Position Sensor (PC12-FN) Control Board (PWB-A FN) Storage Roller/Rolls Spacing Motor (M12-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents)
Page 702: C11B2: Stapling Motor Drive Malfunction 1
Field Service Ver. 1.0 Mar. 2005 9. Trouble code 9.3.7 C11B2: Stapling Motor drive malfunction 1 WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the Stapling motor connectors for proper connection, and correct as nec- — — essary.
Page 703: C11C4: Hole Position Selector Motor Drive Malfunction
9. Trouble code Field Service Ver. 1.0 Mar. 2005 9.3.10 C11C4: Hole Position Selector Motor drive malfunction Relevant electrical parts Punch Unit Control Board (PWB-A FN) Hole Punch Position Switch (S4) Hole Position Selector Motor (M14) WIRING DIAGRAM Location Step Action Control signal (Electrical compo-...
Page 704 SERVICE MANUAL FIELD SERVICE FS-603 2005.03 Ver. 1.0...
Page 706 After publication of this service manual, the parts and mechanism may be subject to change for improvement of their performance. Therefore, the descriptions given in this service manual may not coincide with the actual machine. When any change has been made to the descriptions in the service manual, a revised version will be issued with a revision mark added as required.
Page 708 Field Service Ver. 1.0 Mar. 2005 CONTENTS General Product specification ....................1 Type ........................1 Functions ......................1 Paper type ......................1 1.3.1 Group, Group offset ..................1 1.3.2 Sort, Sort offset..................... 1 1.3.3 Sort staple..................... 2 1.3.4 Center Staple & Fold..................2 Stapling.........................
Page 709 Field Service Ver. 1.0 Mar. 2005 2.3.18 Middle Transport Roller................19 2.3.19 Punch Unit ....................20 2.3.20 Finisher Control Board................21 2.3.21 Punch Control Board .................. 21 2.3.22 Transport Motor Unit ................... 22 2.3.23 Middle Transport Motor ................22 2.3.24 Punch Motor ....................
Page 710 Field Service Ver. 1.0 Mar. 2005 Troubleshooting Jam Display......................51 Misfeed display ....................51 7.1.1 Misfeed display resetting procedure ............51 Sensor layout ...................... 52 Solution....................... 53 7.3.1 Initial check items..................53 7.3.2 Transport section misfeed ................53 7.3.3 Horizontal Transport section misfeed ............54 7.3.4 Folding position section misfeed ..............
Page 711 Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 712: Product Specification
Field Service Ver. 1.0 Mar. 2005 1. Product specification General Product specification Type Type Multi Staple Finisher with Saddle (Booklet) Installation Freestanding Document Alignment Center Supplies Staple Cartridge Functions Modes Normal Group, Sort, Group Offset, Sort Offset, Sort Staple Center Staple & Fold Punch (Option) Group Punch, Sort Punch, Group Offset Punch, Sort Offset Punch, Sort Staple Punch...
Page 713: Sort Staple
1. Product specification Field Service Ver. 1.0 Mar. 2005 1.3.3 Sort staple Paper Type Paper Size Weight Tray Capacity Exit Tray No. of Sheets to be Stapled Plain Paper B5R/B5 to A3 Normal A4R / Normal Mode *1 8.5×11R 8.5×14 or Cardboard 8.5 ×...
Page 714: No. Of Sheets To Be Stapled (Sort Staple)
Field Service Ver. 1.0 Mar. 2005 1. Product specification No. of sheets to be stapled (sort staple) A. A4R, 8.5× 11R or smaller No. of Sets No. of Sheets to be Stapled Rear: Parallel Center: Parallel Front: Parallel 3 to 5 6 to 10 11 to 20 21 to 30...
Page 715 1. Product specification Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 716: Other
Field Service Ver. 1.0 Mar. 2005 2. Other Maintenance Other Disassembly/Adjustment prohibited items A. Paint-locked Screws NOTE • Paint-locked screws show that the assembly or unit secured can only be adjusted or set at the factory and should not be adjusted, set, or removed in the field. B.
Page 717: Disassembly/Assembly List (Other Parts)
2. Other Field Service Ver. 1.0 Mar. 2005 Disassembly/Assembly list (Other parts) Section Part name Ref. page ☞ Exit Tray ☞ Front Cover ☞ Rear Cover Exterior Parts ☞ Upper Door ☞ Finisher Tray Upper Cover ☞ Upper Cover ☞ Side Guide ☞...
Page 718: Disassembly/Assembly Procedure
Field Service Ver. 1.0 Mar. 2005 2. Other Disassembly/Assembly procedure 2.3.1 Exit Tray 1. Remove four screws [1], and remove the Exit Tray [2]. 4583fs2526c0 2.3.2 Front Cover 1. Remove the Middle Transport Unit. ☞ 10 2. Open the Front Door [1]. 3.
Page 719: Upper Door
2. Other Field Service Ver. 1.0 Mar. 2005 2.3.4 Upper Door 1. Open the Upper Door [1], and remove the Door Band Holder [2] by turning it clockwise. 2. Remove the Door Band [3]. 3. Remove the screw [4], and remove the grounding wire.
Page 720: Upper Cover
Field Service Ver. 1.0 Mar. 2005 2. Other 2.3.6 Upper Cover 1. Remove the Front Cover. ☞ 7 2. Remove the Rear Cover. ☞ 7 3. Remove two screws [1]. 4. Open the Upper Door[2],and remove the Upper Cover [3]. 4583fs2535c0 4583fs2536c0 2.3.7...
Page 721: Middle Transport Unit
2. Other Field Service Ver. 1.0 Mar. 2005 2.3.8 Middle Transport Unit 1. Remove four screws [1]. 2. Hold up the Middle Front Cover [2] and the Middle Rear Cover [3], and remove them while shifting them back and forth. 4583fs2540c0 3.
Page 722: Saddle Section
Field Service Ver. 1.0 Mar. 2005 2. Other 2.3.10 Saddle Section 1. Remove the Front Cover. ☞ 7 2. Remove the Rear Cover. ☞ 7 3. Remove the Punch Dust Box. 4. Open the Jam Access Cover [1], remove two screws [2], and remove the Right Stay [3].
Page 723: Paddle Section
2. Other Field Service Ver. 1.0 Mar. 2005 4. Pull out the Finisher Stopper Base [3], and disengage the front claw [5] and the rear claw [6] of the Finisher Stopper [4]. 4583fs2522c0 5. Remove the Motor Harness [8] from two Harness Saddles [7].
Page 724 Field Service Ver. 1.0 Mar. 2005 2. Other 3. Remove the Belt [3], and remove two screws [4]. 4583fs2549c0 4. Separate the section into the Tray Section[5] and the Paddle Section [6]. 4583fs2550c0...
Page 725: Exit Roller (Upper)
2. Other Field Service Ver. 1.0 Mar. 2005 2.3.13 Exit Roller (Upper) 1. Remove the Paddle Section. ☞ 12 2. Place the Paddle Section [1] as shown in the figure. 4583fs2551c0 3. Turn the gear [2] in the direction indi- cated by an arrow to move up the Exit Roller (Upper) section [3].
Page 726: Exit Roller (Lower) And Paper Exit Belt
Field Service Ver. 1.0 Mar. 2005 2. Other 3. Turn the gear [2] in the direction indicted by an arrow to move up the Exit Roller (Upper) section [3]. 4583fs2555c0 4. Push up the Safety Guide [4] from the bottom to release it on one side from the shaft [5].
Page 727 2. Other Field Service Ver. 1.0 Mar. 2005 3. Remove two Holders [4], and remove the Finisher Tray Stopper [5]. 4583fs2560c0 4. Remove the screw [6], and remove the Paper Guide (Front) [8] while dis- engaging two claws [7]. 4583fs2561c0 5.
Page 728: Stapler/Folding Drive Unit
Field Service Ver. 1.0 Mar. 2005 2. Other 8. Remove the Exit Roller (Lower) [16] [17] and two Paper Exit Belts [17]. [16] 4583fs2565c0 NOTE • When installing, align the edge of claws of the Paper Exit Belt [18]. [18] 4583fs2566c0 2.3.16 Stapler/Folding Drive Unit...
Page 729: Transport Roller
2. Other Field Service Ver. 1.0 Mar. 2005 8. Remove the screw [9], and remove the claw of Harness Guide [11] from the square hole [10] in the base plate. [11] [10] 4583fs2570c0 9. Unplug two connectors [12], and remove the Harness from the Wire Saddle.
Page 730: Middle Transport Roller
Field Service Ver. 1.0 Mar. 2005 2. Other 4. Remove the Transport Motor Unit. ☞ 22 5. Remove the screw [3]. 6. Remove the C-clip [4], and remove the bushing [5]. 4583fs2575c0 7. Remove two screws [6]. 4583fs2577c0 8. Remove the gear 1 [7], and remove [10] the gear 2 [8] while disengaging the [12]...
Page 731: Punch Unit
2. Other Field Service Ver. 1.0 Mar. 2005 3. Remove the C-clip[3], and remove the bushing [4]. 4583fs2582c0 4. Shift the Shaft Assy in the orientation as shown on the left. 5. Remove the C-clip [5], the Gear [6], the bushing [7], and remove the Mid- dle Transport Roller [8].
Page 732: Finisher Control Board
Field Service Ver. 1.0 Mar. 2005 2. Other 9. Remove four screws [11], and [12] [11] remove the Sensor Unit (Upper) [12] and the Sensor Unit (Lower) [13]. [13] [11] [11] [11] 4583fs2589c0 10. Remove the spring[14]. [15] [16] 11. Remove the Punch Unit [16] from the Side Registration Motor section [15].
Page 733: Transport Motor Unit
2. Other Field Service Ver. 1.0 Mar. 2005 2.3.22 Transport Motor Unit 1. Remove the Rear Cover. ☞ 7 2. Unplug the connector [1]. 3. Remove screw [2], and remove the Harness Guide [3]. 4. Remove three screws [4], and remove the Transport Motor Unit [5].
Page 734: Adjustment/Setting
Field Service Ver. 1.0 Mar. 2005 3. How to use the adjustment section Adjustment/Setting How to use the adjustment section • “Adjustment/Setting” contains detailed information on the adjustment items and proce- dures for this machine. • Throughout this “Adjustment/Setting” the default settings are indicated by “ ”. A.
Page 735: Sensor Check
4. Sensor check Field Service Ver. 1.0 Mar. 2005 Sensor check Check procedure • To allow sensors to be checked for operation easily and safely, data applied to the IC on the board can be checked on the panel with the main unit in the standby state (including a misfeed, malfunction, and closure failure condition).
Page 736 Field Service Ver. 1.0 Mar. 2005 4. Sensor check Operation characteris- tics/Panel display Symbol Panel display Part/Signal name PI10-FN Crease Position Folding Position Sensor Paper Paper not present present PI13-FN Crease Tray Saddle Tray Sensor Paper Paper not present present PI11-FN Crease Home Folding Home Position Sensor...
Page 737: Mechanical Adjustment
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Mechanical adjustment Adjustment of the stapling position • The stapling position is adjusted by aligning the stapling position to the folding position. • This adjustment is made in the Service Mode of the main unit. Since the adjustment is made in increments of 1 mm, this adjustment is useful for eliminating a displacement of 1mm or more.
Page 738 Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment Standard:0 ± 2 mm <To - side> <Standard> <Standard> <To + side> <To + side> 4583fs3501c0 10. Press the “Clear” Key. 11. Adjust with the +/- Keys. When the stapling position is shifted to the direction A: Adjust the value to the - side.
Page 739: Adjustment Of The Folding Position
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Adjustment of the folding position • The folding position is adjusted by aligning the folding position to the stapling position. • This adjustment is made in the Service Mode of the main unit. Since the adjustment is made in increments of 1 mm, this adjustment is useful for eliminating a displacement of 1mm or more.
Page 740 Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment 9. Press the “Clear” Key. 10. Adjust with the +/- Keys. When the stapling position is shifted to the direction A: Adjust the value to the + side.When the stapling position is shifted to the direction B: Adjust the value to the - side.
Page 741: Adjustment Of Height And Inclination
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Adjustment of height and inclination 1. Gently move the finisher toward the machine and check for following. • Is the positioning pin aligned with the hole in the finisher? 4583fs3503c0 • Does the horizontal transport unit run excessively slantwise? •...
Page 742 Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment 4. Loosen four caster fixing screws [4]. (4 points) 4583fs3507c0 5. Turn the adjustment screw [5] to make adjustment. • To heighten: Turn the screw counter- clockwise. • To bring down: Turn the screw clock- wise.
Page 743: Adjustment Of The Folding Position
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Adjustment of the Folding Position • Folding position is adjusted by adjusting the Tray Section and the Saddle Section. • Adjust the folding position by aligning the Tray Section. Adjust the position of the Saddle Section if the position is still not proper.
Page 744 Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment 3. Remove the Middle Transport Unit. ☞ 10 4. Remove the front cover. ☞ 7 5. Loosen two screws [2] on the Tray Section. 4583F3C519DA 6. Move the Tray Section [3] back and forth, and move the positioning dow- els [4] right and left to adjust.
Page 745 5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 • If it is deviated downward <A>, move the positioning dowels to the left. <A> • If it is deviated upward <B>, move the positioning dowels to the right. NOTE • The folding line will move along with the staples.
Page 746 Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment 9. Move the two positioning dowels [6] to adjust. 4583F3C522DA • If it is deviated downward <C>, move the positioning dowel to the left. <C> • If it is deviated upward <D>, move the positioning dowel to the right.
Page 747: Adjustment Procedure
5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 Stapler Phase Adjustment • Make phase adjustment of the Stapler following the procedures given below whenever the Gear or Timing Belt in front of the Stapler has been replaced or removed for some reason, since such replacement or removal will cause mistiming between the staple driving by the Staple Driver (the lower...
Page 748 Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment 10. Remove the Timing Belt [18]. 11. Remove the E-Ring [19], and remove [19] [20] the Staple Position Confirm Gear [20]. [18] 4583fs2507c0 12. Turn the Gear [21] to position the hole [22] in the Gear of the Staple Driver to the hole behind.
Page 749 5. Mechanical adjustment Field Service Ver. 1.0 Mar. 2005 16. Set the Timing Belt [27] to the Gear [28] and Gear [29] with the Gear and the Cam in the fixed condition. [28] [29] [27] 4583fs2512c0 17. Install the Staple Position Confirm Gear [32] in such a way that the blue [31] mark [30] of the Gear comes face to...
Page 750: Adjustment Procedure
Field Service Ver. 1.0 Mar. 2005 5. Mechanical adjustment Saddle Gear Phase Adjustment • Whenever the Gear in front of the Saddle or the Folding Roller has been replaced or removed for some reason, make gear phase adjustment following the procedures given below.
Page 751: Board Switch
6. Board switch Field Service Ver. 1.0 Mar. 2005 Board switch PWB-A FN (Finisher Control Board) 12 1 CN22 CN18 CN10 CN13 LED2 LED1 PSW2 PSW1 CN21 CN11 4583fs3509c0 Symbol Description Used to adjust the folding position, adjust the center 2-point stapling position and adjust the alignment plate position.
Page 752: Adjustment Of The Folding Positions
Field Service Ver. 1.0 Mar. 2005 6. Board switch 6.1.1 Adjustment of the folding positions • When a folding position is adjusted, adjust the folding position to the stapling position. Make this adjustment after replacing the Finisher Control Board or when the folding posi- tion must be changed for some reason.
Page 753: Adjustment Of The Center Stapling Position
6. Board switch Field Service Ver. 1.0 Mar. 2005 6.1.2 Adjustment of the center stapling position • When a stapling position is adjusted, adjust the stapling position to the folding position. Make this adjustment after replacing the Finisher Control Board or when the stapling position must be changed for some reason.
Page 754: Adjustment Of The Alignment Plate Position
Field Service Ver. 1.0 Mar. 2005 6. Board switch 6.1.3 Adjustment of the Alignment Plate position • Alignment plate should be adjusted when there is a faulty alignment, the staple position deviates. A. Alignment procedure NOTE • When failing to follow the steps properly, turn main power switch OFF/ON and repeat the step from Step 1.
Page 755 6. Board switch Field Service Ver. 1.0 Mar. 2005 8. When the adjustment is complete, turn switch 8 of SW1 ON to set the adjustment value. 9. Turn all adjustment switches OFF. 10. Turn main power switch OFF. NOTE • When not all SW1 are OFF in step 3, return to the original condition according to the written note.
Page 756 Field Service Ver. 1.0 Mar. 2005 6. Board switch PWB-B PK (Punch Control Board) J1007 SW1001 SW1002 SW1003 LED1001 LED1002 LED1003 J1004 J1003 4583fs3514c0 Symbol Description SW1001 Used to register the number of punched holes and adjust the sensor output. SW1002 Used to register the number of punched holes and adjust the sensor output.
Page 757: Adjustment Of The Sensor Output
6. Board switch Field Service Ver. 1.0 Mar. 2005 6.2.1 Adjustment of the sensor output • Be sure to make this adjustment after replacing the Punch Control Board, the Side Reg- istration Sensor (Photosensor Board or LED Board) or the Punch Dust Full Sensor (Punch Dust Full Sensor Board or Punch Dust Full LED Board).
Page 758: Procedure After Replacing The Eep-Rom (Ic1002)
Field Service Ver. 1.0 Mar. 2005 6. Board switch 6.2.3 Procedure after replacing the EEP-ROM (IC1002) 1. Turn OFF the Main Power Switch of the main unit. 2. Set the bits 1 through 4 of DIPSW1001 on the Punch Control Board as shown on the Left fig- ure.Press SW1002 and SW1003 on the Punch Control Board simulta-...
Page 759 6. Board switch Field Service Ver. 1.0 Mar. 2005 8. Turn OFF key 4 of SW1 of the Fin- isher Control Board. 9. Wait until the machine becomes capable of paper feed. 4583fs3526c0 10. Feed one sheet of paper through the machine.
Page 760 Field Service Ver. 1.0 Mar. 2005 6. Board switch 16. Turn ON key 7 of SW1 of the Fin- isher Control Board. NOTES • Flipping ON key 7 of SW1 validates the setting made to the fixed sys- tem based on the paper size as changed from the lateral registra- tion motion (automatic through end 4583fs3530c0...
Page 761 6. Board switch Field Service Ver. 1.0 Mar. 2005 Blank Page...
Page 762: Troubleshooting
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Troubleshooting Jam Display Misfeed display • When misfeed occurs, message, misfeed location “Blinking” and paper location “Light- ing” are displayed on the Touch Panel of the main unit. 4583F4C501DA Code Misfeed location Misfeed access location Action ☞...
Page 763: Sensor Layout
7. Jam Display Field Service Ver. 1.0 Mar. 2005 Sensor layout 4583fs4521c0 [1] Turnover Empty Sensor PC6-HO [3] Folding Position Sensor PI10-FN [2] Entrance Sensor PI1-FN [4] Staple Drive Home Position Sensor PI19-FN...
Page 764: Solution
Field Service Ver. 1.0 Mar. 2005 7. Jam Display Solution 7.3.1 Initial check items • When a paper misfeed occurs, first perform the following initial check items. Check item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper storage procedures.
Page 765: Horizontal Transport Section Misfeed
7. Jam Display Field Service Ver. 1.0 Mar. 2005 7.3.3 Horizontal Transport section misfeed A. Detection timing Type Description horizontal trans- The Turnover Empty Sensor (PC6-HO) is not unblocked even after the lapse of a port section mis- given period of time after the leading edge of the paper has blocked the Turnover feed detection Empty Sensor (PC6-HO).
Page 766: Stapler Section Misfeed
Field Service Ver. 1.0 Mar. 2005 7. Jam Display 7.3.5 Stapler section misfeed A. Detection timing Type Description The Staple Drive Home Position Sensor (PI19-FN) is not turned OFF or does not Stapler section mis- return to its home position even after the set period of time after the stapler has feed detection been driven.
Page 767: Trouble Code
8. Trouble code Field Service Ver. 1.0 Mar. 2005 Trouble code Trouble code display • The main unit’s CPU performs a self-diagnostics function that, on detecting a malfunc- tion, gives the corresponding malfunction code on the Touch Panel. 4583F4E504DA NOTE •...
Page 768 Field Service Ver. 1.0 Mar. 2005 8. Trouble code Code Item Description C1183 Elevate Mechanism malfunctions • The Exit Tray Home Position Sensor (PI9-FN) is not blocked even after the lapse of a given period of time after the tray has started moving up. •...
Page 769 8. Trouble code Field Service Ver. 1.0 Mar. 2005 Code Item Description C11B4 Stapler/Folding Motor malfunc- • The Staple Drive Home Position Sensor (PI19-FN) is tions not blocked even after the lapse of a given period of time after the clinch operation has started. •...
Page 770: How To Reset
Field Service Ver. 1.0 Mar. 2005 8. Trouble code Code Item Description C1401 Backup RAM malfunction • Data written in the Backup Memory differs from what is recorded in it and writing operation is not correctly per- formed even with two retry sequences (a total of three writing sequences).
Page 771: Solution
8. Trouble code Field Service Ver. 1.0 Mar. 2005 Solution 8.3.1 C1180: Transport System Drive malfunctions Relevant electrical parts Folding Roller Home Position Sensor (PI12-FN) Finisher Control Board (PWB-A FN) Transport Motor (M1-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the motor connectors for proper...
Page 772: C1183: Elevate Mechanism Malfunctions
Field Service Ver. 1.0 Mar. 2005 8. Trouble code 8.3.3 C1183: Elevate Mechanism malfunctions (1) Upper Limit Sensor Relevant electrical parts Shift Upper Limit Sensor (PI15-FN) Finisher Control Board (PWB-A FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the sensor connectors for proper —...
Page 773: C1193: Rear Aligning Plate Motor Malfunctions
8. Trouble code Field Service Ver. 1.0 Mar. 2005 8.3.5 C1193: Rear Aligning Plate Motor malfunctions Relevant electrical parts Rear Aligning Plate Home Position Sensor (PI5- Finisher Control Board (PWB-A FN) Rear Aligning Motor (M5-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents)
Page 774: C11B1: Stapler Unit Slide Motor Malfunctions
Field Service Ver. 1.0 Mar. 2005 8. Trouble code 8.3.7 C11B1: Stapler Unit Slide Motor malfunctions Relevant electrical parts Slide Home Position Sensor (PI18-FN) Finisher Control Board (PWB-A FN) Slide Motor (M8-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the motor and sensor connectors for proper connection, and correct as...
Page 775 8. Trouble code Field Service Ver. 1.0 Mar. 2005 (2) Stapler/Crease Clock Sensor (Stapler Section) Relevant electrical parts Staple/Folding Motor Clock Sensor (PI14-FN) Finisher Control Board (PWB-A FN) Staple/Folding Motor (M7-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the motor and sensor connectors for proper connection, and correct as...
Page 776: C11C1: Punch Control Board Malfunctions
Field Service Ver. 1.0 Mar. 2005 8. Trouble code Stapler/Crease Clock Sensor (Saddle Section) Relevant electrical parts Staple/Folding Motor Clock Sensor (PI14-FN) Finisher Control Board (PWB-A FN) Staple/Folding Motor (M7-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the motor and sensor connectors for proper connection, and correct as —...
Page 777: C11C2: Punch Side Registration Motor Malfunctions
8. Trouble code Field Service Ver. 1.0 Mar. 2005 8.3.10 C11C2: Punch Side Registration Motor malfunctions Relevant electrical parts Side Registration Home Sensor (PI2P-PK) Punch Control Board (PWB-B PK) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the sensor connectors for proper —...
Page 778: C11C5: Punch Sensor Malfunctions
Field Service Ver. 1.0 Mar. 2005 8. Trouble code 8.3.12 C11C5: Punch Sensor malfunctions (1) Side Registration Sensor Relevant electrical parts Side Registration Home Sensor (PI2P-PK) Punch Control Board (PWB-B PK) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents) Check the sensor connectors for proper —...
Page 779: C1401: Backup Ram Malfunction
8. Trouble code Field Service Ver. 1.0 Mar. 2005 (3) Finisher Control Board Relevant electrical parts Exit Tray Home Position Sensor (PI9-FN) Finisher Control Board (PWB-A FN) Shift Motor Clock Sensor (PI17-FN) Shift Motor (M6-FN) WIRING DIAGRAM Location Step Action Control signal (Electrical compo- nents)
Page 780 © 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. © 2005 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Printed in Japan Printed in Japan Use of this manual should be strictly supervised to Use of this manual should be strictly supervised to DD4037PE1-0800 DD4037PE1-0800 avoid disclosure of confidential information.

Konica Minolta bizhub C450 Service Manual

Table of Contents

1 System Configuration

2 Product Specifications

Maintenance

3 Periodical Check

4 Service Tool

5 Firmware Upgrade

6 Other

Adjustment/Setting

7 How to Use the Adjustment Section

8 Utility Mode

9 Adjustment Item List

10 Service Mode

11 Enhanced Security

12 Billing Setting

13 Procedure for Resetting

14 Mechanical Adjustment

Troubleshooting

15 Jam Display

16 Malfunction Code

Appendix Parts Layout Drawing

Quick Links

SERVICE MANUAL

Chapters

Troubleshooting

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Summary of Contents for Konica Minolta bizhub C450