Develop INEO 161 Service Manual
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Develop INEO 161 Service Manual

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  • Page 3 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 5: Table Of Contents

    Field Service Ver. 1.0 Apr. 2005 CONTENTS General System configuration....................1 ineo 210 ........................ 1 ineo 161 ........................ 2 Product specification ....................3 Copier ........................3 Fax Kit (FK-505): (Option) ..................6 Maintenance Periodical check ...................... 7 Maintenance parts ....................7 3.1.1...
  • Page 6 6.3.22 Fusing Unit Interlock Switch ............... 57 6.3.23 Inch/Metric Sensor/1 Assy (3rd area Only)..........59 6.3.24 Flickerless Resistor (Only for 200 V area of ineo 161) ....... 59 Cleaning procedure .................... 60 6.4.1 Separation Roller ..................60 6.4.2 Feed Roller ....................60...
  • Page 7 Field Service Ver. 1.0 Apr. 2005 6.4.3 Upper/Lower Synchronizing Rollers............60 6.4.4 Paper Dust Remover................... 61 6.4.5 Bypass Transport Roller/Roll............... 61 6.4.6 Mirrors ......................62 6.4.7 Lens ......................62 6.4.8 CCD Sensor....................62 6.4.9 Scanner Rails/Bearings ................63 6.4.10 PH Window ....................63 6.4.11 Pre-Image Transfer Lower Guide Plate ............
  • Page 8 Field Service Ver. 1.0 Apr. 2005 10.3.3 COUNTER ....................97 10.3.4 DISPLAY ....................101 10.3.5 FUNCTION ....................102 10.3.6 ADMIN. REGISTRATION................105 10.3.7 FIXED ZOOM CHANGE ................105 10.3.8 FACTORY TEST ..................106 10.3.9 CLEAR DATA .................... 107 Security ....................... 109 11.1 Security Function Setting Procedure..............
  • Page 9 Field Service Ver. 1.0 Apr. 2005 14.3.6 Misfeed at the Paper Separating Section..........125 14.3.7 Misfeed at the Fusing/Exit Section............126 14.3.8 Misfeed at the Document Take-up Section (When the optional Automatic Document Feeder DF-502 is mounted)127 14.3.9 Misfeed at the Document Transport Section (When the optional Automatic Document Feeder DF-502 is mounted)128 14.3.10 Misfeed at the Document Exit Section (When the optional Automatic Document Feeder DF-502 is mounted)129...
  • Page 10 Field Service Ver. 1.0 Apr. 2005 15.4 Miscellaneous Errors ..................151 15.4.1 Flash ROM Error..................151 Power supply trouble................... 152 16.1 The copier does not turn ON ................152 Image quality problem..................153 17.1 How to identify problematic part ............... 153 17.1.1 Initial Check Items ..................

  • Page 11: System Configuration

    Field Service Ver. 1.0 Apr. 2005 1. System configuration General System configuration ineo 210 4034F1E501DA Automatic Document Feeder (DF-502) [10] Copy Table (DK-703)*3 Duplexing Document Feeder (DF-605) [11] Key Counter Kit Original Cover Kit (OC-504)*1 [12] 32MB Memory (EM-101) Job Separator (JS-503) [13] 64MB Memory (EM-102) Duplex Unit (AD-504)

  • Page 12: Ineo 161

    1. System configuration Field Service Ver. 1.0 Apr. 2005 ineo 161 4035T1E501DA Automatic Document Feeder (DF-502) Key Counter Kit Original Cover Kit (OC-504)*1 [10] 32MB Memory (EM-101) Job Separator (JS-503) [11] 64MB Memory (EM-102) Multiple Bypass (MB-501) [12] Printer Controller (IC-205)

  • Page 13: Product Specification

    Multiple Copies 1 to 99 Warm-up Time ineo 210: 15 sec. or less (23 °C, Rated Voltage) ineo 161: 30 sec. or less (23 °C, Rated Voltage) First Copy Time 7 sec. or less (A4/Letter, Paper Feed Tray/1, full size mode)
  • Page 14 1250 W (ineo 210: 200 V area) Max. Current Consumption 1200 W (ineo 210: 120 V area) (full system) 1050 W (ineo 161: 200 V area) 1000 W (ineo 161: 120 V area) 5.5 A (ineo 210: 200 V area) Current Consumption...
  • Page 15 38 kg <GDI Printer Functions> Printing Speed ineo 210: 21 printed pages/min (A4, 300 dpi) 12 printed pages/min (A4, 600 dpi) ineo 161: 16 printed pages/min (A4, 300 dpi) 12 printed pages/min (A4, 600 dpi) Memory Shared with the copier Interface IEEE 1284 (parallel), USB Revision 1.1 (except for Windows 95 and...

  • Page 16: Fax Kit (Fk-505): (Option)

    2. Product specification Field Service Ver. 1.0 Apr. 2005 Fax Kit (FK-505): (Option) General Compatibility Scanning Resolution TX Mode Resolution CD direction (dpi) FD direction (dpi) Memory TX FINE S_FINE Non memory TX FINE S_FINE Line PSTN/ PBX Data Transmission Rate 33.6 kbps (V.34 JBIG) Coding Method MH/ MR/ MMR/ JBIG...

  • Page 17: Maintenance

    Field Service Ver. 1.0 Apr. 2005 3. Periodical check Maintenance Periodical check 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 18: Cleaning Parts

    3. Periodical check Field Service Ver. 1.0 Apr. 2005 B. Option Actual Ref.Page Classifi- Parts name durable Pats No. Descriptions in this cation ntity cycle *1 manual Pick-up Roller 120 K 4688-3032-XX Replace those DF-502 Paper Take-up Roller 120 K 4688-3033-XX three parts at the same time.

  • Page 19: Concept Of Parts Life

    Field Service Ver. 1.0 Apr. 2005 3. Periodical check Concept of parts life Life value New Copy/Print Description (Specifica- Cycle Inhibited tion value) PC Drum 40 K Cleaning Blade 40 K The distance traveled by the PC Drum is con- verted to a corresponding number of printed Not inhibited *1 PC Drum Charge...

  • Page 20: Maintenance Procedure (Periodical Check Parts)

    3. Periodical check Field Service Ver. 1.0 Apr. 2005 Maintenance procedure (Periodical check parts) NOTE • The alcohol described in the cleaning procedure of Maintenance represents the isopropyl alcohol. 3.3.1 Replacing the Separation Roller Assy and Feed Roller 1. Slide out the Paper Feed Tray/1. 2.

  • Page 21: Replacing The Paper Dust Remover Assy

    Field Service Ver. 1.0 Apr. 2005 3. Periodical check 3.3.2 Replacing the Paper Dust Remover Assy 1. Open the Right Door. 2. Remove the Imaging Unit. 3. Unhook the two tabs and remove the Paper Dust Remover Assy. 4035D008AB 3.3.3 Replacing the Imaging Unit (IU) NOTE •...

  • Page 22: Disassembly Of The Iu

    3. Periodical check Field Service Ver. 1.0 Apr. 2005 3.3.4 Disassembly of the IU 1. Remove one screw in the rear of the IU and remove the harness cover. 4035D022AA 2. Remove two screws in the rear of the 4035D023AA 3.

  • Page 23: Replacing The Pc Drum

    Field Service Ver. 1.0 Apr. 2005 3. Periodical check 5. Unplug one connector of the Main Erase. 4035D026AA 3.3.5 Replacing the PC Drum 1. Remove two screws and the pivot shaft. 4035D027AA 2. Remove the PC Drum. NOTE • Protect the PC Drum that has been removed with a protective cloth.

  • Page 24: Replacing The Ozone Filter

    3. Periodical check Field Service Ver. 1.0 Apr. 2005 3.3.6 Replacing the Ozone Filter 1. Remove two screws and the Main Erase. 4035D029AB 2. Remove the Ozone Filter. 4035D030AA 3.3.7 Replacing the PC Drum Charge Corona Assy 1. Remove the PC Drum. 2.

  • Page 25: Cleaning Of The Pc Drum Paper Separator Fingers

    Field Service Ver. 1.0 Apr. 2005 3. Periodical check 3.3.9 Cleaning of the PC Drum Paper Separator Fingers 1. Using a soft cloth dampened with alcohol, wipe the five Paper Separa- tor Fingers clean of dirt. 4035D033AA 3.3.10 Cleaning of the Ds Collars 1.

  • Page 26: Replacing The Developer

    3. Periodical check Field Service Ver. 1.0 Apr. 2005 3.3.12 Replacing the Developer 1. Dump the developer. 4035D037AA <<How to Dump Developer>> • Dump developer on the surface of the Sleeve Roller by turning the gear in the direction of the arrow with the Developing Unit tilted as shown.

  • Page 27: Replacing The Atdc Sensor

    Field Service Ver. 1.0 Apr. 2005 3. Periodical check 3.3.14 Replacing the ATDC Sensor 1. Separate the IU into the Drum Assy and Developing Assy. 2. Remove the Developer Scattering Prevention Plate. 3. Dump developer. 4. Unplug one connector, and remove one screw and the ATDC Sensor.

  • Page 28: Replacing The Image Transfer Roller Assy

    3. Periodical check Field Service Ver. 1.0 Apr. 2005 2. Using a brush, apply a light coat of toner to the surface of the PC Drum. 4021U008AB 3. Hold both ends of the PC Drum with your both hands and turn the PC Drum a half turn in the direction of the arrow.

  • Page 29: Replacing The Fusing Unit

    Field Service Ver. 1.0 Apr. 2005 3. Periodical check 3.3.17 Replacing the Fusing Unit 1. Remove the Rear Cover and Rear Right Cover. 2. Unplug two connectors of the Fusing Unit. 4035D045AA 3. Open the Right Door. 4. Remove four screws and the Fusing Unit.

  • Page 30: Service Tool

    4. Service tool Field Service Ver. 1.0 Apr. 2005 Service tool CE Tool list Tool name Shape Parts No. Personnel Remarks Scanner/Mirrors Carriage 4034-7901-XX 1 for each Positioning Jigs 4034-7902-XX 4034F2C501DA Ds Collar Positioning Jigs 4021-7903-XX 4034F2C502DA Db Gap Adjusting Jigs 4021-7904-XX 4034F2C503DA PC Positioning Jig...

  • Page 31: Firmware Upgrade

    Field Service Ver. 1.0 Apr. 2005 5. Firmware upgrade Firmware upgrade Preparations for Firmware rewriting 5.1.1 Installing the Driver NOTE • Since USB is used to upgrade the firmware, the host computer must be run on an OS of Windows 98 or later. •...
  • Page 32 5. Firmware upgrade Field Service Ver. 1.0 Apr. 2005 <For Windows Me/98> 1. Prepare the files necessary for upgrading the firmware, and copy them to PC. 2. Start the host computer. 3. Turn on the power switch of copier. 4. Use a USB cable to connect the copier to host computer. The “Add New Hardware Wizard”...

  • Page 33: Firmware Rewriting

    Field Service Ver. 1.0 Apr. 2005 5. Firmware upgrade Firmware rewriting 5.2.1 Updating method 1. Turn ON the Power Switch of the copier. 2. Start the host computer. 3. Copy the “Update Software” folder and “Update” file to drive C. (Copy them into the highest directory on drive C.) 4.
  • Page 34 5. Firmware upgrade Field Service Ver. 1.0 Apr. 2005 9. Check the Display for status of the firmware upgrading sequence. <PWB-C/C> 4035D530CA NOTE • NEVER turn OFF and ON the Power Switch as long as the above screens are being displayed.

  • Page 35: Procedure When Upgrading The Firmware Has Failed

    Field Service Ver. 1.0 Apr. 2005 5. Firmware upgrade 5.2.2 Procedure when Upgrading the Firmware has failed NOTE • Perform upgrading using BIOS only when upgrading from PC using ordinary USB connection has failed and the PC has not started properly. •...
  • Page 36 5. Firmware upgrade Field Service Ver. 1.0 Apr. 2005 7. Install the BIOS ROMs (U17, U19) on the Fax board. 4035D537AA 8. Attach the Fax board to Control board (PWB-C/C). 9. Turn on the power switch of copier. Following message will appear on message panel and copier waits for file data.

  • Page 37: Other

    Field Service Ver. 1.0 Apr. 2005 6. 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 38 6. Other Field Service Ver. 1.0 Apr. 2005 E. Other Screws not Marked with Red Paint (1) PH Unit Section PH Unit PH Unit Base Plate 4035D137AA (2) IR Unit Section Left Side Right Side 4035D136AA...

  • Page 39: Disassembly/Assembly/Cleaning List (Other Parts)

    Field Service Ver. 1.0 Apr. 2005 6. Other Disassembly/Assembly/Cleaning list (Other parts) 6.2.1 Disassembly/Assembly parts list Section Part name Ref.Page Original Glass Control Panel Control Panel Left Cover Front Cover Paper Exit Cover Front Door Tray 1 Left Cover Exterior parts Paper Exit Tray Rear Inside Cover Original Scanning Glass...

  • Page 40: Cleaning Parts List

    6. Other Field Service Ver. 1.0 Apr. 2005 Section Part name Ref.Page Main Motor Power Unit Cooling Fan Motor Fusing Cooling Fan Motor Paper Size Sensor Assy Fusing Unit Interlock Switch Inch/Metric Sensor/1 Assy Others Flickerless Resistor Separation Roller Feed Roller Upper/Lower Synchronizing Rollers Paper Dust Remover Bypass Transport Roller/Roll...

  • Page 41: Disassembly/Assembly Procedure

    Field Service Ver. 1.0 Apr. 2005 6. Other Disassembly/Assembly procedure 6.3.1 Exterior Parts 4035D047AB Part Name Removal Procedure Remove the Original Scanning Glass. → Remove one screw. → Original Glass Remove the holding bracket. → Remove the Original Glass. Remove the Control Panel Left Cover. → Remove two screws. → Remove one flat cable and unplug one connector.
  • Page 42 6. Other Field Service Ver. 1.0 Apr. 2005 4035D048AB Part Name Removal Procedure Remove the Upper Rear Cover. → Remove three screws. → Right Rear Cover Remove the Right Rear Cover. Remove the Upper Rear Cover. → Remove four screws. → Left Rear Cover Remove the Left Rear Cover.

  • Page 43: Master Board (Pwb-A)

    Field Service Ver. 1.0 Apr. 2005 6. Other 6.3.2 Master Board (PWB-A) 1. Remove the Rear Cover. 2. Unplug all connectors from the Mas- ter Board. 4035D049AA 3. Remove four screws and the Master Board. 4035D050AA 6.3.3 Control Board (PWB-C/C) 1.
  • Page 44 6. Other Field Service Ver. 1.0 Apr. 2005 5. Remove six screws and the Control Board. 4035D053AB Cautions in replacing the Control Board: • When the Control Board (PWB-C/C) is replaced with a new one, Parameter Chip (U16) must be demounted from the old PWB-C/C and remounted on the new PWB- C/C.

  • Page 45: High Voltage Unit (Hv1)

    Field Service Ver. 1.0 Apr. 2005 6. Other 6.3.4 High Voltage Unit (HV1) 1. Remove the Rear Cover. 2. Remove the Master Board. 3. Unplug all connectors from the High Voltage Unit. 4035D054AA 4. Remove two screws and the High Voltage Unit.

  • Page 46: Paper Size Detecting Board (Pwb-I)

    6. Other Field Service Ver. 1.0 Apr. 2005 6. Remove eight screws and protective cover 2. 4035D056AB 7. Unplug all connectors from the Power Supply Unit. 4035D057AB 8. Remove six screws and the Power Supply Unit. 4035D523AA 6.3.6 Paper Size Detecting Board (PWB-I) 1.

  • Page 47: Heater Relay Board (Pwb-Ry): 200 V Area Only

    Field Service Ver. 1.0 Apr. 2005 6. Other 4. Remove the lever. 4035D059AA 5. Unplug one connector and remove the Paper Size Detecting Board. 4035D060AA 6.3.7 Heater Relay Board (PWB-RY): 200 V area only 1. Remove the Front Cover and Left Cover. 2.

  • Page 48: Manual Bypass

    6. Other Field Service Ver. 1.0 Apr. 2005 6.3.9 Manual Bypass 1. Remove the Rear Right Cover. 2. Open the Right Door. 3. Remove two screws, unplug one connector, and remove the Manual Bypass. 4532D008AC 6.3.10 Manual Bypass (Duplex Unit) 1.

  • Page 49: Ph Unit

    Field Service Ver. 1.0 Apr. 2005 6. Other 4. Unplug two connectors. 4035D063AA 5. Remove the Toner Hopper Unit. 4035D064AA 6. Remove two screws and the Toner Replenishing Motor. 4035D065AA 6.3.12 PH Unit 1. Remove the Front Cover, Left Cover, Rear Cover, Paper Exit Tray, and Rear Inside Cover.

  • Page 50: Disassembly Of The Fusing Unit

    6. Other Field Service Ver. 1.0 Apr. 2005 3. Remove two cable holders of the flat cable. 4035D067AA 4. Remove the harness from one wiring saddle. 4035D068AA 5. Remove three screws (with springs) and the PH Unit. 4035D069AA 6.3.13 Disassembly of the Fusing Unit A.
  • Page 51 Field Service Ver. 1.0 Apr. 2005 6. Other 3. Remove the torsion coil spring and the Movable Guide Assy. 4035D145AA 4. Remove four shoulder screws, two washers, and the Fusing Roller/rt Cover. 4035D071AB 5. Remove two Bearings and the Fus- ing Roller/rt.
  • Page 52 6. Other Field Service Ver. 1.0 Apr. 2005 6. Remove one screw. Then, slide the Paper Separator Finger Assy in the direction of the arrow and take it off. 4035D072AA 7. Remove one screw and the Ther- mistor. 4035D073AA 8. Unhook springs and remove the four Paper Separator Fingers.

  • Page 53: Ccd Unit

    Field Service Ver. 1.0 Apr. 2005 6. Other 6.3.14 CCD Unit A. Removal Procedure 1. Remove the Original Glass. 2. Remove four screws and the CCD Unit Cover. 4035D016AA 3. Mark a line along the profile of the CCD Unit mounting bracket as shown on the left.

  • Page 54: Scanner, Exposure Lamp, And Inverter Board (Pu2)

    6. Other Field Service Ver. 1.0 Apr. 2005 B. Reinstallation Procedure 1. Position the CCD Unit along the marking line. Then, temporarily secure three screws at the center of each of the screw slots. 2. Adjust the position of the CCD Unit. 4035D077AA 6.3.15 Scanner, Exposure Lamp, and Inverter Board (PU2)

  • Page 55: Scanner Motor

    Field Service Ver. 1.0 Apr. 2005 6. Other 5. Remove two screws, unplug one connector, and remove the Inverter Board. 4035D081AA 6. Remove two screws and the Expo- sure Lamp. 4035D082AA 6.3.16 Scanner Motor 1. Remove the Right Rear Cover. 2.

  • Page 56: Scanner Drive Cables

    6. Other Field Service Ver. 1.0 Apr. 2005 4. Snap off one C-ring. 5. Loosen four screws and remove the Scanner Motor harness from the gear case assy. 4035D533AA 6. Remove two screws and the Scan- ner Motor. 4035D534AA 6.3.17 Scanner Drive Cables A.
  • Page 57 Field Service Ver. 1.0 Apr. 2005 6. Other 3. Unhook the springs from the cable hooks at the front and rear. 4035D087AB 4. Remove the front cable from the cable pulley. 4035D088AA 5. Remove the rear cable from the cable pulley. 4035D089AA 6.
  • Page 58 6. Other Field Service Ver. 1.0 Apr. 2005 7. Remove one screw from the rear cable pulley. 4035D091AA 8. Snap off one C-ring from the front side of the Pulley Assy. 4035D092AA 9. Snap off one C-ring from the rear side of the Pulley Assy.
  • Page 59 Field Service Ver. 1.0 Apr. 2005 6. Other 11. Remove two screws from the rear side of the Pulley Assy and remove the gear. 12. Remove the cable from the cable pulley. 4035D095AA B. Reinstallation Procedure <Overall View> Wire pulley 2 Wire pulley 1 Pulley D Pulley C...
  • Page 60 6. Other Field Service Ver. 1.0 Apr. 2005 2. Wind the cable on side B around wire pulley 2 four turns counterclock- wise, starting with the slit at the bot- tom in the rear left of the pulley. 4035D111AA 3. Wind the cable on side A around wire pulley 2 four turns clockwise, starting with the slit at the top in the front left of the pulley.
  • Page 61 Field Service Ver. 1.0 Apr. 2005 6. Other 6. Wind the cable on side A around wire pulley 1 four turns counterclock- wise, starting with the slit at the bot- tom in the front left of the pulley. 4035D115AA 7. Wind the cable on side B around wire pulley 1 four turns clockwise, starting with the slit at the top in the rear left of the pulley.
  • Page 62 6. Other Field Service Ver. 1.0 Apr. 2005 12. Secure the front and rear cable pul- leys to the shaft using one screw each. NOTE • The direction in which the screw is installed differs between the front and rear. Note the correct direction. 4035D118AA 13.
  • Page 63 Field Service Ver. 1.0 Apr. 2005 6. Other 16. Wind the lower cable of wire pulley 2 around pulley C. Pulley C 4035D124AA 17. Wind the cable from pulley C around pulley D. NOTE • Wind the cable around the outer groove in pulley D.

  • Page 64: Main Motor

    6. Other Field Service Ver. 1.0 Apr. 2005 21. Wind the upper cable of wire pulley 1 around pulley B and hook it onto the hook. NOTE Wind the cable around the inner groove in pulley B. 4035D123AA 22. Wind the upper cable of wire pulley 2 around pulley D and hook it onto the hook.

  • Page 65: Power Unit Cooling Fan Motor

    Field Service Ver. 1.0 Apr. 2005 6. Other 6.3.19 Power Unit Cooling Fan Motor 1. Remove the Left Cover, Rear Cover, and Upper Rear Cover. 2. Remove the Master Board. 3. Remove the Control Board. 4. Remove nine screws and the protec- tive cover.

  • Page 66: Paper Size Sensor Assy

    6. Other Field Service Ver. 1.0 Apr. 2005 5. Remove four screws and the Duct Assy. 4035D099AC 6. Remove seven screws and the mounting bracket. 4035D100AB 7. Remove two screws, unplug one connector, and remove the Fusing Cooling Fan Motor. 4035D101AA 6.3.21 Paper Size Sensor Assy...

  • Page 67: Fusing Unit Interlock Switch

    Field Service Ver. 1.0 Apr. 2005 6. Other 4. Unplug two connectors and remove the Paper Size Sensor Assy. 4035D103AA 6.3.22 Fusing Unit Interlock Switch 1. Remove the Rear Cover. 2. Remove the harness from one wiring saddle. 4035D130AC 3. Remove two screws (to which red paint has been applied).
  • Page 68 210 4035D541AA 4035D539AA for ineo 161 5. Close the right door, and then use a tester to make sure that the Fusing Unit Interlock Switch is conducting between 2A and 2B. 6. Open the right door, and then use a tester to make sure that the Fusing Unit Interlock...

  • Page 69: Inch/Metric Sensor/1 Assy (3Rd Area Only)

    2. Remove one screw, unplug one con- nector, and remove the Inch/Metric Sensor/1 Assy. 4035D141AA 6.3.24 Flickerless Resistor (Only for 200 V area of ineo 161) 1. Remove the Rear Cover. 2. Remove the Master Board. 3. Remove the harness from one wiring saddle.

  • Page 70: Cleaning Procedure

    6. Other Field Service Ver. 1.0 Apr. 2005 Cleaning procedure NOTE • The alcohol described in the cleaning procedure represents the isopropyl alcohol. 6.4.1 Separation Roller 1. Remove the Separation Roller Assy. 2. Using a soft cloth dampened with alcohol, wipe the Separation Roller clean of dirt.

  • Page 71: Paper Dust Remover

    Field Service Ver. 1.0 Apr. 2005 6. Other 6.4.4 Paper Dust Remover 1. Remove the Paper Dust Remover Assy. 2. Using a brush, whisk dust and dirt off the Paper Dust Remover. 4035D009AA 6.4.5 Bypass Transport Roller/Roll 1. Remove the Rear Right Cover. 2.

  • Page 72: Mirrors

    6. Other Field Service Ver. 1.0 Apr. 2005 6.4.6 Mirrors 1. Remove the Original Glass. 2. Using a soft cloth dampened with alcohol, wipe the mirrors clean of dirt. 4035D014AB 6.4.7 Lens 1. Remove the Original Glass. 2. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt.

  • Page 73: Scanner Rails/Bearings

    Field Service Ver. 1.0 Apr. 2005 6. Other 4. Using a soft cloth dampened with alcohol, wipe the CCD Sensor clean of dirt. 4035D018AA 6.4.9 Scanner Rails/Bearings 1. Remove the Original Glass. 2. Using a soft cloth dampened with alcohol, wipe the Scanner rails and Bearings clean of dirt.

  • Page 74: Charge Neutralizing Plate

    6. Other Field Service Ver. 1.0 Apr. 2005 6.4.12 Charge Neutralizing Plate 1. Open the Right Door. 2. Using a soft cloth dampened with alcohol, wipe the Charge Neutraliz- ing Plate clean of dirt. NOTE • Use care not to allow the Image Transfer Roller to be touched with alcohol.
  • Page 75 Field Service Ver. 1.0 Apr. 2005 6. Other 4. Using two screws, secure the Key Counter Socket. 4623D004AA 5. Using two screws, secure the Key Counter cover. 4623D005AA 6. Plug in the Key Counter. NOTE • When the Key Counter is mounted, set “Machine Counter Copying”...
  • Page 76 6. Other Field Service Ver. 1.0 Apr. 2005 Blank page...

  • Page 77: Adjustment/Setting

    Field Service Ver. 1.0 Apr. 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 78: Utility Mode

    8. Utility Mode Field Service Ver. 1.0 Apr. 2005 Utility Mode • Utility mode is used to make settings for the utility functions. Utility Mode function tree 1. AUTO PANEL RESET 2. ENERGY SAVE MODE 3. AUTO SHUT OFF 4. DENSITY (ADF) MACHINE SETTING 5.

  • Page 79: Utility Mode Function Setting Procedure

    Field Service Ver. 1.0 Apr. 2005 8. Utility Mode Utility Mode function setting procedure 8.2.1 Procedure 1. Press the Utility key. 2. The Utility mode screen will appear. 8.2.2 Exiting • Press the Panel Reset key. 8.2.3 Changing the setting value in Utility Mode functions •...

  • Page 80: Paper Source Setup

    8. Utility Mode Field Service Ver. 1.0 Apr. 2005 D. DENSITY (ADF) Purpose/Use To set the reading image density level when the Automatic Document Feeder is used. NOTE • The low image density is set as the default value to prevent a dirty copy from being produced.

  • Page 81: User Management

    Field Service Ver. 1.0 Apr. 2005 8. Utility Mode B. TRAY1 PAPER Purpose/Use To set the type and size of the paper loaded in Paper Feed Tray/1. Setting/ • The default setting is “PLAIN” and “AUTO.” Procedure <Step> 1. Select the type of paper. “PLAIN”...

  • Page 82: Admin. Management

    8. Utility Mode Field Service Ver. 1.0 Apr. 2005 8.3.4 ADMIN. MANAGEMENT • ADMIN. MANAGEMENT is used to make various settings after the administrator number set using the Service mode has been entered. <Admin. Management Mode Setting Procedure> 1. Press the Utility key. 2.

  • Page 83: Copy Setting 1

    Field Service Ver. 1.0 Apr. 2005 8. Utility Mode <COPY TRACK DATA?> Purpose/Use • To display or clear the total count value of a specific account. • To clear the total count values of all accounts under control. Setting/ <Display/Clear Procedure> Procedure 1.

  • Page 84: Copy Setting 2

    8. Utility Mode Field Service Ver. 1.0 Apr. 2005 E. BINDING POS. Purpose/Use To set the first page to be scanned when copies are made from a book, whether it is on the left or on the right. Setting/ LEFT RIGHT Procedure F.
  • Page 85 Field Service Ver. 1.0 Apr. 2005 8. Utility Mode C. OUTPUT PRIORITY Purpose/Use To set the priority finishing function, either Non-Sort, Sort, or Group. Setting/ • The default setting is “NON.” Procedure “NON” SORT GROUP D. 4IN1 COPY ORDER Purpose/Use To set the layout of copy images in 4in1 copies.

  • Page 86: Adjustment Item List

    9. Adjustment item list Field Service Ver. 1.0 Apr. 2005 Adjustment item list Replacement Part/Service Job Tray1 Adjustment/Setting Items ID Adjust VG Adjust Leading Edge Erase Trailing Edge Erase Service's Choice Vertical Edge Erase Loop Adjust (Tray1) Fuser Temp CCD APS Size PRN Main Regist PRN Sub Regist CCD Main Zoom...
  • Page 87 Field Service Ver. 1.0 Apr. 2005 9. Adjustment item list This table shows the list of adjustment items when replacing a part. Items are numbered by the priority if there is any. DF-605 DF-502 PF-502 MB-501 1, 3 *: Check when setting is changed.
  • Page 88 9. Adjustment item list Field Service Ver. 1.0 Apr. 2005 NOTE • Before executing a Memory Clear, be sure to take notes of the settings and adjust- ment data of Utility, Tech. Rep., Security, and Adjust modes. After the Memory Clear has been executed, re-enter those data.

  • Page 89: 10. Service Mode

    Field Service Ver. 1.0 Apr. 2005 10. Service Mode 10. Service Mode • The Service mode is used to check, set, adjust, or register the various service functions. 10.1 Service Mode function setting procedure NOTE • Care must be used to ensure that only the personnel who are involved in service jobs know the procedure to enter the Service mode.

  • Page 90: 10.2 Service Mode Function Tree

    10. Service Mode Field Service Ver. 1.0 Apr. 2005 10.2 Service Mode function tree SHIPMENT DESTINATION MAINTENANCE COUNTER IU LIFE STOP MODE ID ADJUST VG ADJUST FUSER TEMP. Ad (PLAIN) FUSER TEMP. Ad (THICK) FUSER TEMP. Ad (OHP) LEADING EDGE ERASE 1.
  • Page 91 Field Service Ver. 1.0 Apr. 2005 10. Service Mode TOTAL COUNTER SIZE COUNTER PM COUNTER MAINTENANCE COUNTER SUPPLIES LIFE COUNT. 3. COUNTER APPLICATION COUNTER SCAN COUNTER PAPER SIZE COUNTER MISFEED COUNTER TROUBLE COUNTER TONER DENSITY LEVEL PROCESS CONTROL MAIN F/W VER. ENGINE F/W VER.
  • Page 92 10. Service Mode Field Service Ver. 1.0 Apr. 2005 REDUCTION2 REDUCTION1 7. FIXED ZOOM CHANGE EXPANSION1 EXPANSION2 PANEL BUZZER TEST 8. FACTORY TEST RAM TEST Service Mode MEMORY CLEAR PM COUNTER MAINTENANCE COUNTER SUPPLIES LIFE COUNT. APPLICATION COUNTER 9. CLEAR DATA SCAN COUNTER PAPER SIZE COUNTER MISFEED COUNTER...

  • Page 93: 10.3 Setting In The Service Mode

    Field Service Ver. 1.0 Apr. 2005 10. Service Mode 10.3 Setting in the Service Mode 10.3.1 SERVICE’S CHOICE • SERVICE’S CHOICE is used to make the various service settings. A. SHIPMENT DESTINATION Purpose/Use To select the display of the fixed zoom ratios and paper sizes according to the applica- ble marketing area.
  • Page 94 When the type of paper is changed Setting/ • The default setting is “0.” Procedure Setting range: -1 to +2 <Temperature table for adjusting fusing temperature for plain paper> For ineo 161 Mode selected in Service’s Choice Paper width Setting value Mode 1 Mode 3 Fusing Heater Lamp temperature 200 °C...
  • Page 95 When fusing failure occurs Setting/ • The default setting is “0.” Procedure Setting range: -1 to +1 <Temperature table for adjusting fusing temperature for special paper> For ineo 161 Mode selected in Service’s Choice Paper width Setting value Mode 1 Mode 3 Fusing Heater Lamp temperature 210 °C...
  • Page 96 When fusing failure occurs Setting/ • The default setting is “0.” Procedure Setting range: -1 to +1 <Temperature table for adjusting fusing temperature for OHP film> For ineo 161 Mode selected in Service’s Choice Paper width Setting value Mode 1 Mode 3 Fusing Heater Lamp temperature 180 °C...
  • Page 97 Field Service Ver. 1.0 Apr. 2005 10. Service Mode LEADING EDGE ERASE Purpose/Use To adjust the erase width on the leading edge of the image by varying the laser emis- sion timing. When the PH Unit has been replaced Setting/ •...
  • Page 98 10. Service Mode Field Service Ver. 1.0 Apr. 2005 K. VERTICAL EDGE ERASE Purpose/Use To adjust the erase width on both edges of the image (in CD direction) by varying the laser emission timing. When the PH Unit has been replaced Setting/ Select the erase width value in the CD direction.
  • Page 99 Field Service Ver. 1.0 Apr. 2005 10. Service Mode N. LOOP ADJUST (DUPLEX): ineo 210 only Purpose/Use To adjust the length of the loop formed in the paper before the Synchronizing Roller. When a skew feed, fold, or misfeed of paper occurs When variations in the amount of void on the leading edge occurs Setting/ Refer to the option service manual (AD-504) for details.

  • Page 100: Adjust

    10. Service Mode Field Service Ver. 1.0 Apr. 2005 10.3.2 ADJUST A. PRN MAIN REGIST Function Test Copy Adjust Purpose/Use To adjust by varying the starting position of image writing in the main scanning direc- tion. When the image on the copy deviates in the CD direction When the PH Unit has been replaced Setting/ Press the Start key to start a test copy...
  • Page 101 Field Service Ver. 1.0 Apr. 2005 10. Service Mode B. PRN SUB REGIST Function Test Copy Adjust Purpose/Use To adjust by varying the starting position of image writing in the sub scanning direction. When the image on the copy deviates in the FD direction When the PH Unit has been replaced Setting/ Press the Start key to start a test copy...
  • Page 102 10. Service Mode Field Service Ver. 1.0 Apr. 2005 C. CCD MAIN ZOOM Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different IR parts by vary- ing the scanning zoom ratio in the main scanning direction. When the CCD Unit has been replaced (After the CCD Unit has been adjusted for correct position) Setting/...
  • Page 103 Field Service Ver. 1.0 Apr. 2005 10. Service Mode D. CCD SUB ZOOM Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different IR parts by vary- ing the scanning zoom ratio in the sub scanning direction. When the Scanner Drive Cables have been replaced Setting/ •...
  • Page 104 10. Service Mode Field Service Ver. 1.0 Apr. 2005 E. CCD MAIN REGIST Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different IR parts by vary- ing the starting position of image scanning in the main scanning direction. When the PH Unit has been replaced (After PRN Main Regist, PRN Sub Regist, and CCD Main Zoom have been adjusted) When the CCD Unit has been replaced (After the CCD Unit has been adjusted for...
  • Page 105 Field Service Ver. 1.0 Apr. 2005 10. Service Mode F. CCD SUB REGIST Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different IR parts by vary- ing the starting position of image scanning in the sub scanning direction. When the PH Unit has been replaced (After PRN Main Regist, PRN Sub Regist, and CCD Main Zoom have been adjusted) When the CCD Unit has been replaced (After the CCD Unit has been adjusted for...
  • Page 106 10. Service Mode Field Service Ver. 1.0 Apr. 2005 H. ADF MAIN REGIST appears only when the Automatic Document Feeder (DF-502) or Duplexing Document Feeder (DF-605: ineo 210 only) is installed Function Test Copy Adjust Purpose/Use To adjust variations in machining and installation accuracy of different parts by varying the scanning start position in the main scanning direction when the Automatic Docu- ment Feeder is used.

  • Page 107: Counter

    Field Service Ver. 1.0 Apr. 2005 10. Service Mode L. ADF REG. LOOP2 appears only when the Duplexing Document Feeder (DF-605: ineo 210 only) is installed Purpose/Use To adjust the length of loop formed in the original before the Registration Roller. When a skew feed, fold, or misfeed of the original occurs Setting/ Refer to the option service manual (DF-605) for details.
  • Page 108 10. Service Mode Field Service Ver. 1.0 Apr. 2005 C. PM COUNTER Purpose/Use • To display the count of the number of times each of different parts of the copier has been used. • The count should be cleared when the corresponding PM part is replaced. Setting/ 1: BYPASS Procedure...
  • Page 109 14: OTHER 15: PLAIN PAPER 16: RECYCLE PAPER 17: SPECIAL PAPER 18: 1-SIDE PAPER (should not be used only for ineo 161) 19: OHP 20: THICK PAPER 21: ENVELOPE • To clear the count, use “Clear Data” of the Service mode.
  • Page 110 10. Service Mode Field Service Ver. 1.0 Apr. 2005 J. TROUBLE COUNTER Purpose/Use To display the count of the number of malfunctions detected according to the malfunc- tion code. Setting/ C0000: Main Motor malfunction Procedure C0044: ADF Cooling Fan failure (should not be used only for ineo 210) C0045: Fusing Cooling Fan Motor malfunction C004E: Power Unit Cooling Fan Motor malfunction C0070: Toner Replenishing Motor malfunction...

  • Page 111: Display

    Field Service Ver. 1.0 Apr. 2005 10. Service Mode 10.3.4 DISPLAY • DISPLAY displays various types of information. A. TONER DENSITY LEVEL Purpose/Use To display the current output value of ATDC sensor. Refer to the following table for actual T/C values. Used to check the T/C ratio when the image density is defective.

  • Page 112: Function

    10. Service Mode Field Service Ver. 1.0 Apr. 2005 G. ADF F/W VER. Purpose/Use To display the ADF firmware version information. Only when the optional Duplexing Document Feeder (DF-605) is mounted H. MAIN RAM SIZE Purpose/Use To display the main memory size. PCL RAM SIZE Purpose/Use To display the PCL memory size.
  • Page 113 Field Service Ver. 1.0 Apr. 2005 10. Service Mode C. ATDC AUTO ADJUST Purpose/Use To make an automatic adjustment of the ATDC Sensor. At setup When developer has been changed When IU has been replaced Setting/ <Step> Procedure 1. Press the [Yes] key to start the adjustment. 2.
  • Page 114 10. Service Mode Field Service Ver. 1.0 Apr. 2005 G. CCD MOVE TO HOME Purpose/Use To move the Scanner to its home position and fix it at the home position. When transporting the copier Setting/ • Pressing the Start key will move the Scanner toward the left from its standby position. Procedure <Step>...

  • Page 115: Admin. Registration

    Field Service Ver. 1.0 Apr. 2005 10. Service Mode 10.3.6 ADMIN. REGISTRATION • ADMINISTRATOR NUMBER REGISTRATION is used to register or change the adminis- trator number required when entering the Admin. Management function of the Utility mode. <Step> 1. Using the 10-Key Pad, type the 6-digit administrator number (000000 to 999999) to be registered or changed.

  • Page 116: Factory Test

    10. Service Mode Field Service Ver. 1.0 Apr. 2005 E. Latin America (Metric) Setting name Default fixed zoom ratio Setting range REDUCTION2 51% to 70% REDUCTION1 71% to 99% EXPANSION1 115% 101% to 140% EXPANSION2 141% 141% to 199% F. Latin America (Inch) Setting name Default fixed zoom ratio Setting range...

  • Page 117: Clear Data

    Field Service Ver. 1.0 Apr. 2005 10. Service Mode 10.3.9 CLEAR DATA • CLEAR DATA is used to clear data of various types. A. MEMORY CLEAR Purpose/Use To clear the setting values listed on the right, resetting them to the default values. Setting/ •...
  • Page 118 10. Service Mode Field Service Ver. 1.0 Apr. 2005 J. ADF BACKUP CLEAR (ineo 210 only) Purpose/Use To clear the values adjusted with ADF SENSOR ADJUST and the values adjusted with Org. Width Detect. When PBA-CONT board has been replaced. When PBA-VR board has been replaced.

  • Page 119: 11. Security

    Field Service Ver. 1.0 Apr. 2005 11. Security 11. Security 11.1 Security Function Setting Procedure • Security is used to set the security functions. 11.1.1 Procedure 1. Call the Service mode to the screen. 2. Press the following keys in this order: Stop →...

  • Page 120: 12. Mechanical Adjustment

    12. Mechanical adjustment Field Service Ver. 1.0 Apr. 2005 12. Mechanical adjustment 12.1 Adjustment of the Position of the Scanner and 2nd/3rd Mir- rors Carriage NOTE • This adjustment is to be made when the Scanner Drive Cables has been replaced or rewound.

  • Page 121: Ccd Unit Position Adjustment

    Field Service Ver. 1.0 Apr. 2005 12. Mechanical adjustment 12.2 CCD Unit Position Adjustment NOTE • This adjustment is to be made when the CCD Unit has been replaced. <Adjustment Standard> • Adjust so that the amount of error falls within ±1.0% of the length to be measured. •...

  • Page 122: Adjustment Of The Gap Between The Doctor Blade And Sleeve Roller

    12. Mechanical adjustment Field Service Ver. 1.0 Apr. 2005 12.3 Adjustment of the Gap between the Doctor Blade and Sleeve Roller (Db Adjustment) NOTE • This adjustment is to be made when an image problem (uneven density, low ID, gradation reproducibility failure, etc.) occurs. <Adjustment Standard>...
  • Page 123 Field Service Ver. 1.0 Apr. 2005 12. Mechanical adjustment 7. Using a small piece of paper, remove developer from the shaded area on the surface of the Sleeve Roller and put it in the Developer Mixing Cham- ber. 8. Remove the developer left on the surface of the Sleeve Roller.

  • Page 124: Manual Bypass (For The Optional Ad-504) Cd Registration Adjustment *Ineo

    12. Mechanical adjustment Field Service Ver. 1.0 Apr. 2005 12.4 Manual Bypass (for the optional AD-504) CD Registration Adjustment *ineo 210 only NOTE • This adjustment is to be made when the PH Unit has been replaced. <Adjustment Procedure> 1. Load the Paper Feed Tray/1 with A4 crosswise paper. 2.

  • Page 125: Troubleshooting

    Field Service Ver. 1.0 Apr. 2005 13. Introduction Troubleshooting 13. Introduction • Information required for troubleshooting and steps that must be performed are described in this chapter. 13.1 Electrical Components Check Procedure • If a paper misfeed or malfunction occurs, perform the following operations to check the condition of the electrical components.

  • Page 126: Switch

    13. Introduction Field Service Ver. 1.0 Apr. 2005 13.1.2 Switch Step Check Result Action Replace the switch. Does the input signal (NO) of the control board change from L Replace the control to H when the switch is activated? board. Not Use 4025T523AB 13.1.3...

  • Page 127: Motor

    Field Service Ver. 1.0 Apr. 2005 13. Introduction 13.1.5 Motor Step Check Result Action Replace the control Does the LOCK signal switch to H when the machine goes into board. Replace the standby? motor. Replace the motor. Does the REM signal of the master board change from H to L Replace the control when the motor is turned on? board.

  • Page 128: 14. Jam Display

    14. Jam Display Field Service Ver. 1.0 Apr. 2005 14. Jam Display 14.1 Misfeed Display • When a paper misfeed occurs, the Error indicator lights up steadily and the Display gives a corresponding message. 4980P502DA C4506P298CA Display Message Misfeed/Paper Location Ref.

  • Page 129: 14.2 Sensor Layout

    Field Service Ver. 1.0 Apr. 2005 14. Jam Display 14.2 Sensor layout 14.2.1 System Mounted with DF-502, PF-502 and MB-501. 4035T501AA Exit Paper Sensor (PC3) Registration Sensor (PC3/AF) Synchronizing Roller Sensor (PC1) Separator Sensor (PC4/AF) Paper Set Sensor/Bypass (PC2) Paper Exit Sensor (PC5/AF) Paper Take-Up Sensor (PC12/PF)

  • Page 130: 14.3 Solution

    14. Jam Display Field Service Ver. 1.0 Apr. 2005 14.3 Solution 14.3.1 Initial Check Items • When a paper misfeed occurs, first perform the following initial checks. Check Item Action Does paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct the user on the correct paper stor- age procedures.

  • Page 131: Misfeed At The Paper Feed Tray/1 Paper Take-Up Section

    Field Service Ver. 1.0 Apr. 2005 14. Jam Display 14.3.2 Misfeed at the Paper Feed Tray/1 Paper Take-up Section A. Detection Timing Type Description Paper Take-Up • The leading edge of the paper does not unblock the Synchronizing Roller Sen- Section misfeed sor (PC1) even after the lapse of a given period of time after the Paper Take-up detection...

  • Page 132: Misfeed At The Manual Bypass Paper Take-Up Section

    14. Jam Display Field Service Ver. 1.0 Apr. 2005 14.3.3 Misfeed at the Manual Bypass Paper Take-up Section A. Detection Timing Type Description Manual Bypass • The leading edge of the paper does not unblock the Synchronizing Roller Sen- paper take-up sor (PC1) even after the lapse of a given period of time after the Paper Take-up section misfeed Solenoid/Bypass (SL2) has been energized.

  • Page 133: Misfeed At The Multiple Bypass Paper Take-Up Section

    Field Service Ver. 1.0 Apr. 2005 14. Jam Display 14.3.4 Misfeed at the Multiple Bypass Paper Take-up Section (When the optional Multiple Bypass MB-501 is mounted) A. Detection Timing Type Description Paper take-up • The leading edge of the paper does not unblock the Synchronizing Roller Sen- section misfeed sor (PC1) even after the lapse of a given period of time after the Paper Take-up detection...

  • Page 134: Misfeed At The Paper Feed Unit Paper Take-Up/Vertical Transport Section

    14. Jam Display Field Service Ver. 1.0 Apr. 2005 14.3.5 Misfeed at the Paper Feed Unit Paper Take-up/Vertical Transport Section (When the optional Paper Feed Unit PF-502 is mounted) A. Detection Timing Type Description Paper take-up/ • The leading edge of the paper does not unblock the Synchronizing Roller Sen- vertical transport sor (PC1) even after the lapse of a given period of time after the Paper Take-up section misfeed...

  • Page 135: Misfeed At The Paper Separating Section

    Field Service Ver. 1.0 Apr. 2005 14. Jam Display 14.3.6 Misfeed at the Paper Separating Section A. Detection Timing Type Description • The Exit Paper Sensor (PC3) is not blocked even after the lapse of a given period of time after the paper has unblocked the Synchronizing Roller Sensor (PC1).

  • Page 136: Misfeed At The Fusing/Exit Section

    14. Jam Display Field Service Ver. 1.0 Apr. 2005 14.3.7 Misfeed at the Fusing/Exit Section A. Detection Timing Type Description Fusing/exit section • The Exit Paper Sensor (PC3) is not unblocked even after the lapse of a given misfeed detection period of time after the Synchronizing Roller Sensor (PC1) has been blocked.

  • Page 137: Misfeed At The Document Take-Up Section

    Field Service Ver. 1.0 Apr. 2005 14. Jam Display 14.3.8 Misfeed at the Document Take-up Section (When the optional Automatic Document Feeder DF-502 is mounted) A. Detection Timing Type Description Document take-up • The Separator Sensor (PC4/AF) is not blocked even after the lapse of a given section misfeed period of time after the Main Motor (M1/AF) has been energized.

  • Page 138: Misfeed At The Document Transport Section

    14. Jam Display Field Service Ver. 1.0 Apr. 2005 14.3.9 Misfeed at the Document Transport Section (When the optional Automatic Document Feeder DF-502 is mounted) A. Detection Timing Type Description Document • The Registration Sensor (PC3/AF) is not blocked even after the lapse of a given transport section period of time after the Main Motor (M1/AF) has been energized.

  • Page 139: Misfeed At The Document Exit Section

    Field Service Ver. 1.0 Apr. 2005 14. Jam Display 14.3.10 Misfeed at the Document Exit Section (When the optional Automatic Document Feeder DF-502 is mounted) A. Detection Timing Type Description Document exit • The Paper Exit Sensor (PC5/AF) is not blocked even after the lapse of a given section misfeed period of time after the Main Motor (M1/AF) has been energized.

  • Page 140: 15. Malfunction Code

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.1 Trouble code • The copier’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel.
  • Page 141 Field Service Ver. 1.0 Apr. 2005 15. Malfunction code Code Item Description • The surface temperature of the Fusing Roller does not reach a given level even after the lapse of a given period of time during a warm-up cycle. C0500 Warm-up failure From room temperature to 100°C...
  • Page 142 15. Malfunction code Field Service Ver. 1.0 Apr. 2005 Code Item Description • The Scanner Home Position Sensor (PC10) does not go from HIGH to LOW when the Scanner Motor (M5) is ener- gized for a given number of steps after the sequence to bring the Scanner back to its home position has been Faulty Scanner Home started at the end of a scan motion and during re-shading.
  • Page 143 Field Service Ver. 1.0 Apr. 2005 15. Malfunction code Code Item Description Startup failure • A LOW Polygon Motor (M2) Lock signal is not detected within a given period of time that begins 1 sec. after the Polygon Motor has started turning. Lock signal fault: Unstable after the first Lock signal has been detected •...

  • Page 144: 15.2 How To Reset

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.2 How to reset Code Description Procedure C0000 Main Motor malfunction C0044 ADF Cooling Fan Failure C0045 Fusing Cooling Fan Motor malfunction • Turn OFF and ON the Power Switch. Power Supply Cooling Fan Motor malfunc- C004E tion C0070 Toner Replenishing Motor malfunction...

  • Page 145: 15.3 Solution

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.3 Solution 15.3.1 C0000: Main Motor malfunction A. Detection Timing Trouble Code Description • The Main Motor (M1) Lock signal remains HIGH for a continuous 1-sec. period C0000 at any time 1 sec. after the Main Motor has started turning. B.

  • Page 146: C0044: Adf Cooling Fan Failure

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.3.2 C0044: ADF Cooling Fan Failure (When the optional Duplexing Document Feeder DF-605 is mounted) A. Detection Timing Trouble Code Description • The ADF Fan Motor Lock signal remains set to H for a set period of time while C0044 the EDH Fan Motor is turning.

  • Page 147: C0045: Fusing Cooling Fan Motor Malfunction

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.3.3 C0045: Fusing Cooling Fan Motor Malfunction A. Detection Timing Trouble Code Description • The Fusing Cooling Fan Motor (M3) Lock signal remains HIGH for a continuous C0045 1-sec. period while the Fusing Cooling Fan Motor is turning at full speed or decelerated speed.

  • Page 148: C004E: Power Supply Cooling Fan Motor Malfunction

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.3.4 C004E: Power Supply Cooling Fan Motor Malfunction A. Detection Timing Trouble Code Description • The Power Supply Cooling Fan Motor (M4) Lock signal remains HIGH for a con- C004E tinuous 1-sec. period while the Power Supply Cooling Fan Motor Remote signal remains ON (for full-speed rotation) or OFF (for decelerated-speed rotation).

  • Page 149: C0070: Toner Replenishing Motor Malfunction

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.3.5 C0070: Toner Replenishing Motor Malfunction A. Detection Timing Trouble Code Description • The Toner Bottle Home Position Sensor (PC7) outputs a HIGH signal for a con- tinuous 3.5-sec. period while the Toner Bottle is turning. C0070 •...

  • Page 150: C0210: Abnormal Image Transfer Voltage

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.3.6 C0210: Abnormal Image Transfer Voltage A. Detection Timing Trouble Code Description • The image transfer voltage remains more than 100 V for a continuous given C0210 period of time while the PC Drum remains stationary. B.

  • Page 151: C0500: Warm-Up Failure

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.3.7 C0500: Warm-up Failure 15.3.8 C0501: Warm-up Failure 2 (ineo 210 Only) 15.3.9 C0510: Fusing Failure (Abnormally Low Fusing Temperature) 15.3.10 C0511: Fusing Failure (Abnormally Low Fusing Temperature 2) (ineo 210 Only) 15.3.11 C0520: Fusing Failure (Abnormally High Fusing Temperature) 15.3.12...
  • Page 152 15. Malfunction code Field Service Ver. 1.0 Apr. 2005 B. Detection Timing Relevant Electrical Components Fusing Roller Heater Lamp (H1) Fusing Roller Thermostat (TS1) Fusing Roller Sub Heater Lamp (H2) Fusing Unit Interlock Switch (S2) Fusing Roller Thermistor Power Supply Unit (PU1) Fusing Roller Sub Thermistor (TH2) Master Board (PWB-A) WIRING DIAGRAM...
  • Page 153 Field Service Ver. 1.0 Apr. 2005 15. Malfunction code WIRING DIAGRAM Ref. Location Step Operations Page Control signal (Electrical Components) Check the Fusing Roller Heater Lamp (H1) for continuity and correct – – – or replace as necessary. Check the Fusing Roller Sub Heater Lamp (H2) for continuity and correct –...

  • Page 154: C0650: Faulty Scanner Home Position Sensor

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.3.13 C0650: Faulty Scanner Home Position Sensor A. Detection Timing Trouble Code Description • The Scanner Home Position Sensor (PC10) does not go from HIGH to LOW when the Scanner Motor (M5) is energized for a given number of steps after the sequence to bring the Scanner back to its home position has been started at the end of a scan motion and during re-shading.

  • Page 155: C0F32: Faulty Atdc Sensor

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.3.14 C0F32: Faulty ATDC Sensor 15.3.15 C0F33: Improperly Adjusted ATDC Sensor A. Detection Timing Trouble Code Description • The measurement taken by the ATDC Sensor (UN1) at a time 2.0 sec. after the Main Motor (M1) has started turning is less than 5% (greater than 4.63 V).

  • Page 156: C1038: Engine Connection Failure

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.3.16 C1038: Engine Connection Failure A. Detection Timing Trouble Code Description Master Board (PWB-A) to Control Board (PWB-C/C) connection failure • There is no acknowledge signal transmitted from the Master Board (PWB-A) to Control Board (PWB-C/C) for 1.5 sec.

  • Page 157: C1200: Faulty Asic/Memory

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.3.17 C1200: Faulty ASIC/Memory A. Detection Timing Trouble Code Description ASIC/memory (for image and control) fault C1200 • A write or read error occurs with SRAM on the Control Board (PWB-C/C). B.

  • Page 158: C1300: Polygon Motor Malfunction

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.3.18 C1300: Polygon Motor Malfunction 15.3.19 C13F0: Faulty HSYNC A. Detection Timing Trouble Code Description Startup failure • A LOW Polygon Motor (M2) Lock signal is not detected within a given period of time that begins 1 sec.

  • Page 159: C133B: Communication With Option Error

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.3.20 C133B: Communication with Option Error 15.3.21 C133D: ROM Check Error A. Detection Timing Trouble Code Description • It is not possible to communicate with the Printer Board within a predetermined C133B period of time during a print cycle.

  • Page 160: C14A3: Ir Fluorescent Lamp Fault

    15. Malfunction code Field Service Ver. 1.0 Apr. 2005 15.3.23 C14A3: IR Fluorescent Lamp Fault A. Detection Timing Trouble Code Description The Exposure Lamp (LA2) of the Scanner fails to turn ON. C14A3 • The intensity of the Exposure Lamp is a predetermined value or less during shading and re-shading.

  • Page 161: 15.4 Miscellaneous Errors

    Field Service Ver. 1.0 Apr. 2005 15. Malfunction code 15.4 Miscellaneous Errors 15.4.1 Flash ROM Error • The copier determines that there is an error if writing to the flash ROM fails during upgrading of the firmware. • When the Power Switch is turned ON, the Error indicator lights up steadily and a corre- sponding message appears on the Display.

  • Page 162: 16. Power Supply Trouble

    16. Power supply trouble Field Service Ver. 1.0 Apr. 2005 16. Power supply trouble 16.1 The copier does not turn ON Step Check Result Action A malfunction code appears when the Power • Go to step 2. Switch is turned ON. •...

  • Page 163: 17. Image Quality Problem

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17. Image quality problem 17.1 How to identify problematic part • In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting proce- dures classified by image failures.” • If any image failure has occurred, first make the initial checks, then proceed to the corre- sponding image failure troubleshooting procedure.

  • Page 164: Identification Of The Faulty System

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.1.2 Identification of the Faulty System • Determine if the failure is attributable to an input system (IR) or output system (engine). Check Result Action Full-size Reduced Input system Copy made at a reduced (IR) ratio 1177T04YA...

  • Page 165: 17.2 Solution

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2 Solution 17.2.1 Image Reading Section: Blank copy A. Typical Faulty Images 4011T035AA B. Troubleshooting Procedure Step Check Result Action CCD Board (PWB-J) connector is loose. • Reconnect. • Reconnect. •...

  • Page 166: Image Reading Section: Black Copy

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.2 Image Reading Section: black copy A. Typical Faulty Images 4011T036AA B. Troubleshooting Procedure Step Check Result Action Exposure Lamp turns ON when the Power Switch is turned Go to step 3. Exposure Lamp is abnormally lit (flickers or abnormally Go to step 4.

  • Page 167: Image Reading Section: Low Image Density

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.3 Image Reading Section: Low image density A. Typical Faulty Images 4011T003AA B. Troubleshooting Procedure Step Check Result Action Shading sheet reading portion (the portion on the back- side of the Original Glass to which Original Width Scale is •...

  • Page 168: Image Reading Section: Foggy Background Or Rough Image

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.4 Image Reading Section: Foggy background or rough image A. Typical Faulty Images 4011T004AA B. Troubleshooting Procedure Step Check Result Action Original Glass is dirty. • Clean. Scanner mirrors are dirty. •...

  • Page 169: Image Reading Section: Black Streaks Or Bands

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.5 Image Reading Section: Black streaks or bands A. Typical Faulty Images 4011T017AA 4011T023AA B. Troubleshooting Procedure Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- side of the Original Glass to which Original Width Scale is •...

  • Page 170: Image Reading Section: Black Spots

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.6 Image Reading Section: Black spots A. Typical Faulty Images 4011T521AA B. Troubleshooting Procedure Step Check Result Action Original Glass is dirty or scratchy. • Clean. CCD Board (PWB-J) connector is loose. •...

  • Page 171: Image Reading Section: Blank Streaks Or Bands

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.7 Image Reading Section: Blank streaks or bands A. Typical Faulty Images 4011T015AA 4011T020AA B. Troubleshooting Procedure Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- side of the Original Glass to which Original Width Scale is •...

  • Page 172: Image Reading Section: Uneven Image Density

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.8 Image Reading Section: Uneven image density A. Typical Faulty Images 4011T525AA B. Troubleshooting Procedure Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- side of the Original Glass to which Original Width Scale is •...

  • Page 173: Image Reading Section: Gradation Reproduction Failure

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.9 Image Reading Section: Gradation reproduction failure A. Typical Faulty Images 4011T526AA B. Troubleshooting Procedure Step Check Result Action Original Glass is dirty, scratchy, worn, or damaged. • Clean or change. Shading sheet reading portion (the portion on the back- side of the Original Glass to which Original Width Scale is •...

  • Page 174: Image Reading Section: Periodically Uneven Image

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.10 Image Reading Section: Periodically uneven image A. Typical Faulty Images 4011T528AA B. Troubleshooting Procedure Step Check Result Action Scanner Motor (M5) is securely fastened using the dedi- • Secure in position. cated fixing screws.

  • Page 175: Image Reading Section: Moire

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.11 Image Reading Section: Moire A. Typical Faulty Images 4011T040AA B. Troubleshooting Procedure Step Check Result Action • Change the original Moire distortions recur even after the orientation of original mode (select one other has been changed.

  • Page 176: Printer Section: Blank Copy

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.12 Printer Section: Blank copy A. Typical Faulty Images 4011T035AA B. Troubleshooting Procedure Step Check Result Action Imaging Unit is installed correctly. • Reinstall. Connector between the Imaging Unit and copier is dirty. •...

  • Page 177: Printer Section: Black Copy

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.13 Printer Section: Black copy A. Typical Faulty Images 4011T036AA B. Troubleshooting Procedure Step Check Result Action PC Drum Charge Corona grid mesh and Comb Electrode • Reinstall. are loose. PC Drum Charge Corona contact is dirty, scratchy, folded, •...

  • Page 178: Printer Section: Low Image Density

    • Reconnect. ATDC Sensor (UN1) is dirty with foreign matter (such as • Clean. paper dust) other than developer. The following voltages develop from the ATDC Sensor (UN1). <Check Procedure> • Change ATDC Sensor Check voltage across a Master Board pin and GND when (UN1) and then change the Power Switch is turned ON.

  • Page 179: Printer Section: Foggy Background Or Rough Image

    ATDC Sensor (UN1) is dirty with foreign matter (such as • Clean. paper dust) other than developer. The following voltages develop from the ATDC Sensor (UN1). <Check Procedure> • Change ATDC Sensor Check voltage across a Master Board pin and GND (UN1) and then change when the Power Switch is turned ON.

  • Page 180: Printer Section: Black Streaks Or Bands

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.16 Printer Section: Black streaks or bands A. Typical Faulty Images 4011T017AA 4011T023AA B. Troubleshooting Procedure Step Check Result Action PC Drum is dirty or scratchy. • Clean or change. Foreign matter (such as paper dust) sticks to the Cleaning •...

  • Page 181: Printer Section: Black Spots

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.17 Printer Section: Black spots A. Typical Faulty Images 4011T521AA B. Troubleshooting Procedure Step Check Result Action Toner is present along the paper path. • Clean. PC Drum is dirty or scratchy. •...

  • Page 182: Printer Section: Blank Streaks Or Bands

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.18 Printer Section: Blank streaks or bands A. Typical Faulty Images 4011T015AA 4011T020AA B. Troubleshooting Procedure Step Check Result Action PC Drum ground terminal is dirty, scratchy, deformed, or • Clean, correct, or damaged.

  • Page 183: Printer Section: Void Areas

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.19 Printer Section: Void areas A. Typical Faulty Images 4011T008AA B. Troubleshooting Procedure Step Check Result Action Foreign matter is present along the paper path. • Remove foreign matter. Paper dust plugs up the Paper Dust Remover. •...

  • Page 184: Printer Section: Smear On Back

    17. Image quality problem Field Service Ver. 1.0 Apr. 2005 17.2.20 Printer Section: Smear on back A. Typical Faulty Images 4011T009AA B. Troubleshooting Procedure Step Check Result Action Toner is spilled over area inside copier. • Clean interior. Toner is present along the paper path. •...

  • Page 185: Printer Section: Uneven Image Density

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.21 Printer Section: Uneven image density A. Typical Faulty Images 4011T525AA B. Troubleshooting Procedure Step Check Result Action PC Drum ground plate is dirty, scratchy, deformed, worn, • Clean, correct, or or damaged.

  • Page 186: Printer Section: Gradation Reproduction Failure

    PH window of PH Unit is dirty. • Clean. ATDC Sensor (UN1) is dirty with foreign matter (such as • Clean. paper dust) other than developer. The following voltages develop from the ATDC Sensor • Change ATDC Sensor (UN1). (UN1) and developer. <Check Procedure>...

  • Page 187: Printer Section: Periodically Uneven Image

    Field Service Ver. 1.0 Apr. 2005 17. Image quality problem 17.2.23 Printer Section: Periodically uneven image A. Typical Faulty Images 4011T528AA B. Troubleshooting Procedure Step Check Result Action IU is securely fastened using the dedicated fixing screws. • Secure in position. PH Unit is securely fastened using the dedicated fixing •...
  • Page 188 17. Image quality problem Field Service Ver. 1.0 Apr. 2005 Blank page...

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