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Develop D 16G Service Manual

Develop D 16G Service Manual

Develop d 16g office mfp
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DEVELOP
SERVICE MANUAL & OPTIONS
D 16G
4986-7991-00

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Summary of Contents for Develop D 16G

  • Page 1 DEVELOP SERVICE MANUAL & OPTIONS D 16G 4986-7991-00...
  • Page 3 INDEX (Field Service) GENERAL MECHANICAL/ELECTRICAL MAINTENANCE DIS/REASSEMBLY, ADJUSTMENT CONTROL PANEL/SERVICE MODE DESCRIPTIONS TROUBLESHOOTING...

  • Page 5: Table Of Contents

    CONTENTS GENERAL 1. SPECIFICATIONS ...................G-1 (1) Main Unit ..................G-1 (2) GDI Printer Function ................G-3 2. PRECAUTIONS FOR INSTALLATION ............G-4 2-1. Installation Site ..................G-4 2-2. Power Source ...................G-4 3. PRECAUTIONS FOR USE ................G-5 3-1. To Ensure the Printer is Used in an Optimum Condition ......G-5 3-2.
  • Page 6 9-3. Laser Emission Timing ................M-20 9-4. Laser Emission Area ................M-21 (1) Main scanning direction ..............M-21 (2) Sub-scanning direction ..............M-21 10. PAPER TAKE-UP SECTION ................M-22 10-1.Tray 1 ...................... M-22 (1) Paper take-up mechanism .............. M-22 (2) Double feed preventive mechanism ..........M-23 (3) Paper empty detection ..............
  • Page 7 1-5. Precautions for Handling the Laser Equipment ........D-5 2. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS .........D-6 2-1. Parts That Must Not be Touched .............D-6 (1) Red Painted Screws ................D-6 (2) Variable resistors on board ..............D-6 (3) Other Screws not Marked with Red Paint ........D-6 3.
  • Page 8 5-4. Remedy for a Failed Updating of the Firmware ........D-45 5-5. Moving the EEPROM ................D-47 CONTROL PANEL/SERVICE MODE DESCRIPTIONS 1. CONTROL PANEL DESCRIPTIONS .............. S-1 1-1. Names of Control Panel Parts and Their Functions ........ S-1 2. FUNCTIONS OF SWITCHES AND PARTS ON PWBs ........S-3 2-1.
  • Page 9 3. MALFUNCTIONS/WARNING ................T-11 3-1. List of Malfunctions ..................T-11 3-2. Malfunction Detection Timing and Troubleshooting Procedures ....T-14 (1) C0045: Fuser fan motor error ............T-14 (2) C0210: H.V. abnormal ..............T-15 (3) C0500: Fuser warm up error ............T-16 (4) C0510: Fuser temperature low ............T-17 (5) C0520: Fuser overheat ..............T-18 (6) C0650: Scanner home sensor error ..........T-18 (7) C1200: ASIC memory abnormal ............T-19...

  • Page 11: General

    GENERAL...

  • Page 13: Specifications

    SPECIFICATIONS Main Unit Type Desktop Original scanning system Scanning in main scanning direction with a 3-line color CCD sensor, and scanning in sub-scanning direction with unit scanning and sheet feed-through system Photoconductor type OPC (Organic Photoconductor) Copying system Electrostatic dry Powdered image transfer to plain paper with laser 600 dpi ×...
  • Page 14 12 copies/minute (at full size and 600 dpi × 300 dpi, with Continuous copy speed (copies/min.) ADF) Continuous print speed More than 16 sheets/minute (with plain A4 L or Letter L (sheets/min.) paper) Warm-up time Less than 25 seconds (at a room temperature of 23 °C and at the rated voltage) 16 seconds or less (at full size and 600 dpi ×...

  • Page 15: Gdi Printer Function

    Zoom Ratios Metric Size English Size ×1.00 ×1.00 Full size ×1.15 ×1.29 ×1.41 ×1.54 Enlargement ×2.00 ×2.00 Fixed ×0.81 ×0.78 ×0.70 ×0.64 Reduction ×0.50 ×0.50 ×0.50 to ×2.00 (in ×0.01 increments) Variable Lens Through lens (F=5.0, f=27.195) Exposure Lamp Cold Cathode Florescent Lamp Fusing temperature 200 °C Power /Current Consumption (main unit only)

  • Page 16: Precautions For Installation

    PRECAUTIONS FOR INSTALLATION 2-1. Installation Site To ensure utmost safety and avoid breakdown, the printer should NOT be used in a place: • Where it will be subjected to extremely high or low temperature or humidity. • Where it will be subjected to sudden fluctuations in either temperature or humidity. •...

  • Page 17: Precautions For Use

    PRECAUTIONS FOR USE 3-1. To Ensure the Printer is Used in an Optimum Condition • Never place a heavy object on the printer or subject the printer to shocks. • Insert the power plug all the way into the outlet. •...

  • Page 18: Handling Of The Consumables

    HANDLING OF THE CONSUMABLES Before using any consumables, always read the label on its container carefully. • Paper can easily damp. To prevent absorption of moisture, store paper in a place with lit- tle moisture. • Keep consumables out of the reach of children. •...

  • Page 19: Parts Identification

    PARTS IDENTIFICATION 4980G001AA 1. Automatic Document Feeder AF-11 4. Paper Feed Cassette PF-125 2. Mechanical Counter 5. Main Unit D 16G 3. Expansion memory 32-5 (32 MB) 6. Original Cover OC-7...

  • Page 21: Mechanical/ Electrical

    MECHANICAL/ ELECTRICAL...

  • Page 23: Components Layout

    COMPONENTS LAYOUT 4980M004AA 1: IR Unit 5: Paper Take-Up Roller 2: Exit Roller 6: Toner Cartridge 3: Fusing Unit 7: Drum Cartridge 4: Image Transfer Section 8: Print Head (PH) Unit...

  • Page 24: Copy Process

    COPY PROCESS 4980M018AC 1. PC Drum • A photoconductive layer is formed on an aluminum tube and an electrostatic latent image is formed on this photoconductive layer. 2. PC Drum Charging • Deposits a negative DC charge across the entire surface of the PC Drum. 3.
  • Page 25 8. Paper Feed • Paper is fed from Tray 1. 9. Bypass Paper Feed • Paper is fed from the Multiple Bypass Tray. 10. Image Transfer • A DC positive charge is applied to the Image Transfer Roller to transfer the visible image on the surface of the PC Drum onto the paper.

  • Page 26: Paper Path

    PAPER PATH Exit Roller Exit Tray Fusing Roller Multiple Bypass Tray Tray 1 Image Transfer Roller Paper Take-Up Roll 4980M005AA • The system employs a two-way paper supply system, in which paper is fed from either Tray 1 or the Multiple Bypass Tray. •...

  • Page 27: Drive System

    DRIVE SYSTEM 4980M010AA 1: Scanner Unit 4: Main Motor 2: Image Transfer Roller 5: Scanner Motor 3: Paper Take-up Roller 6: Fusing Roller...

  • Page 28: Operating Sequence

    Start key Polygon Motor Main Motor Paper Take- Up Solenoid Drum Charge Drum charge DC Drum charge DC Output Exposure Output Develop- Charge Charge ing Output Reverse bias Reverse bias Image Unexposed area output Transfer Negative output Negative output Output...

  • Page 29: When The Pre-Start Control Is Provided

    When the pre-start control is provided Start key Polygon Motor Main Motor Paper Take-Up Solenoid Drum Charge Drum charge DC Drum charge DC Output Exposure Output Developing Charge Output Reverse bias Image Unexposed area output Transfer Negative output Output 4980M017AB 5-2.

  • Page 30: Ic (Imaging Cartridge) Section

    IC (IMAGING CARTRIDGE) SECTION 6-1. Overview • The illustration below shows the construction of the Toner Cartridge and the Developing Unit. • This printer adopts the single-component FMT, or Fine Micro Toning, developing system. • The Toner Agitating Screw conveys toner in the Toner Cartridge onto the Toner Supply Roller.
  • Page 31 • The Imaging Cartridge consists of a T/C (Toner Cartridge) and a D/C (Drum Cartridge) (see the illustration below). D/C (Drum Cartridge) Imaging Cartridge 4136M511AA 4136M513AA T/C (Toner Cartridge)

  • Page 32: Pc Drum

    6-2. PC Drum • The PC Drum used in this printer is the organic photoconductor (OPC) type. • The drum consists of two layers - Charge Transport Layer (CTL) and the Charge Gener- ating Layer (CGL) - applied to an aluminum alloy base (cylinder). Handling Precautions: The PC Drum of this type exhibits light fatigue after being exposed to light for a long time, which results in its sensitivity being changed.

  • Page 33: Developing System

    6-3. Developing System • The 1st Toner Blade located above the Sleeve Roller spreads a thin, even coat of toner over the Sleeve Roller. • A negative charge is applied to the 2nd Toner Blade, which negatively charges the toner. •...

  • Page 34: Detection Of Toner Cartridge

    6-4. Detection of Toner Cartridge Installation detection • The Imaging Cartridge, when loaded in position, is detected as follows. At the comple- tion of a warm-up cycle, the IC chip built into the Toner Cartridge (TC detection board) detects electrically whether or not the cartridge is loaded in position. Interchangeability detection •...
  • Page 35 • The Toner Empty Detection Sensor has an LED and a reflecting light detection sensor built into it. Light from the LED enters the toner detection window and is reflected off the Reflection Mirror located inside the Toner Cartridge. The reflecting light detection sensor detects this reflected light.

  • Page 36: Drum Charge

    DRUM CHARGE Overview • The PC Drum is charged with static electricity before laser exposure. • The Drum Charge Brush and the Pre-charge Film are used for charging. • Since the Drum Charge Brush and the Pre-charge Film directly deposit charge on the PC Drum, they produce little ozone.

  • Page 37: Ir Section

    IR SECTION 8-1. Image Data Processing 1. Photoelectric Conversion • The CCD Sensor reads the light reflected off the original and converts the data to a cor- responding analog signal. 2. A/D Conversion • The analog signal output from the CCD Sensor is converted to a corresponding 8-bit dig- ital signal.

  • Page 38: Exposure Components Section

    8-2. Exposure Components Section Lens 4980M019AA 1. Exposure Lamp • A CCFL lamp is used to illuminate the surface of the original. 2. 1st Mirror • Reflects the light reflected off the surface of the original, directing it to the 2nd Mirror. 3.

  • Page 39: Scanner Drive Mechanism

    8-3. Scanner Drive Mechanism Scanner Drive Mechanism • The Scanner Motor drives the Scanner Assy through the Timing Belt. Scanner Motor (M4) Scanner Assy Timing Belt 4980M002AA 8-4. Scanner Motor Drive Control • The speed at which the Scanner moves (for scan and return motion) is controlled by varying the period of the motor drive pulse that is timed with the reference clock.

  • Page 40: Print Head (Ph

    PRINT HEAD (PH) 9-1. Construction • The laser beam light emitted from the Print Head is used to scan the image as driven by the Polygon Motor. SOS Sensor G1 Lens Semiconductor Laser G2 Lens 1st Mirror 2nd Mirror SOS Mirror 4136M005AA Polygon Mirror M-18...

  • Page 41: Laser Exposure Process

    9-2. Laser Exposure Process • The laser beam light emitted from the Print Head is used to create an electrostatic latent image on the surface of the PC Drum. • The following control is provided to correctly time image printing. Laser Diode Print Head Unit Polygon Motor...

  • Page 42: Laser Emission Timing

    9-3. Laser Emission Timing • When a READY signal is detected a given period of time after the print command has been issued, the Controller/Mechanical Control Board outputs a laser ON signal. • The laser ON signal makes a laser beam to be emitted and the laser beam travels to the Polygon Mirror, G1 Lens, and the SOS Mirror to eventually hit the SOS Sensor, which generates an SOS signal.

  • Page 43: Laser Emission Area

    9-4. Laser Emission Area Main scanning direction • The print start position is determined by the main scanning print start signal (/HSYNC) output from the Controller/Mechanical Control Board and the width of the paper. • The laser emission area is determined by the paper size. Sub-scanning direction •...

  • Page 44: 10. Paper Take-Up Section

    10. PAPER TAKE-UP SECTION 10-1. Tray 1 Paper take-up mechanism • When the Paper Take-Up Solenoid is energized, drive from the Main Motor is transmitted to the Paper Take-Up Roll through the Paper Take-Up Clutch, turning the Paper Take-Up Roll. •...

  • Page 45: Double Feed Preventive Mechanism

    Electrical Parts Control Signal WIRING DIAGRAM PWB-P MPJ10P-2 PWB-P MPJ3P-2 Double feed preventive mechanism • A fixed paper separator pad is used to prevent the second and subsequent sheets of paper from being taken up and fed in with the first one. Paper empty detection •...

  • Page 46: 11. Image Transfer

    11. IMAGE TRANSFER 11-1. Overview • The toner image formed on the surface of the PC Drum during the developing process is transferred onto the paper. • This printer adopts the roller image transfer system, in which the Image Transfer Roller is used to transfer the image onto the paper.

  • Page 47: 12. Fusing Unit

    12. FUSING UNIT 12-1. Overview • The toner image transferred onto the paper is securely fixed to the paper. • A heated roller system is used as the fusing system. The paper, to which the toner image has been transferred, is fed between the Fusing Roller heated by the Fusing Roller Heater Lamp and the Pressure Roller.

  • Page 48: Temperature Changes (Plain Paper Having A Length Of 186 Mm Or More

    12-2. Fusing Temperature Control Temperature changes (plain paper having a length of 186 mm or more) Temperature detected by Thermistor Warm-up 200 °C During print cycle (600 dpi) In standby 130 °C Mode 0: Mode 1: Mode 2: Mode 3 180 sec.

  • Page 49: Temperature Control Mode

    Temperature control mode The fusing temperature is controlled during a print cycle according to the period of time elapsed from the completion of the warm-up cycle. • Mode 0 Mode 1 lasts for 3 min. If the temperature detected by the Thermistor is 50 °C or more when mode 0 is interrupted, the operation is switched to mode 1.

  • Page 50: Fusing Temperature Protect Control

    Fusing temperature protect control Fusing Unit Thermistor (TH1) ANIN Comparative Voltage Fusing Roller Heater Lamp Thermostat (TS1) Comparator High-temperature Protect Signal FUSER_LAMP Triac FUSER_LAMP_ Controller/Mechanical Control Board Power Unit 4980M015AB <Soft protect> • The comparator provided on the Controller/Mechanical Control Board is used as means for detecting an abnormally high temperature through software approach.

  • Page 51: 13. Paper Exit

    13. PAPER EXIT 13-1. Paper Exit Mechanism • The paper exit mechanism transports the paper that has been subjected to the fusing process onto the Exit Roller. • The Exit Sensor detects not only a paper misfeed but also an open Upper Cover. Exit Tray Exit Roll Face-down Exit...

  • Page 52: 14. Miscellaneous

    14. MISCELLANEOUS 14-1. Cooling of the Printer Interior • The Cooling Fan Motors provided on the right and left frames of the printer draw outside air from the outside into the printer interior and discharge heat inside the printer out. It thereby prevents the temperature of the PH Unit and the printer interior from increasing.

  • Page 53: 14-2.Original Cover Open/Close Detection Mechanism

    14-2. Original Cover Open/Close Detection Mechanism • There is a magnet provided in the Original Cover, allowing the printer to detect the posi- tion of the cover whether the cover is raised or lowered. • This magnet attracts the Original Cover Set Sensor provided on the printer side, thus activating the sensor.

  • Page 55: Maintenance

    MAINTENANCE...

  • Page 57: Maintenance Schedule

    MAINTENANCE SCHEDULE • To ensure that the printer produces good printed pages and to extend its service life, it is recommended that the maintenance jobs described in this schedule be carried out as instructed. Ref. Page PM Parts Clean Replace 1 Replace 2 in This Manual...

  • Page 58: Guidelines For Life Specifications Values By Unit

    1-1. Guidelines for Life Specifications Values by Unit • The life specifications value represents the number of printed pages produced or figures equivalent to it when given conditions (see the Table given below) are met. It can be more or less depending on how each individual printer is used. Print Conditions Job type 2P/J...

  • Page 59: Replacement/Cleaning Of Parts

    REPLACEMENT/CLEANING OF PARTS Cleaning of the Paper Take-Up Roll 1. Remove the Imaging Cartridge. NOTE • The Imaging Cartridge is the Drum Cartridge, to which the Toner Cartridge is mounted. 2. Using a soft cloth, wipe the surface of the Paper Take-Up Roll clean of dirt.

  • Page 60: Replacement Of The Image Transfer Roller

    Replacement of the Image Transfer Roller 1. Remove the Imaging Cartridge. 2. Place the levers of the bushings (white) on the right and left ends of the Image Transfer Roller toward this side and remove the Image Transfer Roller from the Image Transfer Roller holder. 4 1 3 6 E 0 1 8 A A 3.

  • Page 61: Replacement Of Units

    REPLACEMENT OF UNITS Replacement of the Toner Cartridge <Removal Procedures> 1. Lift up the Exit Tray and remove it. 2. Open the Front Door. 4 9 8 0 E 0 0 9 A A 3. Remove the Imaging Cartridge. 4 1 3 6 E 0 0 6 A A 4.
  • Page 62 2. Remove the protective cover from the Toner Car- tridge. C 4 1 3 6 o 0 4 9 A C 3. Install the new Toner Cartridge to the Drum Car- tridge. NOTE • Insert the Toner Cartridge along the guide provided on the Drum Cartridge side and make sure that the Toner Cartridge is not tilted when inserted.

  • Page 63: Replacement Of The Drum Cartridge

    Replacement of the Drum Cartridge <Removal Procedures> 1. Remove the Imaging Cartridge. 2. Pull the lever of the Toner Cartridge in the direc- tion shown in the illustration and disconnect the Drum Cartridge. 4 1 3 6 E 0 1 1 A C <Installation Procedures>...

  • Page 64: Replacement Of The Fusing Unit

    Replacement of the Fusing Unit NOTE • Immediately after turning off the printer, the area around the Fusing Unit is extremely hot. Therefore, in order to reduce the risk of burns, wait until the unit has cooled down before performing any operation. <Removal Procedures>...
  • Page 65 7. Remove two screws, unplug three connectors, and remove the Fusing Unit. NOTE • The surfaces around the Fusing Unit are very hot. Use utmost care not to touch any surfaces other than the Fusing Unit. 4 9 8 0 E 0 0 2 A B 8.

  • Page 67: Dis/Reassembly, Adjustment

    DIS/REASSEMBLY, ADJUSTMENT...

  • Page 69: Safety Information

    SAFETY INFORMATION 1-1. Laser Safety • This is a digital machine certified as a class 1 laser product. There is no possibility of danger from a laser, provided the machine is serviced according to the instruction in this manual. 1-2. Internal Laser Radiation Semiconductor laser Maximum power of the laser diode...
  • Page 70 the U.S.A., Canada (CDRH Regulation) • This machine is certified as a Class I Laser product under Radiation Performance Stan- dard according to the Food, Drug and Cosmetic Act of 1990. Compliance is mandatory for Laser products marketed in the United States and is reported to the Center for Devices and Radiological Health (CDRH) of the U.S.
  • Page 71 Finland, Sweden VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. LOUKAN 1 LASERLAITE KLASS 1 LASER APPARAT VAROITUS! Laitteen Käyttäminen muulla kuin tässä käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle. Puolijohdelaser Laserdiodin suurin teho 15 mW Aallonpituus 770-800 nm...

  • Page 72: Laser Safety Label

    1-3. Laser Safety Label • A laser safety labels is attached to the outside of the machine as shown below. 4 9 8 0 D 0 7 0 A B 1-4. Laser Caution Label • A laser caution label is attached to the inside of the machine as shown below. 4 9 8 0 D 0 6 1 A A...

  • Page 73: Precautions For Handling The Laser Equipment

    1-5. Precautions for Handling the Laser Equipment • When laser protective goggles are to be used, select ones with a lens conforming to the above specifications. • When a disassembly job needs to be performed in the laser beam path, such as when working around the printerhead and PC Drum, be sure first to turn the copier OFF.

  • Page 74: Parts That Must Not Be Touched

    PRECAUTIONS FOR DISASSEMBLY/ADJUST- MENTS 2-1. Parts That Must Not be Touched Red Painted Screws Purpose of Application of Red Paint Red painted screws show that the assembly or unit secured can only be adjusted or set at the factory and shall not be readjusted, set, or removed in the field. If it becomes unavoidably necessary to disassemble any of these assemblies and units, disassembly may be done provided that the conditions permitting reassembly are met.

  • Page 75: Disassembly/Reassembly

    DISASSEMBLY/REASSEMBLY 3-1. Identification of Exterior Parts and Removal Procedures for Them C 4 9 8 0 o 0 0 3 A C C 4 9 8 0 o 0 5 7 A B...
  • Page 76 Name Removal Procedure Open the Original Cover → Pull it straight up. Original Cover Remove the Original Cover. → Remove the Control Panel. → Remove the six screws, and remove the Upper Upper Cover Assy. (Original Glass) Cover Assy. (Original Glass). D-18 Open the Original Cover.

  • Page 77: Removal Of Circuit Boards And Other Electrical Components

    3-2. Removal of Circuit Boards and Other Electrical Compo- nents NOTES • When removing a circuit board or other electric component, refer to the precautions for handling PWBs and follow the corresponding removal procedures. • The removal procedures given in the following paragraphs omit the removal of the com- ponent in question from a connector or a PWB support.

  • Page 78: Removal Of The Controller/Mechanical Control Board

    Removal of the Controller/Mechanical Control Board <Removal Procedures> 1. Remove the Rear Cover. 2. Disconnect all connectors and flat cables from the Controller/Mechanical Control Board. NOTE • Use utmost care not to snap off the flat cable. 4 9 8 0 D 0 0 3 A B 3.

  • Page 79: Removal Of The Interface Board

    Removal of the Interface Board 1. Remove the Rear Cover. 2. Unplug the three connectors on the Controller/ Mechanical Control Board. 4 9 8 0 D 0 6 3 A A 3. Remove the two screws, and then remove the Left Rear Cover.

  • Page 80: Removal Of The Power Unit

    Removal of the Power Unit 1. Remove the Right Cover. 2. Remove the Left Cover. 3. Remove the Rear Cover. 4. Unplug the two flat cables from the Controller/ Mechanical Control Board. NOTE • Use utmost care not to snap off the flat cable. 4 9 8 0 D 0 0 6 A A 5.
  • Page 81 9. Remove the three screws, unhook the tab, and then remove the Left Rear Frame. 4 9 8 0 D 0 0 9 A B 10. Remove the three screws from the Left Rear Frame. 4 9 8 0 D 0 7 1 A A 11.

  • Page 82: Removal Of The High Voltage Unit

    15. Remove the two screws, unplug the three con- nectors, and then remove the Fusing Unit Assy. 4 9 8 0 E 0 0 2 A A 16. Remove three screws and the Power Switch stay. 17. Remove the Power Switch. 4 9 8 0 D 0 1 1 A C 18.

  • Page 83: Removal Of Units

    3-3. Removal of Units Removal of the IR Unit 1. Remove the Left Cover. 2. Remove the Right Cover. 3. Remove the Rear Cover. 4. Unplug the connector. 4 9 8 0 D 0 0 7 A A 5. Unplug the two flat cables from the Controller/ Mechanical Control Board.

  • Page 84: Removal Of The Ph Unit

    Removal of the PH Unit NOTES • NEVER attempt to replace the PH Unit with power being supplied to the printer. Doing that could lead to exposure to the laser beam, resulting in blindness • NEVER attempt to disassemble or adjust the PH Unit. Doing that could lead to exposure to the laser beam, resulting in blindness.
  • Page 85 Precautions for Removal/Reinstallation of the PH Unit • NEVER touch the window on the backside of the PH Unit. A dirty window can cause an image problem. Window 4 1 3 6 D 0 0 9 A B D-17...

  • Page 86: Disassembly Of The Image Reading Section

    3-4. Disassembly of the Image Reading Section Removal of the Original cover set sensor 1. Remove the Original Cover. 2. Remove the Control Panel. 3. Remove the Original cover set sensor. 4 9 8 0 D 0 7 3 A A Removal of the Upper Cover Assy.

  • Page 87: Removal Of The Scanner Assy

    5. Remove the two screws, and then remove the Scanner Motor Mounting Bracket. 4 9 8 0 D 0 1 8 A B 6. Remove the two screws, and then remove the Scanner Motor. 4 9 8 0 D 0 1 9 A A Removal of the Scanner Assy.

  • Page 88: Removal Of The Timing Belt

    5. Remove the Timing Belt and shaft, and then remove the Scanner Assy. 4 9 8 0 D 0 2 2 A A Removal of the Timing Belt 1. Remove the Original Cover. 2. Remove the Upper Cover Assy. (Original Glass). D-18 3.

  • Page 89: Disassembly Of The Main Drive Section

    3-5. Disassembly of the Main Drive Section Removal of the Main Motor 1. Remove the Left Cover. 2. Disconnect one connector. 3. Remove two screws, two washers, and the Main Motor. 4 1 3 6 D 0 1 0 A B Removal of the Paper Empty Sensors 1.
  • Page 90 6. Unhook two tabs and remove the tray. 4 9 8 0 D 0 2 7 A C 7. Remove the Multi purpose Tray Paper Empty Sensor. 4 9 8 0 D 0 2 8 A B 8. Remove the Multiple Bypass Tray Paper Empty Sensor.

  • Page 91: Removal Of The Paper Take-Up Solenoid

    Removal of the Paper Take-Up Solenoid 1. Remove the Left Cover. 2. Disconnect one connector of the Paper Take-Up Solenoid. 4 1 3 6 D 0 5 8 A A 3. Remove one screw and the Paper Take-Up Sole- noid. 4 1 3 6 D 0 5 9 A A Precautions for Installation of the Paper Take-Up Solenoid 1.

  • Page 92: Removal Of The Paper Take-Up Clutch Gear

    Removal of the Paper Take-Up Clutch Gear 1. Remove the Fusing Unit. 2. Remove the Power Unit. D-12 3. Remove the Paper Take-Up Upper Guide Assy. D-21 4. Disconnect one connector and remove the Cool- ing Fan Motor 2. 5. Disconnect one connector of the Main Motor. D-21 4 9 8 0 D 0 7 4 A A 6.

  • Page 93: Removal Of The Torque Limiter

    12. Remove one screw and the Paper Take-Up Sole- noid. 4 1 3 6 D 0 1 8 A A 13. Unhook two tabs and remove the Paper Take-Up Clutch Gear. 4 1 3 6 D 0 5 7 A A Removal of the Torque Limiter 1.

  • Page 94: Disassembly Of The Fusing Unit

    After setting replaced Paper Take-Up Clutch Gear (Torque Limiter) to the shaft, Rotate the Paper Take- Up Clutch Gear by hand (Need to be released Sole- noid Flapper). 4 1 3 6 D 0 6 0 A A Look at the stop position of the Take-Up Roller from Clutch Gear side. 1.
  • Page 95 3. Remove two bushings and the Pressure Roller. Lower Fusing Roller section 4 1 3 6 D 0 2 2 A A Upper Fusing Precautions for Installation of Bushings Roller • Make sure that the slits in the bushing are properly section aligned with the rib of the Fusing Unit.
  • Page 96 9. Remove one screw and the Thermistor. NOTE • When reinstalling the Thermistor, route the har- ness as shown in the illustration. 10. Remove two screws and the Thermostat. 4 9 8 0 D 0 6 8 A A D-28...

  • Page 97: Adjustments

    ADJUSTMENTS 4-1. Electrical/Image Adjustment Accessing the Service Mode 1. Press the Utility key. 2. Press the following keys in order to enter the Service mode. Stop → 0 → 0 → Stop → 0 → 1 NOTE • Be sure to keep the access procedure for the Service mode from any unauthorized per- sons not involved with service operations.

  • Page 98: Margin Adjustment (Leading Edge/Trailing Edge/Both Sides)

    Margin Adjustment (Leading Edge/Trailing Edge/Both Sides) <Requirement> • Specify the amount erased at the leading edge (width of A), trailing edge (width of B), and both sides (width of C) of the paper. • Default setting: 4 mm 4 0 2 2 D 5 0 3 A A Mode Function Item Setting Range...

  • Page 99: Printer's Main Scanning Registration Adjustment

    Printer’s Main Scanning Registration Adjustment <Requirement> • Adjust the amount that widths A and B in the printed test pattern are shifted so that the following specification is met. 1 3 8 2 D 0 1 1 A A Specification Mode Function Item Setting Range...

  • Page 100: Printer's Sub-Scanning Registration Adjustment

    Printer’s Sub-Scanning Registration Adjustment <Requirement> • Adjust the width of C in the printed test pattern so that the following specification is met. 4 0 0 7 D 0 5 1 A A Specification Mode Function Item Setting Range 87 to 113 20±2.5 mm “ADJUST”...

  • Page 101: Scanner's Main Scanning Zoom Ratio Adjustment

    Scanner’s Main Scanning Zoom Ratio Adjustment <Requirement> • After finishing the printer’s main scanning & sub- scanning registration adjustments, place the printed test pattern on the Original Glass, and make a copy of it. • Adjust the width of D in the copy of the test pattern so that the following specification is met.
  • Page 102 NOTE If the Stop key is pressed, instead of the Yes key, the main screen is displayed and the set- ting returns to that before it was changed. Place the test pattern on the Original Glass again, make another test copy, and check it. D-34...

  • Page 103: Scanner's Sub-Scanning Zoom Ratio Adjustment

    Scanner’s Sub-Scanning Zoom Ratio Adjustment <Requirement> • After finishing the printer’s main scanning & sub- scanning registration adjustments, place the printed test pattern on the Original Glass, and make a copy of it. • Adjust the width of E in the copy of the test pattern so that the following specification is met.
  • Page 104 NOTE If the Stop key is pressed, instead of the Yes key, the main screen is displayed and the set- ting returns to that before it was changed. Place the test pattern on the Original Glass again, make another test copy, and check it. D-36...

  • Page 105: Scanner's Main Scanning Registration Adjustment

    Scanner’s Main Scanning Registration Adjustment <Requirement> • After finishing the printer’s main scanning & sub- scanning registration adjustments, place the printed test pattern on the Original Glass, and make a copy of it. • Adjust the width of E in the copy of the test pattern so that the following specification is met.
  • Page 106 NOTE If the Stop key is pressed, instead of the Yes key, the main screen is displayed and the set- ting returns to that before it was changed. Place the test pattern on the Original Glass again, make another test copy, and check it. D-38...

  • Page 107: Scanner's Sub-Scanning Registration Adjustment

    (10) Scanner’s Sub-Scanning Registration Adjustment <Requirement> • After finishing the printer’s main scanning & sub- scanning registration adjustments, place the printed test pattern on the Original Glass, and make a copy of it. • Adjust the width of C in the copy of the test pattern so that the following specification is met.

  • Page 108: Miscellaneous

    MISCELLANEOUS 5-1. Removal of the Mechanical Counter (Option) 1. Remove the Right Cover. 2. Remove the Rear Cover. 3. Unplug one connector on the Controller/Mechani- cal Control Board. 4 9 8 0 D 0 5 5 A A 4. Remove the Relay Harness. 4 9 8 0 D 0 5 6 A A 5.

  • Page 109: Updating The Firmware

    5-2. Updating the Firmware NOTES • The TWAIN driver must already be installed on the host computer to be used for updat- ing the firmware. • If the GDI printer or TWAIN driver is not installed, follow the procedure described below to install the driver.
  • Page 110 <For Windows Me/98/95> 1. Start up the host computer, and then insert the CD-ROM into the CD-ROM drive. 2. Turn on the printer. 3. Use a USB cable to connect the printer to the host computer. 4. In the “Install Hardware Device Drivers” dialog box, click the [Next] button, select “Search for a suitable driver for my device (recommended)”, and then click the [Next] button again.

  • Page 111: Procedure For Updating The Gdi Firmware

    5. Display the “System Properties” dialog box (“Properties” for “My Computer”), click the “Hardware” tab, click the [Device Manager] button, select “Imaging devices”, and then check that “Develop D 16G” has been added. 4 9 8 0 D 0 4 5 A A 4 9 8 0 D 0 4 6 A A 6.
  • Page 112 4 9 8 0 D 0 5 1 A B 11. Click the [OK] button, and then quit the “Develop Update F/W-V1.XX” application. 4 9 8 0 D 0 4 9 A A 12. Turn the printer off, then on again.

  • Page 113: Remedy For A Failed Updating Of The Firmware

    5-4. Remedy for a Failed Updating of the Firmware 1. Turn off the printer. 2. Remove the USB cable connecting the printer to the host computer. 3. Remove the Rear Cover. 4. Change the settings for jumper switches CJ1 and CJ2 on the Controller/Mechanical Control Board from “1-2”...
  • Page 114 8. Turn on the printer. The following message appears in the display. 4 9 8 0 D 0 5 3 A A 9. Perform steps 6 through 10 of “Procedure for Updating the GDI Firmware” to update the firmware. 10. Check that the following message appears in the display to indicate that the updating of the firmware has been completed correctly.

  • Page 115: Moving The Eeprom

    5-5. Moving the EEPROM NOTE • After the Controller/Mechanical Control Board (PWB-P) is replaced, be sure to move the EEPROM form the old Controller/Mechanical Control Board to the new one. Remove the EEPROM (U39) from the old Controller/Mechanical Control Board, and then attach it to the new Controller/Mechanical Control Board.
  • Page 117 CONTROL PANEL/SERVICE MODE DESCRIPTIONS...

  • Page 119: Control Panel Descriptions

    CONTROL PANEL DESCRIPTIONS 1-1. Names of Control Panel Parts and Their Functions 4980S001AA Key Name Function Printer key Press to enter Printer mode. Utility key Press to enter Utility mode. The indicator lights up if an error or malfunction Error lamp occurs.
  • Page 120 Key Name Function • Press to change the zoom ratio between ×0.50 and ×2.00 in ×0.01 increments. • Press to show the various settings and informa- tion. • Press to specify various settings. Press to select a zoom ratio from the preset fixed Zoom key ratios.

  • Page 121: Functions Of Switches And Parts On Pwbs

    FUNCTIONS OF SWITCHES AND PARTS ON PWBs 2-1. Circuit Board Locations PWB-P PWB-IF 4980S002AA 2-2. PWB-P (Controller/Mechanical Control Board) M32-5(Option) Socket 4980S003AB...

  • Page 122: Pwb-If (Interface Board)

    2-3. PWB-IF (Interface Board) IEEE1284 (parallel) port USB port 4980S004AA...

  • Page 123: Utility Mode

    UTILITY MODE • This mode is used to set various machine functions. 3-1. Utility Mode Function Tree 1:AUTO PANEL RESET 2:ENERGY SAVE MODE 3:DENSITY(ADF) MACHINE SETTING 4:DENSITY(BOOK) 5:PRINT DENSITY 6:LCD CONTRAST 7:LANGUAGE 8:LAMP OFF TIME 1:TRAY1 PAPER UTILITY MODE PAPER SOURCE SETUP 2:TRAY SETTING 1:PAPER PRIORITY 2:DENSITY PRIORITY...

  • Page 124: Utility Mode Setting Procedure

    3-2. Utility Mode Setting Procedure <Procedure> 1. Press the Utility key. 2. The first Utility mode screen appears. <Exiting Procedure> • Press the Panel Reset key. <Changing the Settings for Utility Mode Functions> 1. Press the Zoom Select key, Density Select key or the 10-Key Pad to select the desired function.
  • Page 125 Function Purpose Setting Details/Precautions To specify the scanning density • The default setting is when using the Original Glass. “MODE1”. • MODE1: For printing copies with the DENSITY same density as the docu- (BOOK) ment • MODE2: For a lighter copy density in order to reduce the appear- ance of spots in copies To specify the default print density.

  • Page 126: Paper Source Setting

    Paper Source Setting • Various settings for the paper tray can be specified. Function Purpose Setting Details/Precautions To specify the type and size of • The default settings are paper loaded into Tray1. “PLAIN” in addition to “A4 L” or “LT”. <Procedure>...

  • Page 127: Service Mode

    SERVICE MODE • This mode is used to check, specify, adjust and register service functions. 4-1. Service Mode Function Tree SHIPMENT DESTINATION LEADING EDGE ERASE TRAILING EDGE ERASE Service’s Choice VERTICAL EDGE ERASE FLS PAPER SIZE GDI TIMEOUT TONER EMPTY STOP PRE-ROTATION FUSER TEMP.Ad PRN MAIN REGIST...
  • Page 128 PAPER FEED TEST PRINT TEST PATTERN FUNCTION ADF FEED TEST COPY ADF GLASS AREA CCD MOVE TO HOME SCAN TEST FIXED ZOOM Service Mode PANEL BUZZER TEST FACTORY TEST RAM TEST MEMORY CLEAR PM COUNTER I/C COUNTER CLEAR DATA APPLICATION COUNTER SCAN COUNTER PRINTER JAM COUNTER ADF JAM COUNTER...

  • Page 129: Service Mode Setting Procedure

    4-2. Service Mode Setting Procedure NOTE • Be sure to keep the access procedure for the Service mode from any unauthorized per- sons not involved with service operations. <Procedure> 1. Press the Utility key. 2. Press the following keys in order to enter the Service mode. Stop →...

  • Page 130: Service Mode Functions

    4-3. Service Mode Functions Service's Choice • Various machine service functions can be specified. Function Purpose Setting Details/Precautions To switch the fixed zoom ratios and • The default setting is either SHIPMENT paper sizes according to the “METRIC” or “INCH”. DESTINATION selected marketing area.
  • Page 131 Function Purpose Setting Details/Precautions To select if the pre-rotation opera- • The default setting is “OFF”. tion for the Fusing Roller is per- formed when the Start key is PRE-ROTATION pressed. • If “OFF” is selected, the length of time until the first copy can be printed is shorter.
  • Page 132 Adjust Function Purpose Setting Details/Precautions TEST To vary and adjust the print start Press the Start key to begin COPY position in the main scanning printing the test page. direction. The setting range is 60 to 140. (1 increment = 0.1 mm) MAIN If the image on the copy devi- REGIST...
  • Page 133 “ADJUST” menu. To specify the customer ID. • The default setting is “0” (Develop). CUSTOMER ID • Once the customer ID is speci- fied, “CUSTOMER ID” does not 0 (Develop) 1 (OEM1) appear in the “ADJUST” menu. 2 (Generic) S-15...
  • Page 134 Function Purpose Setting Details/Precautions To specify the type of Toner Car- • The default setting differs tridge that should be installed in depending on the marketing the main unit. area. • Once the type of Toner Cartridge Toner Cartridge Type Setting is specified, “TC TYPE”...

  • Page 135: Counter

    Counter • The counter values can be displayed. Function Purpose Setting Details/Precautions To display the total number of COPY: Number of copies pages used. printed PRINT: Number of computer printouts printed TOTAL COUNTER • Test prints made in Service mode to check the operation are not counted.
  • Page 136 Function Purpose Setting Details/Precautions To display the number of misfeeds • To clear the counter data, ADF JAM that occurred while using the Auto- use the functions on the COUNTER matic Document Feeder. “CLEAR DATA” menu of Ser- vice mode. To display the number of times C0045:Fuser fan error each error was detected.

  • Page 137: Display

    Display • Various information can be displayed. Function Purpose Setting Details/Precautions MAIN F/W VER. To display the version of the main firmware. ENGINE F/W VER. To display the version of the engine firmware. MAIN RAM SIZE To display the size of the main memory. SERIAL NO.
  • Page 138 Function Purpose Setting Details/Precautions To check for dirt in the scanning <Procedure> section of the Automatic Document 1. Load A4 L or Letter L paper Feeder. into Tray1. 2. Press the Start key to start If spots appear in the copies the “COPY ADF GLASS AREA”...

  • Page 139: Fixed Zoom Change

    Fixed Zoom Change • The fixed zoom ratios can be changed. <Procedure> 1. Select the fixed zoom ratio that you wish to change. 2. Use the 10-Key Pad to type in the desired fixed zoom ratio. Default fixed zoom ratios and setting ranges according to marketing area <Metric>...

  • Page 140: Factory Test

    Factory Test • Operation tests can be performed during manufacturing. Function Purpose Setting Details/Precautions PANEL BUZZER To check the operation of the display and all indicators and buttons. TEST RAM TEST To test reading and writing of the memory. Clear Data •...

  • Page 141: Security Mode

    SECURITY MODE • This mode is used to set various security functions. 5-1. Security Mode Function Tree SECURITY MACHINE COUNTER 5-2. Security Mode Setting Procedure NOTE • Be sure to keep the access procedure for the Security mode from any unauthorized per- sons not involved with service operations.
  • Page 143 TROUBLESHOOTING...
  • Page 145 INTRODUCTION • This chapter contains the items required or used when troubleshooting various printer problems. 1-1. Electric Components Check Procedures • The following procedures can be used to check to see if an electric component is fully operational when a paper misfeed or a malfunction occurs in the printer. Sensors Step Check...

  • Page 146: Switches

    Switches Step Check Result Action Replace the switch. Does the input signal (NO) to the Controller/Mechani- Replace the Con- cal Control Board go from LOW to HIGH when the troller/Mechanical switch is actuated? Control Board. Not Use 4025T523AB Solenoids Step Check Result Action...
  • Page 147 Motors Step Check Result Action Replace the Con- Is the LOCK signal of the Controller/Mechanical Con- troller/Mechanical trol Board HIGH when the printer is in the standby Control Board. state? Replace the motor. YES Replace the motor. Does the REM signal of the Controller/Mechanical Replace the Con- Control Board go from HIGH to LOW when the motor troller/Mechanical...
  • Page 148 Step Check Result Action Replace the motor or the Controller/ Mechanical Control Are the hookup connector of the motor and print jack Board. on the Controller/Mechanical Control Board con- nected properly? Connect the con- nector or the print jack properly. 4025T527AA...

  • Page 149: Overall Control Configuration

    1-2. Overall Control Configuration • Understanding the overall control configuration will help perform the troubleshooting pro- cedures for paper misfeeds, malfunctions, and image problems. Automatic Docu- Image Reading Control Panel ment Feeder (IR) Drive System (PWB-O) DC Stabilized Controller/Mechanical High Voltage Power Unit (PU) Control Board (PWB-P) Unit (HV1)
  • Page 150 PAPER MISFEED 2-1. Initial Check Items • When a paper misfeed occurs in the printer, first make the following initial checks. Check Action Does the paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct user in correct paper storage.
  • Page 151 2-2. Paper Misfeed Displays • The Error indicator lights up and a message appears in the display when a paper mis- feed occurs. <Paper Take-Up Section Misfeed> 4980P555DA <Transport Section Misfeed> 4980P502DA <Procedure for cancelling the misfeed display> 1. Open the appropriate covers, remove the misfed paper and any remaining paper, and then close the covers.

  • Page 152: Locations Of Misfeed Detection Sensors

    2-3. Locations of Misfeed Detection Sensors Exit Sensor (PS1) Paper Take- Up Switch (S1) 4980M005AA...
  • Page 153 2-4. Misfeed Detection Timing and Troubleshooting Procedures Paper Take-Up/Transport Misfeed <Detection Timing> Type Description MP tray Pick- up Jam 2nd tray Pick- The Paper Take-Up Switch does not turn on after the predetermined period up Jam of time has elapsed after paper take-up began. Bypass tray Pick-up Jam The Exit Sensor is not blocked after the predetermined period of time has...

  • Page 154: Fusing/Exit Misfeed

    Fusing/Exit Misfeed <Detection Timing> Type Description The Exit Sensor is not unblocked after the predetermined period of time Fuser Jam has elapsed after the Paper Take-Up Switch is turned on. Remains If all of the following conditions are met paper Jam 1 •...

  • Page 155: List Of Malfunctions

    MALFUNCTIONS/WARNING • The CPU performs a self-diagnosis on the condition of the unit, and if a malfunction is detected, the warning appears alternately with the error code in the display. 4980P550DA <Procedure for cancelling a malfunction display> • Cancel the malfunction display by turning the machine off, then on again. 3-1.
  • Page 156 Malfunc- tion Malfunction Name Description Code • The voltage of the Thermistor remains low for a prede- termined period of time when a warm-up cycle is started. • The temperature detected by the Thermistor remains lower than a reference value for a predetermined period of time for the period of time that begins 5 sec.
  • Page 157 Malfunc- tion Malfunction Name Description Code ROM checksum • A malfunction occurred in the ROM. C133D error • The laser output exceeds the upper limit value. C13F0 Laser error • The laser output remains lower than the lower limit value. C1468 EEPROM error •...

  • Page 158: Malfunction Detection Timing And Troubleshooting Procedures

    3-2. Malfunction Detection Timing and Troubleshooting Proce- dures C0045: Fuser fan motor error <Detection Timing> Description • The LOCK signal remains HIGH or LOW continuously for a predetermined period of time while the Cooling Fan Motor remains energized. <Troubleshooting Procedures> Relevant Electric Parts Cooling Fan Motor (M2) Controller/Mechanical Control Board (PWB-P)

  • Page 159: C0210: H.v. Abnormal

    C0210: H.V. abnormal <Detection Timing> Description • The Drum Charge Monitor Voltage (HVC_MON) signal falls outside a predetermined range at any time after the lapse of a predetermined period of time after the Power Switch has been turned ON. • The Image Transfer Voltage Monitor signal (T_MON_V) and Image Transfer Current Monitor signal (T_MON_I) fall outside a corresponding predetermined range.

  • Page 160: C0500: Fuser Warm Up Error

    C0500: Fuser warm up error <Detection Timing> Description • The voltage of the Thermistor remains low for a predetermined period of time when a warm-up cycle is started. • The temperature detected by the Thermistor remains lower than a reference value for a predetermined period of time for the period of time that begins 5 sec.

  • Page 161: C0510: Fuser Temperature Low

    C0510: Fuser temperature low <Detection Timing> Description • The temperature detected by the Thermistor remains lower than the set temperature continuously for a predetermined period of time while the fusing temperature control is being provided. (The set temperatures are as follows: 140 °C during a print mode at 600 dpi;...

  • Page 162: C0520: Fuser Overheat

    C0520: Fuser overheat <Detection Timing> Description • The temperature detected by the Thermistor remains higher than 235 °C for a predeter- mined period of time while the fusing temperature control is being provided. <Troubleshooting Procedures> Relevant Electric Parts Fusing Unit Controller/Mechanical Control Board (PWB-P) Thermistor (TH1) Thermostat (TS1)

  • Page 163: C1200: Asic Memory Abnormal

    C1200: ASIC memory abnormal <Detection Timing> Description • An error occurred while writing to or reading the SRAM on the Control Board (PWB-C). <Troubleshooting Procedures> Relevant Electrical Components Controller/Mechanical Control Board (PWB-P) WIRING DIAGRAM Step Action Ref. Page Location Control Signal (Electric Parts) Turn the copier off, then on –...

  • Page 164: C133B: Communication With Option Error

    C133B: Communication with option error <Detection Timing> Description • Communication could not be established with the Controller Control Board within 5 sec- onds while printing. <Troubleshooting Procedures> Relevant Electrical Components Controller/Mechanical Control Board (PWB-P) WIRING DIAGRAM Step Action Ref. Page Location Control Signal (Electric Parts)

  • Page 165: C13F0: Laser Error

    (11) C13F0: Laser error <Detection Timing> Description • The laser output exceeds the upper limit value. • The laser output remains lower than the lower limit value. <Troubleshooting Procedures> Relevant Electric Parts PH Unit Controller/Mechanical Control Board (PWB-P) Flat cable WIRING DIAGRAM Step Action...

  • Page 166: C14A3: Ir Lamp Malfunction

    (13) C14A3: IR lamp malfunction <Detection Timing> Description • The luminosity level of the Exposure Lamp is not stabilized within the predetermined period of time. <Troubleshooting Procedures> Relevant Electric Parts IR Unit Controller/Mechanical Control Board (PWB-P) WIRING DIAGRAM Step Action Ref.

  • Page 167: Malfunctions Related To Power Supply

    MALFUNCTIONS RELATED TO POWER SUPPLY 4-1. Power is not Turned ON. Relevant Electric Parts Controller/Mechanical Control Board (PWB-P) Power Unit (PU1) Wiring Diagram Step Check Result Action (Location) Is the power cord plugged Plug the power cord into the – into the power outlet? power outlet.

  • Page 168: Image Quality Problems

    IMAGE QUALITY PROBLEMS 5-1. Troubleshooting Image Quality Problems • This chapter is divided into two parts: “Initial Checks” and “Troubleshooting for Specific Image Quality Problems”. • If an image quality problem occurs, first go through the “Initial Checks” and, if the cause is still not identified, continue to “Troubleshooting for Specific Image Quality Problems”.

  • Page 169: Troubleshooting For Specific Image Quality Problems

    5-3. Troubleshooting for Specific Image Quality Problems • Determine if the failure is attributable to the input system (Image Reading Section) or the output system (Engine section). Check Result Cause Full-size copy Reduced copy Copy made at a reduced zoom ratio Input (image reading) system 1177T04YA...

  • Page 170: Image Reading System: Blank Or Black Prints

    Image reading system: Blank or black prints <Sample of Image Quality Problem> 4011T035AA 4011T036AA <Troubleshooting Procedures> Step Check Result Action Are there no bent connector pins on the Correctly plug in the connectors. cables connecting the control boards, Replace connection cables. are all connectors correctly plugged in, and are no cables broken? Does the Exposure Lamp light up?

  • Page 171: Image Reading System: Low Image Density

    Image reading system: Low image density <Sample of Image Quality Problem> 4011T003AA <Troubleshooting Procedures> Step Check Result Action Is the surface of the Original Glass dirty? YES Clean it. Are the Shading Sheet or back surface YES Clean them. of the Original Glass dirty? Are the mirror or lens dirty? YES Clean them.

  • Page 172: Image Reading System: Foggy Background Or Rough Image

    Image reading system: Foggy background or rough image <Sample of Image Quality Problem> 4011T004AA <Troubleshooting Procedures> Step Check Result Action Does sunlight or any other extraneous YES Protect the copier from extrane- light enter the machine? ous light. Is the document damaged or dirty? YES Replace the document.

  • Page 173: Image Reading System: Black Streaks Or Bands

    Image reading system: Black streaks or bands <Sample of Image Quality Problem> 4011T017AA 4011T023AA <Troubleshooting Procedures> Step Check Result Action Is the document damaged or dirty? YES Replace the document. Is the Original Pad dirty? YES Clean it. Does the Original Cover not lie flat? YES If the Original Cover is deformed or the hinges are damaged, replace the Original Cover.

  • Page 174: Image Reading System: Black Spots

    Image reading system: Black spots <Sample of Image Quality Problem> 4011T521AA <Troubleshooting Procedures> Step Check Result Action Is the document damaged or dirty? YES Replace the document. Is the Original Pad dirty? YES Clean it. Is the Original Glass dirty? YES Clean it.

  • Page 175: Image Reading System: Blank Streaks Or Bands

    Image reading system: Blank streaks or bands <Sample of Image Quality Problem> 4011T015AA 4011T020AA <Troubleshooting Procedures> Step Check Result Action Is the document damaged or dirty? YES Replace the document. Is the Original Pad dirty? YES Clean it. Does the Original Cover not lie flat? YES If the Original Cover is deformed or the hinges are damaged, replace the Original Cover.

  • Page 176: Image Reading System: Uneven Image

    Image reading system: Uneven image <Sample of Image Quality Problem> 4011T528AA <Troubleshooting Procedures> Step Check Result Action Is the Scanner Motor drive being trans- Correct drive coupling mecha- mitted? nisms. Replace it. Is the harness of the Exposure Lamp YES Correct it. catching? Is there enough slack in the Timing Belt? Correct it.

  • Page 177: Printer System: Blank Or Black Prints

    Printer system: Blank or black prints <Typical Faulty Images> 4011T035AA 4011T036AA <Troubleshooting Procedures> Step Check Result Action Is a printed page blank? YES Check PH Unit connectors for proper connection. Is the coupling of the drive mechanism of Check coupling of drive the Imaging Cartridge properly connected? mechanism for connection and correct as necessary, or...

  • Page 178: Printer System: Blank Spots

    Printer system: Blank spots <Typical Faulty Image> 4011T008AA <Troubleshooting Procedures> Step Check Result Action Is paper damp? YES Replace paper for one just unwrapped. Is the PC Drum scratchy? YES Replace Drum Cartridge. Is there foreign matter on paper path? YES Remove foreign matter.

  • Page 179: Printer System: Low Image Density

    (11) Printer system: Low image density <Typical Faulty Image> 4011T003AA <Troubleshooting Procedures> Step Check Result Action Is paper damp? YES Replace paper for one just unwrapped. Is there toner left in Toner Cartridge? Replace Toner Cartridge. Is PC Drum faulty (life)? YES Replace Drum Cartridge.

  • Page 180: Printer System: Foggy Background

    (12) Printer system: Foggy background <Typical Faulty Image> 4011T004AA <Troubleshooting Procedures> Step Check Result Action Is PC Drum scratchy? YES Replace Drum Cartridge. Is developing bias contact terminal in good Clean contact terminal or contact with the mating part? check terminal position. Is PH window dirty? YES Clean.

  • Page 181: Printer System: Blank Streaks Or Bands

    (13) Printer system: Blank streaks or bands <Typical Faulty Images> 4011T015AA 4011T020AA <Troubleshooting Procedures> Step Check Result Action Is Image Transfer Roller dented, scratchy, or YES Replace Image Transfer dirty? Roller. Is PC Drum scratchy or dirty? YES Replace Drum Cartridge. Is Fusing Roller scratchy or dirty? YES Replace Fusing Unit (Fusing Roller).

  • Page 182: Printer System: Black Streaks Or Bands

    (14) Printer system: Black streaks or bands <Typical Faulty Images> 4011T017AA 4011T023AA <Troubleshooting Procedures> Step Check Result Action Is paper path dirty with toner? YES Clean. Is PC Drum scratchy or dirty? YES Replace Drum Cartridge. Is Fusing Roller scratchy or dirty? YES Replace Fusing Unit (Fusing Roller).

  • Page 183: Printer System: Uneven Image

    (16) Printer system: Uneven image <Typical Faulty Images> 51-mm-pitch uneven image 51.8-mm-pitch uneven image 4136T004AA 4136T008AA 75.3-mm-pitch uneven image 94.2-mm-pitch uneven image 4136T006AA 4136T005AA <Troubleshooting Procedures> Step Check Cause Result Action Is uneven image at a Image Transfer Roller is YES Replace Image Transfer pitch of 50.6 mm? scratchy or dirty.
  • Page 184 DEVELOP Copyright 2003 Develop Printed in Germany...
  • Page 185 AF-11 Service Manual...
  • Page 186 CONTENTS GENERAL 1. SPECIFICATIONS ...................G-1 MECHANICAL/ ELECTRICAL 1. COMPONENTS LAYOUT ................M-1 2. DRIVE SYSTEM ....................M-2 3. ELECTRICAL PARTS LAYOUT ...............M-3 3-1. Document Take-up Mechanism ...............M-4 (1) Document Take-up Mechanism ............M-4 (2) Document Separation Mechanism ...........M-5 3-2. Document Transport/Exit Mechanism ............M-6 (1) Document transport mechanism ............M-6 (2) Document exit mechanism ...............M-7 3-3.
  • Page 187 TROUBLESHOOTING 1. INTRODUCTION ..................... T-1 1-1. Electric Components Check Procedures ..........T-1 (1) Sensors ................... T-1 (2) Clutches ..................T-2 (3) Motors .................... T-2 2. PAPER MISFEED ................... T-4 2-1. Initial Check Items ................... T-4 2-2. Paper Misfeed Displays ................T-5 2-3.

  • Page 188: General

    GENERAL...

  • Page 189: Specifications

    SPECIFICATIONS Name Automatic Document Feeder Installation method Inserted at upper-rear side of main unit Original type Plain paper: 35 to 128 g/m (9 to 34 lb.) Detectable Original sizes A5 L, B5 L, A4 L, Legal L, Letter L, Invoice L Custom size width: 138 to 216 mm;...

  • Page 190: Mechanical/ Electrical

    MECHANICAL/ ELECTRICAL...

  • Page 191: Components Layout

    COMPONENTS LAYOUT 1382M005AA 1: Pick-up Roller 4: Transport Roll 2: Exit Roller 5: Take-up Roller 3: Transport Roller...

  • Page 192: Drive System

    DRIVE SYSTEM 1382M007AA 1: Pick-up Roller 4: Transport Roller 2: Take-up Roller 5: Exit Roller 3: Document Feed Shaft...

  • Page 193: Electrical Parts Layout

    ELECTRICAL PARTS LAYOUT PWB-A AF 1382M006AA PWB-A AF : AF Control Board : AF Main Motor : Paper take-Up Sensor : AF door set switch : Paper take-Up clutch : Original detection Sensor : Leading Edge Detection Sensor...

  • Page 194: Document Take-Up Mechanism

    3-1. Document Take-up Mechanism Document Take-up Mechanism • The Original Detection Sensor detects a document that has been properly loaded in the Document Feeder. • The Document Stopper establishes the leading edge position of the document loaded in the Document Feeder. The stopper is lowered in the standby state and raised when the document is taken up and fed in.

  • Page 195: Document Separation Mechanism

    Document Separation Mechanism • Double feeding of paper is prevented using coefficient of friction between the Take-up Roller and Separator Pad. Take-up Roller 1382M002AB Separator Pad Single sheet feeding : The coefficient of friction on the front side of the paper fed between the Take-up Roller and Separator Pad is equal to that on the backside of the paper.

  • Page 196: Document Transport/Exit Mechanism

    3-2. Document Transport/Exit Mechanism Document transport mechanism • The original that has been taken up blocks the Paper Take-up Sensor. The Transport Roller turns to transport the original up to the document scanning position of the printer. • The AF Main Motor drives the Transport Roller through a gear train. AF Main Motor (M5) Paper Take-up Sensor (PC2) Transport Roller...

  • Page 197: Document Exit Mechanism

    Document exit mechanism • The Exit Roller turns to feed the original out of the Document Feeder. During this sequence, the original blocks the Leading Edge Detection Sensor and is fed onto the Document Exit Tray. • The AF Main Motor turns the Exit Roller through a gear train. AF Main Motor (M5) Leading Edge Detection Sensor (PC3)

  • Page 198: Miscellaneous

    3-3. Miscellaneous Document Feeder raised/lowered position detection mechanism • There is a magnet provided in the Document Feeder, allowing the printer to detect the position of the Document Feeder whether the Document Feeder is raised or lowered. • This magnet attracts the Original Cover Set Sensor provided on the printer side, thus activating the sensor.

  • Page 199: Dis/Reassembly, Adjustment

    DIS/REASSEMBLY, ADJUSTMENT...

  • Page 200: Maintenance Schedule

    MAINTENANCE SCHEDULE • To ensure that the printer produces good printed pages and to extend its service life, it is recommended that the maintenance jobs described in this schedule be carried out as instructed. PM Parts Clean Replace Ref. Page in This Manual Paper Take-Up Roll Pick-Up Roller –...

  • Page 201: Replacement/Cleaning Of Parts

    REPLACEMENT/CLEANING OF PARTS Cleaning of the Paper Take-Up Roll 1. Open the Document Feeder Cover. 2. Using a soft cloth, wipe clean the surface of the Paper Take-Up Roller. 1382E002AA Replacement of the Paper Take-Up Roll 1. Open the Document Feeder Cover. 2.

  • Page 202: Cleaning Of The Pick-Up Roller

    5. Remove the Pick-Up Roller/Paper Take-Up Roller Assy. 1382E009AA NOTE • When installing the Pick-Up Roller/Paper Take-Up Roller Assy., make sure that the notch in the shaft of the Paper Take-Up Roller is positioned on the top. 1382E013AC 6. Remove the Paper Take-Up Roller. 1382E010AA Cleaning of the Pick-Up Roller 1.

  • Page 203: Removal Of The Pick-Up Roller

    Removal of the Pick-Up Roller 1. Remove the Pick-Up Roller/Paper Take-Up Roller Assy. 2. Remove the Pick-Up Roller. 1382E011AA Cleaning of the Registration Rollers 1. Open the Document Feeder Cover. 2. While turning the Document Feed Knob in the direction shown in the illustration, use a soft cloth to wipe clean the Registration Rollers.

  • Page 204: Cleaning Of The Paper Separator Pad

    Cleaning of the Paper Separator Pad 1. Open the Document Feeder Cover. 2. Using a soft cloth, wipe clean the surface of the Paper Separator Pad. 1382E005AA Removal of the Paper Separator Pad 1. Open the Document Feeder Cover. 2. Remove the Paper Separator Cover. 1382E006AB 3.

  • Page 205: Disassembly/Reassembly

    DISASSEMBLY/REASSEMBLY 3-1. Names/Removal of External Parts 1382D001AB Name Removal Procedure Open the Document Feeder Cover. → Remove the two Document Feeder screws. → Remove the Document Feeder Cover. Cover Open the Document Feeder Cover. → Remove the Rear Cover. → Remove the screw, and then remove the Docu- Document Feeder Tray ment Feed Knob.

  • Page 206: Removal Of Circuit Boards

    3-2. Removal of Circuit Boards NOTE • When removing a circuit board, refer to the precautions for handling printed circuit boards and follow the corresponding removal procedures. • The following removal procedures omit the removal of the applicable component from connectors and circuit board supports.

  • Page 207: Disassembly

    2. Unplug all connectors connected to the circuit board. 1382D003AA 3. Remove the two screws, and then remove the Automatic Document Feeder Control Board. 1382D004AB 3-3. Disassembly Removal of the Automatic Document Feeder Main Motor 1. Remove the Rear Cover. 2.

  • Page 208: Adjustments

    ADJUSTMENTS 4-1. Electrical/Image Adjustment Accessing the Service Mode 1. Press the Utility key. 2. Press the following keys in order to enter the Service mode. Stop → 0 → 0 → Stop → 0 → 1 NOTE • Be sure to keep the access procedure for the Service mode from any unauthorized per- sons not involved with service operations.

  • Page 209: Height Adjustment

    Height Adjustment 1. Check the gap between the Original Glass and the spacer on the Automatic Document Feeder. NOTE • Be sure to open, then close the Automatic Docu- ment Feeder, and then check during pre-lighting of the scanner. 1382U024AA 2.

  • Page 210: Leading Edge Tilt Adjustment

    Leading Edge Tilt Adjustment 1. Print the test pattern. 2. Draw lines 100 mm (A and B) from the center of the test pattern, as shown in the illustration. 100 mm 100 mm 1382D007AA 3. Load the test pattern into the Automatic Docu- ment Feeder, and then print five single-sided cop- ies.

  • Page 211: Automatic Document Feeder Sub-Scanning Zoom Ratio Adjustmentd-12

    <If A is shorter than B> Using a coin, loosen the shoulder screw shown in the illustration, and then slide the scale on the Automatic Document Feeder away from you. NOTE • After finishing the adjustment, be sure to tighten 1382U029AA the loosened shoulder screw.
  • Page 212 NOTE If the Stop key is pressed, instead of the Yes key, the main screen is displayed and the set- ting returns to that before it was changed. Load the test pattern into the Automatic Document Feeder again, make another test copy, and check it.

  • Page 213: Automatic Document Feeder Main Scanning Registration Adjustment

    Automatic Document Feeder Main Scanning Registration Adjustment <Reference> • Adjust the amount that widths D and E in the copy of the test pattern are shifted so that the following specification is met. 1382D011AA Specification Mode Function Setting Range 90 to 110 0 ±...

  • Page 214: Automatic Document Feeder Sub-Scanning Registration Adjustmentd-15

    Automatic Document Feeder Sub-Scanning Registration Adjustment <Reference> • Adjust the width of F in the copy of the test pattern so that the following specification is met. 1382D010AA Specification Mode Function Setting Range 90 to 110 20 ± 3.0 mm “ADJUST”...

  • Page 215: Troubleshooting

    TROUBLESHOOTING...

  • Page 216: Introduction

    INTRODUCTION • This chapter contains the items required or used when troubleshooting various printer problems. 1-1. Electric Components Check Procedures • The following procedures can be used to check to see if an electric component is fully operational when a paper misfeed or a malfunction occurs in the printer. Sensors Step Check...

  • Page 217: Clutches

    Clutches Step Check Result Action Replace the Con- Does the output signal of the Controller/Mechanical troller/Mechanical Control Board go from HIGH to LOW when the clutch Control Board. is energized? YES Replace the clutch. 4025T528AA Motors Step Check Result Action Replace the Con- Is the LOCK signal of the Controller/Mechanical Con- troller/Mechanical...
  • Page 218 Step Check Result Action YES Replace the motor. Does the input signal to the Controller/Mechanical Control Board go from HIGH to LOW when the motor Replace the Con- is energized? (The input signal varies depending on troller/Mechanical the direction of rotation.) Control Board.

  • Page 219: Paper Misfeed

    PAPER MISFEED 2-1. Initial Check Items • When a paper misfeed occurs in the printer, first make the following initial checks. Check Action Does the paper meet product specifications? Replace paper. Replace paper. Is the paper curled, wavy, or damp? Instruct user in correct paper storage.

  • Page 220: Paper Misfeed Displays

    2-2. Paper Misfeed Displays • The Error indicator lights up and a message appears in the display when a paper misfeed occurs. <Automatic Document Feeder Misfeed> C4506P298CA <Procedure for canceling the misfeed display> 1. Open the appropriate covers, remove the misfed paper and any remaining paper, and then close the covers.

  • Page 221: Locations Of Misfeed Detection Sensors

    2-3. Locations of Misfeed Detection Sensors Paper Take-Up Sensor Original Detection Sensor (PC1) (PC2) Leading Edge Detection Senspr (PC1) 4980T002AA...

  • Page 222: Misfeed Detection Timing And Troubleshooting Procedures

    2-4. Misfeed Detection Timing and Troubleshooting Procedures The Original misfeeds <Detection Timing> Type Description • The Paper Take-Up Sensor is not unblocked after the predeter- mined period of time has elapsed after document feeding began. • The Paper Take-Up Sensor is not blocked after the predeter- mined period of time has elapsed after the Paper Take-Up Sen- ADF Jam sor is unblocked.

  • Page 223: Timing Chart

    TIMING CHART...
  • Page 224 PF-125 Service Manual...
  • Page 225 CONTENTS GENERAL 1. SPECIFICATIONS ...................G1 DIS/REASSEMBLY,ADJUSTMENT 1. MAINTENANCE SCHEDULE ................D-1 2. REPLACEMENT/CLEANING OF PARTS ............D-2 (1) Cleaning of the Paper Take-Up Roll ..........D-2 (2) Replacement of the Paper Take-Up Roll .........D-2 3. DISASSEMBLY/REASSEMBLY ..............D-3 3-1. Identification of Exterior Parts and Removal Procedures for Them ..D-3 3-2.

  • Page 226: General

    GENERAL...

  • Page 227: Specifications

    SPECIFICATIONS Name 2nd Paper Feed Cassette Type of paper Plain and recycled paper: 60 to 90 g/m (16 to 24 lb.) Media sizes A4 L and Letter L Paper capacity Maximum 500 sheets (80 g/m ) (21 lb.) Registration Center Power source DC 24 V, DC 5 V (supplied by main unit) Power consumption...
  • Page 228 MECHANICAL/ ELECTRICAL...
  • Page 229 COMPONENTS LAYOUT PWB-A CAS 4516M002AA : Cassette type Detecting Switch SL2 : 2nd Drawer Take-up solenoid PWB-A CAS : 2nd Drawer Control Board...
  • Page 230 1-1. Paper Take-up Mechanism • Because of no drive motor installed for the Paper Feed Cassette, drive from the Main Motor (M1) of the printer is transmitted to the cassette by way of a drive coupling gear for paper take-up and transport. •...
  • Page 231 1-2. Paper Empty Detection • There is a Paper Empty Sensor provided on the 2nd Drawer Control Board. It detects a paper empty condition of the cassette. • When paper is loaded, the actuator is raised and blocks the sensor. •...
  • Page 232 Cassette Type Detection Switch Conditions Cassette Type Switch0 Switch1 Switch2 A4 L Letter L Electrical Component Control Signal WIRING DIAGRAM PWB-A CAS D~E-5 MPJ23A CAS-1,2,4...

  • Page 233: Dis/Reassembly,Adjustment

    DIS/REASSEMBLY, ADJUSTMENT...

  • Page 234: Maintenance Schedule

    MAINTENANCE SCHEDULE • To ensure that the printer produces good printed pages and to extend its service life, it is recommended that the maintenance jobs described in this schedule be carried out as instructed. Replace Ref. Page Making one PM Parts Clean in This Continuous...

  • Page 235: Replacement/Cleaning Of Parts

    REPLACEMENT/CLEANING OF PARTS Cleaning of the Paper Take-Up Roll 1. Raise the main unit to separate it from the Paper Feed Cassette. 2. Using a soft cloth, wipe clean the surface of the Paper Take-Up Roller. 4136E002AA Replacement of the Paper Take-Up Roll 1.

  • Page 236: Disassembly/Reassembly

    DISASSEMBLY/REASSEMBLY 3-1. Identification of Exterior Parts and Removal Procedures for Them 4516D001AA Name Removal Procedure Remove the five screws. → Remove the Rear Cover. Rear Cover Remove the Rear Cover. → Remove the Right Cover. Right Cover Hold down the Paper Feed Cassette with one hand and Tray 2 remove Tray 1.

  • Page 237: Removal Of Circuit Boards

    3-2. Removal of Circuit Boards NOTE • When removing a circuit board, refer to the precautions for handling printed circuit boards and follow the corresponding removal procedures. • The following removal procedures omit the removal of the applicable component from connectors and circuit board supports.

  • Page 238: Disassembly

    3-3. Disassembly Removal of the Paper Feed Cassette Paper Take-Up Unit 1. Raise the main unit to separate it from the Paper Feed Cassette. 2. Unhook the two tabs, and then remove the cover. 4516D003AB 3. Remove the actuator. 4136D035AA 4.

  • Page 239: Removal Of The Paper Feed Cassette Paper Take-Up Solenoid

    Removal of the Paper Feed Cassette Paper Take-Up Solenoid 1. Remove the Paper Feed Cassette Paper Take-Up Unit. 2. Remove the screw, and then remove the cover. 3. Remove the screw, unplug the connector, and then remove the Paper Feed Cassette Paper Take-Up Solenoid.

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