Mita-Kyocera KM-1620 Service Manual

DP-410

SERVICE

MANUAL

Published in May ’03

843HL110

CAUTION

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

CAUTION

Double-pole/neutral fusing.

Safety precautions

This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

Safety warnings and precautions

Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:

DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

WARNING:Serious bodily injury or death may result from insufficient attention to or incorrect compliance

with warning messages using this symbol.

CAUTION:Bodily injury or damage to property may result from insufficient attention to or incorrect

compliance with warning messages using this symbol.

Symbols

The triangle ( ) symbol indicates a warning including danger and caution. The specific point
of attention is shown inside the symbol.

General warning.

Warning of risk of electric shock.

Warning of high temperature.

indicates a prohibited action. The specific prohibition is shown inside the symbol.

General prohibited action.

Disassembly prohibited.

indicates that action is required. The specific action required is shown inside the symbol.

General action required.

Remove the power plug from the wall outlet.

Always ground the copier.

1. Installation Precautions

WARNING

• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check

that it is adequate for the rated current. ............................................................................................

• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes,
lightning rods, ground cables for telephone lines and water pipes or faucets not approved by the

proper authorities. .............................................................................................................................

CAUTION:

• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .....

• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. ..............

• Do not install the copier near a radiator, heater, other heat source or near flammable material.

This may cause fire. ..........................................................................................................................

• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool

as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ..........

• Always handle the machine by the correct locations when moving it. ..............................................

• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may

cause the copier to move unexpectedly or topple, leading to injury..................................................

• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is
accidentally ingested, drink a lot of water to dilute it in the stomach and obtain medical attention
immediately. If it gets into the eyes, rinse immediately with copious amounts of water and obtain

medical attention. ..............................................................................................................................

• Advice customers that they must always follow the safety warnings and precautions in the copier’s

instruction handbook. ........................................................................................................................

2. Precautions for Maintenance

WARNING

• Always remove the power plug from the wall outlet before starting machine disassembly...............

• Always follow the procedures for maintenance described in the service manual and other related

brochures. .........................................................................................................................................

• Under no circumstances attempt to bypass or disable safety features including safety

mechanisms and protective circuits. .................................................................................................

• Always use parts having the correct specifications...........................................................................

• Always use the thermostat or thermal fuse specified in the service manual or other related

brochure when replacing them. Using a piece of wire, for example, could lead to fire or other

serious accident. ...............................................................................................................................

• When the service manual or other serious brochure specifies a distance or gap for installation of a

part, always use the correct scale and measure carefully. ...............................................................

• Always check that the copier is correctly connected to an outlet with a ground connection. ............

• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If

it is dirty, clean it to remove the risk of fire or electric shock. ............................................................

• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may

damage eyesight. ..............................................................................................................................

• Handle the charger sections with care. They are charged to high potentials and may cause

electric shock if handled improperly. .................................................................................................

CAUTION

• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are

safely secured so they will not be caught in rotating sections...........................................................

• Use utmost caution when working on a powered machine. Keep away from chains and belts. .......

• Handle the fixing section with care to avoid burns as it can be extremely hot. .................................

• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause

abnormally high temperatures...........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement....................

• Do not pull on the AC power cord or connector wires on high-voltage components when removing

them; always hold the plug itself. ......................................................................................................

• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a

cable cover or other appropriate item. ..............................................................................................

• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks........

• Remove toner completely from electronic components. ...................................................................

• Run wire harnesses carefully so that wires will not be trapped or damaged. ...................................

• After maintenance, always check that all the parts, screws, connectors and wires that were

removed, have been refitted correctly. Special attention should be paid to any forgotten

connector, trapped wire and missing screws. ..................................................................................

• Check that all the caution labels that should be present on the machine according to the

instruction handbook are clean and not peeling. Replace with new ones if necessary. ...................

• Handle greases and solvents with care by following the instructions below: ....................................

· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.

· Ventilate the room well while using grease or solvents.

· Allow applied solvents to evaporate completely before refitting the covers or turning the main

switch on.

· Always wash hands afterwards.

• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to

fire in a furnace, etc...........................................................................................................................

• Should smoke be seen coming from the copier, remove the power plug from the wall outlet

immediately. ......................................................................................................................................

3. Miscellaneous

WARNING

• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than

the specified refiner; it may generate toxic gas. ................................................................................

CONTENTS

1-1 Specifications

1-1-1 Specifications ....................................................................................................................................... 1-1-1

1-1-2 Parts names and their functions ........................................................................................................... 1-1-2

(1) Parts names ................................................................................................................................... 1-1-2

1-1-3 Machine cross section .......................................................................................................................... 1-1-3

1-1-4 Drive system ........................................................................................................................................ 1-1-4

1-2 Installation

1-2-1 Unpacking and installation ................................................................................................................... 1-2-1

(1) Unpacking ....................................................................................................................................... 1-2-1

1-3 Maintenance Mode

1-3-1 Maintenance mode ............................................................................................................................... 1-3-1

(1) Executing a maintenance item ....................................................................................................... 1-3-1

(2) Maintenance mode item list ............................................................................................................ 1-3-2

(3) Contents of maintenance mode items ............................................................................................ 1-3-3

1-4 Troubleshooting

1-4-1 Original misfeed detection .................................................................................................................... 1-4-1

(1) Original misfeed indication ............................................................................................................. 1-4-1

(2) Original misfeed detection conditions ............................................................................................. 1-4-1

(3) Original misfeeds ............................................................................................................................ 1-4-3

1-4-2 Self-diagnosis ....................................................................................................................................... 1-4-5

(1) Self-diagnostic function .................................................................................................................. 1-4-5

(2) Self-diagnostic codes ..................................................................................................................... 1-4-5

1-4-3 Image formation problems ................................................................................................................... 1-4-6

(1) There is a regular error between the centers of the original and copy image. ............................... 1-4-7

(2) There is a regular error between the leading edges of the original and copy image. ..................... 1-4-7

1-4-4 Electrical problems ............................................................................................................................... 1-4-8

(1) The machine does not operate when the power switch is turned on. ............................................. 1-4-8

(2) The original feed motor does not operate. ...................................................................................... 1-4-8

(3) The original conveying motor does not operate. ............................................................................ 1-4-8

(4) The switchback feedshift solenoid does not operate. ..................................................................... 1-4-8

(5) The switchback pressure solenoid does not operate. .................................................................... 1-4-8

(6) The original size is not detected correctly. ..................................................................................... 1-4-8

(7) A original jam in the DP is indicated when the power switch is turned on. ..................................... 1-4-9

(8) The message requesting cover to be closed is displayed when the DP original

cover is closed. ............................................................................................................................... 1-4-9

(9) Others. ............................................................................................................................................ 1-4-9

1-4-5 Mechanical problems ......................................................................................................................... 1-4-10

(1) No primary original feed. .............................................................................................................. 1-4-10

(2) Multiple sheets of original are fed at one time. ............................................................................. 1-4-10

(3) Originals jam. ................................................................................................................................ 1-4-10

(4) Abnormal noise is heard. .............................................................................................................. 1-4-10

3HL

1-5 Assembly and Disassembly

1-5-1 Precautions for assembly and disassembly ......................................................................................... 1-5-1

(1) Precautions ..................................................................................................................................... 1-5-1

(2) Running a maintenance item .......................................................................................................... 1-5-2

1-5-2 Paper feeder ........................................................................................................................................ 1-5-3

(1) Detaching and refitting the DP forwarding pulley and DP paper feed pulley .................................. 1-5-3

(2) Detaching and refitting the DP separation pad ............................................................................... 1-5-5

(3) Adjusting the DP magnification ....................................................................................................... 1-5-6

(4) Adjusting the DP center line ........................................................................................................... 1-5-7

1-1-1

3HL

(5) Adjusting the DP scanning timing ................................................................................................... 1-5-8

(5-1) Adjusting the DP leading edge registration ........................................................................... 1-5-8

(5-2) Adjusting the DP trailing edge registration ............................................................................ 1-5-9

(6) Adjusting the margins for scanning the original from the DP ........................................................ 1-5-10

2-1 Mechanical construction

2-1-1 Mechanical construction ....................................................................................................................... 2-1-1

(1) Operation of original switchback ..................................................................................................... 2-1-3

2-2 Electrical Parts Layout

2-2-1 Electrical parts layout ........................................................................................................................... 2-2-1

(1) PCBs .............................................................................................................................................. 2-2-1

(2) Switches and sensors ..................................................................................................................... 2-2-2

(3) Motors and solenoids ..................................................................................................................... 2-2-3

2-3 Operation of the PCBs

2-3-1 DP driver PCB ...................................................................................................................................... 2-3-1

2-4 Appendixes

Maintenance parts list..................................................................................................................................... 2-4-1

Periodic maintenance procedures .................................................................................................................. 2-4-2

Timing chart No. 1 .......................................................................................................................................... 2-4-3

Timing chart No. 2 .......................................................................................................................................... 2-4-4

Wiring diagram ............................................................................................................................................... 2-4-5

1-1-2

1-1-1 Specifications

Type ............................................... Machine mounted type duplex sheet-through document processor

Original feed system ...................... Automatic feed

Originals ......................................... Sheets

Original weights.............................. Single-sided original mode: 45 – 160 g/m

Double-sided original mode: 50 – 120 g/m

Original paper................................. Plain paper, recycled paper, thermal paper, art paper and colored paper

1

Original sizes.................................. A3 – A5R/11" × 17" – 5

No. of originals ............................... 50 sheets (50 – 80 g/m

/2" × 81/2"

2

)

30 sheets in the auto selection mode

Original processing speed.............. Original replacement: Max. 20 sheets/min (A4/11" × 8

Original scanning: 100 mm/s (100%)

Power source ................................. Electrically connected to the copier

Dimensions .................................... 552 (W) × 483 (D) × 120 (H) mm

213/4" (W) × 19" (D) × 43/4" (H)

Weight ............................................Approx. 6.0 kg/13.2 lbs

2

2

1

/2")

3HL

1-1-1

3HL

1-1-2 Parts names and their functions

(1) Parts names

Figure 1-1-1

1 Original table
2 Original insert guides
3 DP original cover
4 Switchback tray
5 Ejection extension

1-1-2

1-1-3 Machine cross section

3HL

Original path

Figure 1-1-2 Machine cross section

1 Original feed section
2 Original conveying section
3 Original switchback section

1-1-3

3HL

1-1-4 Drive system

• Original conveying motor

• Inside front of machine • Inside rear of machine

• Original feed motor

Figure 1-1-3 Drive system

1 Original conveying motor gear
2 Gear 16
3 Idle gear 49/13
4 Gear 24/30
5 Belt 174S2M
6 Pulley
7 Conveying pulley 40

8 Exit gear 16
9 Idle gear 15
0 Idle gear 15
! Exit gear 16
@ Gear 40
# Gear 30

$ Original feed motor gear
% Gear 42/29
^ Gear 20
& Gear 30

1-1-4

Figure 1-1-4 Drive system

1-2-1 Unpacking and installation

(1) Unpacking

3HL

Figure 1-2-1 Unpacking

1 Document processor
2 Fixing fitting
3 Pin
4 Bronze TP screw M3x06
5 Chrome TP screw M4x10
6 Outer case
7 Spacer
8 Supports
9 Front pad

0 Rear bottom pad
! Rear upper pad
@ Air cap bag (70 × 280)
# Plastic sheet (1300 × 1300)
$ Bar code labels
% Plastic bag (70 × 110)
^ Plastic bag (240 × 350)
& Caution lavel
* Installation guide

1-2-1

1-3-1 Maintenance mode

The copier is equipped with a maintenance function which can be used to maintain and service the machine.

(1) Executing a maintenance item

Start

3HL

Yes

Enter “10871087” using

the numeric keys.

Enter the maintenance item

number using the zoom

+/- keys or numeric keys.

Press the start key.

The selected maintenance item is run.

Press the stop/clear key.

Repeat the same

maintenance item?

Maintenance mode is entered.

The maintenance item is
selected.

Yes

No

Run another maintenance

item?

No

Enter “001” using the

+/- keys

or numeric keys

and press the start key.

End

zoom

Maintenance mode is exited.

1-3-1

3HL

(2) Maintenance mode item list

Section

DP U019 Displaying the ROM version —

Item

No. setting*

U068 Adjusting the scanning position for originals from the DP 0

U070 Adjusting the DP magnification 0

U071 Adjusting the DP scanning timing

• DP leading edge registration 0

• DP trailing edge registration 0

U072 Adjusting the DP center line 0

U074 Adjusting the DP input light luminosity 1

U087 Turning the DP scanning position adjust mode on/off 35

U203 Operating DP separately —

U243 Checking the operation of the DP motors and solenoids —

U244 Checking the DP switches —

U404 Adjusting margins for scanning an original from the DP —

Maintenance item contents

Initial

* Initial setting for executing maintenance item U020

1-3-2

(3) Contents of maintenance mode items

3HL

Maintenance

item No.

U019 Displaying the ROM version

Description

Displays the part number of the ROM fitted to each board.

Purpose

To check the part number or to decide if the ROM version is new from the last digit of the number.

Method

1. Press the start key. A selection item appears.

2. Select the item to be displayed using the image mode selection key and copy exposure adjustment keys.

Image mode LEDs

Description

Copy exposure
indicator

Exp. 1 number of the main ROM

Exp. 2 number of the main ROM sub

Exp. 1 number of the engine ROM

Exp. 2 number of the engine ROM sub

Exp. 1 number of the first paper feeder ROM

Exp. 2 number of the second paper feeder ROM

Exp. 3 number of the third paper feeder ROM

Copy quantity display

Exp. 1 number of the DP ROM

: Off, : On, : Flashing

Completion

Press the stop/clear key. The indication for selecting a maintenance item No. appears.

U068 Adjusting the scanning position for originals from the DP

Description

Adjusts the position for scanning originals from the DP.

Purpose

Used when there is a regular error between the leading edges of the original and the copy image when the DP
is used.

Method

Press the start key.

Setting

1. Change the setting using the zoom +/– keys.

Description Setting range Initial setting Change in value per step

Scanning position –17 to +17 0 0.254 mm

Increasing the setting moves the image backward, and decreasing it moves the image forward.

2. Press the start key. The value is set.

Completion

Press the stop/clear key. The indication for selecting a maintenance item No. appears.

1-3-3

3HL

Maintenance

item No.
U070 Adjusting the DP magnification

Adjustment

See pages 1-5-6.

U071 Adjusting the DP scanning timing

Adjustment

See page 1-5-8 and 9.

U072 Adjusting the DP center line

Adjustment

See page 1-5-7.

U074 Adjusting the DP input light luminosity

Description

Adjusts the luminosity of the exposure lamp for scanning originals from the DP.

Purpose

Used if the exposure amount differs significantly between when scanning an original on the contact glass and
when scanning an original from the DP.

Method

Press the start key.

Setting

1. Change the setting using the zoom +/– keys.

Description Setting range Initial setting

DP input light luminosity 0 to 8 1

Increasing the setting makes the luminosity higher, and decreasing it makes the luminosity lower.

2. Press the start key. The value is set.

Test copy mode

While this maintenance item is being performed, copying from an original can be made in test copy mode.

Completion

Press the stop/clear key. The indication for selecting a maintenance item No. appears.

Description

1-3-4

3HL

Maintenance

item No.

U087 Turning the DP scanning position adjust mode on/off

Description

Turns on or off the DP scanning position adjust mode, in which the DP original scanning position is adjusted
automatically by determining the presence or absence of dust on the slit glass. Also changes the reference
data for identifying dust.

Reference

In the DP original scanning position adjust mode, the presence or absence of dust is determined by comparing
the scan data of the original trailing edge and that taken after the original is conveyed past the DP original
scanning position. If dust is identified, the DP original scanning position is adjusted for the following originals.

Purpose

Used to prevent appearance of black lines due to dust adhering in the original scanning position on the slit
glass when the DP is used.

Method

1. Press the start key.

2. Select the item to be set by lighting a copy exposure indicator using the copy exposure adjustment keys.

Copy exposure indicator Description

Exp. 1 Setting the mode on/off
Exp. 2 Setting the reference data for identifying dust

Setting the mode on/off

1. Select “on” or “oFF” using the zoom +/– keys.

Display Description

on DP scanning position adjust mode on
oFF DP scanning position adjust mode off

Initial setting: on

2. Press the start key. The setting is set.

Setting the reference data for identifying dust

Available only when the mode is turned on.

1. Change the setting using the zoom +/– keys.

Description Setting range Initial setting

Minimum density to be regarded as dust 10 to 95 35

Example
The figure indicates the density in 256 levels of gray (0: white, 255: black). When the setting is 35, data of
the level of 35 or higher is regarded as dust and data of lower level is regarded as the background (scan
data taken when there is no original).

Description

2. Press the start key. The value is set.

Completion

Press the stop/clear key while a selection item is displayed. The indication for selecting a maintenance item No.
appears.

1-3-5

3HL

Maintenance

item No.
U203 Operating DP separately

Description

Simulates the original conveying operation separately in the DP.

Purpose

To check the DP.

Method

1. Press the start key.

2. Place an original in the DP if running this simulation with paper.

3. Select the item to be operated using the copy exposure adjustment keys.

Display (copy exposure indicator) Operation

d-P (exp. 1) With paper
d-n (exp. 2) Without paper (continuous operation)
dp2 (exp. 3) With paper (duplex mode)
dn2 (exp. 4) Without paper (duplex mode)

4. Press the start key. The operation starts.

5. To stop continuous operation, press the stop/clear key.

Completion

Press the stop/clear key when the operation stops. The indication for selecting a maintenance item No.
appears.

U243 Checking the operation of the DP motors and solenoids

Description

Turns the motors and solenoids in the DP on.

Purpose

To check the operation of the DP motors and solenoids.

Method

1. Press the start key.

2. Select the motor or solenoid to be operated using the copy exposure adjustment keys.

3. Press the start key. The operation starts.

Indication (copy exposure indicator)

F-0 (exp. 1) Original feed motor (OFM)
C-0 (exp. 2) Original conveying motor (OCM)
b-S (exp. 3) Switchback feedshift solenoid (SBFSSOL)
P-S (exp. 4) Switchback pressure solenoid (SBPSOL)

Description

Motor

1-3-6

4. To turn each motor off, press the stop/clear key.

Completion

Press the stop/clear key when operation stops. The indication for selecting a maintenance item No. appears.

3HL

Maintenance

item No.

U244 Checking the DP switches

Description

Displays the status of the switches in the DP.

Purpose

To check if switches in the DP operate correctly.

Method

1. Press the start key. "-S-" appears.

2. Turn each switche on and off manually to check the status. When the on-status of a switch is detected, the
LEDs on the operation panel corresponding to the operated switch lights.

LEDs Switch

Auto Exp. Original set switch (OSSW)
Text & Photo DP timing switch (DPTSW)
Photo Original detection switch (ODSW)
Text DP original cover switch (DPOCSW)
Program Original size length switch (OSLSW)
Eco-copy Original switchback switch (OSBSW)

Completion

Press the stop/clear key. The indication for selecting a maintenance item No. appears.

U404 Adjusting margins for scanning an original from the DP

Adjustment

See pages 1-5-10.

Description

1-3-7

3HL

1-4-1 Original misfeed detection

(1) Original misfeed indication

When an original jams, the copier immediately stops copying and displays the jam location on the operation panel.
To remove the jammed original in the DP, open the DP original cover.
To reset the original misfeed detection, open and close the DP original cover to turn DP original cover switch off and on.

(2) Original misfeed detection conditions

DPTSW

OFM

OCM

OSBSW

Figure 1-4-1

1-4-1

3HL

Section Jam code Description Conditions

Original
feed sec­tion

70

No original feed

During the primary feed of the second original in the single­sided or double-sided original mode, even if retry operation is
performed five times, primary original feed is not performed.

Original
conveying
section

Original
switchback
section

71

72

73

74

75

An original jam in the
original conveying sec­tion 1

An original size error jam

An original jam in the
original conveying sec­tion 2

An original jam in the
original conveying sec­tion 3

An original jam in the
original switchback sec­tion

During the secondary original feed in the single-sided or
double-sided original mode, the DP timing switch (DPTSW)
does not turn off within 6500 ms of the original conveying
motor (OCM) turning on.

During the secondary original feed in the single-sided or
double-sided original mode, the DP timing switch (DPTSW)
does turn off within 750 ms of the original conveying motor
(OCM) turning on.

During scanning of the second side or reversing of the origi­nal for ejection in the double-sided original mode, the DP tim­ing switch (DPTSW) does not turn off within 6500 ms of the
original conveying motor (OCM) turning on.

During scanning of the second side or reversing of the origi­nal for ejection in the double-sided original mode, the DP tim­ing switch (DPTSW) does not turn on within 750 ms of the
original conveying motor (OCM) turning on.

During the switchback operation of an original in the double­sided original mode, the original switchback switch (OSBSW)
does not turn on within 1300 ms of the original conveying
motor (OCM) turning on.

1-4-2

(3) Original misfeeds

Problem Causes/check procedures Corrective measures

(1)
An original jams
when the power
switch is turned on.

A piece of paper torn from
an original is caught
around the DP timing
switch or original
switchback switch.

Check visually and remove it, if any.

3HL

(2)
An original jams in
the original feed
section is indicated
during copying (no
original feed).
Jam code 70

(3)
An original jams in
the original convey­ing section is indi­cated during copy­ing (An original jam
in the original con­veying section 1).
Jam code 71

Defective DP timing
switch.

Defective original
switchback switch.

Defective original set
switch.

Check if the original feed
motor malfunctions.

Check if the DP paper
feed pulley or DP separa­tion pad is deformed.

Broken DP timing switch
actuator.

Defective DP timing
switch.

Check if the original con­veying motor malfunctions.

Run maintenance item U244 and turn DP timing switch on and
off manually. Replace DP timing switch if indication of the corre­sponding switch is not light.

Run maintenance item U244 and turn original switchback switch
on and off manually. Replace original switchback switch if indi­cation of the corresponding switch is not light.

Run maintenance item U244 and turn original set switch on and
off manually. Replace original set switch if indication of the cor­responding switch is not light.

Run maintenance item U243 and select the original feed motor
to be turned on and off. Check the status and remedy if neces­sary.

Check visually and replace the deformed pulley.

Check visually and replace DP timing switch if its actuator is bro­ken.

Run maintenance item U244 and turn DP timing switch on and
off manually. Replace DP timing switch if indication of the corre­sponding switch is not light.

Run maintenance item U243 and select the original conveying
motor to be turned on and off. Check the status and remedy if
necessary.

(4)
An original jams in
the original convey­ing section is indi­cated during copy­ing (An original size
error jam).
Jam code 72

(5)
An original jams in
the original convey­ing section is indi­cated during copy­ing (An original jam
in the original con­veying section 2).
Jam code 73

Broken DP timing switch
actuator.

Defective DP timing
switch.

Check if the original con­veying motor malfunctions.

Broken DP timing switch
actuator.

Defective DP timing
switch.

Check if the original con­veying motor malfunctions.

Check if the switchback
feedshift solenoid malfunc­tions.

Check visually and replace DP timing switch if its actuator is bro­ken.

Run maintenance item U244 and turn DP timing switch on and
off manually. Replace DP timing switch if indication of the corre­sponding switch is not light.

Run maintenance item U243 and select the original conveying
motor to be turned on and off. Check the status and remedy if
necessary.

Check visually and replace DP timing switch if its actuator is bro­ken.

Run maintenance item U244 and turn DP timing switch on and
off manually. Replace DP timing switch if indication of the corre­sponding switch is not light.

Run maintenance item U243 and select the original conveying
motor to be turned on and off. Check the status and remedy if
necessary.

Run maintenance item U243 and select the switchback feedshift
solenoid to be turned on and off. Check the status and remedy if
necessary.

1-4-3

3HL

Problem Causes/check procedures Corrective measures

(6)
An original jams in
the original convey­ing section is indi­cated during copy­ing (An original jam
in the original con­veying section 3).
Jam code 74

Broken DP timing switch
actuator.

Defective DP timing
switch.

Check if the original con­veying motor malfunctions.

Check visually and replace DP timing switch if its actuator is bro­ken.

Run maintenance item U244 and turn DP timing switch on and
off manually. Replace DP timing switch if indication of the corre­sponding switch is not light.

Run maintenance item U243 and select the original conveying
motor to be turned on and off. Check the status and remedy if
necessary.

(7)
An original jams in
the original
switchback section
is indicated during
copying (An original
jam in the original
switchback section).
Jam code 75

(8)
Original jams fre­quently.

Check if the switchback
feedshift solenoid malfunc­tions.

Defective original
switchback switch.

Check if the original con­veying motor malfunctions.

Check if the switchback
feedshift solenoid malfunc­tions.

An original outside the
specifications is used.

The DP forwarding pulley
or DP paper feed pulley is
dirty with paper powder.

The DP paper feed pulley
and DP separation pad do
not contact correctly.

Run maintenance item U243 and select the switchback feedshift
solenoid to be turned on and off. Check the status and remedy if
necessary.

Run maintenance item U244 and turn original switchback switch
on and off manually. Replace original switchback switch if indi­cation of the corresponding switch is not light.

Run maintenance item U243 and select the original conveying
motor to be turned on and off. Check the status and remedy if
necessary.

Run maintenance item U243 and select the switchback feedshift
solenoid to be turned on and off. Check the status and remedy if
necessary.

Use only originals conforming to the specifications.

Clean with isopropyl alcohol.

Check and remedy.

1-4-4

1-4-2 Self-diagnosis

(1) Self-diagnostic function

When a problem is detected, copying is disabled. "C" and a number 041 altenates.
After removing the problem, the self-diagnostic function can be reset by turning safety switch off and back on.

(2) Self diagnostic codes

3HL

Code Contents

C041

(A041*)

Optional DP communication problem

• Communication fails five times suc­cessively.

Remarks

Causes Check procedures/corrective measures

DP installed incor­rectly.

Defective main
PCB or DP driver
PCB.

Check the installation state of the DP and
adjust it if it is not properly installed.

Replace the main PCB or DP driver PCB
and check for correct operation.

“A” is displayed on the operation panel.

1-4-5

3HL

1-4-3 Image formation problems

(1) There is a regular error

between the centers of
the original and copy
image.

See page 1-4-7

(2) There is a regular error

between the leading
edges of the original
and copy image.

See page 1-4-7

1-4-6

3HL

(1) There is a regular

error between the
centers of the
original and copy
image.

Causes

1. Misadjusted DP center line.

(2) There is a regular

error between the
leading edges of
the original and
copy image.

Causes

1. Misadjusted DP center line.

Check procedures/corrective measures

Readjust the DP center line (see page 1-5-7).

Causes

1. Misadjusted DP original scanning start
position.

Causes

1. Misadjusted DP original scanning start
position.

Check procedures/corrective measures

Readjust the DP original scanning start position (see page 1-5-8).

1-4-7

3HL

1-4-4 Electrical problems

Problem Causes Check procedures/corrective measures

(1)
The machine does
not operate when
the power switch is
turned on.

The DP original cover is
not closed completely.

Defective DP original
cover switch.

Check the DP original cover.

Check for continuity across the contacts of switch. If none, re­place the switch.

(2)
The original feed
motor does not
operate.

(3)
The original convey­ing motor does not
operate.

(4)
The switchback
feedshift solenoid
does not operate.

Poor contact in the original
feed motor connector ter­minals.

Broken original feed motor
gear.

Defective original feed mo­tor.

Defective DP driver PCB.

Poor contact in the original
conveying motor connec­tor terminals.

Broken original conveying
motor gear.

Defective original convey­ing motor.

Defective DP driver PCB.

Defective switchback
feedshift solenoid coil.

Poor contact in the switch­back feedshift solenoid
connector terminals.

Reinsert the connector. Also check for continuity within the con­nector cable. If none, remedy or replace the cable.

Check visually and replace the original feed motor if necessary.

Run maintenance item U243 and check if the original feed motor
operates when YC8-3,4,5,6 on the DP driver PCB goes low. If
not, replace the original feed motor.

Run maintenance item U243 and check if YC8-3,4,5,6 on the DP
driver PCB goes low. If not, replace the DP driver PCB.

Reinsert the connector. Also check for continuity within the con­nector cable. If none, remedy or replace the cable.

Check visually and replace the original conveying motor if nec­essary.

Run maintenance item U243 and check if the original conveying
motor operates when YC8-9,10,11,12 on the DP driver PCB
goes low. If not, replace the original conveying motor.

Run maintenance item U243 and check if YC8-9,10,11,12 on the
DP driver PCB goes low. If not, replace the DP driver PCB.

Check for continuity across the coil. If none, replace the
switchback feedshift solenoid.

Reinsert the connector. Also check for continuity within the con­nector cable. If none, remedy or replace the cable.

(5)
The switchback
pressure solenoid
does not operate.

(6)
The original size is
not detected cor­rectly.

1-4-8

Defective DP driver PCB.

Defective switchback pres­sure solenoid coil.

Poor contact in the switch­back pressure solenoid
connector terminals.

Defective DP driver PCB.

Poor contact in the original
size length switch connec­tor terminals.

Defective original size
length switch.

Run maintenance item U243 and check if YC7-5 on the DP
driver PCB goes low. If not, replace the DP driver PCB.

Check for continuity across the coil. If none, replace the
switchback pressure solenoid.

Reinsert the connector. Also check for continuity within the con­nector cable. If none, remedy or replace the cable.

Run maintenance item U243 and check if YC7-2,3 on the DP
driver PCB goes low. If not, replace the DP driver PCB.

Reinsert the connector. Also check for continuity within the con­nector cable. If none, remedy or replace the cable.

Check if YC2-4 on the DP driver PCB goes low when the original
size length switch is turned on. If not, replace the original size
length switch.

Problem Causes Check procedures/corrective measures

(6)
The original size is
not detected cor­rectly.

Poor contact in the original
size width switch connec­tor terminals.

Defective original size
width switch.

Reinsert the connector. Also check for continuity within the con­nector cable. If none, remedy or replace the cable.

Check if YC2-2 on the DP driver PCB goes low when the original
size width switch is turned on. If not, replace the original size
width switch.

3HL

(7)
A original jam in the
DP is indicated
when the power
switch is turned on.

(8)
The message re­questing cover to be
closed is displayed
when the DP origi­nal cover is closed.

(9)
Others.

A piece of paper torn from
copy paper is caught
around DP timing switch or
original switchback switch.

Defective DP timing
switch.

Defective original
switchback switch.

Poor contact in the DP
original cover switch con­nector terminals.

Defective DP original
cover switch.

Wiring is broken, shorted
or makes poor contact.

Noise.

Check and remove if any.

Run maintenance item U244 and turn DP timing switch on and
off manually. Replace DP timing switch if indication of the corre­sponding sensor is not light.

Run maintenance item U244 and turn original switchback switch
on and off manually. Replace original switchback switch if indi­cation of the corresponding sensor is not light.

Reinsert the connector. Also check for continuity within the con­nector cable. If none, remedy or replace the cable.

Run maintenance item U244 and turn DP original cover switch
on and off manually. Replace DP original cover switch if indica­tion of the corresponding sensor is not light.

Check for continuity. If none, repair.

Locate the source of noise and remove.

1-4-9

3HL

1-4-5 Mechanical problems

Problem Causes/check procedures Corrective measures

(1)
No primary original
feed.

Check if the surfaces of the following pulleys
are dirty with paper powder: DP forwarding
pulley, DP paper feed pulley and DP separa­tion pad.

Clean with isopropyl alcohol.

(2)
Multiple sheets of origi­nal are fed at one time.

(3)
Originals jam.

(4)
Abnormal noise is
heard.

Check if the DP forwarding pulley, DP paper
feed pulley or DP separation pad is de­formed.

Check if the DP separation pad is worn.

Deformed guides along the paper conveying
path.

Check if the contact between the conveying
roller and pulley is correct.

Check if the contact between the exit roller
and pulley is correct.

Check if the contact between the switchback
roller and pulley is correct.

Check if the pulleys, rollers and gears oper­ate smoothly.

Check visually and replace any deformed
pulleys (see page 1-5-3 and 5).

Replace the DP separation pad if it is worn
(see page 1-5-5).

Repair or replace if necessary.

Check visually and remedy if necessary.

Check visually and remedy if necessary.

Check visually and remedy if necessary.

Grease the bearings and gears.

1-4-10

1-5-1 Precautions for assembly and disassembly

(1) Precautions

• Be sure to turn the power switch off and disconnect the power plug before starting disassembly.

• When handling PCBs, do not touch connectors with bare hands or damage the board.

• Do not touch any PCB containing ICs with bare hands or any object prone to static charge.

• Use the following testers when measuring voltages:

Hioki 3200
Sanwa MD-180C
Sanwa YX-360TR
Beckman TECH300
Beckman DM45
Beckman 330*
Beckman 3030*
Beckman DM850*
Fluke 8060A*
Arlec DMM1050
Arlec YF1030C
* Capable of measuring RMS values.

3HL

1-5-1

3HL

(2) Running a maintenance item

Start

Yes

Enter “10871087” using

the numeric keys.

Enter the maintenance item

number using the zoom

+/- keys or numeric keys.

Press the start key.

The selected maintenance item is run.

Press the stop/clear key.

Repeat the same

maintenance item?

Maintenance mode is entered.

The maintenance item is
selected.

Yes

No

Run another maintenance

item?

No

Enter “001” using the

or numeric keys

+/- keys

and press the start key.

End

zoom

Maintenance mode is exited.

1-5-2

1-5-2 DP

(1) Detaching and refitting the DP forwarding pulley and DP paper feed pulley

Follow the procedure below to clean or replace the DP forwarding pulley or DP paper feed pulley.

Procedure

• Detaching the DP forwarding pulley

1. Open the DP original cover.

2. Raise the DP paper feed pulley unit and pull
the hooking portion for the DP forwarding
pulley shaft toward the front side to remove
the DP forwarding pulley shaft.

3. Remove the DP forwarding pulley.

DP paper feed pulley unit

DP forwarding
pulley shaft

3HL

• Detaching the DP paper feed pulley

4. Remove the stop ring and paper feed guide
at front side of the DP paper feed pulley
shaft.

* When mounting the paper feed guide, fit the

projection of the paper feed guide into the
groove of the DP paper feed pulley shaft.

5. Remove the DP paper feed pulley unit from
DP.

DP forwarding pulley

Figure 1-5-1

Groove

Projection

Stop ring

DP paper
feed pulley
shaft

Figure 1-5-2

Paper feed
guide

1-5-3

3HL

6. Remove the two stop rings and then remove
the DP paper feed pulley shaft from the DP
paper feed pulley unit.

7. Remove the DP paper feed pulley from the
DP paper feed pulley shaft.

8. Clean or replace the DP forwarding pulley
and the DP paper feed pulley and refit all the
removed parts.

Stop ring

DP paper feed pullry

Stop ring

DP paper feed
pullry shaft

Figure 1-5-3

1-5-4

(2) Detaching and refitting the DP separation pad

Follow the procedure below to clean or replace the DP separation pad.

Procedure

1. Remove the DP paper feed pulley unit (see
page 1-5-3).

2. Push the fitting portions of the DP separation
pad. Remove the DP separation pad.

3. Clean or replace the DP separation pad and
refit all the removed parts.

Fitting portion

3HL

DP separation pad

Fitting portion

Figure 1-5-4

1-5-5

3HL

(3) Adjusting the DP magnification

Adjust magnification in the auxiliary scanning direction if magnification is incorrect when the DP is used.

U053

(See the service manual

of the copier.)

U065(auxiliary scanning

direction)

(See the service manual

of the copier.)

U070

Caution

Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

Procedure

Main scanning

direction

Start

Auxiliary

Enter maintenance mode.

Enter “070” using the numeric keys.

Press the start key.

scanning

direction

Original

Copy

example 1

Figure 1-5-5

Copy

example 2

Press the interrupt key.

Place an original on the DP

and make a test copy.

Is the image correct?

Yes

Press the stop/clear key to

exit maintenance mode.

End

Press the start key.

The new setting
is stored.

For copy example 1, increase
the value using the zoom (+) key.

No

For copy example 2, decrease
the value using the zoom (–) key.

Setting range: –25 – +25
Initial setting: 0
Changing the value by 1 changes
the magnification by 0.1%.
Increasing the value makes
the image longer, and decreasing it
make the image shorter.

1-5-6

3HL

(4) Adjusting the DP center line

Perform the following adjustment if there is a regular error between the centers of the original and the copy image when
the DP is used.

U034

(See the service manual

of the copier.)

(See the service manual

U067

U072

of the copier.)

Caution

Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

Procedure

Reference

Start

Enter maintenance mode.

Copy

example 2

Enter “072” using the numeric keys.

Original Copy

example 1

Figure 1-5-6

Press the start key.

Press the interrupt key.

Place an original on the DP

and make a test copy.

Press the start key.

The new setting
is stored.

Is the image correct?

Yes

Press the stop/clear key to

exit maintenance mode.

End

For copy example 1, decrease

No

the value using the zoom (–) key.
For copy example 2, increase
the value using the the zoom (+) key.

Setting range: –6.6 – +6.6
Initial setting: 0
Changing the value by 1 moves
the center line by 0.1 mm.
Increasing the setting moves image
to the left, and decreasing it moves
the image to the right.

1-5-7

3HL

(5) Adjusting the DP scanning timing

Perform the following adjustment if there is a regular error between the leading or trailing edges of the original and the
copy image.

U034

(See the service manual

of the copier.)

(See the service manual

U066

U071

of the copier.)

Caution

Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

(5-1) Adjusting the DP leading edge registration

Procedure

Start

Enter maintenance mode.

Enter “071” using the numeric keys.

Press the start key.

Original

Copy

example 1

Copy

example 2

Figure 1-5-7

Select “exp. 1”.

Press the interrupt key.

Place an original on the DP

and make a test copy.

Is the image correct?

Yes

Press the stop/clear key to

exit maintenance mode.

End

Press the start key.

The new setting
is stored.

For copy example 1, decrease

No

the value using the zoom (–) key.
For copy example 2, increase
the value using the zoom (+) key.

Setting range: –32 – +32
Initial setting: 0
Changing the value by 1 moves
the leading edge by 0.254 mm.
Increasing forward and decreasing it moves
the image backward.

1-5-8

(5-2) Adjusting the DP trailing edge registration

Procedure

Start

Enter maintenance mode.

3HL

Enter “071” using the numeric keys.

Press the start key.

Select “exp. 2”.

Press the interrupt key.

Place an original on the DP

and make a test copy.

Is the image correct?

Yes

Press the stop/clear key to

exit maintenance mode.

End

Original Copy

Figure 1-5-8

Press the start key.

The new setting
is stored.

For copy example 1, decrease

No

the value using the zoom (–) key.
For copy example 2, increase
the value using the zoom (+) key.

Setting range: –42 – +32
initial setting: 0
Changing the value by 1 moves
the trailing edge by 0.254 mm.
Increasing forward and decreasing it moves
the image backward.

example 1

Copy

example 2

1-5-9

3HL

(6) Adjusting the margins for scanning the original from the DP

Perform the following adjustment if margins are not correct.

(See the service manual

U402

of the copier.)

(See the service manual

U403

U404

of the copier.)

Caution

Before making the following adjustment, ensure that the above adjustments have been made in maintenance mode.

Procedure

DP leading edge margin (3 ± 2.5 mm)

Ejection direction

(reference)

Start

Enter maintenance mode.

Enter “404” using the numeric keys.

DP left margin

+1.5

(2.5 mm)

–2.0

DP right margin
(2.5 mm)

DP trailing edge margin
(3 ± 2.5 mm)

+1.5
–2.0

Figure 1-5-9

Press the start key.

Select the item to be adjusted.

Press the interrupt key.

Place an original on the DP

and make a test copy.

(A test copy is output at the

reduction ratio of 95%).

Are the margins correct?

Yes

Proceed to another mode?

Press the stop/clear key to

exit maintenance mode.

Yes

No

No

Exp. 1 (lit): DP left margin
Exp. 2 (lit): DP leading edge margin
Exp. 3 (lit): DP right margin
Exp. 4 (lit): DP trailing edge margin

Press the start key.

The new setting
is stored.

Change the setting.

Increasing the value using the zoom
(+) key makes the margin wider.
Decreasing the value using the
zoom (–) key makes the margin
narrower.

Setting range (initial setting)

DP left margin: 0 – +10.0 (2.0)
DP leading edge margin: 0 – +10.0 (3.0)
DP right margin: 0 – +10.0 (2.0)

DP trailing edge margin: 0 – +10.0 (2.0)
Changing the value by one moves
the margin by 0.5 mm for all.

1-5-10

End

3HL

2-1-1 Mechanical construction

The DP consists of the original feed section, original conveying section and original switchback section.
The original feed section conveys an original set on the original table to the original conveying section in synchronization
with original scanning of the scanner on the copier.
The original conveying section conveys an original onto the slit glass and ejects it after scanning is complete.
The original switchback section reverses an original conveyed from the original conveying section and conveys it again
to the original conveying section in the double-sided original mode.

1 DP forwarding pulley
2 DP paper feed pulley
3 DP separation pad
4 Conveying pulley
5 Conveying roller
6 Conveying pulley
7 Switchback feedshift guide
8 Switchback roller

Figure 2-1-1

9 Switchback pulley
0 Exit pulley
! Exit roller
@ Original set switch (OSSW)
# DP timing switch (DPTSW)
$ Original switchback switch

(OSBSW)

2-1-1

3HL

OCM OFM

OSBSW

OFM

OCM

DPTSW

DPTSW

YC4-2

Paper feed start
request signal

SBFSSOL

OCM A,B,_A,_B

YC8-6

YC8-3-

SBFSSOL

YC7-5

DPDPCB

Figure 2-1-2 Block diagram

Scanning start
request signal

100 pls 214 pls

7400 pls

SBPSOL

OFM A,B,_A,_B

YC8-9-

YC8-12

SBPSOL

YC7-2,3

4000 pls

OSBSW

YC2-7

214 pls

980 pls

DPTSW

OVSYNC

740 pls

Timing chart 2-1-1 Original feed (A3, single-sided original mode)

a When the paper feed start request signal is input from the copier, the original feed motor (OFM) turns on and an

original is fed.

b 100 pulses after the DP timing switch (DPTSW) turns on, the original feed motor (OFM) turns off and original

conveying motor (OCM) turns on.

c 7400 pulses after the original conveying motor (OCM) turns on, the original feed motor (OFM) turns on.
d 214 pulses after the original feed motor (OFM) turns on, the original feed motor (OFM) turns off.
e 4000 pulses after the DP timing switch (DPTSW) turns off, the original conveying motor (OCM) turns off.

2-1-2

3HL

(1) Operation of original switchback

In the double-sided original mode, after the first side of an original is scanned, the switchback feedshift guide is activated
to switch the conveying path to the switchback tray side and the original is fed to the switchback tray. Then, the original is
reversed by the reverse rotation of the original conveying motor (OCM) and conveyed again to the original conveying
section. After the second side is scanned, the original is fed temporarily to the switchback tray, is reversed, is conveyed
without scanning, and then is ejected to the exit tray. Also the switchback press solenoid (SBPSOL) is activated to
release the switchback pulley for preventing original jams in the original switchback section.

• First side scanning→Switchback tray

Original conveying motor (OCM): forwerd rotation

Switchback feedshift solenoid (SBFSSOL): ON

• Original switchback operate

Original conveying motor (OCM): reverse rotation

Switchback feedshift solenoid (SBFSSOL): OFF

• Second side scanning→Switchback tray

Original conveying motor (OCM): forwerd rotation

Switchback feedshift solenoid (SBFSSOL): ON

• Original switchback operate

Original conveying motor (OCM): reverse rotation

Switchback feedshift solenoid (SBFSSOL): OFF

• Conveyed without scanning→Exit tray

Original conveying motor (OCM): forwerd rotation

Switchback feedshift solenoid (SBFSSOL): OFF

Figure 2-1-3 Operation of original switchback

2-1-3

3HL

OFM

OCM

DPTSW

OSBSW

SBFSSOL

SBPSOL

Paper feed start
request signal

100 pls

2840 pls

980 pls

214 pls

2600 pls

740 pls

100 ms

Scanning start
request signal

100 ms

150 pls

100 pls

980 pls

2600 pls

740 pls

100 ms

150 pls

100 ms

50 pls

OVSYNC

Timing chart 2-1-2 Original feed (A4, double-sided original mode)

a When the paper feed start request signal is input from the copier, the original feed motor (OFM) turns on and an

original is fed.

b 100 pulses after the DP timing switch (DPTSW) turns on, the original feed motor (OFM) turns off and original

conveying motor (OCM) rotates forward.

c 980 pulses after the original conveying motor (OCM) turns on, the switchback feedshift solenoid (SBFSSOL) turns on.
d 2840 pulses after the original conveying motor (OCM) turns on, the original feed motor (OFM) turns on for 214

pulses.

e 2600 pulses after the DP timing switch (DPTSW) turns on, the original feed motor (OFM) and switchback feedshift

solenoid (SBFSSOL) turns off.

f 100 pulses after the original conveying motor (OCM) turns off, the original conveying motor (OCM) rotates reverse.
g 150 pulses after the DP timing switch (DPTSW) turns on, the original conveying motor (OCM) turns off, and 100 ms

later, the motor turns on (forward).

h 100 pulses after the original conveying motor (OCM) turns on, the switchback feedshift solenoid (SBFSSOL) and

switchback pressure (SBPSOL) turns on.

i The DP timing switch (DPTSW) turns off at the same time, the switchback pressure (SBPSOL) turns off.
j 2600 pulses after the DP timing switch (DPTSW) turns off, the original conveying motor (OCM) and switchback

feedshift solenoid (SBFSSOL) turns off.

k 100 pulses after the original conveying motor (OCM) turns off, the original conveying motor (OCM) rotates reverse.
l 150 pulses after the DP timing switch (DPTSW) turns on, the original conveying motor (OCM) turns off, and 100 ms

later, the motor turns on (forward).

2-1-4

2-2-1 Electrical parts layout

(1) PCBs

3HL

1

Machine front

Machine inside

Machine rear

Figure 2-2-1 PCBs

1. DP driver PCB (DPDPCB) ........................... Controls electrical components of the DP.

2-2-1

3HL

(2) Switches and sensors

6

1

2

3

4

Machine front

5

Machine inside

7

Machine rear

Figure 2-2-2 Switches and sensors

1. DP original cover switch (DPOCSW) ........... Breaks the safety circuit when the DP original cover is opened; resets

original misfeed detection.

2. Original set switch (OSSW) ......................... Detects the presence of an original.

3. DP timing switch (DPTSW) .......................... Detects the original scanning timing.

4. Original switchback switch (OSBSW) .......... Detects an original misfeed in the original switchback section.

5. Original size width switch (OSWSW) ........... Detects the width of the original.

6. Original size length switch (OSLSW) ........... Detects the length of the original.

7. DP open/close switch (OPOCSW) ............... Detects the opening/closing of the DP.

2-2-2

(3) Motors and solenoids

1

3

3HL

2

4

Machine front

Machine inside

Machine rear

Figure 2-2-3 Motors and solenoids

1. Original feed motor (OFM) ........................... Drives the original feed section.

2. Original conveying motor (OCM) ................. Drives the original conveying and switchback sections.

3. Switchback feedshift solenoid

(SBFSSOL) .................................................. Operates the switchback feedshift guide.

4. Switchback pressure solenoid (SBPSOL) ... Operates the switchback pulley.

2-2-3

2-3-1 DP driver PCB

DPDPCB

OSSW

3HL

OSSW

Copier

DPOCSW

ORGVSYNC

DPRDY

DPSEL

SCLK

SDO

SDI

24V

5V

DPOCSW

CPU

U1

DPOCSW

Motor
Driver

DPTSW

OSBSW

OSLSW

OSWSW

SBFSSOL

SBPSOL (RET)

SBPSOL (ACT)

OFM A,B,_A,_B

DPTSW

OSBSW

OSLSW

OSWSW

SBFSSOL

SBPSOL

OFM

OCM A,B,_A,_B

OCM

FG

Motor
Driver

Figure 2-3-1 DP driver PCB block diagram

The DP driver PCB (DPDPCB) is controlled by the engine PCB (EPCB) in the copier, and the engine PCB (EPCB) uses
serial communication to control input and output of each motor, solenoid, and switch of the DP through the CPU (U1)
equipped with a function of bidirectional serial/parallel conversion of 8-bit data.

2-3-1

3HL

YC8

12 1

27

26

2

1

U3

1

2

14

YC6

1

YC5

3

X1

YC7

51

26

27

U2

16

YC1

1

YC4

1

8

13

YC2

PH1

E

YC3

71

A

K

Figure 2-3-2 DP driver PCB silk-screen diagram

2-3-2

Connector Pin No. Signal I/O Description

YC1

Connected
to the
copier

1 FG - Ground
2 24 V I 24 V DC power supply from copier
3 24 V I 24 V DC power supply from copier
4 P.GND - Ground
5 P.GND - Ground
6 SRESETN I Reset signal from copier
7 ORGVSYNC O DP original scanning interval signal
8 DPRDY O DP READY signal

9 DPSEL I DP SEL signal
10 DPCLK I DP clock signal
11 SDI I DP serial communication reception
12 SDO O DP serial communication transmission
13 FG - Ground
14 FG - Ground
15 S.GND - Ground
16 5 V I 5 V DC power supply from copier

3HL

YC2

Connected
to the
original size
width
switch,
original size
length
switch and
original
switchback
switch

YC4

Connected
to the DP
timing
switch

YC5

Connected
to the
original set
switch

YC6

Connected
to the DP
original
cover swich

1 5 V O 5 V DC power supply for OSWSW

2 OSWSW I OSWSW on/off

3 S.GND - Ground

4 OSLSW I OSLSW on/off

5 5 V O 5 V DC power supply for OSLSW

6 5 V O 5 V DC power supply for OSBSW

7 OSBSW I OSBSW on/off

8 S.GND - Ground

1 5 V O 5 V DC power supply for DPTSW

2 DPTSW I DPTSW on/off

3 S.GND - Ground

1 5 V O 5 V DC power supply for OSSW

2 OSSW I OSSW on/off

3 S.GND - Ground

1 24 V O 24 V DC power supply for DPOCSW

2 Reserve - Not used

3 Reserve - Not used

4 24 V I 24 V DC power supply

YC7

Connected
to the
switchback
pressure
solenoid
and
switchback
feedshift
solenoid

1 24 V O 24 V DC power supply for SBPSOL

2 SBPSOL (ACT) O SBPSOL (ACT) on/off

3 SBPSOL (RET) O SBPSOL (RET) on/off

4 24 V O 24 V DC power supply for SBFSSOL

5 SBFSSOL O SBFSSOL on/off

2-3-3

3HL

Connector Pin No. Signal I/O Description

YC8

Connected
to the
original
feed motor
and original
conveying
motor

1 OFM 24 V O 24 V DC power supply for OFM
2 OFM 24 V O 24 V DC power supply for OFM
3 OFM A O OFM control signal (A)
4 OFM B O OFM control signal (B)
5 OFM _A O OFM control signal (_A)
6 OFM _B O OFM control signal (_B)
7 OCM 24 V O 24 V DC power supply for OCM
8 OCM 24 V O 24 V DC power supply for OCM

9 OCM A O OCM control signal (A)
10 OCM B O OCM control signal (B)
11 OCM _A O OCM control signal (_A)
12 OCM _B O OCM control signal (_B)

2-3-4

Maintenance parts list

Maintenance part name

Name used in service manual Name used in parts list

DP forwarding pulley PULLEY, LEADING FEED ADF 36211110 3 47
DP paper feed pulley PULLEY, PAPER FEED 3BR07040 3 44
DP separation pad PAD, SEPARATION 3HL07100 3 11
Friction plate FRICTION PLATE, CASSETTE 2A107060 3 36

Conveying roller CONVEYING ROLLER, ASS’Y 3HL00010 4 1
Conveying pulley PULLEY CONVEYING 3HL08080 3,4 32,8
Reading guide GUIDE READING 3HL08040 2 19

Switchback roller ROLLER LOOP 3HL10030 4 15
Switchback pulley PULLEY LOOP 3HL10140 4 25
Exit roller ROLLER EJECT 3HL10100 4 21
Exit pulley PULLEY CONVEYING 3HL08080 4 8

Original holder mat MAT, ORIGINAL HOLDER 2A612810 1 14

Part No. Fig. No. Ref. No.

3HL

2-4-1

3HL

Periodic maintenance procedures

Section

Test copy and Perform at the maximum Test copy Every service
test print copy size

Section

Original feed DP forwarding pulley Replace or clean Every 100,000 counts Clean with alcohol when visiting 1-5-3
section the user.

Section

Original Conveying roller Clean Every service Clean with alcohol or a dry cloth.
conveying Conveying pulley Check or clean Every service Clean with alcohol or a dry cloth
section if it is dirty.

Maintenance
part/location

Maintenance
part/location

DP paper feed pulley Replace or clean Every 100,000 counts Clean with alcohol when visiting 1-5-3

DP separation pad Replace or clean Every 100,000 counts Clean with alcohol when visiting 1-5-5

Friction plate Clean Every service Clean with alcohol when visiting

Maintenance
part/location

Reading guide Clean Every service Clean with alcohol or a dry cloth.

Method Maintenance cycle Points and cautions Page

Method Maintenance cycle Points and cautions Page

the user.

the user.

the user.

Method Maintenance cycle Points and cautions Page

Section

Original Switchback roller Clean Every service Clean with alcohol or a dry cloth.
Switchback Switchback pulley Check or clean Every service Clean with alcohol or a dry cloth
section if it is dirty.

Section

Other Original holder mat Clean Every service Clean with alcohol or a dry cloth.

Maintenance
part/location

Exit roller Clean Every service Clean with alcohol or a dry cloth
Exit pulley Check or clean Every service Clean with alcohol or a dry cloth

Maintenance
part/location

Method Maintenance cycle Points and cautions Page

if it is dirty.

Method Maintenance cycle Points and cautions Page

2-4-2

3HL

OFM

OCM

DPTSW

OSBSW

SBFSSOL

SBPSOL

OVSYNC

YC8-3,4,5,6

YC8-9,10,

11,12

YC4-2

YC2-7

YC7-5

YC7-2,3

YC1-1

100 pls

214 pls

214 pls

7400 pls

4000 pls

740 pls980 pls

Paper feed start

request signal

Scanning start

request signal

××

××

× 17", 1 sheet, single-sided mode

Timing chart No. 1 Original size A3/11"

2-4-3