KONICA 7415 SERVICE HANDBOOK

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Page 1

7415

SERVICE HANDBOOK

FIELD SERVICE

KONICA CORPORATION

TECHNOLOGY SUPPORT CENTER

TOKYO JAPAN

Page 2

INDEX (FIELD SERVICE) DIS/REASSEMBLY,

ADJUSTMENT SWITCHES ON PWBs,

TECH. REP. SETTINGS

TROUBLESHOOTING

Page 3

SAFETY AND IMPORTANT WARNING ITEMS

Read carefully the Safety and Important Warning Items described below to understand them before doing service work.

IMPORTANT NOTICE

Because of possible hazards to an inexperienced person servicing this copier, as well as the risk of damage to the copier, Konica Corporation, strongly recommends that all servicing be performed only by Konica-trained service technicians.

Changes may have been made to t his copier to improv e i ts perf ormance after this Service Handbook was printed. Accordingly, Konica Corporation, makes no representations or warranties, either expressed or implied, that the information contained in this Service Handbook is complete or accurate. It is understood that the user of this Service Handbook must assume all risks or personal injury and/or damage to the copier while servicing the copier for which this Service Handbook is intended. Therefore, this Service Handbook must be read carefully before doing service work both in the course of the technical training and even after that, for keeping the correct maintenance and control of the copier. Keep the Service Handbook also for the future service. When it is impossible to read the description about safety and warning (due to contamination or tear), the relevant page should be replaced.

DESCRIPTION ITEMS FOR DANGER, WARNING AND CAUTION

In this Service Handbook, each of three expressions, “ DANGER”, “ WARNING” and “ CAUTION” is defined as follows together with a symbol mark to be used in a limited mean-

ing. When servicing, the relevant works (disassembling, assembling, adjustment, repair and maintenance) need to be conducted with utmost care.

DANGER: WARNING: CAUTION:

Actions having a high possibility of suffering death or serious wound Actions having a possibility of suffering death or serious wound Actions having a possibility of s uffering a slight wound, medium trouble

and material damage

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SAFETY AND IMPORTANT WARNING ITEMS

SAFETY WARNINGS

[1] MODIFICATIONS NOT AUTHO-

RIZED BY Konica

Konica copiers are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network.

Photocopier design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degrading performance and safety. Such modifications are therefore strictly prohibited. The points listed below are not exhaustive, but they illustrate the reasoning behind this policy.

PROHIBITED ACTIONS:

(1) Using extension cables or a different

power cord than specified by Konica.

(2) Using other fuses than specified by

Konica. Safety will not be assured, leading to a risk of fire and injury.

(3) Disabling fuses or bridging fuse termi-

nals with wire, metal clips, s older or similar. (This applies also to thermal fuses.)

(4) Removing air filters (except for

replacement).

(5) Dis a bling relay fun ctions (such as

wedging paper between relay contacts, etc.).

(6) Disabling safety functions (interlocks,

safety circuits, etc.). Safety will not be assured, leading to a risk of fire and injury.

(7) Performi ng actions to copier not

described in the instruction manual or the service handbook.

(8) Usi ng pa rts othe r than specified by

Konica.

[2] CHECKPOINTS WHEN PER-

FORMING ON -S I T E SE RVICE

Konica copiers are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engineer from the risk of injury . However, in daily use, any electrical equipment may be subject to parts wear and eventual failure. In order to maintain safety and reliability, the customer engineer must perform regular safety checks.

1. Advance Preparation for Safety Checks

CAUTION:

(1) Wear clothing that facilitates work and

is designed for safety.

(2) Carry out all procedures carefully to

prevent injury.

(3) Be sure to disconnect the power cord

of the copier and all optional equipment from the AC outlet. Simply turning off the power switch is not sufficient, because paper feed units or other electrical equipment may be powered also when the power switch is turned of f.

(4) Proceed with special care when per-

forming operation checks or adjustment while the unit is powered. When carrying out operation checks or adjustment while external covers are removed, the risk of electrical shock exists when touc hing parts which c arry high voltage or electrical charge. The risk of injury exists when touching moving parts such as gears or chains.

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SAFETY AND IMPORTANT WARNING ITEMS

2. Safety Checkpoints

The following list is not exhaustive, but it includes actions which must be carried out at every on-site service.

CAUTION:

(1) Check external covers and the frame

for sharp edges, burrs, or nicks.

(2) Check external covers and hinges for

loosening or damage. (3) Check wiring for squeezing or damage. (4) Check power cord for insulatio n prob-

lems (conductor m us t not be exposed). (5) Check power cord and cable ties etc.

for loosening from frame.

WARNING:

(1) Verify that the copier is properly

grounded. If a problem is detected,

establish a proper ground connection. (2) Connecting the ground lead to an

improper point such as listed below

results in a risk of explosion and elec-

tric shock.

Unsuitable ground points:

a. Gas pipe b. Lightning rod c. Telephone line ground d. Plastic water pipe or water pipe or

faucet that has not been approved by authorities for grounding use

3. Precautions for on-site service

CAUTION:

(1) Before performing safety check work,

read all relevant documentation (ser-

vice handbook, technical notices, etc.)

and proceed according to the pre-

scribed procedure, using only the pre-

scribed tools. Do not carry out any

adjustments not described in the docu-

mentation. (2) If the power cord is damaged, replace it

only with the specified power cord. If

the power cord insulation has been

damaged and there are exposed sec-

tions, short-circuits and overheating

may occur, leading to a serious fire

risk.

(3) Do not route the power cord so that it

can be stepped on or pinc he d. Otherwise overheating may occur , leading to a serious fire risk.

(4) When disconnecting any cables,

always grasp the connector and not the cable (especially in the case of AC and high-voltage leads).

(5) Carefully remove all toner remnants

from electrical parts, electrodes, etc.

(6) Make sure that wiring cannot come

into contact with sharp edges, burrs, or other pointed parts.

(7) Double-check to make sure that all

screws, components, wiring, connectors, etc. that were removed for safety check maintenance have been reinstalled in the original loc a tion. (Pa y special attention to forgotten connectors, pinched cables, forgotten scre ws, etc.)

(8) When installation and preventive main-

tenance, verify that the power cord has been securely plugged into the AC outlet. Contact problems may lead to increased resistance, overheating, and the risk of fire.

WARNING:

(1) Bef ore disassembling or adjusting the

optical unit or any parts that use a laser, make sure that the power cord has been disconnected.

(2) Do not remove the main cover of the

write unit. Direct exposure of the eye to laser beams may lead to blindness.

(3) Do not turn the copier on while the

write unit is not install e d in its normal position.

(4) Da nger of explosion if bat ter y is inc or -

rectly replaced, replace only with the same or equivalent recommended by the manufacturer. Discard used batteries according to the manufacture’s instructions.

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SAFETY AND IMPORTANT WARNING ITEMS

VORSICHT: Expiosionsgefahr dei unsachegemäßem Austausch der Battetie. Ersatz nur durch denselben oder einen vom. Hersteller empfohlenen gleichwertigen Typ. Entsorgung gebrauchter Batterie n na c h Angaben des Herstellers.

[3] HANDLING OF MATERIALS

FOR SERVICING

CAUTION: Drum cleaner (alcohol-based) and roller cleaner (acetone-based) are highly flammable and must be handled with care. When using these materials for cleaning of copier parts, observe the following precautions. (1) Disconnect the power cord from the A C

outlet.

(2) Use only a small amount of cleaner at a

time and take care not to spill any liquid. If this happens, immediately wipe it off.

(3) Perform cleaning only in an enviro n-

ment where sufficient ventilation is assured. Breathing large quantities of organic solvents can lead to discomfort.

(4) Do not replace the cover or turn the

unit on before any solvent remnants on the cleaned parts have fully evaporated.

CAUTION: Toner and deve lo per are not harmful substances, but care must be taken not to breathe excessive amounts or let the substances come into contact with eyes etc. If the substances get in the eye, rinse it with plenty of water immediately. When symptoms are noticeable, consult a physician.

[4] MEASURES TO TAKE IN CASE

OF AN ACCIDENT

(1) It an accident has occurred, the distributor

who has been notified first must immediately take emergency measures to provide relief to affected persons and to prevent further damage.

(2) It a report of a serious accident has been

received from a customer, an on-site evaluation must be carried out quickly and Konica Corporation must be notified.

(3) To determine the cause of the accident,

conditions and materials must be recorded through direct on-site checks, in accordance with instructions issued by Konica Corporation.

(4) For reports and measures concerning

accidents, consult your superior, and follow the regulations set in “Standards for the Control Program for Measures Against Electrical Equipment Accidents”.

[5] CONCLUSION

(1) Safet y of users and customer engineers

depends highly on accurate maintenance and administration. Therefore, safety can be maintained by the appropriate by the proper daily service work conducted by the customer engineer.

(2) When performing service, each copier on

the site must be tested for safety. The customer engineer must verify the safety of parts and ensure appropriate management of the equipment.

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Safety Precautions for Inspection and Service

When performing inspection and service procedures, observe the following precautions to prevent accidents and ensure utmost safety.

✽

Depending on the model, some of the precautions given in the following do not apply.

Different markings are used to denote specific meanings as detailed below.

Indicates a potentially hazardous situation which, if not avoided,

WARNING

CAUTION

The following graphic symbols are used to give instructions that need to be observed.

Used to call the service technician’s attention to what is graphically represented inside the marking (including a warning).

Used to prohibit the service technician’s from doing what is graphically represented inside the marking.

Used to instruct the service technician’s to do what is graphically represented inside the marking.

1. Always observe precautions.

•

Parts requiring special attention in this product will include a label containing the mark shown on the left plus precautionary notes. Be sure to observe the precautions.

•

Be sure to observe the “Safety Information” given in the Operator’s Manual.

could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

WARNING

2. Before starting the procedures, be sure to unplug the power cord.

•

This product contains a high-voltage unit and a circuit with a large current capacity that may cause an electric shock or burn.

•

The product also contains parts that can jerk suddenly and cause injury .

•

If this product uses a laser, laser beam leakage may cause eye damage or blindness.

3. Use the specified parts.

•

For replacement parts, always use the genuine parts specified in the manufacturer’s parts manual. Installing a wrong or unauthorized part could cause dielectric breakdown, overload, or undermine safety devices resulting in possible electric shock or fire.

•

Replace a blown electrical fuse or thermal fuse with its corresponding genuine part specified in the manufacturer’s parts manual. Installing a fuse of a different make or rating could lead to a possible fire. If a thermal fuse blows frequently, the temperature control system may have a problem and action must be taken to eliminate the cause of the problem.

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4. Handle the power cord with care and never use a multiple outlet.

•

Do not break, crush or otherwise damage the power cord. Placing a heavy object on the power cord, or pulling or bending it may damage it, resulting in a possible fire or electric shock.

•

Do not use a multiple outlet to which any other appliance or machine is connected.

•

Be sure the power outlet meets or exceeds the specified capacity.

5. Be careful with the high-voltage parts.

•

A part marked with the symbol shown on the left carries a high voltage. Touc hing it could result in an electric shock or burn. Be sure to unplug the power cord before servicing this part or the parts near it.

6. Do not work with wet hands.

•

Do not unplug or plug in the power cord, or perform any kind of service or inspection with wet hands. Doing so could result in an electric shock.

7. Do not touch a high-temperature part.

•

A part marked with the symbol shown on the left and other parts such as the exposure lamp and fusing roller can be very hot while the machine is energized. Touching them may result in a burn.

•

Wait until these parts have cooled down before replacing them or any surrounding parts.

8. Maintain a grounded connection at all times. (This item may not apply in the USA.)

•

Be sure to connect the ground wire to the ground terminal even when performing an inspection or repair. Without proper grounding, electrical leakage could result in an electric shock or fire.

•

Never connect the ground wire to a gas pipe, water pipe, telephone ground wire, or a lightning conductor.

9. Do not remodel the product.

•

Modifying this product in a manner not authorized by the manufacturer may result in a fire or electric shock. If this product uses a laser, laser beam leakage may cause eye damage or blindness.

10. Restore all parts and harnesses to their original positions.

•

To promote safety and prevent product damage, make sure the har nesses are returned to their original positions and properly secured in their clamps and saddles in order to avoid hot parts, high-voltage parts, sharp edges, or being crushed.

•

To promote safety, make sure that all tubing and other insulating materials are returned to their original positions. Make sure that floating components mounted on the circuit boards are at their correct distance and position off the boards.

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CAUTION

1. Precautions for Service Jobs

•

A toothed washer and spring washer, if used originally, must be reinstalled. Omitting them may result in contact failure which could cause an electric shock or fire.

•

When reassembling parts, make sure that the correct screws (size, type) are used in the correct places. Using the wrong screw could lead to stripped threads, poorly secured parts, poor insulating or grounding, and result in a malfunction, electric shock or injury.

•

Take great care to avoid personal injury from possible burrs and sharp edges on the parts, frames and chassis of the product.

•

When moving the product or removing an option, use care not to injure your back or allow your hands to be caught in mechanisms.

2. Precautions for Servicing with Covers and Parts Removed

•

Wherever feasible, keep all parts and covers mounted when energizing the product.

•

If energizing the product with a cover removed is absolutely unavoidable , do not touch any exposed live parts and use care not to allow your clothing to be caught in the moving parts. Never leave a product in this condition unattended.

•

Never place disassembled parts or a container of liquid on the product. Parts falling into, or the liquid spilling inside, the mechanism could result in an electric shock or fire.

•

Never use a flammable spray near the product. This could result in a fire.

•

Make sure the power cord is unplugged before removing or installing circuit boards or plugging in or unplugging connectors.

•

Always use the interlock switch actuating jig to actuate an interlock s wit ch when a cover is opened or removed. The use of folded paper or some other object may damage the interlock switch mechanism, possibly resulting in an electric shock, injury or blindness.

3. Precautions for the Working Environment

•

The product must be placed on a flat, level surface that is stable and secure.

•

Never place this product or its parts on an unsteady or tilting workbench when servicing.

•

Provide good ventilation at regular intervals if a service job must be done in a confined space for a long period of time.

•

Avoid dusty locations and places exposed to oil or steam.

•

Avoid working positions that may block the ventilation ports of the product.

4. Precautions for Handling Batteries

•

Replace a rundown battery with the same type as specified in the manufacturer’s parts manual.

•

Before installing a new battery, make sure of the correct polarity of the installation or the battery could burst.

•

Dispose of used batteries according to the local regulations. Never dispose of them at the user’s premises or attempt to try to discharge one.

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5. Precautions for the Laser Beam (Only for Products Employing a Laser)

•

Removing the cover marked with the following caution label could lead to possible exposure to the laser beam, resulting in eye damage or blindness. Be sure to unplug the power cord before removing this cover.

•

If removing this cover while the power is ON is unavoidab le , be sure to wear protective laser goggles that meet specifications.

•

Make sure that no one enters the room when the machine is in this condition.

•

When handling the laser unit, observe the “Precautions for Handling Laser Equipment.”

1167P001AA

DANGER

Invisible laser radiation when open.

AVOID DIRECT EXPOSURE TO BEAM

0947-7127-01

1144D270AA

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Other Precautions

•

To reassemble the product, reverse the order of disassembly unless otherwise specified.

•

While the product is energized, do not unplug or plug connectors into the circuit boards or harnesses.

•

The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.

•

An air gun and vacuum cleaner generates a strong electrostatic charge that can destroy the ATDC sensor and other sensors. Before cleaning a component with one of these devices, be sure to remove all the sensors. Otherwise, use a blower brush and cloth when cleaning parts.

•

When handling circuit boards with MOS ICs, observe the “INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS IC s” (applicable only to the products using MOS ICs).

•

The PC Drum is a very delicate component. Observe the precautions given in “HANDLING OF THE PC DRUM” because mishandling may result in serious image problems.

•

Note that replacement of a circuit board may call for readjustments or resetting of particular items, or software installation.

•

After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions.

•

Check the area surrounding the service site for any signs of damage, wear or need of repair.

•

Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged hopper motor or locking mechanism.

•

If the product is to be run with the front door open, make sure that the toner hopper is in the locked position.

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Used Batteries Precautions

ALL Areas

Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions.

CAUTION

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PRECAUTIONS FOR SERVICE

When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts.

✽

Depending on the model, some of the precautions given in the following do not apply.

Precautions Before Service

•

When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads.

•

Never disturb the LAN by breaking or making a network connection, altering termination, installing or removing networking hardware or software, or shutting down networked devices without the knowledge and ex press permission of the network administrator or the shop supervisor.

How to Use this Book

1. DIS/REASSEMB LY, ADJUST MENT

•

To reassemble the product, reverse the order of disassembly unless otherwise specified.

2. TROUBLESHOOTING

•

If a component on a PWB or any other functional unit including a motor is defec tive, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defect ive unit.

•

All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions.

•

The procedures preclude possible malfunctions due to noise and other external causes.

Precautions for Service

•

Check the area surrounding the service site for any signs of damage, wear or need of repair.

•

Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged.

•

After completing a service job, perform a safety check. Make sure that all parts, wiring and screws are returned to their original positions.

•

Do not pull out the toner hopper while the toner bottle is turning. This could result in a damaged motor or locking mechanism.

•

If the product is to be run with the front door open, make sure that the toner hopper is in the locked position.

•

Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit.

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Precautions for Dis/Reassembly

•

Be sure to unplug the copier from the outlet before attempting to service the copier.

•

The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow y our clothing to be caught in revolving parts such as the timing belt and gears.

•

Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet.

•

Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed.

•

Do not plug in or unplug print jacks on the PWB or connect or disconnect the PWB connectors while power is being supplied to the copier.

•

Never use flammable sprays near the copier .

•

A battery (lithium, nickel-cadmium, etc.) is used in this machine. Do not charge or short circuit it and make sure of the correct polarity at replacement.

•

A used battery should be disposed of according to the local regulations and never be discarded casually or left unattended at the user's premises.

•

When reassembling parts, make sure that the correct screws (size, type) and toothed washer are used in the correct places.

•

If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice.

Precautions for Circuit Inspection

•

Never create a closed circuit across connector pins except those specified in the text and on the printed circuit.

•

When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the GND wire.

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Handling of PWBs

1. During Transpor tation/St orage:

•

During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags.

•

Do not store or place P.W. Boards in a location exposed to direct sunlight and high temperature.

•

When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity.

•

Do not touch the pins of the ICs with your bare hands.

•

Protect the PWBs from any external force so that they are not bent or damaged.

2. During Inspection/Replacement:

•

Avoid checking the IC directly with a multimeter; use connectors on the Board.

•

Never create a closed circuit across IC pins with a metal tool.

•

Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet.

•

When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board.

•

When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch a metal part to discharge static electricity before touching the PWB.

•

Note that replacement of a PWB may call for readjustments or resetting of particular items.

Handling of Other Parts

•

The magnet roller generates a strong magnetic field. Do not bring it near a watch, floppy disk, magnetic card, or CRT tube.

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Handling of the PC Drum

✽

Only for Products Not Employing an 7415 Supply Unit.

1. During Transpor tation/St orage:

•

Use the specified carton whenever moving or storing the PC Drum.

•

The storage temperature is in the range between –20°C and +40°C.

•

In summer, avoid leaving the PC Drum in a car for a long time.

2. Handling:

•

Ensure that the correct PC Drum is used.

•

Whenever the PC Drum has been removed from the copier , store it in i ts carton or protect it with a Drum Cloth.

•

The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight.

•

Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.

•

Do not scratch the surface of the PC Drum.

•

Do not apply chemicals to the surface of the PC Drum.

•

Do not attempt to wipe clean the surface of the PC Drum.

If, however, the surface is contaminated with fingerprints, clean it using the following procedure.

1. Place the PC Drum into one half of its carton.

1076D001

1076D002

2. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad.

A. Turn the PC Drum so that the area of its surface on

which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum.

B. Turn the PC Drum slightly and wipe the newly

exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned.

✽

At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is e vident on the face of the Pad after wiping.

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3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times.

✽

Never move the Pad back and forth.

1076D003

4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OV ERLA P the areas when wiping. Two complete turns of the PC Drum would be appropriate for cleaning.

1076D004

NOTES

• Even when the PC Drum is only locally dirtied, wipe the entire surface.

• Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under

interior illumination.

• If dirt remains after cleaning, repeat the entire procedure from the beginning one more time.

Handling of the 7415 Supply Unit

✽

Only for Products Employing an 7415 Supply Unit.

1. During Transpor tation/St orage:

•

The storage temperature is in the range between –20°C and +40°C.

•

In summer, avoid lea v ing the 7415 Supply Unit in a car for a long time.

2. Handling:

•

Store the 7415 Supply Unit in a place that is not exposed to direct sunlight.

3. Precautionary Information on the PC Drum Inside the 7415 Supply Unit:

•

Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter.

•

Do not scratch the surface of the PC Drum.

•

Do not attempt to wipe clean the surface of the PC Drum.

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DIS/REASSEMBLY,

ADJUSTMENT

18605

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1. SERVICE INSTRUCTIONS .............................................................................D-1

1-1. IDENTIFICATION OF FUSES ......................................... ........................D-1

1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT ...............D-1

1-3. PARTS WHICH MUST NOT BE TOUCHED ....................... ....................D-2

(1) Red Screws .... ............. ......................... ......................... ..................D-2

(2) Variable Resistors on Board ............................................................D-2

(3) Other Screws ...................................................................................D-2

1-4. READING THE TEXT ..............................................................................D-3

2. DISASSEMBLY/REASSEMBLY ......................................................................D-4

2-1. COVERS AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL

PROCEDURES ....................................................................................... D-4

2-2. REMOVAL OF PWBs ..............................................................................D-6

2-3. MAINTENANCE SCHEDULE .................................................................. D-7

2-4. REMOVAL OF UNITS .............................................................................D-8

(1) Removal of the Upper Half of the Copier .........................................D-8

(2) Removal of the IR Unit .................................................................... D-11

(3) Removal of the PH Unit ...................................................................D-12

(4) Removal of the Fusing Unit .............................................................D-15

2-5. IMAGE TRANSFER SECTION ................................................................D-17

(1) Replacement of the Image Transfer Roller ......................................D-17

2-6. FUSING SECTION ..................................................................................D-18

(1) Removal of the Fusing Backup Roller .............................................D-18

(2) Removal of the Fusing Heater Lamp ............................................... D-20

(3) Removal of the Fusing Roller ..........................................................D-21

2-7. MISCELLANEOUS ..................................................................................D-22

(1) Removal of the Scanner and Timing Belt ........................................D-22

(2) Removal of the Scanner Motor ........................................................D-24

(3) Removal of the Paper Take-Up Roll ................................................D-25

(4) Removal of the Paper Take-Up Solenoid ........................................D-26

(5) Removal of the Main Motor and PH Section Cooling Fan Motor .....D-28

3. ADJUSTMENT .................................................................................................D-30

3-1. ADJUSTMENT REQUIREMENTS LIST .................................................. D-30

3-2. ADJUSTMENT OF UPPER UNIT INTERLOCK SWITCH S2 ..................D-31

3-3. ELECTRICAL/IMAGE ADJUSTMENT .....................................................D-32

(1) Entering the Tech. Rep. Mode .........................................................D-32

(2) Entering the Adjust Mode ................... .............................................D-32

(3) Producing a Test Pattern .................................................................D-32

(4) CD Registration Adjustment (Paper Tray) .......................................D-33

(5) FD Registration Adjustment (Paper Tray) .......................................D-34

(6) CD Zoom Ratio Adjustment (Scanner) ............................................D-35

(7) FD Zoom Ratio Adjustment (Scanner) ............................................D-36

(8) CD Registration Adjustment (Scanner) ...........................................D-37

(9) FD Registration Adjustment (Scanner) ............................................D-38

4. MISCELLANEOUS ..........................................................................................D-39

4-1. TORSION BAR POSITION ADJUSTMENT .............................................D-39

4-2. REMOUNTING EEPROM (U21) .................................. ............................D-40

Page 20

1. SERVICE INSTRUCTIONS

1-1. IDENTIFICATION OF FUSES

Control Board PWB-I 250V 3A (F1)

Power Supply Board PU1 100V Area 250V 6.3A (F1) 250V 15A (F2) 200V Area

4007D040AA

250V 4A(F1) 250V 6.3A(F2)

1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

• The laser used in this copier is a semiconductor laser with the following specifications: Max. power: 5 mW

Output wavelength: 770 to 795 nm

• 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 PH and PC Drum, be sure to turn the copier OFF first.

• If the job requires that the copier be left ON, take off your watch and ring and wear laser

protective goggles.

• A highly reflective tool can be dangerous if it is brought into the laser beam path. Use

utmost care when handling such tools near the laser.

• The PH is not maintainable in the field. It is to be replaced as a unit including the control

board. Never, therefore, attempt to remove the laser diode or adjust trimmers on the control board.

D-1

Page 21

1-3. PARTS WHICH MUST NOT BE TOUCHED

(1) Red 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 should not be readjusted, set, or removed in the field. Note that when two or more screws are used on the part in question, only one representative screw may be marked with red paint.

(2) Variable Resistors on Board

Do not turn the variable resistors on boards for which no adjusting instructions are given in “ADJUSTMENT.”

(3) Other Screws

Scanner

PH Unit

4007D043AA

Pulley Fixing Screw

4007D045AA

4007D075AA

D-2

Page 22

1-4. READING THE TEXT

Disassembly procedures are given under separate titles; illustrations identify each part only. Parts that require special attention and service jobs are given at the corresponding part name in the illustration. The disassembly procedures omit removal of exterior parts.

☞

D-4

Remove the roller after the Supply Unit has been taken out of the copier.

1. Image Transfer Roller cover

2. Image Transfer Roller

Disassembly Procedures

Image Transfer Roller Replace.

Image Transfer Roller Cover

Part requiring service jobs.

Pusher Spring

Image Transfer Roller Holder

4007D017AA

D-3

Page 23

2. DISASSEMBLY/REASSEMBLY

2-1. COVERS AND EXTERIOR PARTS: IDENTIFICATION AND

REMOVAL PROCEDURES

4007D001AB

4007D002AB

D-4

Page 24

No. Name Removal Procedure

1 Platen Cover Remove screws that secure the Platen Cover. 2 Original Glass Remove 1. → Remove 13. → Remove 12. → Remove 3. →

Remove 7. → Remove the Original Glass holding brackets (two

at the front). 3 Front Upper Cover Remove screws that secure the Front Upper Cover. 4 Control Panel Remove 3. → Remove screws that secure the control panel. 5 Front Middle

Cover

6 Front Lower Cover Release and swing up the upper half of the copier. → Remove

7 Front IR Cover Remove 3. → Remove screws that secure the Front IR Cover. 8 Paper Tray Remove 9. → Release and swing up the upper half of the copier.

9 Manual Bypass

Tray

10 Paper Exit Tray

Lower Cover

11 Left IR Cover Remove 1. → Remove 3. → Remove 7. → Remove 13. →

12 Rear IR Upper

Cover

13 Rear Upper Cover Remove 14. → Remove screws that secure the Rear Upper

14 Rear Lower Cover Remove screws that secure the Rear Lower Cover. 15 Right Cover Release and swing up the upper half of the copier. → Remove

16 Right IR Cover Remove 3. → Remove 1. → Remove 13. → Remove 12. →

Remove 3. → Remove 4. → Remove screws that secure the

Front Middle Cover.

screws that secure the Front Lower Cover.

→

Remove 6. → Remove 14. → Remove the screw that secures

the Paper Tray.

Remove 9. → Remove 6. → Remove 14. → Remove 8. →

Remove screws that secure the Paper Exit Tray Lower Cover.

Remove 12. → Remove screws that secure the Left IR Cover.

Remove 1. → Remove 13. → Remove screws that secure the

Rear IR Upper Cover.

Cover.

the 14. → Remove screws that secure the Right Cover.

Remove screws that secure the Right IR Cover.

D-5

Page 25

2-2. REMOVAL OF PWBs

• The removal procedures given below omit the steps of unplugging connectors and removing the PWB from the PWB support.

• Where it is absolutely necessary to touch the ICs and other electrical components on the board, be sure to ground your body.

PWB-I

PWB-M

PWB-A

Symbol Name Removal Procedure

PWB-A Master Board

PWB-B Control Panel

PWB-G

PWB-I Control Board

PWB-M Memory Board

PWB-S

PU1

HV1 High Voltage Unit

Toner Empty Board

Scanner Interface Board

Power Supply Board

Remove the Rear Upper Cover and Rear Lower Cover. → Remove the protective cover. → PWB-A

Remove the Front Upper Cover. → Remove the Control Panel. → PWB-B

Remove all exterior covers . → Remove the upper half of the copier. → Remove the rear side plate. → Remove the Paper Take-Up Roll Cover Assy. → PWB-G

Remove the Rear Lower Cover and Rear Upper Cover. → Remove the protective cover. → PWB-I

Remove the Rear Lower Cover and Rear Upper Cover. → Remove the protective cover. → PWB-M

Remove the Front Upper Cover, Front IR Cover, Rear IR Upper Cover , Rear Upper Cov er, and Rear Lower Cover. → Remove the Original Glass bracket . → Remove the Original Glass. → Remove the protective cover. → PWB-S

Release and swing up the upper half of the copier. → Remove the Right Cover. → Remove the Power Switch. → Remove the Fusing Section Cooling Fan Motor . → Remove the Fusing Section Cooling Fan Motor mounting brack et. → Remove the Inlet mounting bracket. → PU1

Remove the Paper Exit Tray Lower Cover. → Remove the Paper Exit Tray. → Release and swing up the upper half of the copier. → Remove the Cover. → Remove the Supply Unit. → Remove the PH Unit. → HV1

PWB-S

4007D003AB

PU1

PWB-B

PWB-G

HV1

D-6

Page 26

2-3. MAINTENANCE SCHEDULE

• To ensure that the copier produces good copies and to extend its service life, it is recommended that the maintenance jobs described in this schedule be carried out as instructed.

Maintenance Schedule

PM Parts

Fusing Section

Fusing Unit — 50

Image Transfer Section

Image Transfer Roller — 50 4110-4103-01 1

Cleaning Replacement

(K)

Part No. Qty

100V Area

4007-0431-02

200V Area

4007-0432-02

Reference

Page

☞

D-15

☞

D-17

D-7

Page 27

2-4. REMOVAL OF UNITS

(1) Removal of the Upper Half of the Copier

Remove the upper half of the copier after the Front Upper Cover, control panel, Front Middle Cover, Rear Upper Cover, and Paper Exit Tray Lower Cover have been removed.

1. Protective cover

2. Control Board

NOTE

Unplug all print jacks from the PWB.

Protective Cover

Control Board

4007D010AB

3. IR Lower Cover

4. Paper Exit Tray

Paper Exit Tray

IR Lower Cover

4007D062AA

4007D005AC

D-8

Page 28

5. Torsion Bars A and B

Torsion Bar B

Torsion Bar Mounting Position

Torsion Bar B

Torsion Bar A

4007D006AB

Front Side

Torsion Bar A

4007D063AA

Rear Side

Torsion Bar B

Torsion Bar A

4007D064AA

NOTE

Before removing or reinstalling the torsion bars, be sure to release and swing up the upper half of the copier to release pressure. When reinstalling them, install torsion bar A first, then torsion bar B.

D-9

Page 29

6. Lock Plate

Lock Plate

7. Shoulder screws and other screws Front Side Rear Side

4007D073AA

Screws

Shoulder Screw

4007D007AA 4007D008AA

NOTE

When mounting the shoulder screws, make sure that the round hole and the slot in the frames are properly aligned with each other.

8. Upper half of the copier

Upper Half of the Copier

4007D009AA

D-10

Page 30

(2) Removal of the IR Unit

Remove the IR Unit after the Front Upper Cover, Front IR Cover, Rear IR Upper Cover, Rear Upper Cover, Rear Lower Cover, and Right IR Cover have all been removed.

1. Protective Cover

2. Control Board

NOTE

Unplug all print jacks from the PWB.

Protective Cover

Control Board

4007D010AB

3. ADF Set Switch hookup connector

4. IR Unit

IR Unit

ADF Set Switch Hookup Connector

4007D011AB

D-11

Page 31

(3) Removal of the PH Unit

Remove the PH Unit after the Front Lower Cov er, Rear Lower Cover, P aper Exit Tray Lower Cover, and Supply Unit have been removed.

1. Protective cover

2. Control Board

NOTE

Unplug all print jacks from the PWB.

Protective Cover

Control Board

4007D010AB

3. IR Lower Cover

IR Lower Cover

4. Paper Exit Tray

Paper Exit Tray

4007D062AA

4007D005AC

D-12

Page 32

5. Protective Cover

Protective Cover

6. Print Jack

Master Board

7. PH Unit fixing screws

4007D012AA

4007D013AB

PH Unit

4007D015AC

D-13

Page 33

8. Cover

9. PH Unit

Cover

PH Unit

4007D014AA

NOTE

Take care with the torsion bars: They will come off when the upper half of the copier is swung up.

D-14

Page 34

(4) Removal of the Fusing Unit

Remove the Fusing Unit after the Right Cover, Rear Lower Cover, Front Lower Cover, and Supply Unit have been removed.

1. Fusing cover

Fusing Cover

4007D067AA

2. Cover

Cover

3. Fusing Section Cooling Fan Motor

4. Right Side Plate

Right Side Plate

Fusing Section Cooling Fan Motor

4007D074AA

4007D068AA

D-15

Page 35

5. Fusing Unit

Fusing Unit Replace.

4007D069AA

D-16

Page 36

2-5. IMAGE TRANSFER SECTION

(1) Replacement of the Image Transfer Roller

Remove the Image Transfer Roller after the Supply Unit have been removed.

1. Image Transfer Roller cover

2. Image Transfer Roller Image Transfer Roller Replace.

Pusher Spring

Image Transfer Roller Cover

NOTE

Be sure not to lose the pusher springs hooked to the Image Transfer Roller holder.

3. Gear

4. Bushing

5. Roll

6. Image Transfer Roller

Roll

Bushing

Image Transfer Roller

Bushing

Pusher Spring

Image Transfer Roller Holder

4007D017AA

Roll

Bushing

4007D018AB

Gear

D-17

Page 37

2-6. FUSING SECTION

(1) Removal of the Fusing Backup Roller

1. Thermistor hookup harness

4007D070AA

2. Lower Fusing Unit

3. Fusing Entrance Guide Plate

Thermistor hookup harness

Lock in the Rear

Lower Fusing Unit

Lock at the Front

Fusing Entrance Guide Plate

4007D019AC

D-18

Page 38

4. Pressure spring

5. Fusing Backup Roller

Fusing Backup Roller

4007D020AB

Pressure Springs

NOTE

During reinstallation, make sure that the pressure springs fit over the protrusions on the Lower Fusing Unit.

Front Side

Rear Side

Protrusions

4007D047AA 4007D060AB

D-19

Page 39

(2) Removal of the Fusing Heater Lamp

1. Terminal

2. Fusing Heater Lamp

Gear

Fusing Heater Lamp

Terminal

4007D021AB

NOTE

When inserting the Fusing Heater Lamp, make sure that the end marked with the specifications is on the gear end.

D-20

Page 40

(3) Removal of the Fusing Roller

1. Gear

2. Fusing Roller

Fusing Roller

Gear

Fusing Entrance Guide Plate

4007D022AA

NOTES

• When mounting the Fusing Roller, take care not to allow the Paper Separator Fingers to

damage the surface of the roller.

• When installing the gear, make sure that the protrusion on the inner side of the gear fits

into the slit on the end of the Fusing Roller.

• When installing the Fusing Entrance Guide Plate, fit the ground plate of the Fusing

Entrance Guide Plate inside the ground plate on the Fusing Unit side.

Where the Ground Plate is Mounted

Ground Plate of the Fusing Entrance Guide Plate

Ground Plate of the Fusing Unit

4007D071AA

D-21

Page 41

2-7. MISCELLANEOUS

(1) Removal of the Scanner and Timing Belt

Remove these parts after the Front Upper Cover, Front IR Cover, Left IR Cover, Rear IR Upper Cover, Rear Upper Cov er, Rear Lower Cover, and Right IR Cover have all been removed.

1. Original Glass holding bracket

2. Original Glass

Original Glass

Original Glass Holding Brackets

4007D023AB

3. Timing belt pulley

4. Timing belt

Timing belt pulley

Timing belt

4007D072AA

D-22

Page 42

5. Scanner Rail fixing screw (on timing belt side)

6. Scanner Rail (on timing belt side)

Scanner Rail

7. Scanner plate

8. Flexible harness

9. Scanner

Scanner

Scanner Rail Fixing Screw

4007D024AB

Protective Cover

Flexible Harness

4007D025AC

NOTE

When installing the Scanner, always connec t the flexible harness first.

D-23

Scanner Plate

Page 43

(2) Removal of the Scanner Motor

1. IR Unit

2. Fixing bracket

3. Scanner Motor

IR Unit

Fixing Bracket

Scanner Motor

4007D026AA

D-24

Page 44

(3) Removal of the Paper Take-Up Roll

Remove the Paper Take-Up Roll after the Supply Unit has been taken out of the copier.

1. Paper Take-Up Roll

Paper Take-Up Roll

Paper Take-Up Roll Cover

4007D027AA

NOTE

When securing the Paper Take-Up Roll, make sure that the positioning pin on the back side of the roll fits into the hole in the shaft.

D-25

Page 45

(4) Removal of the Paper Take-Up Solenoid

Remove the solenoid after the Front Lower Cov er, Paper Tray, Manual Bypass Tray, Manual Bypass Tray Lower Cover, Rear Lower Cover, and Right Cover have all been removed.

1. Protective cover

Protective Cover

4007D012AA

2. Print jack

Master Board

3. Paper Take-Up Solenoid hookup connector

D-26

4007D048AA

4007D049AB

Page 46

4. Base plate fixing screws

Front

5. Base plate

6. Paper Take-Up Solenoid

Rear

4007D031AA 4007D032AA

Base Plate

4007D030AA

D-27

Paper Take-Up Solenoid

4007D033AB

Page 47

(5) Removal of the Main Mot or a nd PH Se c tion Cooling Fan Motor

Remove these parts after the upper half of the copier, and Supply Unit has been removed.

1. Protective cover

2. Master Board

Master Board

Protective Cover

4007D046AA

3. Base plate

☞

D-27

4. Rear side plate fixing screws (marked with black dots)

5. Gear Assy fixing screws (marked with black squares)

6. Rear side plate, gear assy

NOTE

Install the rear side plate first, then the base plate.

D-28

4007D035AB

Gear Assy

Rear Side Plate

4007D037AA

Page 48

7. Main Motor, PH Section Cooling Fan Motor

PH Section Cooling Fan Motor

Main Motor

4007D038AA

D-29

Page 49

3. ADJUSTMENT

3-1. ADJUSTMENT REQUIREMENTS LIST

Adjustment Item Requirements Adjustment Point Ref. Page

Registration (Paper Tray) Control panel

CD FD 20 ± 2.0 mm

Zoom Ratios (Scanner)

CD 100 ± 1.0 mm FD 200 ± 2.0 mm

Registration (Scanner)

CD FD 20 ± 2.0 mm

→ → → → → → → →

☞ ☞

D-33 D-34

D-35 D-36

D-37 D-38

D-30

Page 50

3-2. ADJUSTMENT OF UPPER UNIT INTERLOCK SWITCH S2

1. Release and swing up the upper half of the copier and remove the Right Cover.

2. Remove the Fusing Cover.

3. Loosen the screw on the Upper Unit Interlock Switch adjusting bracket and slide it

downward until it is stops.

4. Swing down the upper half of the copier into its locked position.

5. Moving the Upper Unit Interlock Switch adjusting bracket upward, find the position at

which a click of the switch is heard. Then tighten the screw to secure the adjusting bracket in that position. [Check Method] When the Power Switch is turned ON, the Exposure Lamp should turn ON.

Upper Unit Interlock Switch Adjusting Bracket

D-31

4007D039AA

Page 51

3-3. ELECTRICAL/IMAGE ADJUSTMENT

(1) Entering the Tech. Rep. Mode

Procedure: Press the following keys in this order: Clear/Stop → Exposure Control Lighter (<) → Clear/Stop → Exposure Control Darker (>)

(2) Entering the Adjust Mode

Procedure:

1. Enter the Tech. Rep. mode.

2. Press the following keys in this order: 1Key → 1Key → 1Key → Start key → Press the 1Key until the specific function is displayed.

(3) Producing a Test Pattern

NOTE

A test pattern is used when making the following adjustments:

• CD registration adjustment (Paper Tray)

• FD registration adjustment (Paper Tray)

• Registration adjustment (Scanner)

• Zoom ratio adjustment (Scanner)

Procedure

1. Enter the Tech. Rep. mode.

2. Press the following keys in this order to enter the function of “F5 Test Pattern 1”: 1Key → 1Key → Start key → 1Key → 1Key → 1Key → 1Key

3. Press the Start key.

NOTE

To exit the test pattern function, press the Clear/Stop key to go back to the Basic screen.

D-32

Page 52

(4) CD Registration Adjustment (Paper Tray)

Requirement

B Side

A Side

Requirement Adjust Mode Function Setting Range

NOTE

This adjustment must be made whenever the PH Unit is replaced.

Procedure

1. Produce a test pattern (F5: Test Pattern 1).

2. Fold the test pattern in half and make sure that the centerline on the test pattern is aligned with the crease. If it is not aligned with the crease, perform the following adjustment procedure.

3. Enter Adjust function A9.

4. Change the setting value using the 1Key or 10Key as necessary (1 step equivalent to

0.5 mm).

If the centerline deviates on the B side, increase the setting value. If the centerline deviates on the A side, decrease the setting value.

✽

If one adjustment sequence does not bring the centerline into the required range, perform the sequence again.

5. Press the Start key to validate the setting value.

NOTE

If the Clear/Stop key is pressed to go back to the Basic screen without pressing the Start key, the setting will be restored to the original value.

4007D050AA

CD registration

adjustment

43 to 57

(-3.5 to +3.5 mm)

D-33

Page 53

(5) FD Registration Adjustment (Paper Tray)

Requirement

4007D051AA

Requirement Adjust Mode Function Setting Range

A4C 20 ±2.0 mm

NOTE

This adjustment must be made whenever the PH Unit is replaced. Should be made after the CD registration adjustment (Paper Tray) has been completed.

Procedure

1. Produce a test pattern (F5: Test Pattern 1).

2. Make sure that dimension C on the test pattern falls within the specified range. If it falls outside the specified range, perform the following adjustment procedure.

3. Enter Adjust function AA.

4. Change the setting value using the 1Key or 10Key as necessary (1 step equivalent to

0.5 mm).

If dimension C on the test pattern is longer than the specified range, decrease the setting value. If dimension C on the test pattern is shorter than the specified range, increase the setting value.

✽

If one adjustment sequence does not bring the dimension into the required range, perform the sequence again.

Dimension C on the test pattern produced should fall within the range specified below.

FD registration

adjustment

43 to 57

(-3.5 to +3.5 mm)

5. Press the Start key to validate the setting value.

NOTE

If the Clear/Stop key is pressed to go back to the Basic screen without pressing the Start key, the setting will be restored to the original value.

D-34

Page 54

(6) CD Zoom Ratio Adjustment (Scanner)

Requirement

4007D052AA

Zoom Ratio Requirement Adjust Mode Function Setting Range

Full size (100%) 100 ±1.0 mm

NOTE

This adjustment must be made whenever the Scanner is replaced. Should be made after the CD and FD registration adjustments (Paper Tray) have been completed.

Procedure

1. Produce a test pattern (F5: Test Pattern 1).

2. Place the test pattern produced on the Original Glass and make a copy.

3. Make sure that dimension D on the copy of the test pattern falls within the specified range. Calculation formula: (1 – Dimension D on test pattern ÷ Dimension D on copy) × 100 If dimension D falls outside the specified range, perform the follo wing adjustment procedure.

4. Enter Adjust function A1.

5. Change the setting value using the 1Key or 10Key as necessary (1 step equivalent to

0.4%).

Produce a test pattern after the CD and FD registration adjustments (Paper Tray) have been made. Place this test pattern on the Original Glass and make a copy. Dimension D on the copy of the test pattern should fall within the range specified below.

CD zoom ratio

adjustment

45 to 55

(Reduced ↔ Enlarged)

If dimension D on the copy of the test pattern is longer than the specified range, decrease the setting value. If dimension D on the copy of the test pattern is shorter than the specified range, increase the setting value.

✽

If one adjustment sequence does not bring the dimension into the required range, perform the sequence again.

6. Press the Start key to validate the setting value.

NOTE

If the Clear/Stop key is pressed to go back to the Basic screen without pressing the Start key, the setting will be restored to the original value.

D-35

Page 55

(7) FD Zoom Ratio Adjustment (Scanner)

Requirement

Produce a test pattern after the CD and FD registration adjustments (Paper Tray) have been made. Place this test pattern on the Original Glass and make a copy. Dimension E on the copy of the test pattern should fall within the range specified below.

4007D053AA

Zoom Ratio Requirement Adjust Mode Function Setting Range

Full size (100%) 200 ±2.0 mm

NOTE

This adjustment must be made whenever the Scanner is replaced. Should be made after the CD and FD registration adjustments (Paper Tray) have been completed.

Procedure

1. Produce a test pattern (F5: Test Pattern 1).

2. Place the test pattern produced on the Original Glass and make a copy.

3. Make sure that dimension E on the copy of the test pattern falls within the specified range. Calculation formula: (1 – Dimension E on test pattern ÷ Dimension E on copy) × 100 If dimension E falls outside the specified range, perform the following adjustment procedure.

4. Enter Adjust function A2.

5. Change the setting value using the 1Key or 10Key as necessary (1 step equivalent to

0.4%).

FD zoom ratio

adjustment

45 to 55

(Reduced ↔ Enlarged)

If dimension E on the copy of the test pattern is longer than the specified range, decrease the setting value. If dimension E on the copy of the test pattern is shorter than the specified range, increase the setting value.

✽

If one adjustment sequence does not bring the dimension into the required range, perform the sequence again.

6. Press the Start key to validate the setting value.

NOTE

If the Clear/Stop key is pressed to go back to the Basic screen without pressing the Start key, the setting will be restored to the original value.

D-36

Page 56

(8) CD Registration Adjustment (Scanner)

Requirement

B Side

A Side

Requirement Adjust Mode Function Setting Range

NOTE

This adjustment must be made whenever the Scanner is replaced. Should be made after the CD and FD registration adjustments (Paper Tray), and CD zoom ratio adjustment (Scanner) have been completed.

Procedure

1. Produce a test pattern (F5: Test Pattern 1).

2. Place the test pattern produced on the Original Glass and make a copy.

3. Fold the test pattern in half and check that the centerline on the test pattern is aligned with the crease. If it is not aligned with the crease, perform the following adjustment procedure.

4. Enter Adjust function A3.

5. Change the setting value using the 1Key or 10Key as necessary (1 step equivalent to

0.5 mm).

If the centerline deviates on the B side, increase the setting value. If the centerline deviates on the A side, decrease the setting value.

✽

If one adjustment sequence does not bring the centerline into the required range, perform the sequence again.

6. Press the Start key to validate the setting value.

4007D050AA

CD registration

adjustment

40 to 60

(-5.0 to +5.0 mm)

NOTE

If the Clear/Stop key is pressed to go back to the Basic screen without pressing the Start key, the setting will be restored to the original value.

D-37

Page 57

(9) FD Registration Adjustment (Scanner)

Requirement

4007D051AA

Requirement Adjust Mode Function Setting Range

20 ±2.0 mm

NOTE

This adjustment must be made whenever the Scanner is replaced. Should be made after the CD and FD registration adjustments (Paper Tray), and FD zoom ratio adjustment (Scanner) have been completed.

Procedure

1. Produce a test pattern (F5: Test Pattern 1).

2. Place the test pattern produced on the Original Glass and make a copy.

3. Make sure that dimension C on the copy of the test pattern falls within the specified range. If it falls outside the specified range, perf orm the following adjustment procedure.

4. Enter Adjust function A4.

5. Change the setting value using the 1Key or 10Key as necessary (1 step equivalent to

0.5 mm).

Produce a test pattern after the CD and FD registration adjustments (Paper Tray) have been made. Place this test pattern on the Original Glass and make a copy. Dimension C on the copy of the test pattern should fall within the range specified below.

FD registration

adjustment

40 to 60

(-5.0 to +5.0 mm)

If dimension C on the copy of the test pattern is longer than the specified range, decrease the setting value. If dimension C on the copy of the test pattern is shorter than the specified range, increase the setting value.

✽

If one adjustment sequence does not bring the dimension into the required range, perform the sequence again.

6. Press the Start key to validate the setting value.

NOTE

If the Clear/Stop key is pressed to go back to the Basic screen without pressing the Start key, the setting will be restored to the original value.

D-38

Page 58

4. MISCELLANEOUS

4-1. TORSION BAR POSITION ADJUSTMENT

NOTE

When an Automatic Document Feeder or FK-116 (Fax Unit) is mounted on the copier, the position of the torsion bar must be adjusted as detailed below.

1. Remove the Front Upper Cover and control panel.

2. Release and swing up the upper half of the copier.

3. Remove the torsion bar attachment plate.

4007D054AA

Torsion Bar Attachment Plate

4. Change the position of the torsion bar in the attachment plate as necessary.

Torsion Bar

Hole Copier Configuration

Factory setting or when the Platen Cover is mounted

When the FK-116 (Fax Unit) is mounted

B When the Automatic Document Feeder is mounted

When both the Automatic Document Feeder and FK-116 (Fax Unit) are

mounted

5. Secure the torsion bar attachment plate into position.

D-39

4007D055AA

Page 59

4-2. REMOUNTING EEPROM (U21)

NOTES

• If the Control Board has been replaced, be sure to remount EEPROM (U21) from the old

to new Control Board.

• If the Control Board has been replaced and EEPROM (U21) has not been remounted, be

sure to make settings and readjustments as necessary because New EEPROM (U21) contains no data in this case.

1. Remove the Control Board.

2. Remove EEPROM (U21) from the new Control Board.

3. Remove EEPROM (U21) from the old Control Board and remount it onto the new Control Board.

New EEPROM

New Control Board Old Control Board

4007D057AA

NOTE

Note the alignment notch (A) on EEPROM (U21) when mounting the IC.

Old EEPROM

4007D056AA

D-40

Page 60

SWITCHES ON PWBs,

TECH. REP. SETTINGS

17196

Page 61

1. CONTROL PANEL KEYS AND INDICATORS ................................................S-1

1-1. Control Panel Keys ..................................................................................S-1

2. USER’S CHOICE MODE ........... ......................................................................S-5

2-1. Functions Available from the User’s Choice Mode ..................................S-5

2-2. User’s Choice Function Setting Procedure ..............................................S-5

2-3. Settings in the User’s Choice Mode .........................................................S-6

3. TECH. REP. MODE .........................................................................................S-10

3-1. Tech. Rep. Mode Function Tree ..............................................................S-10

3-2. Tech. Rep. Mode Setting Procedure .......................................................S-11

(1) Display .............................................................................................S-11

(2) Function ...........................................................................................S-13

(3) Tech. Rep. Choice ...........................................................................S-15

(4) Adjust .............................................................................................S-17

Page 62

1. CONTROL PANEL KEYS AND INDICATORS

1-1. Control Panel Keys

1. Start Key

• Press to start a copy cycle.

2. Clear/Stop Key

• Press to cancel a copy operation.

• Press to reset the Copies setting to “1”.

• Press to retur n the zoom ratio setting to 100%.

• Press for three seconds to enable the total check function.

3. 1 Key

• Use to change the values for each setting.

4. 10 Key

• Use to change the values for each setting.

5. Copies/Function Key

• Use to change the Copies setting and the Function Mode settings.

6. Zoom Key

• Press to change the zoom ratio.

• Use to select the standard zoom ratio.

7. Exposure Control Key (Darker)

• Use to manually adjust the density of the document.Image will become darker by pressing this key.

8. Auto Exposure Mode Key

• Press to select either the Auto Exposure Mode, the Manual Exposure Mode or the Photo Mode.

9. Exposure Control Key (Lighter)

• Use to manually adjust the density of the document.Image will become lighter by pressing this key.

• Press for three seconds enter the User's Choice mode.

10. Paper Select Key

• Press to select the drawer that contains the desired paper size.

S-1

Page 63

Inch Areas

Auto/Photo

OHP

Card

Non-Sort

S-2

Sort

2in1-Sort

2in1-Non-Sort

4007S001EA

Page 64

F1-F4

Metric Areas

A /

OHP

Card

S-3

2in1-Non-Sort

Non-Sort

Sort

2in1-Sort

4007S002DA

Page 65

Others

Auto/Photo

OHP

Card

Non-Sort

S-4

2in1-Sort

2in1-Non-Sort

Sort

4007S003CA

Page 66

2. USER’S CHOIC E MOD E

• User’s Choice Mode is used to make various settings according to the user’s needs.

2-1. Functions Available from the User’s Choice Mode

Code Function Code Function

U1 Auto Panel Reset U8 Manual Feed Input Size U2 Sleep U3 Disable Sleep

Exposure Mode Priority/Photo

Mode U5 Auto Exposure Level Priority U6 Manual Exposure Level Priority U7 Paper Size Select

✽

Functions of U9 to UC are available on the display only when the copier is equipped with the corresponding options as detailed below. U9: Automatic Document Feeder (DF216) U0: Memory for Copier (MU-7415C1 (16M)/MU-7415C2 (32M)) UA: Paper Feed Unit (PF-120) Ub: Printer Controller (IP-412) UC: Paper Feed Unit (PF-120) and Printer Controller (IP-412)

✽ ✽ ✽ ✽

✽

2-2. User’s Choice Function Setting Procedure

1. On the copying mode screen, hold down the Exposure Control Lighter < key for about 3 sec. or more.

2. Using the 10Key and 1Key, select the appropriate choice code.

3. Press the Start key to show the current setting.

4. Using the 10Key and 1Key, select the appropriate choice data.

5. Press the Start key to validate the choice data entered.

Density (Automatic Document

Feeder)

U0 Function

UA Tray Priority (for Copier mode)

Ub Image Density (for Printer mode)

UC Tray Priority (for Printer mode)

• Press the Clear/Stop key.

S-5

Page 67

2-3. Settings in the User’s Choice Mode

Highlighted

Choice Code.

Setting (The default is ).

<Auto panel Reset> Select the time it takes the Auto Panel Reset function, which resets the panel settings when the set period of time elapses after a copy cycle has been completed or the last key operated, to be activated.

Data Description Data Description

OF Disabled 2 2min.

05 30sec. 3 3min.

Set the time it takes the copier to enter the P ower Sa v e mode after the copy cycle has been completed or the last key operated.

NOTE

• The choice data “OF” may be selected when “Enabled” is selected

in “U3, Disable Sleep.”

Data OF

Description Disabled The data value is the time in min.

Select whether to enable the “OF” setting of Sleep.

Data 2

Description Disabled Enabled

Select the priority exposure mode, either Text Auto Exposure, Text Manual Exposure, or Photo Manual Exposure.

Data Description

2 Photo Manual exposure ON U6 default setting ON 3 Text Manual exposure OFF U6 default setting ON

1min. 4 4min.

<Sleep>

1.......................... ......................120

Photo

LED

Text Auto exposure OFF All ON

Exposure Level LED

Select the priority exposure level in the Auto Exposure mode.

Data 0 2

Description Darker Standard Lighter

S-6

Page 68

Choice Code

Highlighted

Setting (The default is ).

Select the priority exposure level in the Manual Exposure mode.

Data Description Exposure Level LEDs

4 3 2 1

-1

-2

-3

-4

Darker

Standard

Lighter

Select the paper size of the Paper Tray.

- Metric Areas - - Inch Areas -

Data Description Data Description

1 1

2 A5L 2 Legal L

Set the size of the paper of a nonstandard size to be used for Manual Bypass feeding. After the CD size has been set, press the Start key, which allows the user to set the FD size.

- CD Size Data Description

128 - 134mm (5” - 5-1/4”)

14 135 - 144mm (5-1/4” - 5-3/4”) 15 145 - 154mm (5-3/4” - 6”) 16 155 - 164mm (6” - 6-1/2”) 17 165 - 174mm (6-1/2” - 6-3/4”) 18 175 - 184mm (7” - 7-1/4”) 19 185 - 194mm (7-1/4” - 7-3/4”) 20 195 - 204mm (7-3/4” - 8”) 21 205 - 216mm (8” - 8-1/4”)

A4L Letter L

3 Half Letter L

S-7

Page 69

Choice Code

Highlighted

Setting (The default is ).

- FD Size Data Description

182 - 184mm (7-1/4”)

19 185 - 194mm (7-1/4” - 7-3/4”) 20 195 - 204mm (7-3/4” - 8”) 21 205 - 214mm (8” - 8-1/2”) 22 215 - 224mm (8-1/2” - 8-3/4”) 23 225 - 234mm (8-3/4” - 9-1/4”) 24 235 - 244mm (9-1/4” - 9-1/2”) 25 245 - 254mm (9-3/4” - 10”) 26 255 - 264mm (10” - 10-1/2”) 27 265 - 274mm (10-1/2” - 10-3/4”) 28 275 - 284mm (10-3/4” - 11-1/4”) 29 285 - 294mm (11-1/4” - 11-1/2”) 30 295 - 304mm (11-1/2” - 12”) 31 305 - 314mm (12” - 12-1/4”) 32 315 - 324mm (12-1/2” - 12-3/4”) 33 325 - 334mm (12-3/4” - 13-1/4”) 34 335 - 344mm (13-1/4” - 13-1/2”) 35 345 - 356mm (13-1/2” - 13-3/4”)

Select the copy image density level when the copier is equipped with an Automatic Document Feeder.

Data Description

When the standard original (text original) is used.

2 For sharper reproduction of a faint original.

S-8

Page 70

Choice Code

Highlighted

Setting (The default is ).

Select the priority Function mode.

NOTES:

• If the copier is not equipped with an Automatic Document Feeder, choice data of F1 and F2 only are available.

• If the copier is equipped with an Automatic Document Feeder, all of the following choice data are available.

Data Description Data Description

F1 Non-Sort Sort F2 2in1 Non-Sort F4 2in1 Sort

✽

The default setting is “F1” if the copier is not equipped with an Automatic Document Feeder.

Select the priority paper source selected when the copier is turned ON.

Data Description

2 Paper Feed Unit (PF-120) 3 Paper Tray + Auto Tray Switching 4 Paper Feed Unit (PF-120) + Auto Tray Switching

Select the image density level of printer outputs.

Data

Description

Paper Tray

32 1 -1-2-3

Darker Standard Lighter

Select the priority paper source for printer outputs.

Data Description

2 Paper Tray 3 Paper Feed Unit (PF-120)

Auto selection

S-9

Page 71

3. TECH. REP. MODE

• This mode is used by the Tech. Rep. to set, adjust, and/or program various service functions.

3-1. Tech. Rep. Mode Function Tree

d1: Supply Unit Counter d3: LED Test d4: MIsfeed Counter d5: Copy Counter d6: PC Print Counter d7: ROM V ersion d8: Total Memory Size for Copier d9: Total Memory Size for Printer Controller

F1: Paper Passa ge Test F2: Scanner Test F3: Original Passage Test F4: Scanner & Paper Passage Test F5: Test Pattern 1 F6: Test Pattern 2 FA: EEPROM Test Fb: Sleep Mode Test FE: Original Sc ann i ng Position

Contamination Test (DF-216)

FF: Scanner Home Position

C1: Market ing Area C2: Toner Empty Stop C3: Predrive C6: Data Clear C8: Exposure Lamp OFF Time Setting

TECH. REP. MODE

Display

Function

Tech. Rep. Choice

Adjust

A1: Zoom Adjustment in CD Direction (Copy) A2: Zoom Adjustment in FD Direction (Copy) A3: Registration Adjustment in CD

Direction (Copy)

A4: Registration Adjustment in FD

Direction (Copy)

A5: Zoom Adjustment in CD Direction

(DF-216)

A6: Zoom Adjustment in FD Direction

(DF-216)

A7: Registration Adjustment in CD

Direction (DF-216)

A8: Registration Adjustment in FD

Direction (DF-216)

A9: Registration Adjustment in CD

Direction (Paper Tray)

AA: Registration Adjustment in FD

Direction (Paper Tray)

Ab: Registration Adjustment in CD

Direction (PF-120)

AC:Registration Adjustment in FD

Direction (PF-120)

S-10

Page 72

3-2. Tech. Rep. Mode Setting Procedure

1. Press the following keys in this order: Clear/Stop → Exposure Control Lighter (<) → Clear/Stop → Exposure Control Darker (>)

2. Press the 1Key until the desired Tech. Rep. sub-mode is reached. Sub-modes cycle as follows:

Display “d” Tech. Rep. Choice “C” Function “F” Adjust “A”

3. When the code that represents the desired sub-mode is displayed, press the Start key.

• Press the Clear/Stop key.

(1) D isplay

• Displays the count of each of different counters and makes some checks.

• The maximum value that can be displayed for the counter is 999,999.

• Press the 1Key as necessary until “d” appears on the display.

• Press the Start key to let the copier start the sequence.

• Press the Clear/Stop key.

Code Description

Displays the count of the Supply Unit counter. Two digits each are displayed on the display, cycling through all digits of the count as detailed below. E.g.: 1234

d1 00 12 34

<LED Test> Turns ON and flashes OFF and ON all LEDs on the control panel to check for correct operation.

<Misfeed Counter> Displays the count of the misfeed counter. Two digits each are displayed on the display, cycling through all digits of the count as detailed below. E.g.: 12

d4 00 00 12

S-11

Page 73

Code Description

Displays the count of the copy counter. Two digits each are displayed on the display, cycling through all digits of the count as detailed below. E.g.: 12345

d5 01 23 45

Displays the count of the PC print counter.

Two digits each are displayed on the display, cycling through all digits of the count as detailed below. E.g.: 12345

d6 01 23 45

<ROM Version> Displays the ROM version. Two digits each are displayed on the display, cycling through all digits of the ROM version number as detailed below. E.g.: 1.00

d7 00 01 00

Displays the capacity of the copier memory.

Display 08 24 40

Capacity (MB) 0 16 32

Displays the capacity of the printer controller memory.

Display 08 16 32

Capacity (MB) 0 16 32

S-12

Page 74

(2) Function

• Allows the Tech. Rep. to run paper passage and other tests.

1. Press the 1Key as necessary until “F” appears on the display.

2. Press the Start key to let the copier start the sequence.

• Press the Clear/Stop key.

Code Description

Checks for correct paper passage. <Procedure>

1. Select the paper source before entering the Tech. Rep. mode (when the copier is equipped with a Paper Feed Unit).

2. Press the Start key to let the copier start the paper passage sequence.

3. Press the Clear/Stop key to stop the sequence.

Checks to see if the Exposure Lamp turns ON properly and the Scanner operates correctly. <Procedure>

1. Press the Start key. This turns ON the Exposure Lamp and lets the Scanner make a scan motion.

2. Press the Clear/Stop key to stop the operation.

Checks the Automatic Document Feeder for corr ect docum ent passage. <Procedure>

1. Place paper on the Document Feed Tray.

2. Press the Start key to let the Automatic Document Feeder start the document take-up and feeding sequence.

Checks to see if the Scanner operates properly and paper is fed through the copier correctly. <Procedure>

1. Place the original on the Original Glass.

2. Press the Start key. This turns ON the Exposure Lamp and lets the Scanner make a scan motion.

3. A copy is produced.

4. Press the Clear/Stop key to stop the operation.

Produces a test pattern for adjusting the Paper Tray for correct alignment and registration in the main scanning and sub-scanning directions.

Produces a halftone pattern.

S-13

Page 75

Code Description

Checks EEPROM to determine if it is fully operational or not.

Display 00 FF

Description O K NG

Carries out a test for Sleep function.

<Original Scanning Position Contamination Test (DF-216)> Checks the Automatic Document Feeder original scanning position (Original Glass) for contamination. <Procedure>

1. Place A4 blank paper on the original scanning part.

2. Press the Start key to let the copier produce a copy.

3. Check the copy for possible contamination.

<Scanner Home Position> Moves the Scanner to its home position. Used to lock the Scanner in position when the copier is to be moved.

S-14

Page 76

(3) Tech. Rep. Cho ice

Highlighted

• Allows the Tech. Rep. to make the settings for the various service functions.

1. Press the 1Key as necessary to select the desired Tech. Rep. Choice code.

2. Press the Start key to validate the choice code.

3. Using the 10Key and 1Key, select the choice data.

4. Press the Start key to validate the choice data setting (C1 to C3).

• Press the Clear/Stop key.

Choice Code

Setting (The default is ).

Select the display options for paper sizes and fixed zoom ratios according to the applicable marketing areas.

Data 0 1

Description Metric areas Inch areas

Default: 0 (Metric areas)/1 (Inch areas)

Select whether or not to inhibit the initiation of a new copy cycle after a toner-empty condition has been detected.

Data 1

Description Cop ying permitted Copying inhibited

Select whether or not to stop predrive of the Fusing Rollers when the Start key is pressed.

Data 1

Description Predrive disabled Predrive enabled

S-15

Page 77

Choice Code

Highlighted

Setting (The default is ).

Use to clear the counters and initialize the various types of setting data. <Procedure>

1. Using the 10Key and 1Key, select the desired function.

2. Press the Start key to validate the selected function (counter or

setting data).

3. Turn OFF and ON the Power Switch. (This completes the clearing

of the data.)

NOTES

•“9” or “A” can be selected when the Auto Exposure Mode key is

pressed.

•“A” is selected when clearing all counters at once (C6-1 to -7).

Data Description Data Description

0 None 7 PM counter 1 Supply Unit counter 8 Use’s/Tech. Rep. Choice 4 M isfeed counter 9 Adjust 5 Copy counter A All counters 6 PC print counter

✽

Be sure to clear the Supply Unit counters “C6-1” when Supply Unit is replaced.

Select the time it takes the Exposure Lamp to turn OFF after a copy cycle has been completed.

Description 30 sec. 20 sec. 3 min.

Data 1 2

S-16

Page 78

(4) A djust

Highlighted

• Used for adjustments to be made before shipment at the factory.

1. Press the 1Key as necessary to select the desired Adjust code.

2. Press the Start key to validate the Adjust code. At the same time, currently set data is displayed.

3. Using the 10Key and 1Key, change the data.

4. Press the Start key to validate the data setting.

• Press the Clear/Stop key.

Adjust Code

Setting (The default is ).

Adjust the zoom ratio in the CD direction on the IR side (for copies).

Description

Adjust the zoom ratio in the FD direction on the IR side (for copies).

Description

Adjust registration in the CD direction on the IR side (for copies).

Description

Adjust registration in the FD direction on the IR side (for copies).

Description

Adjust the zoom ratio in the CD direction on the IR side (when the Automatic Document Feeder is used).

Description

Data

45................................. ................................55

Smaller Greater

45................................. ................................55

Smaller Greater

40................................. ................................60

-5.0mm ±0 +5.0mm

46................................. ................................60

-3.0mm ±0 +5.0mm

45................................. ................................55

Smaller Greater

S-17

Page 79

Adjust Code

Highlighted

Setting (The default is ).

Adjust the zoom ratio in the FD direction on the IR side (when the Automatic Document Feeder is used).

Description

Adjust registration in the CD direction on the IR side (when the Automatic Document Feeder is used).

Description

Data

45................................. ................................55

Smaller Greater

40................................. ................................60

-5.0mm ±0 +5.0mm

Adjust registration in the FD direction on the IR side (when the Automatic Document Feeder is used).

Adjust registration in the CD direction on the engine side (when the Paper Tray is used).

Adjust registration in the FD direction on the engine side (when the Paper Tray is used).

Adjust registration in the CD direction on the engine side (when the Paper Feed Unit is used).

Adjust registration in the FD direction on the engine side (when the Paper Feed Unit is used).

Data

Description

Data

Description

Data

Description

Data

Description

Data

Description

40................................. ................................60

-5.0mm ±0 +5.0mm

43................................. ................................57

-3.5mm ±0 +3.5mm

43................................. ................................57

-3.5mm ±0 +3.5mm

43................................. ................................57

-3.5mm ±0 +3.5mm

43................................. ................................57

-3.5mm ±0 +3.5mm

S-18

Page 80

TROUBLESHOOTING

10794

Page 81

1. INTRODUCTION .............................................................................................T-1

1-1. Reading the Text .....................................................................................T-1

2. PAPER TRANSPORT FAILURE .....................................................................T-2

2-1. Paper Misfeed ..........................................................................................T-2

2-2. Size Error .................................................................................................T-2

2-3. Misfeed Detection Sensor Layout ............................................................T-3

2-4. Types of Misfeed Detection and Detection Timings ................................T-3

2-5. Misfeed Clearing Procedures ..................................................................T-4

(1) Copier/Manual Bypass Paper Take-Up Misfeed .............................T-4

(2) Transport Misfeed ............................................................................T-5

(3) Exit Misfeed .....................................................................................T-6

(4) PF-120 Paper Take-Up Misfeed ......................................................T-7

3. MALFUNCTIONS ............................................................................................T-8

3-1. Detection Timing Classified by Malfunctio n Code ........................ ...........T-8

3-2. Troubleshooting Procedures ....................................................................T-10

(1) C0000: Main Motor’s Failure to Turn ...............................................T-10

(2) C0045: Fusing Section Cooling Fan Motor’s Failure to Turn

C0049: PH Section Cooling Fan Motor’s Failure to Turn ................T-11

(3) C0200: HV Output Failure ...............................................................T-12

(4) C0500: Warm-up Failure

C0510: Abnormally Low Fusing Temperature

C0520: Abnormally High Fusing Temperature ................................ T-13

(5) C0650: Scanner Motor’s Failure to Turn, Scanner Home Position

Sensor Malfunction ................. ..................................... ....................T-14

(6) C14A3: Exposure Lamp Malfun ction ................... ............................T-15

(7) C1200: System Memory Failure

C1300: Polygon Motor Malfunction

C133B: Option Communications Error

C13F0: SOS Detection Failure

C1468: Hardware (EEPROM) Malfunction ......................................T-16

(8) Power Failure ..................................................................................T-17

4. IMAGE FAILURE .............................................................................................T-18

4-1. Image Failure Troubleshooting ................. .. .. .... ....... .. .. .... .. .... ..... .... .. .... .. .T-18

4-2. Initial Checks ...........................................................................................T-18

4-3. Troubleshooting Procedures Classified by Image Failure .......................T-19

(1) Blank copy .......................................................................................T-20

(2) Black copy .......................................................................................T-20

(3) Low image density ...........................................................................T-21

(4) Foggy background ...........................................................................T-21

(5) Black streaks or bands ....................................................................T-22

(6) Black spots ......................................................................................T-22

(7) Blank streaks or bands .................................................................... T-2 3

(8) Void areas ...................................................................................... .T-23

(9) Smear on back ............ ....................................................................T-24

(10) Uneven image density .....................................................................T-24

(11) Gradation reproduction failure .........................................................T-25

Page 82

(12) Rough image .............................. .... .. .. .... .. ....... .. .... .. .... .. ....... .. .... .. .. .T-25

(13) Periodically uneven image ............................................................... T-2 6

Page 83

1. INTRODUCTION

1-1. Reading the Text

1. The paper transport failure troubleshooting procedures are given according to the symptom. First, identify the location of the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward.

2. Make checks in the numerical order of steps and, if an item is checked okay, go to the next step.

Pattern 1

Step Check Result Ac tion

1~ YES ~ 2

Go to step 2 if you answered No.

Pattern 2

Step Check Result Action

1~ YES ~

NO ~

Go to step 2 if it checks okay.

T-1

Page 84

2. PAPER TRANSPORT FAILURE

2-1. Paper Misfeed

When a paper misfeed occurs, the display shows both the misfeed location and paper location.

Lit Misfeed/Paper Location Action Ref. Item OP

Copier paper take-up 2-5. (1)

J2 Transport 2-5. (2) J3 Exit 2-5. (3)

J8 DF-216

Misfeed in the copier Misfeed in the option

2-2. Size Erro r

When a size error occurs, the display gives a warning code.

Warning Code Size Error

Manual bypass paper take-up 2-5. (1)

PF-120 paper take-up 2-5. (4)

✽

Open the relevant door, remove the misfeed and paper left inside, and close the door.

The paper size setting on the paper source does not match the size of the paper actually loaded.

See the relevant option

service manual.

When the option is mounted.

✽

<Resetting error display> Press the Clear/Stop key.

• Wrong paper size setting is made on the paper source.

• User loads paper of a wrong size in the paper source.

• Double feeding of paper occurs.

T-2

Page 85

2-3. Misfeed Detection Sensor Layout

Paper Exit Sensor PS3

Paper Take-Up Sensor PS1

4007T001AA

2-4. Types of Misfeed Detection and Detection Timings

• The following lists the types of misfeed detection and detection timings for different mis-

feed locations within the copier.

• The symbols “L” (for the leading edge) and “T” (for the trailing edge) given in ( ) indicate

the particular edge of the paper detected by the sensor.

NOTE

For the types of misfeed detection and detection timings of options, see the relevant option service manual.

Type Detection Star t Detection

Paper take-up fail ure detection Paper Take-Up Solenoid

energized

Paper Take-Up Sensor (L)

Type Detection Star t Detection

Trailing edge detection by Paper Take-Up Sensor

Leading edge detection by Paper Exit Sensor

Type Detection Star t Detection

Trailing edge detection by Paper Exit Sensor

Type Detection Star t Detection

Size error detection Paper Take-Up Sensor (L) Paper length calculated

Paper Take-Up Sensor (L) Paper Take-Up Sensor (T)

Paper Take-Up Sensor (L) Paper Exit Sensor (L)

Paper Take-Up Sensor (T) Paper Exit Sensor (T)

based on the time it takes Paper Take-Up Sensor to detect (T).

T-3

Page 86

2-5. Misfeed Clearing Procedures

(1) Copier/Manual Bypass Paper Take-Up Misfeed

Relevant Electrical P arts

Paper Take-Up Sensor PS1

Master Board PWB-A

Paper Take-Up Solenoid SL1

CN2

SL1

1 2

PJ3A-1(DC24V)

PJ3A-2(FEED1)

PJ8A-1(ANODE PS1) PJ8A-2(GND) PJ8A-3(PS1 ON)

CN3

3 2 1

PJ4

PS1

PWB-A

4007C02TAB

Copier/Manual Bypass Paper Take-Up Misfeed Clearing Procedure

• Paper is not taken up at all. Step Check Result Action

1 Paper meets product specifications. NO Change paper. 2 Paper is curled, wavy, or damp. YES Change paper.

3 Paper Take-Up Roll is deformed, worn, or has

paper dust.

4 Paper Take-Up Solenoid operation: the voltage

across PJ3A-2 on the Master Board and GND is DC24 V (solenoid deenergized) and DC0 V (instantaneously) (solenoid energized) when the Start key is pressed.

5 Paper Take-Up Sensor operation: the voltage

across PJ8A-3 on the Master Board and GND is DC5 V (sensor unblocked) and DC0 V (sensor blocked).

Advise user on correct paper storage.

YES Clean or change.

YES Change solenoid.

NO Change Master Board.

YES Change Master Board.

NO Correct actuator.

Change sensor.

T-4

Page 87

(2) Transport Misfeed

Paper Take-Up Sensor PS1 Paper Exit Sensor PS3

Relevant Electrical P arts

PJ8A-1(ANODE PS1) PJ8A-2(GND) PJ8A-3(PS1 ON)

Master Board PWB-A

PJ4

CN3

3 2 1

3 2

PS1

PJ8A-4(ANODE PS3) PJ8A-5(GND) PJ8A-6(PS3 ON)

3 2 1

PS3

PWB-A

4007C03TAB

Transport Misfeed Clearing Procedure

• Paper has stopped near the PC Drum. Step Check Result Action

1 Transport Roller is dirty, deformed, or worn. YES Clean or change.

PJ5

2 Pre-Image Transfer Guide Plate is dirty or

deformed.

3 Image Transfer Roller is dirty, deformed, or

worn.

4 PC Drum Paper Separator Fingers are dirty or

deformed.

• Paper has stopped at the Fusing Unit. Step Check Result Action

1 Fusing Guide Plate is dirty or deformed. YES Clean or change. 2 Fusing Roller is dirty, defor m ed, or worn. YES Clean or change. 3 Fusing Roller Paper Separator Fingers are

dirty, deformed, or worn.

4 Paper Exit Sensor operation: the voltage

across PJ8A-6 on the Master Board and GND is DC0 V (sensor unblocked) and DC5 V (sensor blocked).

YES Clean or change.

YES Clean. Or, change Supply

Unit.

YES Clean, correct, or change.

YES Change Master Board.

NO Correct actuator.

Change sensor.

T-5

Page 88

(3) Exit Misfeed

Relevant Electrical P arts

Paper Exit Sensor PS3 Master Board PWB-A

PJ5

PJ8A-4(ANODE PS3) PJ8A-5(GND) PJ8A-6(PS3 ON)

3 2 1

PS3

PWB-A

4007C04TAB

Exit Misfeed Clearing Procedure

• Paper has stopped at the exit section. Step Check Result Action

1 Paper Exit Roller rotation NO Correct drive coupling. 2 Paper Exit Roller is dirty, def ormed, or worn. YES Clean or change. 3 Paper Exit Sensor operation: the voltage

across PJ8A-6 on the Master Board and GND is DC0 V (sensor unblocked) and DC5 V (sensor blocked).

YES Change Master Board.

NO Correct actuator.

Change sensor.

T-6

Page 89

(4) PF-120 Paper Take-Up Misfeed

Relevant Electrical P arts

Paper Take-Up Sensor PS1

Master Board PWB-A

Paper Take-Up Solenoid SL5

CN3

PJ4

1 2 1

SL5

CN2

1 2

CN15

7 6

PJ8A-1(ANODE PS1) PJ8A-2(GND) PJ8A-3(PS1 ON)

PJ11A-7(DC24V)

14 13

PJ11A-8(FEED2)

PWB-A

4007C05TAB

PF-120 Paper Take-Up Misfeed Clearing Procedure

• Paper is not taken up at all. Step Check Result Action

1 Paper meets product specifications. NO Change paper. 2 Paper is curled, wavy, or damp. YES Change paper.

Advise user on correct paper storage.

3 Paper Take-Up Roll is deformed, worn, or has

paper dust.

4 Paper Transport Roller is deformed, worn, or

has paper dust.

5 Paper Take-Up Solenoid operation: the voltage

across PJ11A-8 on the Master Board and GND is DC24 V (solenoid deenergized) and DC0 V (instantaneously) (solenoid energized) when the Start key is pressed.

6 Paper Take-Up Sensor operation: the voltage

across PJ8A-3 on the Master Board and GND is DC5 V (sensor unblocked) and DC0 V (sensor blocked).

YES Clean or change.

YES Change solenoid.

NO Change Master Board.

YES Change Master Board.

NO Correct actuator.

Change sensor.

PS1

T-7

Page 90

3. MALFUNCTIONS

The copier’s CPU is equipped with a self-diagnostic function that, on detecting a malfunction, gives the corresponding malfunction code on the display.

Resetting a Malfunction

• Turn OFF and then ON the power switch.

3-1. Detection Timing Classified by Malfunction Code

Code Description Detection Timing

C0000 Main Motor’s failure to

turn

C0045 Fusing Section Cooling

Fan Motor’s failure to turn

C0049 PH Section Cooling Fan

Motor’s failure to turn

C0200 HV output failure • The drum charge monitor voltage is lower than 4.5 V

C0500 Warm-up failure • During the period from 12 s to 30 s after the start of

C0510 Abnormally low fusing

temperature

C0520 Abnormally high fusing

temperature

C0650 Scanner Mot or’s failure

to turn, Scanner Home Position Sensor malfunction

• The Lock signal does not go LOW within 1 s after the motor has been energized.

• The Lock signal remains HIGH for continuous 0.1 s or more while the motor remains energized.

A voltage of 0.3 V or less is detected for a continuous 1 s period while the motor remains energized.

A voltage of 0.35 V or less is detected for a continuous

0.5 s period while the motor remains energized.

when the power switch is turned ON.

• The drum char ge monitor voltage remains 4.5 V or more when the drum charge output is turned ON.

• The image transfer monitor voltage is 0.5 V or more immediately before the image transfer output is turned ON.

• The image transfer monitor voltage does not increase 0.5 V or more within 40 ms after the image transfer output is turned ON.

the warm-up cycle, a condition of small temperature difference from the temperature at the start of the warm-up cycle is detected for a 50 ms period.

• The temperature detected by the Thermistor does not reach the set level within 120 s after the start of the warm-up cycle.

• The temperature detected by the Thermistor remains lower than 94 °C for a continuous 50 ms period while the copier is in the standby state.

• The temperature detected by the Thermistor remains lower than 110 °C for a continuous 50 ms period during a copy cycle.

The temperature detected by the Thermistor remains higher than 240 °C for a continuous 50 ms period while fusing temperature control is in progress.

The Scanner Home Position Sensor is not activated within a given period of time after the Scanner Motor has been energized.

T-8

Page 91

Code Description Detection Timing

C1200 Syst em mem ory failure A memory test error is detected during the power-on

C1300 Polygon Motor malfunc-

tion

C13F0 SOS detection failure

C133B Option communications

error

C1468 Hardware (EEPROM)

malfunction

C14A3 Exposure Lamp malfunc-

tion

initialization procedure.

• During the period 6 s after the Polygon Motor has been energized, a cluster of 56 or more SOS signals output for a 20 ms period is detected five consecutive times.

• After the lapse of 6 s after the Polygon Motor has been energized, a cluster of below 43 or above 56 SOS signals output for a 20 ms period is detected five consecutive times.

• No SOS signal is detected during the period from the start of laser emission to the deenergization of the Polygon Motor .

The Controller Board is not detected within 5 s after the start of a print cycle.

An EEPROM read/write error occurs during the poweron initialization procedure.

The intensity level of the Exposure Lamp does not stabilize within a given period of time.

T-9

Page 92

3-2. Troubleshooting Procedures

(1) C0000: Main Motor’s Failure to Turn

Relevant Electrical P arts

Main Motor M1 Master Board PWB-A

PJ3

1 2 3 4

PJ6A-1(GND) PJ6A-2(DC24V) PJ6A-3(M1 ON) PJ6A-4(M1 LOCK)

PWB-A

4007C06TAB

C0000

Step Check Result Action

1 Main Motor turns after the malfunction has

NO Correct drive.

been reset.

2 Main Motor operation: the voltage across

NO Change Master Board. PJ6A-3 on the Master Board and GND is DC5 V (motor deenergized) and DC0 V (motor energized) after the malfunction has been reset.

3 The voltage across PJ6A-4 on the Master

Board and GND is DC5 V (motor deenergized) and DC0 V (motor energized) after the mal-

YES Change Master Board.

NO Change motor. function has been reset.

T-10

Page 93

(2) C0045: Fusing Section Cooling Fan Motor’s Failure to Turn

C0049: PH Section Cooling Fan Motor’s Failure to Turn

Relevant Electrical P arts

Fusing Section Cooling Fan Motor M3 PH Section Cooling Fan Motor M5

Power Supply Board PU1 Master Board PWB-A

PJ13A-1(M5 REM) PJ13A-2(DC24V)

PWB-A

PJ14A-1(FAN)

PU1

C0045

Step Check Result Action

1 Fusing Section Cooling Fan Motor operation:

the voltage across CN7-2 on the Power Supply Board and GND is DC24 V after the malfunction has been reset.

2 Fusing Section Cooling Fan Motor operation:

the voltage across CN7-1 on the Power Supply Board and GND is DC1.2 V (during high-speed rotation) and DC12 V (during low-speed rotation) after the malfunction has been reset.

CN7-1 CN7-2

PJ31-11

4007C07TAB

NO Change Power Supply

Board.

YES Change motor.

NO Change Power Supply

Board. Change Master Board.

C0049

Step Check Result Action

1 PH Section Cooling Fan Motor operation: the

voltage across PJ13A-2 on the Master Board and GND is DC24 V after the malfunction has been reset.

2 PH Section Cooling Fan Motor operation: the

voltage across PJ13A-1 on the Master Board and GND is DC1 V (motor energized) and DC24 V (motor deenergized) after the malfunction has been reset.

NO Change Master Board.

YES Change motor.

NO Change Master Board.

T-11

Page 94

(3) C0200: HV Output Failure

Relevant Electrical P arts

High Voltage Unit HV1 Master Board PWB-A

PJ10HV-11 PJ10HV-10 PJ10HV-9 PJ10HV-8 PJ10HV-7 PJ10HV-6 PJ10HV-5 PJ10HV-4 PJ10HV-3 PJ10HV-2 PJ10HV-1

HV1

Image Tr ansfer

Drum Charg

Developing Bias

Seal Bias

Toner Blade Bias

PJ4A-1(DC5V) PJ4A-2(SS_H/L_CTL) PJ4A-3(T_VR) PJ4A-4(HV_REM) PJ4A-5(T_MON) PJ4A-6(B_MON) PJ4A-7(B_REM) PJ4A-8(C_REM) PJ4A-9(C_MON) PJ4A-10(GND) PJ4A-11(DC24V)

PWB-A

4007C09TAB

C0200

Step Check Result Action

1 High Voltage Unit operat ion: the vol tage across

YES Change High Voltage Unit. PJ4A-4 on the Master Board and GND is DC24 V after the malfunction has been reset.

2 Proper connection between the High Voltage

Unit and Master Board.

YES Change Master Board.

NO Correct connection.

T-12

Page 95

(4) C0500: Warm-up Failure

C0510: Abnormally Low Fusing Temperature C0520: Abnormally High Fusing Temperature

Relevant Electrical P arts

Fusing Heater Lamp H1 Thermoswitch TS1 Thermistor TH1

Power Supply Board PU1 Master Board PWB-A

PJ7A-1(DC24V IN)

PJ14A-3(H1 REM)

PWB-A

TS1

CN14

1 2

PJ31-1

PJ31-10

1 2

ST3 ST4

PU1

TH1

C0500, C0510

Step Check Result Action

1 Fusing Heater Lamp turns ON after the mal-

function has been reset.

2 Thermistor operation: resistance across CN1-1

and 2 on the Fusing Unit side is infinite, as measured with CN1 disconnected.

3 Thermoswitch and Fusing Heater Lamp opera-

tion: there is continuity across CN14-1 and 2 on the Fusing Unit side, as measured with CN14 disconnected.

4 The voltage across PJ14A-3 on the Master

Board and GND is DC0 V (Fusing Heater Lamp ON) and DC24 V (Fusing Heater Lamp OFF) after the malfunction has been reset.

CN1

1 2

4007C08TAB

YES Correct Thermistor for

mounting position and/or clean.

YES Change Thermistor.

NO Change Thermoswitch.

Change Fusing Heater Lamp.

YES Change Power Supply

Board. Change Fuse 2 of Power Supply Board.

NO Change Master Board.

PJ2A-2(DC5V)

PJ2A-1(TH1 ON)

C0520

Step Check Result Action

1 Thermistor installed at the correct position. NO Correct. 2 Thermistor contaminated. YES Clean. 3 The circuit across CN1-1 and 2 on the Fusing

Unit side is shorted as checked with CN1 disconnected.

YES Change Thermistor.

NO Change Master Board.

Change Power Supply Board.

T-13

Page 96

(5) C0650: Scanner Motor’s Failure to Tu rn, Scanner Home Position Sensor Mal-

function

Relevant Electrical P arts

Scanner Motor M6

Control Board PWB-I

Scanner Home Position Sensor PS5

PJ31-1(DC24V) PJ31-3(DC15V) PJ31-5(DC-9V) PJ31-7(GND)

PJ32-2(DC5V) PJ32-3(DC5V) PJ32-4(GND) PJ32-6(DC5V REM/SLP) PJ32-7(DC24V REM/SLP)

PS5

JP9-1(A) JP9-2(A/) JP9-3(B) JP9-4(B/)

JP14-1(PS5 ON) JP14-2(GND) JP14-3(GND) JP14-4(Power)

1 2 3 4 5 6 7 8 9

JP7

PU1

JP5

12 11 10

9 8 7 6 5

PWB-I

4 3 2 1

2 1

JP6

C0650

Step Check Result Action

1 Scanner movement after the malfunction has

been reset

2 Scanner motion as it is moved manually NO Correct drive coupling.

3 Proper JP9 connector connection of Control

Board

4 Scanner Home Position Sensor operation: the

voltage across JP14-1 on the Control Board and GND is DC0 V (sensor unblocked) and DC3 V (sensor blocked) after the malfunction has been reset.

PJ1A-1 PJ1A-2 PJ1A-3 PJ1A-4 PJ1A-5 PJ1A-6 PJ1A-7 PJ1A-8 PJ1A-9 PJ1A-10 PJ1A-11 PJ1A-12

PJ18A-1(GND) PJ18A-2(VIDEO)

PWB-A

4007C10TAC

YES To step 4

Install belt.

YES Change Scanner Motor.

Change Control Board.

NO Correct connections.

YES Change Control Board.

NO Change sensor.

T-14

Page 97

(6) C14A3: Exposure Lamp Malfunction

Relevant Electrical P arts

Scanner Scanner Interface Board PWB-S

Control Board PWB-I

Connector

12 11 10

5 4 3 2

JP5

PJ1A-1 PJ1A-2 PJ1A-3 PJ1A-4 PJ1A-5 PJ1A-6 PJ1A-7 PJ1A-8 PJ1A-9 PJ1A-10 PJ1A-11 PJ1A-12

PWB-A

4007C11TAC

CN1

PJ31-1(DC24V) PJ31-3(DC15V) PJ31-5(DC-9V) PJ31-7(GND)

PJ32-2(DC5V) PJ32-3(DC5V) PJ32-4(GND) PJ32-6(DC5V REM/SLP) PJ32-7(DC24V REM/SLP)

PU1

LA1

CN2

Scanner

CN1

JP7

Flat Cable

1 2 3 4 5 6 7 8 9

CN1

PWB-I

JP8-1(LA1 REM)

JP2

PWB-S

C14A3

Step Check Result Action

1 Proper connections between the Scanner,

Scanner Interface Board, and Control Board

YES Change Scanner Interface

Board. Change Control Board. Change Scanner.

NO Correct connections.

T-15

Page 98

(7) C1200: System Memory Failure

C1300: Polygon Motor Malfunction C133B: Option Communications Error C13F0: SOS Detection Failure C1468: Hardware (EEPROM) Malfunction

• These malfunctions are detected mainly when there is a fault occurring in software, hardware, or communications.

Code Action

C1200 1. Reset the malfunction.

C1300, C13F0

C133B 1. Reset the malfunction.

C1468 1. Run “FA” of Function.

2. If the malfunction is detected again, check the Control Board and Memory Board for proper connections.

3. If connections are okay, change the Control Board and/or Memory Board.

1. Reset the malfunction.

2. If the malfunction is detected again, check the harness between, and PJ connections on, the PH Unit and Master Board.

3. If connections are okay, change the PH Unit and Master Board.

2. If the malfunction is detected again, check the Control Board and the controller board.

3. If connections are okay, change the Control Board and the controller board.

2. If it has not been checked okay (“FF” appears on the display ), change the EEPROM on the Control Board. If it has been checked okay (“00” appears on the display), change the Control Board itself.

T-16

Page 99

(8) Power Failur e

Power Supply Board PU1 Power Switch S1 Upper Unit Interlock Switch S2

Relevant Electrical P arts

Control Board PWB-I Master Board PWB-A

PJ30-2(DC24V OUT)

PU1

ST2 ST1

Plug

L N

GND

1 2

L N

PJ31-1 (DC24V) PJ31-3 (DC15V) PJ31-4 (DC15V) PJ31-5 (DC-9V) PJ31-6 (DC-9V) PJ31-7 (GND) PJ31-8 (GND)

PJ32-1 (DC5V) PJ32-2 (DC5V) PJ32-3 (DC5V) PJ32-4 (GND) PJ32-5 (GND) PJ32-6 (DC5V REM/SLP) PJ32-7 (DC24V REM/SLP)

• Power failure Step Check Result Action

1 No power is supplied when the Power Switch is

turned ON. Blown Fuse 1 of the Power Supply Board.

YES Change Fuse 1 of Power

Supply Board.

NO Change Power Switch.

Change Power Supply Board.

2 Only the display and Fusing Section Cooling

Fan Motor operate. The voltage across PJ30-2 on the Power Supply Board and GND is DC24 V when the P o wer Switch is turned ON.

YES Change Upper Unit Inter-

lock Switch. Change Control Board. Change Master Board.

NO Change Power Supply

Board.

3 Only the Fusing Section Cooling Fan Motor

operates. The voltage across JP7-2/3 on the Control Board and GND is DC5 V when the Po wer

YES Change Control Board.

NO Change Power Supply

Board.

Switch is turned ON.

4 Only the display and Scanner operate.

The voltage across PJ7A-4 on the Master Board and GND is DC5 V when the Po wer Switch is turned ON.

YES Change Master Board.

NO Change Power Supply

Board.

PWB-A

PJ7A-1 (DC24V IN) PJ7A-2 (GND) PJ7A-3 (GND) PJ7A-4 (DC5V)

PJ17A-2 (DC15V IN) PJ17A-1 (DC-9V IN)

PWB-I

JP7-1 (DC24V IN) JP7-2 (DC5V) JP7-3 (DC5V) JP7-4 (DC15V) JP7-5 (DC-9V) JP7-6 (GND) JP7-7 (GND) JP7-8 (DC5V REM/SLP) JP7-9 (DC24V REM/SLP)

4007C12TAC

T-17

Page 100

4. IMAGE FA ILURE

4-1. Image Failure Troubleshooting

• In this chapter, troubleshooting is divided into “initial checks” and “troubleshooting procedures classified by image failures.”

• If any image failure has occurred, first make the initial checks; then proceed to the corresponding image failure troubleshooting procedure.

4-2. Initial Checks

• Determine if the failure is attributable to a basic cause or causes.

Section Step Check Result Action

Installation site

Paper 2 Recommended paper used. NO Instruct user.

Original 4 Original not flat YES Correct original.

PM parts 8 The PM parts, as they relate

1 See “PRECAUTI ON S FOR

INSTALLATION” in GENERAL.

3 Paper is damp. YES Change paper.

5 The original is written in light

pencil.

6 The original is transparent

(OHP transparencies, etc.).

7 Original Glass is dirty and

scratched.

to image formation, have reached the end of cleaning/ replacement cycles.

NO Change the installation site.

Instruct user in paper storage.

YES Instruct user.

YES Clean or change.

YES Clean or change. (See the PM

list.)

• Deter mine if the failure is attributable to an input system (IR) or output system (engine) fault.

Check Result Cause

Copy made at a reduced ratio.

Original

1177T03YA

Full-size copy Reduced copy

Input

system

4007T002AA

Full-size copy Reduced copy

Output system

4007T003AA

T-18

KONICA 7415 SERVICE HANDBOOK

FIELD SERVICE

SAFETY AND IMPORTANT WARNING ITEMS

Safety Precautions for Inspection and Service

PRECAUTIONS FOR SERVICE

CONTENTS

1. SERVICE INSTRUCTIONS

1-1. IDENTIFICATION OF FUSES

1-2. PRECAUTIONS FOR HANDLING THE LASER EQUIPMENT

1-3. PARTS WHICH MUST NOT BE TOUCHED

(1) Red Screws

(2) Variable Resistors on Board

(3) Other Screws

1-4. READING THE TEXT

2. DISASSEMBLY/REASSEMBLY

2-2. REMOVAL OF PWBs

2-3. MAINTENANCE SCHEDULE

2-4. REMOVAL OF UNITS

(1) Removal of the Upper Half of the Copier

(2) Removal of the IR Unit

(3) Removal of the PH Unit

(4) Removal of the Fusing Unit

2-5. IMAGE TRANSFER SECTION

(1) Replacement of the Image Transfer Roller

2-6. FUSING SECTION

(1) Removal of the Fusing Backup Roller

(2) Removal of the Fusing Heater Lamp

(3) Removal of the Fusing Roller

2-7. MISCELLANEOUS

(1) Removal of the Scanner and Timing Belt

(2) Removal of the Scanner Motor

(3) Removal of the Paper Take-Up Roll

(4) Removal of the Paper Take-Up Solenoid

(5) Removal of the Main Mot or a nd PH Se c tion Cooling Fan Motor

3. ADJUSTMENT

3-1. ADJUSTMENT REQUIREMENTS LIST

3-2. ADJUSTMENT OF UPPER UNIT INTERLOCK SWITCH S2

3-3. ELECTRICAL/IMAGE ADJUSTMENT

(1) Entering the Tech. Rep. Mode

(2) Entering the Adjust Mode

(3) Producing a Test Pattern

(4) CD Registration Adjustment (Paper Tray)

(5) FD Registration Adjustment (Paper Tray)

(6) CD Zoom Ratio Adjustment (Scanner)

(7) FD Zoom Ratio Adjustment (Scanner)

(8) CD Registration Adjustment (Scanner)

(9) FD Registration Adjustment (Scanner)

4. MISCELLANEOUS

4-1. TORSION BAR POSITION ADJUSTMENT

4-2. REMOUNTING EEPROM (U21)

CONTENTS

1. CONTROL PANEL KEYS AND INDICATORS

1-1. Control Panel Keys

2. USER’S CHOIC E MOD E

2-1. Functions Available from the User’s Choice Mode

2-2. User’s Choice Function Setting Procedure

2-3. Settings in the User’s Choice Mode

3. TECH. REP. MODE

3-1. Tech. Rep. Mode Function Tree

3-2. Tech. Rep. Mode Setting Procedure

(1) D isplay

(2) Function

(3) Tech. Rep. Cho ice

(4) A djust

TROUBLESHOOTING

CONTENTS

1. INTRODUCTION

1-1. Reading the Text

2. PAPER TRANSPORT FAILURE

2-1. Paper Misfeed

2-2. Size Erro r

2-3. Misfeed Detection Sensor Layout

2-4. Types of Misfeed Detection and Detection Timings

2-5. Misfeed Clearing Procedures

(1) Copier/Manual Bypass Paper Take-Up Misfeed

(2) Transport Misfeed

(3) Exit Misfeed

(4) PF-120 Paper Take-Up Misfeed

3. MALFUNCTIONS

3-1. Detection Timing Classified by Malfunction Code