Kyocera FS-C1020MFP Service Manual
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Kyocera FS-C1020MFP Service Manual

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FS-C1020MFP
SERVICE
MANUAL
Published in April 2008
5JLSM060
First Edition

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Summary of Contents for Kyocera FS-C1020MFP

  • Page 1: Service Manual

    FS-C1020MFP SERVICE MANUAL Published in April 2008 5JLSM060 First Edition...
  • Page 2 CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS. It may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for proper disposal. ATTENTION IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE DE TYPE INCORRECT.
  • Page 3 Revision history Revision Date Replaced pages Remarks...
  • 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

    Product Information Product Information ......................5 Specifications ........................5 Machine Overview......................6 Component Layout ......................6 Paper Path........................8 Drive Layout ........................9 Installation........................... 11 Installation Requirements....................11 Environment ........................ 11 Machine level....................... 11 Machine Space Requirement..................12 Power Requirements ....................12 Installation Procedure ....................
  • Page 12 Product Information ITB (Image Transfer Belt) Contact Sensor..............36 TM (Toner Mark) Sensor Base..................37 Waste Toner Bottle Set Sensor..................38 Waste Toner Overflow Sensor ..................39 Paper Transfer ........................ 41 Transfer Unit ........................ 41 Transfer Roller ......................41 Registration Roller ....................... 43 Registration Sensor .....................
  • Page 13 Product Information ADF..........................71 ADF Unit ........................71 Original Tray ........................ 72 ADF Feed Unit......................73 ADF Separation Pad....................73 ADF Front Cover ......................74 ADF Rear Cover ......................74 ADF Cover........................75 ADF Motor ........................75 Original Set Sensor ..................... 77 ADF Cover Open Sensor.....................
  • Page 14 Product Information INDEX..........................105...

  • Page 15: Product Information

    Product Information Product Information Specifications See "Appendices" for the following information: "General Specifications" "Supported Paper Sizes"...

  • Page 16: Machine Overview

    Product Information Machine Overview Component Layout Engine 1. Laser Optics Housing Unit 9. Registration Roller 2. Print Cartridge (AIO) 10. By-pass 3. Development Roller (AIO) 11. Paper Feed Roller 4. Paper Exit 12. ITB (Image Transfer Belt) Unit 5. Fusing Unit 13.
  • Page 17 Product Information 1. Feed Sensor 5. Exit Roller 2. Feed Roller 6. Original Set Sensor 3. Separation Roller 7. DF Exposure Glass 4. Pick-up Roller Scanner 1. Scanner Carriage Unit 4. Carriage Drive Bar 2. DF Exposure Glass 5. White Plate 3.

  • Page 18: Paper Path

    Product Information Paper Path Engine Paper path from tray 1 Duplex path By-pass tray Paper path from tray 2 (optional) Original path...

  • Page 19: Drive Layout

    Product Information Drive Layout 1. Color AIO Motor 5. Registration Clutch 2. Black AIO Motor 6. Paper Feed Clutch 3. Duplex Motor 7. Agitator Motor 4. Transport/Fusing Motor 8. ITB (Image Transfer Belt) Contact Motor Color AIO Motor: This drives the color AIOs (Cyan, Magenta and Yellow) Black AIO Motor: This drives the black AIO and the ITB (Image Transfer Belt).
  • Page 20 Product Information Agitator Motor: This moves the agitators in the waste toner bottle. ITB Contact Motor: This moves the ITB into contact with and away from the color OPCs.

  • Page 21: Installation

    Installation Installation Installation Requirements Environment Temperature Range: 10°C to 32°C (50°F to 89.6°F) Humidity Range: 15% to 80% RH Ambient Illumination: Less than 2,000 lux (do not expose to direct sunlight) Ventilation: 3 times/hr/person Do not put the machine in areas that get sudden temperature changes. This includes: Areas directly exposed to cool air from an air conditioner Areas directly exposed to heat from a heater.

  • Page 22: Machine Space Requirement

    Installation Machine Space Requirement Put the machine near the power source with these clearances: Left side: Over 20 cm (7.9") Rear: Over 20 cm (7.9") Right side: Over 10 cm (4") Front: Over 70 cm (27.5") Top: Over 24 cm (9.5") Power Requirements Make sure that the plug is tightly in the outlet.

  • Page 23: Preventive Maintenance

    Preventive Maintenance Preventive Maintenance Preventive Maintenance See "Appendices" for the "User Replaceable Items".

  • Page 24: Replacement And Adjustment

    Replacement and Adjustment Replacement and Adjustment Before You Start If there are printer jobs in the machine, print out all jobs in the printer buffer. Turn off the main power switch and unplug the machine before you do the procedures in this section.

  • Page 25: Special Tools

    Replacement and Adjustment Special Tools PC: Windows 2000/XP/Vista, Windows Server 2003/2003 R2, or Mac OS X. USB cable or Crossover cable...

  • Page 26: Exterior Covers

    Replacement and Adjustment Exterior Covers Turn off the main power switch and unplug the machine before you do the procedures in this section. Rear Cover Rear tray cover [A] Rear cover [B] ( x 2)

  • Page 27: Operation Panel

    Replacement and Adjustment Operation Panel Open the top cover [A]. Open the front cover [B]. Front harness cover [C] ( x 1)

  • Page 28: Right Cover

    Replacement and Adjustment Operation panel [D] ( x 1, x 1) Right Cover Rear cover (→ p.16) Operation panel (→ p.17) Right cover [A] ( x 4) Top front screw: M3x8, others: M4x10 Left Cover Rear cover (→ p.16)

  • Page 29: Front Cover Unit

    Replacement and Adjustment Operation panel (→ p.17) Left cover [A] ( x 3, hook at arrow mark) Top front screw: M3x8, others: M4x10 Front Cover Unit Rear cover (→ p.16) Operation panel (→ p.17) Transfer unit (→ p.41) Right cover (→ p.18) Cover link gear unit [A] ( x 2)
  • Page 30 Replacement and Adjustment Release the belt [B] Front cover unit [C] ( x 4)

  • Page 31: Laser Optics

    Replacement and Adjustment Laser Optics Turn off the main power switch and unplug the machine before beginning any of the procedures in this section. Laser beams can cause serious eye injury. Caution Decal Location Caution decals are attached as shown below. Be sure to turn off the main power switch and disconnect the power plug from the power outlet before beginning any disassembly or adjustment of the laser unit.
  • Page 32 Replacement and Adjustment Disconnect the three harnesses from CN301, 302 and 303 on the EGB ( x 3). Open the top cover [A]. Lift up the hook [B] of the harness guide at the rear-left frame and slide the harness guide to the right.
  • Page 33 Replacement and Adjustment Remove the springs [D] (left side and right side). Stoppers [C] ( x 2 each; left side and right side) Remove the laser optics housing unit [E] from the top cover and place it on the main body.
  • Page 34 Replacement and Adjustment 10. Take out the harnesses [F] ( x 1). 11. Pull out the harnesses from the rear side. 12. Remove the laser optics housing unit. After replacing the laser optics housing unit Do the following step 4 with the front cover of the machine open.
  • Page 35 Replacement and Adjustment Open the front cover and turn on the machine. Look for the lot number [A] attached to the new laser optics housing unit. Then look for this lot number on the information sheet (this sheet will be released separately, and will contain lists of input data for each lot number) Input the data for this lot number from the information sheets with steps 3 to 7 below.

  • Page 36: Aio Cartridge

    Replacement and Adjustment AIO Cartridge AIO Cartridge (All In One Cartridge) Open the top cover. AIO cartridge [A] Black AIO Motor Left cover (→ p.18) Disconnect the fusing connector [A] and remove the fusing relay harness [B] (hooks).
  • Page 37 Replacement and Adjustment Fusing harness guide [C] ( x 2) Disconnect the connectors shown by arrows in the above picture and release all harnesses on the harness guide [D]. Harness guide [D] ( x 4) Interlock switch base (→ Interlock Switches) Controller bracket (→...
  • Page 38 Replacement and Adjustment LSU fan motor base [E] ( x 2, x 1) 10. Drive unit [F] ( x 4)

  • Page 39: Color Aio Motor

    Replacement and Adjustment 11. Drive unit guide [G] ( x 3) 12. Black AIO gear [H] (snap ring x 1) 13. Black AIO motor [I] ( x 3) Color AIO Motor Drive unit (→ p.26 "Black AIO Motor")
  • Page 40 Replacement and Adjustment Drive unit guide [A] ( x 3) Color AIO gears [B] (ring stopper x 1 each) Color AIO motor [C] ( x 3)

  • Page 41: Image Transfer

    Replacement and Adjustment Image Transfer Image Transfer Belt Unit Remove all the AIO cartridges (→ p.26). Transfer unit (→ p.41) Pull out the waste toner bottle [A]. Release the hook [B] under the guide plate. Move the guide plate [C] underneath the fusing unit to the left, and then remove it.

  • Page 42: Itb (Image Transfer Belt) Cleaning Unit

    Replacement and Adjustment Pull out the image transfer belt unit [D] ( x 2). After replacing the image transfer belt unit Do the following step 2 with the front cover of the machine open. Open the front cover and turn on the machine. Execute "Reset Transfer Unit Life Counter"...

  • Page 43: Agitator Motor

    Replacement and Adjustment Left handle [A] (hook, bushing x 1) Right handle [B] (hook, bushing x 1) ITB cleaning unit [C] ( x 2) Agitator Motor Right cover (→ p.18)
  • Page 44 Replacement and Adjustment Motor bracket [A] ( x 2) Agitator motor assembly [B] ( x 1, x 1)

  • Page 45: Itb (Image Transfer Belt) Contact Motor

    Replacement and Adjustment Agitator motor [C] ( x 2) ITB (Image Transfer Belt) Contact Motor Agitator motor (→ p.33) Release the wire [A]. ITB contact motor assembly [B] ( x 1, x 1)

  • Page 46: Itb (Image Transfer Belt) Contact Sensor

    Replacement and Adjustment ITB contact motor [C] ( x 2) ITB (Image Transfer Belt) Contact Sensor Right cover (→ p.18) High voltage power supply board (→ p.66) ITB contact sensor assembly [A] ( x 1, x 1)

  • Page 47: Tm (Toner Mark) Sensor Base

    Replacement and Adjustment ITB contact sensor [B] (hooks) TM (Toner Mark) Sensor Base Open the top cover. Remove all AIO cartridges (→ p.26). Slide the ITB unit to the front side or remove it. Rear cover (→ p.18) Controller box cover (→ p.57 "Controller Board") Controller bracket (→...

  • Page 48: Waste Toner Bottle Set Sensor

    Replacement and Adjustment Harness cover [A] (hook) TM sensor base [B] Waste Toner Bottle Set Sensor Remove all AIO cartridges. (→ p.26) Image transfer belt unit (→ p.31) EGB (→ p.59) Remove two screws [A] for the waste toner sensor base.

  • Page 49: Waste Toner Overflow Sensor

    Replacement and Adjustment Waste toner sensor base [B] Remove the mylar fixing three hooks of the waste toner bottle set sensor. Waste toner bottle set sensor [C] (hooks, x 1) When reinstalling the waste toner bottle set sensor, connect it to the white connector of the harness.
  • Page 50 Replacement and Adjustment Remove the mylar fixing three hooks of the waste toner bottle set sensor. Waste toner overflow sensor [A] (hooks, x 1) When reinstalling the waste toner overflow sensor, connect it to the black connector of the harness.

  • Page 51: Paper Transfer

    Replacement and Adjustment Paper Transfer Transfer Unit Open the front cover. Release the locks [A]. Transfer unit [B] Transfer Roller Transfer Unit (→ p.41) Release the two hooks [A] at both sides of the transfer unit.
  • Page 52 Replacement and Adjustment Open the transfer roller unit [B] and remove it. Transfer roller assembly [C] ( x 2) Release the holder [D] at the left side of the transfer roller unit (hook). Transfer roller [E]...

  • Page 53: Registration Roller

    Replacement and Adjustment Registration Roller Transfer unit (→ p.41) Transfer roller unit (→ p.41) Tension springs [A] (both sides) Registration idle roller [B] ( x 2, gear x 1, bushing x 2) Registration roller [C] ( x 2, gear x 2, bushing x 2) Reassembling the registration roller unit When installing the tension spring, make sure that the tension spring correctly hooks onto the bushing of the registration idle roller as shown above [A].

  • Page 54: Registration Sensor

    Replacement and Adjustment Registration Sensor Rear cover (→ p.16) Right Cover (→ p.18) Registration sensor assembly [A] ( x 1, x 1) Registration sensor [B] (hooks) Registration Clutch Rear cover (→ p.16) Left cover (→ p.18) Transport/Fusing motor (→ p.48)
  • Page 55 Replacement and Adjustment Registration clutch [A] ( x 1)

  • Page 56: Image Fusing

    Replacement and Adjustment Image Fusing Make sure that the fusing unit is cool before you touch it. The fusing unit can be very hot. Make sure to restore the insulators, shields, etc after you service the fusing unit. Fusing Unit Open the front cover.

  • Page 57: Fusing Lamp

    Replacement and Adjustment Fusing unit [D] ( x 2) Fusing Lamp Fusing unit (→ p.46) Fusing front cover [A] ( x 4) Fusing lamp [B] ( x 2, ground cable x 1)

  • Page 58: Transport/Fusing Motor

    Replacement and Adjustment When Reinstalling the Fusing Lamp The terminal [A], which shows the voltage and power ratings, must be placed at the left side of the fusing unit (fusing cable side). Transport/Fusing Motor Rear cover (→ p.16) Left cover (→ p.18) Disconnect the fusing connector [A] (hook).
  • Page 59 Replacement and Adjustment Transport/Fusing motor assembly [D] ( x 3, x 3, ground plate x 1) Transport/Fusing motor [E] ( x 3)

  • Page 60: Paper Feed

    Replacement and Adjustment Paper Feed Paper Feed Clutch Rear cover (→ p.16) Left cover (→ p.18) Disconnect the fusing relay harness [A] (hook). Paper feed clutch [B] ( x 1, x 1) Paper Feed Roller Remove all the AIO cartridges. Remove the waste toner bottle.

  • Page 61: Separation Pad

    Replacement and Adjustment Stand the machine with the rear side facing the table. Slide the paper feed shaft [A] to the left side ( x 2). 10. Paper feed roller [B] (hook) Separation Pad Pull out the tray.

  • Page 62: Paper End Sensor

    Replacement and Adjustment Push down the bottom plate [A]. Separation pad [B] (hooks, spring x 1) When reinstalling the separation pad, make sure that the mylar [C] is not placed under the separation pad. The right side image above shows incorrect installation. Paper End Sensor Rear cover (→...
  • Page 63 Replacement and Adjustment Paper end sensor assembly [A] ( x 1) Paper end sensor [B] (hooks)

  • Page 64: Paper Exit

    Replacement and Adjustment Paper Exit Paper Exit Roller Operation panel (→ p.17) Remove the bushing [A] ( x 1) Move the bushing [B] to the left side ( x 1). Paper exit roller [B] Remove the four exit guides [D], gear [E] (ε x 1) and bushing [F].

  • Page 65: Paper Exit Sensor

    Replacement and Adjustment When reinstalling the paper exit roller Make sure that the ground wire [A] from the discharge sheet touches the ground plate [B] on the machine after reinstalling the paper exit roller. Paper Exit Sensor Rear cover (→ p.16) Right cover (→...
  • Page 66 Replacement and Adjustment Mylar [C] This mylar is necessary for reinstalling the paper exit sensor. Paper exit sensor [D] (hooks, x 1)

  • Page 67: Electrical Components

    Replacement and Adjustment Electrical Components Controller Board Main Controller Board Rear cover (→ p.16) Controller box cover [A] ( x 7) Interface bracket [B] ( x 2)
  • Page 68 Replacement and Adjustment Main controller board [C] (flat cable x 1, all x 6) PDL Board Rear cover (→ p.16) Controller box cover (see "p.57 "Main Controller Board "" above) Interface bracket (see "p.57 "Main Controller Board "" above) PDL board [A] ( x 4)

  • Page 69: Egb (Engine Board)

    Replacement and Adjustment EGB (Engine Board) Rear cover (→ p.16) Controller box cover (→ p.57 "Controller Board") Controller bracket [A] ( x 3, ground cable x 1, all s, flat cable x 1) EGB [B] ( x 6, all...
  • Page 70 Replacement and Adjustment EEPROM [C] When installing the new EGB Remove the EEPROM from the old EGB. Install it on the new EGB with the mark [A] pointing to the left side of the board after you replace the EGB. Replace the EEPROM if the EEPROM on the old EGB is defective.

  • Page 71: Fcu

    Replacement and Adjustment Rear cover (→ p.16) Controller box cover (→ p.57 "Controller Board") Controller bracket (→ p.59 "EGB (Engine Board)") FCU [A] ( x 4) Interlock Switches Operation panel (→ p.17) Rear cover (→ p.16) Left cover (→ p.18) Remove the spring [A].

  • Page 72: Fusing Fan Motor

    Replacement and Adjustment Remove all the connectors after the interlock switch base has been removed. Two interlock switches [C] at the outside of the base and one interlock switch [D] at the inside of the base (hooks) Fusing Fan Motor Operation panel (→...

  • Page 73: Lsu Fan Motor

    Replacement and Adjustment Fusing fan motor [B] (hooks, x 1) Install the fusing fan motor with its decal facing the outside of the machine. LSU Fan Motor Operation panel (→ p.17) Rear cover (→ p.16) Left cover (→ p.18) LSU fan motor [A] (hooks, x 1) Install the LSU fan motor with its decal facing the outside of the machine.

  • Page 74: Id Chip Board

    Replacement and Adjustment ID Chip Board Operation panel (→ p.17) Rear cover (→ p.16) Left cover (→ p.18) Controller bracket (→ p.57 "Controller Board") Disconnect the connector (CN305) on the EGB. Interlock switch base (→ p.61 "Interlock Switches") Fusing fan base (→ p.62 "Fusing Fan Motor") Drive unit (→...
  • Page 75 Replacement and Adjustment PSU guide [A] ( x 3) Power cord bracket [B] ( x 2) Ground cable [C] ( x 1) Power switch assembly [D] (washer screw [a] x 2, x 1, x 2) 10. PSU assembly [E] ( x 4, all...

  • Page 76: High Voltage Power Supply Board

    Replacement and Adjustment 11. PSU [F] ( x 4) There are two types of PSUs for this model. Do not install a wrong PSU in the machine. PSU has yellow [a] on the transistor is for NA models and PSU has green [b] on the transistor is for EU models.

  • Page 77: Temperature/Humidity Sensor

    Replacement and Adjustment High Voltage Power Supply Board [A] ( x 7, ground cable x 1, x 1) Temperature/Humidity Sensor Operation panel (→ p.17) Rear cover (→ p.16) Right cover (→ p.18) Temperature/Humidity sensor [A] ( x 1, x 1) Duplex Motor Operation panel (→...

  • Page 78: Speaker

    Replacement and Adjustment Disconnect the fusing connector [A] Duplex timing belt [B] Left bracket [C] ( x 4) Duplex motor [D] ( x 2, x 1) Speaker Rear cover (→ p.16) Controller box cover (→ p.57 "Controller Board")

  • Page 79: Eeprom

    Replacement and Adjustment Speaker [A] ( x 2, x 1) EEPROM Replacement and Reinstallation procedures for the EEPROM are included in the "EGB (Engine Board)" replacement procedure. Refer to "EGB (Engine Board)" for details. When replacing an old EEPROM with a new EEPROM, EEPROM setting is required. Follow the EEPROM setting procedure described below.
  • Page 80 Replacement and Adjustment Exit the serial number input display, and then enter "Engine Maintenance" again. Select "Destination", and then select a destination. Select "Model", and then select a model. Select "PnP Name", and then select a plug and play name. 10.

  • Page 81: Adf

    Replacement and Adjustment ADF Unit Stand left cover [A] Disconnect the ADF harness [B] and power cord [C].

  • Page 82: Original Tray

    Replacement and Adjustment Open the ADF unit [D] Release the three hooks of the right hinge [E] Lift the ADF unit. Original Tray Open the ADF cover.

  • Page 83: Adf Feed Unit

    Replacement and Adjustment Release the front tab [A]. Original tray [B] ADF Feed Unit Open the ADF cover. Release the lock lever [A] ADF feed unit [B] ADF Separation Pad Open the ADF cover. ADF feed unit (→ p.73)

  • Page 84: Adf Front Cover

    Replacement and Adjustment ADF separation pad [A] (hook x 2, spring x 1) ADF Front Cover ADF unit (→ p.71) Original Tray (→ p.72) ADF feed unit (→ p.73) ADF front cover [A] ( x 1) ADF Rear Cover ADF unit (→ p.71) Original Tray (→...

  • Page 85: Adf Cover

    Replacement and Adjustment ADF rear cover [A] ( x 2) ADF Cover ADF unit (→ p.71) ADF front cover (→ p.74) ADF rear cover (→ p.74) ADF top cover [A] (two tabs) ADF Motor ADF unit (→ p.71) Original Tray (→ p.72)
  • Page 86 Replacement and Adjustment ADF feed unit (→ p.73) ADF front cover (→ p.74) ADF rear cover (→ p.74) ADF drive unit [A] ( x 4, all ADF motor assembly [B] ( x 2)

  • Page 87: Original Set Sensor

    Replacement and Adjustment ADF motor [C] ( x 2) Original Set Sensor ADF unit (→ p.71) ADF feed unit (→ p.73) ADF motor assembly (→ p.75) Feed roller holder [A] ( x 1) Upper guide [B] ( x 2)

  • Page 88: Adf Cover Open Sensor

    Replacement and Adjustment Original set sensor [C] (hooks) ADF Cover Open Sensor Original tray (→ p.72) ADF rear cover (→ p.74) ADF cover open sensor ( x 1, x 1) ADF Feed Sensor ADF unit (→ p.71) ADF feed unit (→ p.73)

  • Page 89: Adf Drive Board

    Replacement and Adjustment Sensor cover [A] ( x 2) ADF feed sensor [B] (hooks) ADF Drive Board Original tray (→ p.72) ADF rear cover (→ p.74)
  • Page 90 Replacement and Adjustment ADF drive board [A] (all s, hooks)

  • Page 91: Scanner

    Replacement and Adjustment Scanner Scanner Unit Controller box cover (→ p.57 "Controller Board") Disconnect the flat cable [A]. Stand left cover [B] and right cover [C] (1 hook each) Disconnect the scanner harness, power cord and ground cable (and the ADF harness and power cord if the ADF is installed in the scanner unit) ( x 1).
  • Page 92 Replacement and Adjustment Remove the stepped screw [D]. Push the lock button [E] and slide the scanner unit to the rear side. ADF unit (→ p.71) Scanner unit...

  • Page 93: Scanner Top Cover

    Replacement and Adjustment Scanner Top Cover Scanner unit (→ p.81) Turn over the scanner unit. Scanner front cover [A] (tabs x 3) Remove the six screws at the bottom of the scanner base [B].

  • Page 94: Scanner Carriage Unit

    Replacement and Adjustment Scanner top cover [C] Scanner Carriage Unit Scanner unit (→ p.81) Scanner top cover (→ p.83) Slide the scanner carriage unit [A] to the right side.
  • Page 95 Replacement and Adjustment Remove the timing belt tension spring [B] Remove the flat cable [C] from the scanner carriage unit. Bar holder [D] ( x 1)

  • Page 96: Exposure Lamp

    Replacement and Adjustment Carriage bar [E] and scanner carriage unit [F] Exposure Lamp Scanner carriage unit (→ p.84) Carriage top cover [A] ( x 2, x 1)

  • Page 97: Lamp Stabilizer Board

    Replacement and Adjustment Exposure lamp [B] (hooks) When reinstalling the exposure lamp Wire the lamp cords as shown above. Otherwise, the top cover pinches the lamp cords and damages them when reinstalling the top cover on the scanner carriage unit. Lamp Stabilizer Board Scanner carriage unit (→...

  • Page 98: Scanner Motor

    Replacement and Adjustment Carriage bottom cover [A] ( x 2) Lamp stabilizer [B] ( x 1) Scanner Motor Scanner carriage unit (→ p.84)
  • Page 99 Replacement and Adjustment Scanner motor [A] ( x 3) Carriage rail [B] ( x 2) Ground plate [C] (double-sided tape) Scanner motor...

  • Page 100: System Maintenance Reference

    System Maintenance Reference System Maintenance Reference Service Program See "Appendices" for "Service Menu". Overview There is an LCD on these models. To execute the service program, access the "Maintenance Mode Menu" or "Fax Service Menu" with special key assignments. For details, refer to the "Service Menu"...

  • Page 101: Configuration Page Information

    System Maintenance Reference Configuration Page Information Overview The configuration page and maintenance page have information about the machine's status. Print this sheet as shown below. Check the configuration page or maintenance page when doing machine maintenance. To Print the Configuration Page/ Maintenance Page Turn on the machine.

  • Page 102: Firmware Updating

    System Maintenance Reference Firmware Updating Do not turn off the main power of the machine during the firmware updating. If doing so, the engine board or controller board may be damaged. Checking the Machine Firmware Version Turn the machine on. Press "User/Tools"...
  • Page 103 System Maintenance Reference Updating Procedure The update may take a while to complete. Do not turn off the power during the update. Turn off the power only when the machine beeps and "Firmware Update Done Please Reboot" appears on the control panel display. When using a computer running on a Windows operating system, you must have an account that has Manage Printers permission.
  • Page 104 System Maintenance Reference For a USB connection, click [F/W Update (USB)] [A]. For a network connection, enter the machine’s IP address in [MFP IP] [B], and then click [F/W Update (NET)] [C]. Check the control panel display for messages and the update’s current percentage of completion.
  • Page 105 System Maintenance Reference The update's percentage of completion might not be displayed, depending on which version of the firmware is currently installed. In addition to printing a configuration page, you can check the machine's firmware version by accessing the machine using a web browser. For details, see "Checking Machine Status", in the User Guide.
  • Page 106 System Maintenance Reference Message Cause/ Solutions Turn off the power, turn it back on, and then perform the update again. If this message reappears after you turn the power back on, see "Error and Status Messages on the Screen" in the User Guide. The IP address specified for either the machine or your computer is invalid.
  • Page 107 System Maintenance Reference Message Cause/ Solutions Firmware has been transferred to the machine successfully. Net Upload : End of data Follow the instructions in this manual to complete the update. Firmware has been transferred to the machine successfully. USB Upload : End of data Follow the instructions in this manual to complete the update.

  • Page 108: Updating Failure

    System Maintenance Reference Updating Failure If the initial screen does not appear and the message below remains on the operation panel display for more than one minute following firmware update, a power failure or similar interruption prevented the update from completing. If this happens, use the following procedure to recover from the failure and complete the update.

  • Page 109: Updating The Engine Firmware

    System Maintenance Reference 13. Reconnect the telephone line cable to the machine. The update’s percentage of completion might not be displayed, depending on which version of the firmware is currently installed. In addition to printing a configuration page, you can check the machine’s firmware version by accessing the machine using a web browser.

  • Page 110: Boot Loader Firmware

    System Maintenance Reference displayed on the operation panel. Then, you can close this window at your PC. Do not turn off the machine until "Done Please reboot" is displayed in the operation panel. Otherwise, the controller board will be damaged. If “Done Please reboot“...

  • Page 111: Troubleshooting

    Troubleshooting Troubleshooting Troubleshooting Guide See "Appendices" for the following information: Error Messages Service Call Conditions...

  • Page 112: Image Problems

    Troubleshooting Image Problems Overview Image problems may appear at regular intervals that depend on the circumference of certain components. The following diagram shows the possible symptoms (black or white dots at regular intervals). Abnormal image at 24-mm intervals: Paper feed roller Abnormal image at 25.5-mm intervals: Image transfer belt unit Colored spots at 27-mm intervals: Print cartridge (Development roller) Abnormal image at 30-mm intervals: Charge roller...
  • Page 113 Troubleshooting Printer Driver Setting for Printing a Sample Click "Properties" on the printer driver.
  • Page 114 Troubleshooting Click the "Print Quality" tab. Check "Manual" in the color setting. Click "Advanced…". Select "Off" from the pull-down menu in "Color Profile" in the "Text" area. Select "Off" from the pull-down menu in "Color Profile" in the "Graphics" area. Select "Off"...
  • Page 115 INDEX INDEX Installation Specifications Install..........11 Specification ........5 System Maintenance Preventive Maintenance SP............. 90 PM.............13 Troubleshooting Replacement Trouble..........101 Adjustment ........14...
  • Page 116 Appendix: Specifications....................... 2 General Specifications ...................... 2 Engine ........................... 2 Option ..........................8 Supported Paper Sizes ..................... 9 Appendix: Preventive Maintenance ..................12 Preventive Maintenance....................12 User Replaceable Items ....................12 Appendix: Troubleshooting Guide..................13 Error Messages....................... 13 Overview........................13 Error Messages List.....................

  • Page 117: General Specifications

    Appendix: Specifications Appendix: Specifications General Specifications Engine Type Desktop Flatbed with CCD array image-sensor Laser beam scanning and electro-photographic printing Technology Mono-component toner development 4-drum tandem method 600 × 600 dpi Speed (1bit) Resolution (dpi, bit/pixel) 600 × 600 dpi Standard (2bits) 600 ×...
  • Page 118 Appendix: Specifications Std Tray 250 sheets (80 g/m Standard Bypass tray 1 sheet Input capacity Op. Paper Paper Feed 500 sheets (80 g/m ) x 1 Tray Unit Up to 751 sheets Standard Output capacity Face down Up to 150 sheets (A4/LT or 80g/m , 20lb) Tray A4, B5, A5, B6, A6, Legal, Letter, HLT,...
  • Page 119 Appendix: Specifications Original size 35 sheets (80g/m , 20lb) Letter/A4: Width 139.7-215.9 mm (5.5" - Original weight 8.5"), Length: 139.7-355.6 mm (5.5" - 14") NA version 52 - 105 g/m (14 - 28lbs.) EU version 120V, 60Hz Rating Power Spec. NA version 220 to 240V, 50/60Hz Max.
  • Page 120 Appendix: Specifications B/W: 20 cpm (A4), 21 cpm (LT) Single Platen FC: 20 cpm (A4), 21 cpm (LT) Document Multiple B/W: 20 cpm, FC: 20 cpm (A4), Copy Copy Speed B/W: 21 cpm, FC: 21 cpm (LT) Multiple Document B/W: 20 cpm, FC: 10 cpm Single Copy Multiple copy Up to 99...
  • Page 121 Appendix: Specifications Directional Size Magnification Photo Mode Auto Start User Program Electronic Sorting Standard (collation, ADF only) Image Rotation Series Copy Scanner Scanning Device CCD array image-sensor Scanner: 1200 x 1200 dpi Resolution Driver: Max. 19200 x 19200 dpi (interpolated) Gray scale 256 levels ADF:...
  • Page 122 Appendix: Specifications Scanner utilities and TWAIN Driver, Scanner utility Drivers Circuit PSTN/ PABX Compatibility: ITU-T Group 3 Coding system: MH/MR/MMR Modem speed: Automatic Fallback: 33600 bps Platen: A4/ LT/ LG Width max: 216 mm (8.5"), Length max: 297 mm (11.7") Document size: ADF: A4/ LT/ DLT Width: 139.7-215.9mm (5.5”...
  • Page 123 Appendix: Specifications Speed: 33.6kbps 100 pages (ITU No.1 chart, Compression: MMR, Resolution: SAF Memory Standard) Memory Backup 1 hour One-touch dial: 20 (10 x 2) Broadcasting: 100 stations Communication Public switched telephone network source: PC Fax utility: Not available Automatic re-dial 5/4/3/2 times after 5 minutes (Default 5 times) Auto Answer 1-99 rings (Default 2 rings)

  • Page 124: Supported Paper Sizes

    Appendix: Specifications Supported Paper Sizes Supported and the size is molded in the tray. Need to select paper size by operation panel/driver. Supported but size is not molded in the tray. Need to select paper size by operation panel/driver. Need to input paper size by operation panel and driver. Not supported.
  • Page 125 Appendix: Specifications Input Tray SEF/ Auto. Type Size Standard Option Bypass Dup. Tray Tray 8 1/2”x11” Letter 11”x 8 1/2” Half 5 1/2” x 8 Letter 1/2” 7 1/4”x10 1/2” Executive 10 1/2”x7 1/4” 8” x 13” Foolscap 8 1/2” x 13” Folio 8 1/4”...
  • Page 126 Appendix: Specifications Input Tray SEF/ Auto. Type Size Standard Option Bypass Dup. Tray Tray 90-216mm Custom Width (3.6”x 8.5”) 148 – 356mm Length (5.8”x 14.24”)

  • Page 127: Appendix: Preventive Maintenance

    Appendix: Preventive Maintenance Appendix: Preventive Maintenance Preventive Maintenance User Replaceable Items Item Yield Approx. 1.0 k prints/cartridge(Starter) Print Cartridge (AIO) 6.5 k for BK, 6.0 k for CMY (prints/cartridge) Approx. 25 k prints/ bottle Waste Toner Bottle (See condition 5) Condition: An A4 (8.5"x11")/ 5% chart was used to measure the above yield except the Print Cartridge (AIO).

  • Page 128: Error Messages

    Appendix: Troubleshooting Guide Appendix: Troubleshooting Guide Error Messages Overview The error codes will be displayed on the LCD if the machine has a problem. These can be recovered by a customer. Error Messages List Cover Open The front or top cover is open. Close the front or top cover.
  • Page 129 Appendix: Troubleshooting Guide Waste Toner Bottle Set Error Waste toner bottle not set Disconnected or defective harness of the waste toner bottle set sensor Defective waste toner bottle set sensor Install the waste toner bottle. Check or replace the harness of the waste toner bottle set sensor. Replace the waste toner bottle set sensor.
  • Page 130 Appendix: Troubleshooting Guide Inner Jam Error: Registration/ Paper Exit A sheet of paper stays at the registration sensor or paper exit sensor. Paper slipped Paper double feed Remove the paper jam at the registration sensor or paper exit sensor. Paper Exit Jam Error: Paper Exit/ Fusing Unit A sheet of paper stays at the paper exit sensor or winds around the rollers in the fusing unit.

  • Page 131: Fax Error Code

    Appendix: Troubleshooting Guide Toner Near End: Cyan AIO Toner End: Cyan AIO Cyan toner near-end or end Replace the Cyan AIO. Toner Near End: Yellow AIO Toner End: Yellow AIO Yellow toner near-end or end Replace the yellow AIO. Waste Toner Bottle: Near Full Waste Toner Bottle: Full Waste toner bottle near-full or full Replace the waste toner bottle.
  • Page 132 Appendix: Troubleshooting Guide Basic error code structure Error codes consist of six hexadecimal digits (0–5). Digit 5 (far left) TX or RX TX: 1xxxxx RX: 2xxxxx Digit 4 Coding (MH/MR/MMR) MH: x1xxxx MR: x2xxxx MMR: x3xxxx Digit 3 MODEM mode V27ter nonECM: xx1xxx V29 nonECM: xx2xxx V17 nonECM: xx3xxx...
  • Page 133 Appendix: Troubleshooting Guide Digit 2 MODEM speed 7200: xxx3xx 9600: xxx4xx 12000: xxx5xx 14400: xxx6xx 16800: xxx7xx 19200: xxx8xx 21600: xxx9xx 24000: xxxaxx 26400: xxxbxx 28800: xxxcxx 31200: xxxdxx 33600: xxxexx Error code table Error Type Error Description Error Code STOP xxxx01 General...
  • Page 134 Appendix: Troubleshooting Guide Error Type Error Description Error Code Conn ection Fail xxxx21 Dial failure Dial Fail xxxx22 Redial All Failed xxxx23 TX T1 Time Out xxxx31 V8 negotiation Fail xxxx32 Retry Out xxxx40 Too many FTT xxxx41 Too many CRP xxxx42 T2 Time Out xxxx43...
  • Page 135 Appendix: Troubleshooting Guide Error Type Error Description Error Code Too many PPR xxxx64 RNR time Out xxxx65 RTN/PIN Received, xxxx66 EOR/ERR/DCN Invalid xxxx67 Command/Response RX Command Rec Error xxxx68 Resp Rec Error xxxx69 4. Phase-E Time Out xxxx70 Error modem hang-up xxxx80 V34 abort received xxxx81...

  • Page 136: Service Call Conditions

    Appendix: Troubleshooting Guide Service Call Conditions Summary This machine issues an SC (Service Call) code if an error occurs on the machine. The error code can be seen on the operation panel. Make sure that you understand the following points; All SCs are logged.
  • Page 137 Appendix: Troubleshooting Guide SC 2xx (Laser Optics Error) Polygon motor error 1: ON timeout The polygon mirror motor does not reach the targeted operating speed within 5 sec. after turning on or changing speed Polygon motor error 2: OFF timeout The polygon mirror motor does not leave the READY status within 3 sec.
  • Page 138 Appendix: Troubleshooting Guide Check the connectors. Replace the laser optics unit. Replace the EGB. LD error The IPU (EGB) detects a problem at the LD unit. Worn-out LD Disconnected or broken harness of the LD. Replace the laser optics unit. SC 3xx (Charge Error) High voltage power output error The measured voltage is not correct when the EGB measures each charge output...
  • Page 139 Appendix: Troubleshooting Guide Color drum motor error The LOCK signal error is detected when the EGB monitors the color drum motor state. (This monitoring is done immediately after power-on, when the motor starts rotating, and immediately after the motor stops.) Disconnected or defective motor harness.
  • Page 140 Appendix: Troubleshooting Guide power-on or after the cover is closed. Disconnected or defective harness Defective agitator motor Check or replace the harness. Replace the agitator motor. ITB (Image Transfer Belt) Unit Set Error The TM sensor does not detect the reflection from the ITB. No ITB unit in the machine Dirty TM sensor Check the installation of the ITB unit.
  • Page 141 Appendix: Troubleshooting Guide Check or replace the motor harness. Replace the LSU fan motor. Fusing Fan Motor Error A LOCK signal is not detected for more than ten seconds while the motor START signal is on and if this error occurs twice consecutively, this SC is issued. Disconnected or defective motor harness.
  • Page 142 Appendix: Troubleshooting Guide Replace the fusing lamp. Execute "Engine Maintenance Menu" to recover the machine after completing the recovery procedure. Otherwise, the machine continues to issue this SC code and cannot be operated. High Temperature Detection Error This SC is issued if one of following conditions occurs: The thermistor (center) detects 255°C or thermistor (end) detects 245°C.
  • Page 143 Appendix: Troubleshooting Guide Zero Cross Error The zero cross signal is not detected for three seconds even though the fusing lamp relay is on after turning on the main power or closing the front door. Defective fusing lamp relay Turn the main power switch off and on. Execute "Engine Maintenance Menu"...
  • Page 144 Appendix: Troubleshooting Guide Execute "Engine Maintenance Menu" to recover the machine after completing the recovery procedure. Otherwise, the machine continues to issue this SC code and cannot be operated. Consecutive Fusing Jam The paper jam counter for the fusing unit reaches 3. The paper jam counter is cleared if the paper is fed correctly.

  • Page 145: Controller Sc

    Appendix: Troubleshooting Guide The chip ID of the GAVD cannot be detected by the machine at power-on. Defective EGB Replace the EGB. Controller SC SC8xx Service Cycle Power Incorrect combination of EGB and controller board. An unexpected error occurs in the EEPROM on the controller board. Controller board defective Install the correct EGB and controller boards for this machine.
  • Page 146 Appendix: Troubleshooting Guide Replace the controller board. ROM Checksum Error A ROM checksum error at power-on occurs. Replace the controller board.

  • Page 147: Service Menu

    Appendix: SP Mode Tables Appendix: SP Mode Tables Service Menu Overview This model has several service menus. Each service menu has several adjustment items. This section explains how to enter each service menu and what you can do in each service menu.
  • Page 148 Appendix: SP Mode Tables "Ready" display appears. Menu List Display Info Displays the Model Name, Depends on Engine Model Name Firmware Settings CTL FW Ver. Displays the Firmware Version FAX FW Ver. Displays the PDL Firmware Version. FW Ver. MCTL FW Ver. Displays the Engine Firmware Version PDL FW Ver.
  • Page 149 Appendix: SP Mode Tables printed. Off (Default)/ Error/ On Engine Maintenance Determines the maximum amount of ink/toner you can use in any area of your text. This is where you are controlling exactly how much ink will be used Text during printing.
  • Page 150 Appendix: SP Mode Tables Engine Maintenance Adjusts the transfer roller current, based on the 2nd Transfer default value. Back [-15 to 15 / 0 (Default) / 1 μA/step] Adjusts the temperature of the fusing unit, based Fuser on the default value. Temperature [-30 to 0 / 0 (Default) / 2°C/step] Plain Paper (90-105 g/m...
  • Page 151 Appendix: SP Mode Tables Engine Maintenance Adjusts the horizontal registration for the bypass tray. If the machine settings are reset to the Horiz.Bypass factory defaults, this value does not change. [-15 to 15 / 0 (Default) / 4 mm/step] Adjusts the vertical registration for the bypass tray.
  • Page 152 Appendix: SP Mode Tables Engine Maintenance Displays the current model in a dropdown list. Do not change this setting (Designed for Factory Use). 00* – 7F Brand ID Displays the current brand ID number. Do not change this setting (Designed for Factory Use). Character: alphanumeric "0-9", "a-f", "A-F", only Input 160 bytes LSU Adjustment...
  • Page 153 Appendix: SP Mode Tables Scan Maintenance Adjusts the ADF Scan main-scan registration. ADF Main Reg. [-2.0 to 2.0 / 0 (Default)/ 0.1 mm/step] Adjusts the ADF Scan sub-scan registration. ADF Sub Reg. [-2.0 to 2.0 / 0 (Default)/ 0.1 mm/step] Regist Adjust Flatbed Main Adjusts the Flatbed Scan main-scan registration.
  • Page 154 Appendix: SP Mode Tables Fax Maintenance the telephone line. [0Km (Default)/ 1.8Km/ 3.6Km/ 7.2Km] This sets the number of training retries to be Training Retries repeated before automatic fallback. Protocol [1 Time/ 2 Times (Default)/ 3 Times/ 4 Times] Definition Sets the compression method for Tx/Rx.
  • Page 155 Appendix: SP Mode Tables Fax Maintenance Determines the period when tones from the line Tone Sound are monitored. Monitoring [No Monitoring/ Up To Phase B (Default)/ All TX Phases] Pressing the Stop/Clear key can stop the current Stop/Clear key receiving operation. Received data is lost. [Not Functional (Default)/ Functional] Sets the off-hook detection threshold.
  • Page 156 Appendix: SP Mode Tables Fax Maintenance Tone Signal Sets the tone signal transmission time length Transmission [100 ms (Default)] Time Length Minimum Pause Sets the minimum pause during tone dialing In Tone Dialing [100 ms (Default)/ 150 ms/ 200 ms] Attenuator For Sets the attenuator for pseudo ringback tone to the Pseudo Ring...
  • Page 157 Appendix: SP Mode Tables Fax Maintenance Hz/ 350-500 Hz/ 350-550 Hz/ 375-475 Hz/ 380-520 Hz] BT Level [-35 dB/ -36 dB/ -37 dB/ -38 dB/ -39 dB] BT Cadence [0.10/ 0.15/ 0.20/ 0.25/ 0.30/ 0.35/ 0.40/ 0.45/ 0.50/ 0.75] The machine checks the actual data reconstruction errors and then transmits an RTN depending on the decoding error rate that is set by RTN Rate...
  • Page 158 Appendix: SP Mode Tables Fax Maintenance This setting limits the transmission speed range in V.34 mode by masking the desired symbol rate(s). Symbol Rate [Not Used (Default)/ 3429 Sym/Sec / 3200 Sym/Sec/ 3000 Sym/Sec / 2800 Sym/Sec/ 2400 Sym/Sec] The "Reseller Default" menu can be entered directly at power-on. If you want to enter this mode directly, try the following procedure.
  • Page 159 Appendix: SP Mode Tables CED Test Executes the CED test. CNG Test 1100 Hz Executes the CNG test ANSam Executes the ANSam test. Ring Tone Test Executes the ring tone test. Tone [0] to [9] Executes the DTMF tone 0 to 9 test. Tone [*] Executes the DTMF tone * test.

  • Page 160: Appendix: Machine Swap

    Appendix: Machine Swap Appendix: Machine Swap Exchange and Replace Procedure If the machine exchange and replacement is required, arrange to send a machine without the four print cartridges (AIO) to the customer site. Instruction Instruct the customer to do the following procedure. Before the substitute machine gets to the customer site Save the customer settings by using a web browser.
  • Page 161 Appendix: Machine Swap Pull out the waste toner bottle [A]. Release the hook [A] under the guide plate. Move the guide plate [B] underneath the fusing unit to the left, and then remove it. Pull out the image transfer belt unit [A] ( x 2).
  • Page 162 Appendix: Machine Swap Clean inside the machine, especially around the circled area [A]. Clean the circled area at the waste toner bottle [A] and circled area [B] at image transfer belt unit. 10. Reassemble the machine.
  • Page 163 AIO: K AIO: Y J-FAX1 Pin# Signal Name Pin# Signal Name AIO: M +3.3VE +3.3VE /SRD +3.3VE /SRD AIO: C +3.3VE IRQN IRQN /SWR /SWR Operation Panel +3.3VE Board (PCB1) /RESET FAX_ID0 Option FAX_ID0 CN101 CN221 (nc) Paper +3.3VE Feed Unit (G849) (PCB8) PCB7...
  • Page 164 g165v106 m018v103 g165v104 g165v105 g180v103 g180v102 g180v101 Index Index Index Index Symbol Name P to P Symbol Name P to P Symbol Name P to P Symbol Name P to P Motors Sensors Magnetic Clutches PCBs Waste Toner Overflow PCB1 Operation Panel Duplex Motor Registration Clutch LSU Fan Motor...

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