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Copystar CS-1620 Service Manual

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CS-1620/2020
SERVICE
MANUAL
Published in June '05
2C970946
Revision 6

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Summary of Contents for Copystar CS-1620

  • Page 1 CS-1620/2020 SERVICE MANUAL Published in June ’05 2C970946 Revision 6...
  • Page 2 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. ATTENTION IL Y A DANGER D’EXPLOSION S’IL Y A REMPLACEMENT INCORRECT DE LA BATTERIE. REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MÊME TYPE OU D’UN TYPE REC- OMMANDÉ...
  • Page 3 Version history Version Date Replaced pages Remarks June 14, 2005 Contents, 1-1-1, 1-2-2, 1-3-5, 1-3-9, 1-3-11, 1-3-12, 1-3-13, 1-4-2, 1-4-3, 1-4-4, 1-4-16-1, 1-4-20, 1-4-23, 1-4-26, 1-5-3, 1-5-4, 1-5-5, 1-5-9, 1-5-10, 1-5-11, 1-5-12, 1-5-15, 1-5-17, 1-5-25, 1-5-29, 1-5-32, 1-6-7, 1-6-20, 1-6-30, 1-6-38, 1-6-38-1, 1-6-44, 2-3-8, 2-3-11, 2-4-7, 2-4-8...
  • Page 4 This page is intentionally left blank.

  • Page 5: Safety Precautions

    Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.
  • Page 6 Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

  • Page 7: Installation Precautions

    1.Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current....................•...
  • Page 8 2.Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 9 • Do not remove the ozone filter, if any, from the copier except for routine replacement..... • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself...................... •...
  • Page 10 This page is intentionally left blank.

  • Page 11: Table Of Contents

    2C9-1 CONTENTS 1-1 Specifications 1-1-1 Specifications............................1-1-1 1-1-2 Parts names............................1-1-3 (1) Copier..............................1-1-3 (2) Operation panel..........................1-1-4 1-1-3 Machine cross section ..........................1-1-5 1-1-4 Drive system ............................1-1-6 1-2 Handling Precautions 1-2-1 Drum ...............................1-2-1 1-2-2 Toner...............................1-2-1 1-2-3 Installation environment ..........................1-2-2 1-3 Installation 1-3-1 Unpacking and installation ........................1-3-1 (1) Installation procedure ........................1-3-1 1-3-2 Setting initial copy modes ........................1-3-5 1-3-3 Installing the paper feeder (option) ......................1-3-6...
  • Page 12 2C9-4 (14) Offset occurs...........................1-5-25 (15) Image is partly missing........................1-5-26 (16) Fixing is poor...........................1-5-26 (17) Image is out of focus........................1-5-26 (18) Image center does not align with the original center...............1-5-27 1-5-4 Electric problems ..........................1-5-28 (1) The machine does not operate when the power switch is turned on..........1-5-28 (2) The drive motor does not operate (C2000).
  • Page 13 2C9-6.0 1-6-3 Optical section ............................1-6-17 (1) Detaching and refitting the exposure lamp..................1-6-17 (2) Detaching and refitting the scanner wires ..................1-6-18 (2-1) Detaching the scanner wires ....................1-6-18 (2-2) Fitting the scanner wires ......................1-6-20 (3) Detaching and refitting the ISU (reference)..................1-6-23 (4) Detaching and refitting the laser scanner unit .................1-6-24 (5) Adjusting the longitudinal squareness (reference) ................1-6-27 (6) Adjusting magnification of the scanner in the main scanning direction ...........1-6-28 (7) Adjusting magnification of the scanner in the auxiliary scanning direction........1-6-29...
  • Page 14 2-3 Operation of the PCBs 2-3-1 Power source PCB..........................2-3-1 2-3-2 Main PCB..............................2-3-4 2-3-3 Engine PCB ............................2-3-8 2-3-4 Operation unit PCB ..........................2-3-14 2-3-5 CCD PCB..............................2-3-17 2-4 Appendixes Timing chart No.1............................2-4-1 Timing chart No.2............................2-4-2 Timing chart No.3............................2-4-3 Timing chart No.4............................2-4-4 Chart of image adjustment procedures....................2-4-5 Maintenance parts list ..........................2-4-8 Periodic maintenance procedures ......................2-4-9 Optional devices supplied parts list.......................2-4-11...

  • Page 15: Specifications

    2C9-6.0 1-1 Specifications 1-1-1 Specifications Type ..........Desktop Copying system ......Indirect electrostatic system Originals.......... Sheets, books and 3-dimensional objects (Maximum original size: A3) Maximum size: A3/11" x 17" Original feed system ....... Fixed Copy paper ........Paper weights Drawer: 64 - 105 g/m Bypass table: 45 - 160 g/m Paper type Drawer: Plain paper, recycled paper and colored paper Bypass table: Plain paper, recycled paper, thin paper, thick paper and colored paper...
  • Page 16 2C9-3 Light source ........Inert gas lamp Dimensions ........574 (W) x 552 (D) x 545 (H) mm " (W) x 21 " (D) x 21 " (H) Weight..........Approx. 40.7 kg/89.7 lbs Floor requirements......827 (W) x 552 (D) mm "...

  • Page 17: Parts Names

    1-1-2 Parts names (1) Copier Figure 1-1-1 Original cover 11. Contact glass Copy storage section 12. Original size indicator plate Operation panel 13. Left cover Drawer 14. Waste toner box Width guide 15. Toner container release lever Length guide 16. Toner container Left cover handle 17.
  • Page 18 (2) Operation panel Metric Inch Figure 1-1-2 Start key (Indicator) 19. Paper supply indicator Stop/Clear key 20. Paper supply level indicator Reset key 21. Paper jam indicator Numeric keys 22. Bypass tray indicator Energy Saver key (Indicator) 23. Original size Select key Interrupt key (Indicator) 24.

  • Page 19: Machine Cross Section

    1-1-3 Machine cross section Light path Paper path Figure 1-1-3 Machine cross section Paper feed section Optical section Drum section Developing section Transfer and separation section Fixing section Exit and switchback section Duplex section 1-1-5...

  • Page 20: Drive System

    1-1-4 Drive system Figure 1-1-4 Drive motor gear 15. Developing gear 25 Gear 122 16. Developing gear 26 Registration gear 51 17. Fixing joint gear 29 Registration motor gear 18. Gear 40 Gear 32 19. Gear 40 Gear 25 20. Gear 88/34 Gear 25 21.

  • Page 21: Drum

    1-2 Handling Precautions 1-2-1 Drum Note the following when handling or storing the drum. When removing the drum unit, never expose the drum surface to strong direct light. ° ° ° ° Keep the drum at an ambient temperature between -20 C/-4 F and 55 C/131...

  • Page 22: Installation Environment

    2C9-6.0 1-2-3 Installation environment ° ° Temperature: 10 - 32.5 C/50 - 90.5 Humidity: 15 - 80%RH Power supply: 120 V AC, 9.0 A 220 - 240 V AC, 5.0 A (Average) ± ± Power source frequency: 50 Hz 0.3%/60 Hz 0.3% Installation location Avoid direct sunlight or bright lighting.

  • Page 23: Unpacking And Installation

    1-3 Installation 1-3-1 Unpacking and installation (1) Installation procedure Start Unpacking. Installing the toner (maintenance item U130). Install the optional paper feeder. Load paper. Remove the tapes and pins. Output an own-status report Install the original cover or the optional DP. (maintenance item U000).
  • Page 24 2C9-3 Unpacking. Figure 1-3-1 Unpacking Copier 10. Left spacer 19. Original holder (Asia and Power cord 11. Rear spacer Oceania) Toner container 12. Rear pad 20. Operation guide Outer case 13. Skid Cassette size sheet Lower left pad 14. Belt Paper protection bag Lower right pad 15.
  • Page 25 2C9-3 Install the optional paper feeder. 1. Install the optional paper feeder as necessary (see page 1-3-6 to 1-3-7). Remove the tapes and pins. 1. Remove the ten tapes. Tape Tapes Tape Tapes Tape Tapes Figure 1-3-2 2. Remove the two pins for light source unit. Pins Figure 1-3-3 Install the original cover or the optional DP.
  • Page 26 Install the toner container. Toner container release lever 1. Open the front cover. 2. Tap the top of the toner container five to six times. 3. Shake the toner container approximately 10 times in the horizontal direction to stir toner. 4.

  • Page 27: Setting Initial Copy Modes

    2C9-6.0 1-3-2 Setting initial copy modes Factory settings are as follows: Maintenance Contents Factory setting item No. U253 Switching between double and single counts Double count U254 Turning auto start function on/off U255 Setting auto clear time U258 Switching copy operation at toner empty detection SINGLE MODE U260 Changing the copy count timing...

  • Page 28: Installing The Paper Feeder (Option)

    1-3-3 Installing the paper feeder (option) <Procedure> 1. Place the copier on the paper feeder by aligning the positioning insertion sections of the copier with the positioning pins at the rear part of the paper feeder. * When placing the copier, take care not to hit the copier against the drawer, the pins or Positioning pins ground plate of the paper feeder.
  • Page 29 Adjusting the leading edge timing 1. Run maintenance mode 034. Press the image quality mode key until "Text" is lit. (group 1) First paper feeder: Press the exposure key until "exp3" is lit. (mode 3) Second paper feeder: Press the exposure key until "exp4" is lit. (mode 4) Third paper feeder: Press the exposure key until "exp5"...

  • Page 30: Installing The Dp (Option)

    1-3-4 Installing the DP (option) <Procedure> 1. Remove the original holder and remove the two screws from the rear top cover. Screw 2. Pass the two pins through the screw holes of the rear top cover and attach them to the Screw lower frame.
  • Page 31 2C9-6.0 5. Close the DP, fit the fixing fitting from the rear side of the right hinge, and secure it with the two bronze TP screws M3 x 06. 6. Connect the cable of the DP to the copier. * Be sure to tighten the fixing screws on both side of the connec- tor.
  • Page 32 2C9-1 Maintenance mode 070 (sub-scan line adjustment) For copy example a: decrease the value. For copy example b: increase the value. Changing the value by one changes the sub-scan line by 0.1%. The larger the value, the larger the magnification of the sub-scan line of the copy image. The smaller the value, the smaller the magnification of the sub-scan line of the copy image.

  • Page 33: Installing The Duplex Unit (Option)

    2C9-6.0 1-3-5 Installing the duplex unit (option) <Procedure> 1. Open the left cover. 2. Remove the stop ring and the strap from the rear side. 3. Restore the conveyor section. 4. Remove the pin and plate, and then remove the stopper from the front side. 5.
  • Page 34 2C9-6.0 8. Press the duplex unit in the direction indi- Duplex unit cated by the arrow to fit the claws into the conveyer unit. Claw Claw Figure 1-3-22-1 9. Hang the hook of the plate lock on the con- veying unit and then turn the plate lock to fit the hole to the claw of the duplex unit.
  • Page 35 2C9-6.0 11. Open the conveyer unit and connect the connector of the duplex unit to the copier. 12. Reattach the removed parts to their original positions. 13. Connect the copier power plug to the wall outlet and turn the copier power switch on. Duplex unit Connector Figure 1-3-24...

  • Page 36: Installing The Drawer Heater (Option)

    1-3-6 Installing the drawer heater (option) Drawer heater installation requires the following parts: Drawer heater (P/N 120 V specifications: 2C960030, 220-240 V specifications: 2C960040) One (1) M4 x 10 tap-tight S binding screw (P/N B3024100) <Procedure> 1. Remove the right cover. 2.
  • Page 37 4. Insert the cassette heater from the bottom of the machine and attach it to the copier. 1) Pass the connector of the cassette heater through the hole located in the right frame of the machine to pull it out. 2) Insert the projections at the rear side of the cassette heater mounting plate into the two holes in the rear frame of the machine.
  • Page 38 Wire of the drawer heater 5. Remove the two screws and open the power source PCB in the direction indicated by the arrow. * Take care not to open the power source PCB too much. 6. Fit the wire of the drawer heater into the groove of the frame and put it inside the power source PCB.

  • Page 39: Installing The Key Counter (Option)

    2C9-1 1-3-7 Installing the key counter (option) Key counter installation requires the following parts: Key counter cover (P/N 2A360010) Key counter retainer (P/N 66060030) Key counter mount (P/N 66060040) Key counter assembly (P/N 41529210) Four (4) M4 x 6 bronze TP-A screws (P/N B4304060) One (1) M4 x 35 round head screw (P/N B0004350) Two (2) M3 x 6 bronze flat-head screws (P/N B2303060) One (1) M3 bronze nut (P/N C2303000)
  • Page 40 2C9-1 Aperture 3. Remove the rear cover. 4-pin connector 4. Cut out the aperture plate on the right cover using nippers. 7-pin connector 5. Connect the 4-pin connector of the key counter wire (located at a longer distance Clamp from the tube) to YC13 on the engine PCB, pass the wire through the two clamps, and pull the other 4-pin connector out from the aperture of the right cover.
  • Page 41 2C9-1 8. Connect the 4-pin connector of the key counter to the key counter wire. 9. Engage the projection of the key counter mounting plate with the aperture of the right cover. 10. Secure the key counter cover and the key counter mounting plate together with the copier using a M4 x 35 screw.

  • Page 42: Maintenance Mode

    1-4 Maintenance Mode 1-4-1 Maintenance mode The copier is equipped with a maintenance function which can be used to maintain and service the machine. (1) Executing a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the zoom The maintenance item is...

  • Page 43: Maintenance Mode Item List

    2C9-6.0 (2) Maintenance mode item list Item Initial Section Content of maintenance item setting* General U000 Outputting an own-status report U001 Exiting the maintenance mode U002 Setting the factory default data U004 Checking the machine number U005 Copying without paper U019 Displaying the ROM version Initialization...
  • Page 44 2C9-6.0 Item Initial Section Content of maintenance item setting* Optical U093 Setting the exposure density gradient Text/text and photo/photo mode 0/0/0 U099 Checking the original size detection High voltage U100 Setting the main high voltage Grid control voltage Copy interval Copy quantity Correction amount U101...
  • Page 45 2C9-6.0 Item Initial Section Content of maintenance item setting* Mode setting U255 Setting auto clear time U258 Switching copy operation at toner empty detection Single mode U260 Changing the copy count timing After ejection U265 Setting the destination specifications U332 Setting the size conversion factor U342 Setting the ejection restriction...

  • Page 46: Contents Of Maintenance Mode Items

    2C9-4 (3) Contents of maintenance mode items Maintenance Description item No. Outputting an own-status report U000 Description Outputs lists of the current settings of the maintenance items, and paper jam and service call occurrences. Purpose To check the current setting of the maintenance items, or paper jam or service call occurrences. Before initial- izing the backup RAM, output a list of the current settings of the maintenance items to reenter the settings after initialization or replacement.
  • Page 47 2C9-4 Maintenance Description item No. Checking the machine number U004 Description Displays the machine number. Purpose To check the machine number. Method 1. Press the start key. The currently set machine number is displayed. 2. Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys.
  • Page 48 2C9-4 This page is intentionally left blank. 1-4-7...
  • Page 49 Maintenance Description item No. Copying without paper U005 Description Simulates the copy operation without paper feed. Purpose To check the overall operation of the machine. Method 1. Press the start key. A selection item appears. 2. Select the item to be operated using the copy exposure adjustment keys. Display Operation Only the copier operates.
  • Page 50 Maintenance Description item No. Initializing all data U020 Description Initializes all the backup RAM on the main board to return to the original settings. Purpose Run as needed. Method 1. Press the start key. 2. Select "on" using the zoom +/- keys. Display Operation - - -...
  • Page 51 Maintenance Description item No. Checking motor operation U030 Description Drives each motor. Purpose To check the operation of each motor. Method 1. Press the start key. A selection item appears. 2. Select the motor to be operated using the copy exposure adjustment keys. Display Motor Drive motor (DM)
  • Page 52 2C9-4 Maintenance Description item No. Checking clutch or solenoid operation U032 Description Turns each clutch or solenoid on. Purpose To check the operation of each clutch or solenoid. Method 1. Press the start key. A selection item appears. 2. Select the clutch or solenoid to be operated using the copy exposure adjustment keys. 3.
  • Page 53 2C9-4 Maintenance Description item No. Performing fine adjustment of the motor speed U053 Description Performs fine adjustment of the speeds of the motors. Purpose Used to adjust the speed of the respective motors when the magnification is not correct. Also speed adjust- ment for each paper source can be performed in group 2.
  • Page 54 Maintenance Description item No. Adjusting the scanner input properties U060 Description Adjusts the image scanning density. Purpose Used when the entire image appears too dark or light. Method Press the start key. Setting 1. Change the setting using the zoom +/- keys. Description Setting range Initial setting...
  • Page 55 Maintenance Description item No. Adjusting the shading position U063 Description Changes the shading position. Purpose Used when white lines continue to appear longitudinally on the image after the shading plate is cleaned. This is due to flaws or stains inside the shading plate. To prevent this problem, the shading position should be changed so that shading is possible without being affected by the flaws or stains.
  • Page 56 2C9-4 Maintenance Description item No. Adjusting the DP magnification U070 Description Adjusts the DP original scanning speed. Purpose To be executed if the correct magnification is not obtained in the auxiliary scanning direction when the optional DP is used. Caution Before making this adjustment, ensure that the following adjustments have been made in maintenance mode.
  • Page 57 2C9-4 Maintenance Description item No. Adjusting the DP scanning timing U071 Description Adjusts the DP original scanning timing. Purpose To be executed if there is a regular error between the leading or trailing edges of the original and the copy image when the optional DP is used.
  • Page 58 2C9-4 Maintenance Description item No. Adjusting the DP center line U072 Description Adjusts the scanning start position for the DP original. Purpose To be executed if there is a regular error between the centers of the original and the copy image when the optional DP is used.
  • Page 59 Maintenance Description item No. Checking scanner operation U073 Description Simulates the scanner operation under arbitrary conditions. Purpose To check scanner operation. Method 1. Press the start key. 2. Select the item to be changed by lighting a copy exposure indicator using the copy exposure adjustment keys.
  • Page 60 2C9-6.0 Maintenance Description item No. Adjusting the DP automatically U076 Description Uses a specified original and automatically adjusts the following items in the DP scanning section. Adjusting the DP magnification (U070) Adjusting the DP scanning timing (U071) Adjusting the DP center line (U072) When this maintenance item is performed, the settings in U070, U071 and U072 are also changed.
  • Page 61 2C9-4 This page is intentionally left blank. 1-4-18...
  • Page 62 Maintenance Description item No. Turning the DP scanning position adjust mode on/off U087 Description Turns on or off the DP scanning position adjust mode, in which the DP original scanning position is adjusted automatically by determining the presence or absence of dust on the slit glass. Also changes the reference data for identifying dust.
  • Page 63 2C9-4 Maintenance Description item No. Setting the input filter (moire reduction mode) U088 Description Turns moire reduction mode on and off by switching the input filter on and off. Purpose Used to prevent regular density unevenness (moiré) on halftone image areas of the copy image in text mode and text and photo mode.
  • Page 64 Maintenance Description item No. Checking shading U091 Description Performs scanning under the same conditions as before and after shading is performed, displaying the origi- nal scanning values at nine points of the contact glass. Purpose To check the change in original scanning values before and after shading. The results may be used to decide the causes for fixing unevenness (uneven density) of the gray area of an image: either due to optical (shading or CCD) or other problems.
  • Page 65 2C9-6.0 Maintenance Description item No. Adjusting the scanner automatically U092 Description Makes auto scanner adjustments in the order below using the specified original. Adjusting the scanner center line (U067) Adjusting the scanner leading edge registration (U066) Adjusting scanner magnification in the auxiliary direction (U065) When this maintenance item is performed, the settings in U065, U066 and U067 are also changed.
  • Page 66 Maintenance Description item No. Setting the exposure density gradient U093 Description Changes the exposure density gradient in manual density mode, depending on respective image modes (text, text and photo, photo). Purpose To set how the image density is altered by a change of one step in the manual density adjustment. Also used to make copy image darker or lighter.
  • Page 67 Maintenance Description item No. Checking the original size detection U099 Description Displays the original width detection data and sets the original width detection threshold. Purpose To check the original width detection. Also to change the original size detection threshold if the size of the orig- inal on the contact glass is detected incorrectly.
  • Page 68 2C9-6.0 Maintenance Description item No. Method to set or check the original size detection threshold U099 1. Place an original on the contact glass and turn the original detection switch on. The original size detec- (cont.) tion starts and detection data is displayed. 2.
  • Page 69 2C9-4 Maintenance Description item No. Setting the main charging copy quantity correction U100 1. Change the setting using the zoom +/- keys. (cont.) Display Setting Setting range Initial setting Exp. 4 (lit) Copy interval 1 to 255 (minute) Exp. 5 (lit) Copy quantity 1 to 255 (10 sheets) Exp.
  • Page 70 Maintenance Description item No. Checking/clearing the drum count U110 Description Displays the drum counts for checking, clearing or changing a figure. Purpose To check the drum status. Also used to clear the count after replacing the drum during regular maintenance. Since the count was cleared before shipping, do not clear it when installing.
  • Page 71 2C9-6.0 Maintenance Description item No. Setting toner loading operation U144 Description Sets toner loading operation. Purpose To run when drum filming (background blur in paper edge section) occurs. Method Press the start key. Setting 1. Change the setting using the zoom +/- keys. Display Description Toner not loaded...
  • Page 72 2C9-4 Maintenance Description item No. Checking/clearing the developing count U158 Description Displays the developing count for checking, clearing or changing a figure. Purpose To check the developing count. Method 1. Press the start key. 2. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys. Copy exposure indicator Description Setting range...
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  • Page 74 Maintenance Description item No. Setting the fixing control temperature U161 Description Changes the fixing control temperature. Purpose Normally no change is necessary. However, can be used to prevent curling or creasing of paper, or solve a fix- ing problem on thick paper. Method Press the start key.
  • Page 75 2C9-4 Maintenance Description item No. Checking/clearing the fixing count U167 Description Displays the fixing count for checking, clearing or changing a figure. Purpose To check the fixing count. Method 1. Press the start key. 2. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys. Copy exposure indicator Description Setting range...
  • Page 76 Maintenance Description item No. Operating DP separately U203 Description Simulates the original conveying operation separately in the DP. Purpose To check the DP. Method 1. Press the start key. 2. Place an original in the DP if running this simulation with paper. 3.
  • Page 77 Maintenance Description item No. Checking the operation of the DP motors and solenoids U243 Description Turns the motors and solenoids in the optional DP on. Purpose To check the operation of the DP motors and solenoids. Method 1. Press the start key. 2.
  • Page 78 2C9-4 Maintenance Description item No. Checking/clearing the maintenance count U251 Description Displays, clears and changes the maintenance count. Purpose To check the maintenance count. Also to clear the count during maintenance service. Method 1. Press the start key. 2. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys. Copy exposure indicator Description Setting range...
  • Page 79 Maintenance Description item No. Switching between double and single counts U253 Description Switches the count system for the total counter and other counters. Purpose According to user (copy service provider) request, select if A3/11" x 17" paper is to be counted as one sheet (single count) or two sheets (double count).
  • Page 80 Maintenance Description item No. Setting auto clear time U255 Description Sets the time to return to initial settings after copying is complete. Purpose To be set according to frequency of use. Set to a comparatively long time for continuous copying at the same settings, and a comparatively short time for frequent copying at various settings.
  • Page 81 Maintenance Description item No. Changing the copy count timing U260 Description Changes the copy count timing for the total counter and other counters. Purpose To be set according to user (copy service provider) request. If a paper jam occurs frequently in the eject sec- tion when the number of copies is counted at the time of paper ejection, copies are provided without copy counts.
  • Page 82 2C9-4 Maintenance Description item No. Setting the size conversion factor U332 Description Sets the coefficient of nonstandard sizes in relation to the A4/11" x 8 " size. The coefficient set here is used to convert the black ratio in relation to the A4/11" x 8 "...
  • Page 83 2C9-4 Maintenance Description item No. Switching between duplex/simplex copy mode U343 Description Switches the Initial setting between duplex and simplex copy. Purpose To be set, according to frequency of use, to the more frequently used mode. Method Press the start key. Setting 1.
  • Page 84 2C9-4 This page is intentionally left blank. 1-4-37...
  • Page 85 Maintenance Description item No. Adjusting margins of image printing U402 Adjustment See page 1-6-15. Adjusting margins for scanning an original on the contact glass U403 Adjustment See page 1-6-32. Adjusting margins for scanning an original from the DP U404 Description Adjusts margins for scanning the original from the DP.
  • Page 86 Maintenance Description item No. Checking/clearing copy counts by paper feed locations U901 Description Displays or clears copy counts by paper feed locations. Purpose To check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts. Method 1.
  • Page 87 Maintenance Description item No. Checking/clearing the paper jam counts U903 Description Displays or clears the jam counts by jam locations. Purpose To check the paper jam status. Also to clear the jam counts after replacing consumable parts. Method 1. Press the start key. 2.
  • Page 88 2C9-4 Maintenance Description item No. Checking/clearing counts by the DP U905 Description Displays or clears the counts of the DP. Purpose To check the use of the DP. Also to clear the counts after replacing consumable parts. Method 1. Press the start key. 2.
  • Page 89 Maintenance Description item No. Checking the total count U908 Description Display the total count value. Purpose To check the total count value. Method 1. Press the start key. 2. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys. Copy exposure indicator Copy quantity display (count value) Exp.
  • Page 90 Maintenance Description item No. Checking/clearing copy counts by paper size U911 Description Displays or clears the paper feed count value by paper size. Purpose To check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts. Method 1.
  • Page 91 Maintenance Description item No. U911 Image mode LED Copy exposure Copy quantity display (count value) (group No.) indicator Exp. 1 (lit) “-Lg” display the Legal size Exp. 2 (lit) First 3 digits of Legal size copy count Exp. 3 (lit) Last 3 digits of Legal size copy count Exp.
  • Page 92 2C9-4 Maintenance Description item No. Checking the machine life count U928 Description Displays the machine life counts for checking a figure. Purpose To check machine status. Method 1. Press the start key. 2. Select the item by lighting a copy exposure indicator using the copy exposure adjustment keys. Copy exposure indicator Description Setting range...
  • Page 93 2C9-4 Maintenance Description item No. Setting of amount of slack for feeding from DP U942 Description Adjusts the amount of slack generated when the optional DP is used. Purpose Use this mode if an original non-feed jam, oblique feed or wrinkling of original occurs when the DP is used. Method Press the start key.
  • Page 94 2C9-4 This page is intentionally left blank. 1-4-45...
  • Page 95 Maintenance Description item No. Checking the scanner count U991 Description Display the scanner count value. Purpose To check the scanner count value. Method 1. Press the start key. 2. Change the indication of the copy quantity display by lighting a copy exposure indicator using the copy exposure adjustment keys.

  • Page 96: Copier Management

    1-4-2 Copier management In addition to a maintenance function for service, the copier is equipped with a management function which can be oper- ated by users (mainly by the copier administrator). In this copier management mode, settings such as default settings can be changed.

  • Page 97: Setting Department Management Items

    (2) Setting department management items Eco-copy Selects the eco-copy mode at power-on. Management on/off setting 1. Select "F04" and press the enter key. 1. Select "d01" and press the enter key. 2. Select "ON" or "OFF" and press the enter key. 2.
  • Page 98 Photo processing 2. Select the paper size and press the enter key. Select the image processing method for photo origi- Setting range: AtC (auto detection metric)/ AtI (auto nals. detection inch)/o2r (oficio2) 1. Select "F11" and press the enter key. 2.
  • Page 99 Custom 2 size 1. Select "F30" and press the enter key. Sets the size of the paper to be set to the custom 2 2. Select "ON" or "OFF" and press the enter key. size. Setting range: ON (enabled)/OFF (disabled) 1.

  • Page 100: Paper Misfeed Detection

    1-5 Troubleshooting 1-5-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the copier immediately stops copying and displays the jam location on the operation panel. Paper misfeed counts sorted by the detection condition can be checked in maintenance item U903. To remove paper jammed in the copier, open the front cover, left cover, or pull the drawer out.

  • Page 101: Paper Misfeed Detection Conditions

    2C9-3 (2) Paper misfeed detection conditions OCM OFM OSBSW DPTSW FSSW DUPPCSW DUPFCL BYPPFSOL PFCL DPFCL1 DFSW1 DPFCL2 DFSW2 DPFCL3 Figure 1-5-2 1-5-2...
  • Page 102 2C9-6.0 Section Jam code Description Conditions System No paper feed When the power switch is turned on, the machine detects acti- vation of the registration switch (RSW), the exit switch (ESW) or the feedshift switch (FSSW). Cover open JAM A cover open state is detected during copying. Secondary paper feed tim- When the machine waits for secondary paper feed, 15 s or eout...
  • Page 103 2C9-6.0 Section Jam code Description Conditions Paper con- Multiple sheets in the The drawer feed switch 2 (DFSW2)* does not turn off within veying sec- drawer 4* (third paper 6320 ms of drawer feed switch 2 (DFSW2)* turning on. tion feeder) The drawer feed switch 2 (DFSW2)* does not turn off within 2490 ms of drawer paper feed clutch 3 (DPFCL3)* turning on.
  • Page 104 2C9-6.0 Section Jam code Description Conditions Feedshift Misfeed in the feedshift The feedshift switch (FSSW) does not turn on within 6320 ms section section* (paper feed from of feedshift switch (FSSW) turning on. second paper feeder) The feedshift switch (FSSW) does not turn off within 1530 ms of paper switchback.

  • Page 105: Paper Misfeeds

    2C9-3 (3) Paper misfeeds Copier Problem Causes/check procedures Corrective measures A piece of paper torn from Check visually and remove it, if any. A paper jam in the copy paper is caught paper feed, paper around registration switch, conveying or exit exit sensor or feedshift section is indicated switch.
  • Page 106 Problem Causes/check procedures Corrective measures Paper in the first paper Change the paper. A paper jam in the feeder is extremely curled. paper feed section is Check if the paper feed pul- Check visually and replace any deformed pulley. indicated during ley, separation pulley or for- copying (no paper ward pulley in the first paper...
  • Page 107 Problem Causes/check procedures Corrective measures Check if the drawer paper Run maintenance item U032 and select the drawer paper feed A paper jam in the feed clutch 3 malfunctions. clutch 3 to be turned on and off. Check the status and remedy if paper feed section is necessary.
  • Page 108 2C9-6.0 Problem Causes/check procedures Corrective measures Broken drawer feed switch Check visually and replace drawer feed switch 1 if its actuator is A paper jam in the 1 actuator. broken. paper feed section is Defective drawer feed Run maintenance item U031 and turn drawer feed switch 1 on indicated during switch 1.
  • Page 109 2C9-6.0 Problem Causes/check procedures Corrective measures (10) Electrical problem with the Check (see page 1-5-29). A paper jam in the paper feed clutch. paper conveying sec- Check if the right and left Check visually and remedy if necessary. tion is indicated dur- registration rollers contact ing copying (multiple each other.
  • Page 110 2C9-6.0 Problem Causes/check procedures Corrective measures (14) Deformed guides along the Repair or replace if necessary. A paper jam in the paper conveying path. transfer section is Broken registration switch Check visually and replace registration switch if its actuator is bro- indicated during actuator.
  • Page 111 2C9-6.0 Problem Causes/check procedures Corrective measures (17) Broken feedshift switch Check visually and replace the feedshift switch if its actuator is A paper jam in the actuator. broken. feedshift section is Defective feedshift switch. Run maintenance item U031 and turn feedshift switch on and off indicated during manually.
  • Page 112 Problem Causes/check procedures Corrective measures A piece of paper torn from Check visually and remove it, if any. An original jams an original is caught around when the power the DP timing switch or switch is turned on. original switchback switch. Defective DP timing switch.
  • Page 113 Problem Causes/check procedures Corrective measures Broken DP timing switch Check visually and replace DP timing switch if its actuator is bro- An original jams in actuator. ken. the original convey- Defective DP timing switch. Run maintenance item U244 and turn DP timing switch on and off ing section is indi- manually.

  • Page 114: Self-Diagnosis

    2C9-6.0 1-5-2 Self-diagnosis (1) Self-diagnostic function This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled. "C" and a number between 0100 and 7810 altenates, indicating the nature of the problem. After removing the problem, the self-diagnostic function can be reset by opening and closing the front cover to turn safety switch off and on or power switch turns off and (2) Self diagnostic codes Remarks...
  • Page 115 2C9-2 Remarks Code Contents Causes Check procedures/corrective measures C0420 Optional first paper feeder communi- Paper feeder Check the installation state of the paper (A0420*) cation problem installed incor- feeder and adjust it if it is not properly Communication fails five times succes- rectly.
  • Page 116 2C9-6.0 Remarks Code Contents Causes Check procedures/corrective measures C3100 Scanner carriage problem Poor contact of the Reinsert the connector. Also check for conti- The home position is not correct when connector termi- nuity within the connector cable. If none, the power is turned on or copying the nals.
  • Page 117 2C9-2 Remarks Code Contents Causes Check procedures/corrective measures C4200 BD steady-state problem Defective laser Replace the LSU. (A4200*) The MIC detects a BD error for 600 ms diode. after the polygon motor rotation has Defective polygon Replace the LSU. been stabilized. motor.
  • Page 118 2C9-2 Remarks Code Contents Causes Check procedures/corrective measures C6400 Zero-crossing signal problem Poor contact in the Reinsert the connector. Also check for conti- The engine PCB does not detect the connector termi- nuity within the connector cable. If none, zero-crossing signal for the time speci- nals.

  • Page 119: Image Formation Problems

    1-5-3 Image formation problems (1) No image (2) No image (3) Image is too (4) Background is (5) A white line appears appears light. visible. appears longitu- (entirely white). (entirely black). dinally. See page 1-5-21. See page 1-5-21. See page 1-5-22. See page 1-5-22.
  • Page 120 (1) No image appears (entirely white). Causes 1. No transfer charging. 2. No LSU laser is output. 3. No developing bias is output. Causes Check procedures/corrective measures 1. No transfer charging. A. The connector terminals of the high-volt- Reinsert the connector. Also check for continuity within the connector age PCB make poor contact.
  • Page 121 (3) Image is too light. Causes 1. Insufficient toner. 2. The transfer voltage is not output properly. 3. Dirty main charger wire. 4. Dirty main charger grid. Causes Check procedures/corrective measures 1. Insufficient toner. If the add toner indicator lights, replace the toner container. 2.
  • Page 122 (6) A black line appears longitudinally. Causes 1. Dirty contact glass. 2. Dirty or flawed drum. 3. Dirty scanner mirror. 4. Dirty main charger wire. Causes Check procedures/corrective measures 1. Dirty contact glass. Clean the contact glass. 2. Dirty or flawed drum. Clean the drum or, if it is flawed, replace the drum unit (see page 1-6-33).

  • Page 123: Image Is Blurred

    (9) Black dots appear on the image. Causes 1. Dirty or flawed drum. 2. Dirty contact glass. 3. Deformed or worn cleaning blade. 4. Dirty drum separation claws. 5. Dirty heat roller separation claws. Causes Check procedures/corrective measures 1. Dirty or flawed drum. Clean the drum or, if it is flawed, replace the drum unit (see page 1-6-33).

  • Page 124: The Leading Edge Of The Image Is Sporadically Misaligned With The Original

    2C9-6.0 (12) The leading edge of the image is Causes sporadically misaligned with the 1. Paper feed clutch, bypass paper feed solenoid or registration motor installed original. or operating incorrectly. Causes Check procedures/corrective measures 1. Paper feed clutch, bypass paper feed Check the installation position and operation of the paper feed clutch, solenoid or registration motor installed or bypass paper feed solenoid and registration motor.

  • Page 125: Image Is Partly Missing

    (15) Image is partly missing. Causes 1. Paper damp. 2. Paper creased. 3. Dirty or flawed drum. 4. Dirty transfer roller. Causes Check procedures/corrective measures 1. Paper damp. Check the paper storage conditions. 2. Paper creased. Replace the paper. 3. Dirty or flawed drum. Clean the drum or, if it is flawed, replace the drum unit (see page 1-6-33).

  • Page 126: Image Center Does Not Align With The Original Center

    (18) Image center does not align with Causes the original center. 1. Misadjusted center line of image printing. 2. Misadjusted scanner center line. 3. Original placed incorrectly. Causes Check procedures/corrective measures 1. Misadjusted center line of image printing. Readjust the center line of image printing (see page 1-6-14). 2.

  • Page 127: Electric Problems

    2C9-2 1-5-4 Electric problems Problem Causes Check procedures/corrective measures No electricity at the power Measure the input voltage. The machine does outlet. not operate when the The power cord is not Check the contact between the power plug and the outlet. power switch is plugged in properly.

  • Page 128: The Scanner Motor Does Not Operate

    2C9-6.0 Problem Causes Check procedures/corrective measures Broken scanner motor coil. Check for continuity across the coil. If none, replace the scanner The scanner motor motor. does not operate. Poor contact in the scanner Reinsert the connector. Also check for continuity within the con- motor connector terminals.

  • Page 129: The Exposure Lamp Does Not Turn Off

    2C9-2 Problem Causes Check procedures/corrective measures (12) Defective inverter PCB. If the exposure lamp does not turn off with YC1-1 and YC1-6 on The exposure lamp the inverter PCB high, replace the inverter PCB. does not turn off. Defective engine PCB. If YC17-1 and YC17-6 on the engine PCB are always low, replace the engine PCB.

  • Page 130: Left Cover Are Closed

    Problem Causes Check procedures/corrective measures (20) Poor contact in the paper Reinsert the connector. Also check for continuity within the con- The message switch connector terminals. nector cable. If none, remedy or replace the cable. requesting paper to Defective paper switch. If the level of YC8-2 on the engine PCB does not change when be loaded is shown the paper switch is turned on and off, replace the paper switch.

  • Page 131: Mechanical Problems

    2C9-6.0 1-5-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following rollers or Clean with isopropyl alcohol. No primary paper feed. pulleys are dirty with paper powder: forward- ing pulley, paper feed pulley, separation pul- ley, registration rollers, bypass paper feed pulley and bypass separation pad.

  • Page 132: Assembly And Disassembly

    1-6 Assembly and Disassembly 1-6-1 Precautions for assembly and disassembly (1) Precautions Be sure to turn the power switch off and disconnect the power plug before starting disassembly. When handling PCBs, do not touch connectors with bare hands or damage the board. Do not touch any PCB containing ICs with bare hands or any object prone to static charge.

  • Page 133: Running A Maintenance Item

    (2) Running a maintenance item Start Enter “10871087” using Maintenance mode is entered. the numeric keys. Enter the maintenance item number using the zoom The maintenance item is +/- keys or numeric keys. selected. Press the start key. The selected maintenance item is run. Press the stop/clear key.

  • Page 134: Paper Feed Section

    1-6-2 Paper feed section (1) Detaching and refitting the separation pulley Follow the procedure below to replace the separation pulley. Procedure 1. Open the front cover and left cover. Remove the waste toner box. 2. Pull out the drawer. Drawer Figure 1-6-1 3.
  • Page 135 5. Remove the separation pulley unit from the lower paper feed unit. 6. Remove the separation pulley from the sep- aration pulley unit. 7. Replace the separation pulley and refit all the removed parts. Separation pulley Separation pulley unit Lower paper feed unit Figure 1-6-4 1-6-4...

  • Page 136: Detaching And Refitting The Forwarding Pulley And Paper Feed Pulley

    (2) Detaching and refitting the forwarding pulley and paper feed pulley Follow the procedure below to replace the forwarding pulley and paper feed pulley. Procedure Stop ring 1. Remove the lower paper feed unit (see page 1-6-3). 2. Remove the drum unit (see page 1-6-33). 3.
  • Page 137 7. Remove the springs, stop ring and bushing Shaft holder and then the shaft holder from the upper Spring paper feed unit. Spring Stop ring Upper paper feed unit Bushing Figure 1-6-8 8. Remove the forwarding pulley from the Paper feed pulley upper paper feed unit.

  • Page 138: Detaching And Refitting The Paper Conveying Unit

    2C9-6.0 (3) Detaching and refitting the paper conveying unit Follow the procedure below to maintenance of the paper feed section. Procedure 1. Remove the drum unit (see page 1-6-33). 2. Remove the stop ring and strap from the rear side. Restore the paper conveying unit. Remove the pin and plate, and then remove the stopper from the front side.
  • Page 139 5. Remove the left cover from the copier. 6. Push the fitting portions of the bypass upper cover. Remove the bypass upper cover from the bypass unit. Bypass upper guide Figure 1-6-12 7. Detach the connector and remove the bypass lower cover from the copier. Connector Bypass lower cover Figure 1-6-13...

  • Page 140: Detaching And Refitting The Bypass Paper Feed Pulley And Bypass Separation Pad

    (4) Detaching and refitting the bypass paper feed pulley and bypass separation pad Follow the procedure below to replace the bypass paper feed pulley and bypass separation pad. Procedure 1. Open the front cover and remove the waste toner box. Pull out the drawer. 2.
  • Page 141 7. Temporarily push the bypass paper feed pul- Bypass paper feed pulley unit ley unit into the rear side to unlock the front side and then remove it from the copier. Figure 1-6-18 8. Remove the bypass paper feed pulley from the bypass paper feed pulley shaft.

  • Page 142: Detaching And Refitting The Registration Left Roller

    2C9-3 (5) Detaching and refitting the registration left roller Follow the procedure below to replace the registration left roller. Procedure Stopper 1. Remove the paper conveying unit (see page 1-6-7). Paper conveying unit 2. Remove the transfer roller (see page 1-6- 37).

  • Page 143: Adjustment After Roller And Clutch Replacement

    2C9-4 (7) Adjustment after roller and clutch replacement Perform the following adjustment after refitting rollers and clutches. (7-1) Adjusting the leading edge registration of image printing Make the following adjustment if there is a regular error between the leading edges of the copy image and original. U066 U071 U034...

  • Page 144: Adjusting The Leading Edge Registration For Memory Image Printing

    (7-2) Adjusting the leading edge registration for memory image printing Make the following adjustment if there is a regular error between the leading edge of the copy image and the leading edge of the original during memory copying. U066 U403 U053 U034 U065...

  • Page 145: Adjusting The Center Line Of Image Printing

    2C9-4 (7-3) Adjusting the center line of image printing Make the following adjustment if there is a regular error between the center lines of the copy image and original when paper is fed from the drawer. U067 U072 U034 (P. 1-6-35) (P.

  • Page 146: Adjusting The Trailing Edge Margin Of Image Printing

    2C9-4 (7-4) Adjusting the trailing edge margin of image printing Make the following adjustment if there is a regular error between the trailing edges of the copy image and original. Procedure Start Enter maintenance mode. Trailing edge margin Correct image Output Enter “034”...
  • Page 147 2C9-4 This page is intentionally left blank. 1-6-16...

  • Page 148: Adjusting The Margins For Printing

    2C9-4 (7-5) Adjusting the margins for printing Make the following adjustment if the margins are not correct. U403 U404 U402 (P. 1-6-32) (P. 1-4-36) Caution: Check the copy image after the adjustment. If the margins are still incorrect, perform the above adjustments in mainte- nance mode.

  • Page 149: Adjusting The Amount Of Slack In The Paper

    2C9-4 (7-6) Adjusting the amount of slack in the paper Make the following adjustment if the leading edge of the copy image is missing or varies randomly, or if the copy paper is Z-folded. Procedure Start Original Copy Copy example 1 example 2 Enter maintenance mode.

  • Page 150: Optical Section

    1-6-3 Optical section (1) Detaching and refitting the exposure lamp Take the following procedure when the exposure lamp is to be replaced. Contact glass Procedure 1. Remove the original cover or the DP. 2. Remove the two screws holding the upper right cover and then the cover.

  • Page 151: Detaching And Refitting The Scanner Wires

    (2) Detaching and refitting the scanner wires Take the following procedure when the scanner wires are broken or to be replaced. (2-1) Detaching the scanner wires Uppeer rear cover Procedure 1. Remove the exposure lamp (see page 1-6- 17). 2. Remove the two screws holding the upper rear cover and then the cover.
  • Page 152 5. Remove the screw holding each of the front and rear wire retainers and then remove the mirror 1 frame from the scanner unit. Mirror 1 frame Rear wire Front wire retainer retainer Figure 1-6-35 6. Unhook the round terminal of the scanner Round terminal wire from the scanner tension spring on the left side of the scanner unit.

  • Page 153: Fitting The Scanner Wires

    2C9-6.0 (2-2) Fitting the scanner wires Caution: When fitting the wires, be sure to use those specified below. Machine front: P/N 2C91236 (gray) Machine rear: P/N 2C91235 (black) Fitting requires the following tools: Two frame securing tools (P/N 302C968310) Two scanner wire stoppers (P/N 3596811) Procedure 1.
  • Page 154 4. Insert the locating ball on each of the scan- ner wires into the hole in the respective scanner wire drum and wind the scanner wire three turns inward and four turns out- ward. With the locating ball as the reference point, wind the shorter end of each of the wires outward.
  • Page 155 8. Loop the outer ends of the scanner wires around the outer grooves in the pulleys on the mirror 2 frame, winding from below to above........................(1) 9. Hook the round terminals onto the catches inside the scanner unit............. (2) 10.

  • Page 156: Detaching And Refitting The Isu (Reference)

    (3) Detaching and refitting the ISU (reference) Take the following procedure when the ISU is to be replaced. Procedure ISU cover Detaching the ISU 1. Remove the contact glass (see page 1-6- 17). 2. Remove the four screws holding the ISU cover and then the cover.

  • Page 157: Detaching And Refitting The Laser Scanner Unit

    (4) Detaching and refitting the laser scanner unit Take the following procedure when the laser scanner unit is to be replaced. Procedure 1. Remove the original cover or the DP. 2. Remove the upper right cover, contact glass, upper rear cover, middle left cover, upper left cover, slit glass and front scanner cover (see page 1-6-18).
  • Page 158 5. Remove the four pins holding the scanner unit and then the unit. Scanner unit Figure 1-6-48 6. Remove the screw holding the exit cover Exit cover Inner rear cover and then the cover. Remove the two screws holding the inner rear cover and then the cover.
  • Page 159 8. Remove the two screws holding the exit unit and then pull out the unit a little. Exit unit Figure 1-6-51 9. Remove the exit tray. Exit tray Figure 1-6-52 Connector 10. Remove the four screws and detach the two connector and then remove the laser scan- ner unit.

  • Page 160: Adjusting The Longitudinal Squareness (Reference)

    (5) Adjusting the longitudinal squareness (reference) Perform the following adjustment if the copy image is longitudinally skewed (longitudinal squareness not obtained). Caution: Adjust the amount of slack in the paper (page 1-6-16) first. Check for the longitudinal squareness of the copy image, and if it is not obtained, perform the longitudinal squareness adjustment.

  • Page 161: Adjusting Magnification Of The Scanner In The Main Scanning Direction

    (6) Adjusting magnification of the scanner in the main scanning direction Perform the following adjustment if the magnification in the main scanning direction is not correct. U065 U065 U053 U067 (auxiliary scanning (main scanning (P. 1-4-10) (P. 1-6-31) direction) (P. 1-6-29) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 162: Adjusting Magnification Of The Scanner In The Auxiliary Scanning Direction

    2C9-4 (7) Adjusting magnification of the scanner in the auxiliary scanning direction Perform the following adjustment if the magnification in the auxiliary scanning direction is not correct. U065 U065 U053 U070 (main scanning (auxiliary scanning (P. 1-4-10) (P. 1-4-13) direction) (P. 1-6-28) direction) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

  • Page 163: Adjusting The Scanner Leading Edge Registration

    2C9-6.0 (8) Adjusting the scanner leading edge registration Perform the following adjustment if there is regular error between the leading edges of the copy image and original. U034 U071 U066 (P. 1-6-12) (P. 1-4-14) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner leading edge registration Start...

  • Page 164: Adjusting The Scanner Center Line

    2C9-4 (9) Adjusting the scanner center line Perform the following adjustment if there is a regular error between the center lines of the copy image and original. U034 U072 U067 (P. 1-6-14) (P. 1-4-15) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Scanner center line Start...

  • Page 165: Adjusting The Margins For Scanning An Original On The Contact Glass

    2C9-4 (10) Adjusting the margins for scanning an original on the contact glass Perform the following adjustment if the margins are not correct. U402 U404 U403 (P. 1-6-15) (P. 1-4-36) Caution: Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode. Procedure Start Enter maintenance mode.

  • Page 166: Drum Section

    1-6-4 Drum section (1) Detaching and refitting the drum unit Follow the procedure below to replace the drum unit. Cautions: Avoid direct sunlight or strong light when detaching and refitting the drum unit. Never touch the drum surface when holding the drum unit. Procedure Inner cover 1.

  • Page 167: Detaching And Refitting The Drum Separation Claws

    (2) Detaching and refitting the drum separation claws Follow the procedure below to replace the drum separation claws. Procedure 1. Remove the drum unit (see page 1-6-33). Drum unit 2. Push the drum separation claws with the minus driver from the top of the corner hole and remove the claws.

  • Page 168: Detaching And Refitting The Main Charger Unit

    (3) Detaching and refitting the main charger unit Follow the procedure below to replace the main charger unit. Procedure 1. Open the front cover. Main charger 2. While lifting the main charger unit toward the release lever upper right, remove the unit from the copier. 3.

  • Page 169: Developing Section

    1-6-5 Developing section (1) Detaching and refitting the developing unit Follow the procedure below to replace the developing unit. Procedure 1. Remove the drum unit (see page 1-6-33). 2. While lifting the developing unit a little, remove the unit from the copier. 3.

  • Page 170: Transfer Section

    1-6-6 Transfer section (1) Detaching and refitting the transfer roller Follow the procedure below to replace the transfer roller. Procedure Rear release 1. Remove the paper conveying unit (see page lever stopper 1-6-7). Front release 2. Remove the screw holding each of the front lever stopper and rear release lever stoppers and then the stoppers from the release lever shaft.

  • Page 171: Fixing Section

    2C9-6.0 1-6-7 Fixing section (1) Detaching and refitting the fixing unit Follow the procedure below to replace the fixing unit. Procedure 1. Open the front cover and left cover and then remove the inner cover. 2. Insert a flat-blade screwdriver or the like through the groove at the left side of the machine and unlock the engaged portion of front left cover 1 to remove it.
  • Page 172 2C9-6.0 Figure 1-6-69a 5. Remove the screw and detach the two con- nectors and then remove the fixing unit from copier. 6. Replace the fixing unit and refit all the removed parts. Connectors Fixing unit Figure 1-6-69b 1-6-38-1 1-6-39...
  • Page 173 2C9-6.0 This page is intentionally left blank. 1-6-40...

  • Page 174: Detaching And Refitting The Press Roller

    (2) Detaching and refitting the press roller Follow the procedure below to replace the press roller. Procedure 1. Remove the fixing unit (see page 1-6-38). 2. Remove the two screws and then separate the fixing right unit and left unit. Fixing right unit Fixing left unit Figure 1-6-70...

  • Page 175: Detaching And Refitting The Fixing Heater M And S

    (3) Detaching and refitting the fixing heater M and S Follow the procedure below to replace the fixing heater M and S. Procedure 1. Remove the fixing unit and separate the fix- ing right unit and left unit (see pages 1-6-38, 39).

  • Page 176: Detaching And Refitting The Heat Roller Separation Claws

    (4) Detaching and refitting the heat roller separation claws Follow the procedure below to replace the heat roller separation claws. Procedure 1. Remove the fixing unit and separate the fixing right unit and left unit (see page 1-6- Fixing left unit 38, 39).

  • Page 177: Detaching And Refitting The Heat Roller

    (5) Detaching and refitting the heat roller Follow the procedure below to replace the heat roller. Procedure 1. Remove the fixing unit and separate the fix- ing right unit and left unit (see pages 1-6-38, 39). 2. Remove the heat roller separation claws. (see page 1-6-41).

  • Page 178: Detaching And Refitting The Fixing Thermostat

    (6) Detaching and refitting the fixing thermostat Follow the procedure below to replace the fixing thermostat. Procedure Fixing thermostat 1. Remove the fixing unit and separate the fix- ing right unit and left unit (see page 1-6-38, 39). 2. Remove the heat roller (see page 1-6-42). 3.

  • Page 179: Adjusting The Fixing Unit Height (Adjusting Lateral Squareness)

    2C9-6.0 (8) Adjusting the fixing unit height (adjusting lateral squareness) Follow the procedure below if the drum is not parallel to the fixing unit and therefore paper is not fed straight to the fixing section and the trailing edge of image on either the front or rear side becomes longer. Procedure 1.

  • Page 180: Upgrading The Firmware On The Main Pcb

    2C9-2 1-7 Requirements on PCB Replacement 1-7-1 Upgrading the firmware on the main PCB Firmware upgrading requires the following tools: Flash DIMM (P/N 2C968131) Procedure 1. Run maintenance mode U019 to check the version of the ROM. Jumper switch 2. Turn the power switch off and disconnect the power plug.

  • Page 181: Adjustment-Free Variable Resistors (Vr)

    1-7-2 Adjustment-free variable resistors (VR) The variable resistors listed below are set at the factory prior to shipping and cannot be adjusted in the field. High-voltage PCB: VR201, VR202, VR301 Drum unit zener PCB: VR1 1-7-3 Remarks on engine PCB or main PCB replacement When replacing the engine PCB or main PCB, remove the EEPROM from the engine PCB or main PCB that has been removed and then reattach it to the new engine PCB or main PCB.

  • Page 182: Paper Feed Section

    2-1 Mechanical construction 2-1-1 Paper feed section The paper feed section conveys paper from the drawer or bypass tray to the left and right registration rollers, at which point secondary feed takes place and the paper travels to the transfer section in sync with the printing timing. Drawer can hold up to 300 sheets of paper.
  • Page 183 2C9-3 RMPCB EPCB YC2-1, 2, 4, 5 YC1-4 YC4-4 DPCB YC5-12 YC1-9 YC8-9 PFCL PFCL YC2-1 YC1-15 YC8-3 PFCL BYPPFCL BYPPFCL BYPPFCL YC3-2 YC1-13 YC8-5 YC6-2 YC1-16 YC8-2 BYPPWSW BYPPWSW BYPPWSW YC5-9 YC1-10 YC8-8 PLSW YC22-1, 2, 4 PLSW Figure 2-1-2 Paper feed section block diagram 2-1-2...
  • Page 184 Primary feed Secondary feed Primary feed Secondary feed 105 ms 105 ms 250 ms PFCL 550 ms 1900 ms 430 ms 430 ms 320 ms 150 ms 150 ms 330 ms Dev.BIAS 290 ms 290 ms Separation charging 100 ms 10 ms 670 ms 10 ms...

  • Page 185: Optical Section

    2-1-2 Optical section The optical section consists of the scanner, mirror frames and the image scanning unit for scanning and the laser scanner unit for printing. Figure 2-1-3Optical section Mirror 1 frame Mirror 2 frame Exposure lamp (EL) Mirror 1 Mirror 2 Mirror 3 Image scanning unit (ISU)

  • Page 186: Original Scanning

    (1) Original scanning The original image is illuminated by the exposure lamp (EL) and scanned by the CCD PCB (CCDPCB) in the image scan- ning unit via the three mirrors, the reflected light being converted to an electrical signal. The scanner and mirror frames travel to scan on the optical rails on the front and rear of the machine to scan from side to side.

  • Page 187: Image Printing

    (2) Image printing The image data scanned by the CCD PCB (CCDPCB) is processed on the main PCB (MPCB) and transmitted as image printing data to the laser scanner unit (LSU). By repeatedly turning the laser on and off, the laser scanner unit forms a latent image on the drum surface.
  • Page 188 The dimensions of the laser beam are as shown in Figure 2-1-6. Less than 100 m Less than 85 m Figure 2-1-6 Scanning in the main direction is provided by the rotating polygon mirror, while scanning in the auxiliary direction is pro- vided by the rotating drum, forming a static latent image on the drum.

  • Page 189: Drum Section

    2C9-2 2-1-3 Drum section The drum section consists of the drum, main charger section, cleaning section and cleaning lamp. The main charger section consists of main charger wire, main charger grid and main charger shield, and the drum is charged by a high voltage applied to the main charger wire. In addition, this section is equipped with a manual main charger cleaner that is used for cleaning the main charger wire.
  • Page 190 YC3-7, 8 MHVADJC YC1-8 YC9-9 MHVDRN YC1-12 YC9-5 Grid Drum ZENER HVTPCB EPCB Figure 2-1-9Drum section block diagram 840 ms 100 ms Main charging Timing chart 2-1-2 Main charging section operation a: The drive motor (DM) turns on at the same time, the cleaning lamp (CL) turns on. b: 100 ms after the drive motor (DM) turns on, main charging starts.

  • Page 191: Developing Section

    2-1-4 Developing section The developing section consists of the developing unit and the toner container. The developing unit consists of the developing roller where a magnetic brush is formed, the doctor blade and the develop- ing spirals that agitate the toner. Also, the toner container sensor (TCS) checks whether or not toner remains in the toner container.

  • Page 192: Formation Of Magnetic Brush

    (1) Formation of magnetic brush The developing roller consists of a magnet roller with four poles and a sleeve roller. Rotation of the sleeve roller around the magnet roller entrains toner, which in turn forms a magnetic brush at pole N1 on the magnet roller. The height of the magnetic brush is regulated by the doctor blade;...

  • Page 193: Single Component Developing System

    2C9-3 (2) Single component developing system This machine uses the single component developing system, and reversal processing is performed with a + charged drum (a-Si) and a + charged magnetic toner. With the single component developing system, toner is electrically charged by friction with the developing sleeve and + charged when it passes through the magnetic doctor blade.

  • Page 194: Transfer And Separation Sections

    2-1-5 Transfer and separation sections The transfer and separation sections consists of the transfer roller, separation electrode and drum separation claws. A high voltage generated by the high-voltage PCB (HVTPCB) is applied to the transfer roller for transfer charging. Paper after transfer is separated from the drum by applying separation bias that is output from the high-voltage PCB (HVT- PCB) to the separation electrode.
  • Page 195 Primary feed Primary feed Secondary feed Secondary feed 105 ms 250 ms 105 ms 250 ms PFCL 1900 ms 430 ms 430 ms 150 ms 150 ms 320 ms 330 ms Dev.BIAS 290 ms Separation charging 100 ms 10 ms 670 ms 10 ms Transfer...

  • Page 196: Fixing Section

    2C9-2 2-1-6 Fixing section The fixing section consists of the parts shown in figure. When paper reaches the fixing section after the transfer process, it passes between the press roller and heat roller, which is heated by fixing heaters M or S (FH-M or FH-S). Pressure is applied by the fixing unit pressure springs so that the toner on the paper is melted, fused and fixed onto the paper.

  • Page 197: Fixing Temperature System

    (1) Fixing temperature system Temperature ( C) Preset temperature ( C) (secondary stabilization) Time Warm-up Ready state control control 500 ms HEAT signal Fixing heater S (FH-S) HEAT signal Fixing heater M (FH-M) Figure 2-1-19Fixing temperature system Warm-up control 1. 500 ms after the fixing heater S (FH-S) turns on, the fixing heater M (FH-M) turns on. 2.

  • Page 198: Exit And Switchback Sections

    2-1-7 Exit and switchback sections The exit and switchback sections exit paper on which fixing has ended with the exit roller that is rotated by forward rotation of the exit motor. In duplex copying, paper is turned over by reverse rotation of the exit motor. Figure 2-1-20Exit and switchback sections Feedshift guide Exit roller...

  • Page 199: Duplex Section

    2-1-8 Duplex section In duplex mode, after copying on to the reverse face of the paper, the paper is reversed in the switchback section and con- veyed to the duplex unit. The paper is then conveyed to the copier paper feed section by the upper and lower duplex feed rollers.

  • Page 200: Paper Conveying Operation In Duplex Copying

    (1) Paper conveying operation in duplex copying Paper of which copying onto the reverse side is complete is conveyed to the switchback section, the exit motor switches from forward rotation to reverse rotation to switch the exit roller to reverse rotation, and the paper conveying direction is reversed.

  • Page 201: Electrical Parts Layout

    2-2 Electrical Parts Layout 2-2-1 Electrical parts layout (1) PCBs Machine front Machine inside Machine rear Figure 2-2-1 PCBs Engine PCB (EPCB) ........Controls the other PCBs, electrical components and optional devices. Main PCB (MPCB) ........Controls the operation panel and laser scanner unit. Power source PCB (PSPCB) .......

  • Page 202: Switches And Sensors

    2C9-3 (2) Switches and sensors Machine front Machine inside Machine rear Figure 2-2-2Switches and sensors Power switch (PSW) ........Turns the AC power on and off. Front cover safety switch (FCSSW)..... Breaks the safety circuit when the front cover is opened. Left cover safety switch (LCSSW) ....

  • Page 203: Motors

    (3) Motors Machine front Machine inside Machine rear Figure 2-2-3Motors Drive motor (DM) ......... Drives the machine. Scanner motor (SM)........Drives the optical system. Exit motor (EM) ..........Drives the exit section. Cooling fan motor 1 (CFM1) ......Cools the machine interior. Cooling fan motor 2 (CFM2) ......

  • Page 204: Other Electrical Components

    2C9-3 (4) Other electrical components Machine front Machine inside Machine rear Figure 2-2-4Other electrical components Paper feed clutch (PFCL) ......Primary paper feed from the drawer. Bypass paper feed solenoid (BYPPFSOL) .. Primary paper feed from the bypass tray. Exposure lamp (EL) ........Exposes originals. Cleaning lamp (CL) ........

  • Page 205: Power Source Pcb

    2-3 Operation of the PCBs 2-3-1 Power source PCB IL001 Rectifier circuit ON/OFF +24V T001 SW001 F002 L004 D005 switch circuit L003 DC24V D101 output C008 circuit Q006 C102 INPUT D206 F201 DC5V F001 output Switching C204 circuit control circuit (IC001) F003 DC5V...
  • Page 206 Q206 Q101 C104 PC005 C008 L102 PC004 D101 Q006 D005 YC3 YC5 C204 C006 F201 C301 L004 T001 C102 C017 TR001 TR002 IC301 C027 L003 L001 L012 F003 F002 C003 SW001 L013 F001 Figure 2-3-2Power source PCB silk-screen diagram Connector Pin No.
  • Page 207 Connector Pin No. Signal Description +5 V1 5 V DC power supply for FCSSW Connected Not used to the front +5 V3 5 V DC power supply cover safety switch H.LIVE AC power supply for FH-M/S (LIVE) Connected MH.OUT AC power supply for FH-M to the fixing MH.OUT AC power supply for FH-S...

  • Page 208: Main Pcb

    2-3-2 Main PCB CCDPCB EPCB MPCB SBSY 3.3V SDIR 2.5V EGIRN RSTN EGSO SCKN EGSI PDMASKN OVSYNK ASIC OUTPEN PLGCLK PLGCLK OUTPEN PLGDR VDATAN PLGRDYN SAMPLEN 24V4 Figure 2-3-3Main PCB block diagram 2-3-4...
  • Page 209 Figure 2-3-4Main PCB silk-screen diagram 2-3-5...
  • Page 210 Connector Pin No. Signal Description +5 V 5 V DC power supply for OPCB Connected BUZERDRN OPCB buzzer signal to the opera- SCAN7N Key switch scan signal 7 tion unit SCAN6N Key switch scan signal 6 SCAN5N Key switch scan signal 5 SCAN4N Key switch scan signal 4 SCAN3N...
  • Page 211 Connector Pin No. Signal Description CCDO CCDPCB image scanning signal Connected CCDON Ground to the CCD CCDE CCDPCB image scanning signal CCDEN Ground +5 V 5 V DC power supply for CCDPCB S.GND Ground +12 V 12 V DC power supply for CCDPCB S.GND Ground CCDCLK...

  • Page 212: Engine Pcb

    2C9-6.0 2-3-3 Engine PCB HVTPCB CFM1, 2 PSPCB INPCB MHVDR LAMPN FAN1N 24V1 ILOCK THVDR FAN1LOW ILOCKL SHVDR FAN2N SHVISEL FAN2LOW SLEPN ORGTIM 24V4 HVCLK 24V1 (DB) DOPSEL, DOPRDY ERASER MHVIADJ 24V4 DOPSI, DOPSO THVIADJ DOPSCLK 24V1 TONEEPY Scanner unit TONEFUL OPSWN ORGLSWN...
  • Page 213 YC17 YC16 YC18 YC19 YC22 Figure 2-3-6Engine PCB silk-screen diagram 2-3-9...
  • Page 214 Connector Pin No. Signal Description +12 V 12 V DC power supply for MPCB Connected OVSYNC Original scanning interval signal to the Main RSTN Reset signal EGRN Engine communication EGRN signal SDIR Engine communication SDIR signal SBSY Engine communication SBSY signal PDMASKN Printing image interval signal EGSI...
  • Page 215 2C9-6.0 Connector Pin No. Signal Description +24V4 24 V DC power supply for DM Connected P.GND Ground to the drive S.GND Ground motor +5 V 5 V DC power supply for DM DM on/off DM rotation sync signal DM clock signal BPPESW BYPPSW on/off Connected...
  • Page 216 Connector Pin No. Signal Description YC13 +24 V1 24 V DC power supply for key counter Connected KEYCN Key counter count signal to the key S.GND Ground counter KEYENBN Key counter set signal YC14 COMDA EM control signal (A) Connected COMDNB EM control signal (_B) to the exit...
  • Page 217 Connector Pin No. Signal Description YC21 SLEPN Power source sleep signal Connected ZCROS O Zero-cross signal to the power S.GND Ground source PCB +24 V2 LCSSW on/off S.GND Ground +5 V3 FCSSW on/off YC22 C1PLSW3N PLSW on/off Connected C1PLSW2N PLSW on/off to the paper S.GND Ground...

  • Page 218: Operation Unit Pcb

    2-3-4 Operation unit PCB BUZERDRN SCAN7N SCAN6N SCAN5N SCAN4N SCAN3N Dig1 SCAN2N Dig1 SCAN1N Dig2 SCAN0N Dig3 7 segment KEY4 KEY3 KEY2 KEY1 KEY0 LED12 LED11 LED10 LED9 LED8 LED7 LED6 LED5 LED4 LED3 LED2 LED1 LED0 Figure 2-3-7Operation unit PCB block diagram The operation unit PCB (OPPCB) consists of key switches, LEDs, 7 segment LED and buzzer.
  • Page 219 Figure 2-3-8Operation unit PCB silk-screen diagram 2-3-15...
  • Page 220 Connector Pin No. Signal Description SCAN0N Key switch scan signal 0 Connected SCAN1N Key switch scan signal 1 to the main SCAN2N Key switch scan signal 2 SCAN3N Key switch scan signal 3 SCAN4N Key switch scan signal 4 SCAN5N Key switch scan signal 5 SCAN6N Key switch scan signal 6...

  • Page 221: Ccd Pcb

    2-3-5 CCD PCB CCDPCB Tr.AMP CCD sensor MPCB Driver Figure 2-3-9CCD PCB block diagram The CCD PCB (CCDPCB) is equipped with a CCD sensor (U2) for original scanning. The clock signals for driving the CCD sensor (U2) are sent from the main PCB (MPCB), and then input to the CCD sensor (U2) via the clock driver (U1 and U3).
  • Page 222 Figure 2-3-10CCD PCB silk-screen diagram Connector Pin No. Signal Description S.GND Ground Connected MPCB SH signal to the main S.GND Ground MPCB CP signal S.GND Ground MPCB RS signal S.GND Ground CCDCLKN CCDCLKN signal S.GND Ground CCDCLK CCDCLK signal S.GND Ground +12 V 12 V DC power supply from MPCB...
  • Page 223 2C9-3 2-4-1...
  • Page 224 2C9-3 2-4-2...
  • Page 225 2-4-3...
  • Page 226 2-4-4...
  • Page 227 2-4-5...
  • Page 228 2-4-6...
  • Page 229 2C9-6.0 2-4-7...

  • Page 230: Maintenance Parts List

    2C9-6.0 Maintenance parts list Maintenance part name Alternative Fig. Ref. Part No. part No. Name used in service manual Name used in parts list Paper feed pulley PULLEY, PAPER FEED 2AR07220 Separation pulley PULLEY, SEPARATION 2AR07230 Forwarding pulley PULLEY, LEADING FEED 2AR07240 Bypass paper feed pulley PARTS,BYPASS PULLEY,SP...

  • Page 231: Periodic Maintenance Procedures

    2C9-3 Periodic maintenance procedures Maintenance Section Method Maintenance cycle Points and cautions Page part/location Test copy and Perform at the maxi- Test copy Every service test print mum copy size Maintenance Section Method Maintenance cycle Points and cautions Page part/location Paper feed Paper feed pulley Clean or replace -...
  • Page 232 Maintenance Section Method Maintenance cycle Points and cautions Page part/location Developing Developing unit Check or replace - Replace if the problem occurs. 1-6-36 section Maintenance Section Method Maintenance cycle Points and cautions Page part/location Drum section Drum unit Check or replace Every 150,000 counts Replace if the problem occurs.

  • Page 233: Optional Devices Supplied Parts List

    Optional devices supplied parts list Name used in service manual Name used in installation guide Part No. Fixing fitting Fixing fitting 3HL02150 3HL02180 Bronze TP screw M3 x 06 Bronze TP screw M3 x 06 B4303060 Chrome TP screw M4 x 10 Chrome TP screw M4 x 10 B4104100 2-4-11...

  • Page 234: General Wiring Diagram

    2C9-3 General wiring diagram 2-4-12...

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