Ricoh S-C1 Service Manual

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Page 1

Model S-C1

(Machine Code: B045/B049/B044/B046)

SERVICE MANUAL

B046I100.WMF

17 July, 2001

Subject to change

Page 2

IMPORTANT SAFETY NOTICES

PREVENTION OF PHYSICAL INJURY

1. Be sure that the power cord is unplugged before disassembling or assembling parts of the copier or peripherals.

2. The wall outlet should be near the copier and easily accessible.

3. Note that electrical voltage is supplied to some components of the copier and the paper tray unit even while the main power switch is off.

4. If you start a job before the copier completes the warm-up or initializing period, keep hands away from the mechanical and electrical components until job execution has started. The copier will start making copies as soon as warm-up or initialization is finished.

5. The inside and the metal parts of the fusing unit become extremely hot while the copier is operating. Be careful to avoid touching those components with your bare hands.

HEALTH SAFETY CONDITIONS

Toner and developer are nontoxic, but getting either of these into your eyes may cause temporary eye discomfort. Try to remove with eye drops or flush with water. If material remains in eye or if discomfort continues, get medical attention.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those relevant models.

LITHIUM BATTERIES

Incorrect replacement of lithium battery(s) on the FCU may pose risk of explosion. Replace only with the same type or with an equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer’s instructi ons.

SAFE AND ECOLOGICAL DISPOSAL

1. Do not incinerate toner bottles or used toner. Toner dust may ignite suddenly if exposed to an open flame.

2. Dispose of used toner, developer, and organic photoconductors in accordance with local regulations. (These are nontoxic supplies.)

3. Dispose of replaced parts in accordance with local regulations.

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LASER SAFETY

The Center for Devices and Radiological Health (CDRH) prohibits the repair of laser-based optical units in the field. The optical housing unit can only be repaired in a factory or at a location with the requisite equipment. The laser subsystem is replaceable in the field by a qualified Customer Engineer. The laser chassis is not repairable in the field. Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when replacement of the optical subsystem is required.

WARNING Use of controls not specified in this manual, or performance of adjustments or procedures not specified in this manual, may result in hazardous radiation exposure.

WARNING FOR LASER UNIT WARNING: Turn off the main switch before atte mpting any of the

procedures in the Laser Unit section. Laser beams can cause serious damage to eyes.

CAUTION MARKING:

Symbols and Abbreviations

This manual uses the symbols and abbrev i ati ons show n below.

Symbol Meaning

☛

SEF Short Edge Feed LEF Long Edge Feed

"See," "Refer to" Clip ring Screw Connector

Core Technology manual

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1 INSTALLATION ........................................................................... 1-1

1.1 INSTALLATION REQUIREMENTS ...........................................................1-1

1.1.1 ENVIRONMENT ...............................................................................1-1

1.1.2 MACHINE LEVEL.............................................................................1-2

1.1.3 MINIMUM OPERATIONAL SPACE REQUIREMENTS ....................1-2

1.1.4 POWER REQUIREMENTS ..............................................................1-3

1.2 COPIER.....................................................................................................1-4

1.2.1 ACCESSORY CHECK......................................................................1-4

1.2.2 INSTALLATION PROCEDURE ........................................................1-4

Initial Programming: Faxless models (B044, B045) .............................1-8

Initial Programming: Fax-equipped models (B046, B049)....................1-8

1.3 PAPER TRAY UNIT ................................................................................1-10

1.3.1 ACCESSORY CHECK....................................................................1-10

1.3.2 INSTALLATION PROCEDURE ......................................................1-10

1.4 PAPER TRAY UNIT HEATER.................................................................1-12

1.4.1 ACCESSORY CHECK....................................................................1-12

1.4.2 INSTALLATION PROCEDURE ......................................................1-12

1.5 DOCUMENT FEEDER ............................................................................1-17

1.5.1 ACCESSORY CHECK....................................................................1-17

1.5.2 INSTALLATION PROCEDURE ......................................................1-17

1.6 DIMM.......................................................................................................1-21

1.6.1 INSTALLATION PROCEDURE ......................................................1-21

2 PREVENTIVE MAINTENANCE SCHEDULES............................. 2-1

2.1 PM TABLES ..............................................................................................2-1

2.2 HOW TO CLEAR THE PM COUNTER......................................................2-2

3 REPLACEMENT AND ADJUSTMENT......................................... 3-1

3.1 PRECAUTIONS.........................................................................................3-1

3.1.1 GENERAL ........................................................................................3-1

3.1.2 LITHIUM BATTERIES ......................................................................3-1

3.1.3 PCU (PHOTOCONDUCTOR UNIT) .................................................3-1

3.1.4 TRANSFER ROLLER.......................................................................3-1

3.1.5 SCANNER UNIT...............................................................................3-2

3.1.6 LASER UNIT ....................................................................................3-2

3.1.7 FUSING UNIT...................................................................................3-2

3.1.8 PAPER FEED...................................................................................3-2

3.1.9 IMPORTANT ....................................................................................3-3

3.2 SPECIAL TOOLS AND LUBRICANTS ......................................................3-3

3.3 EXTERIOR COVER AND OPERATION PANEL .......................................3-4

3.3.1 PLATEN COVER..............................................................................3-4

3.3.2 REAR COVER..................................................................................3-4

3.3.3 COPY TRAY.....................................................................................3-5

3.3.4 SCALE PLATE (B044 AND B045 ONLY) .........................................3-5

3.3.5 LEFT COVER ...................................................................................3-6

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3.3.6 RIGHT COVER.................................................................................3-6

3.3.7 FRONT LEFT COVER AND OPERATION PANEL ..........................3-6

3.3.8 FRONT RIGHT COVER ...................................................................3-6

3.3.9 RIGHT DOOR...................................................................................3-7

3.3.10 BYPASS TRAY (B044 AND B046 ONLY) ......................................3-7

3.3.11 PLATEN COVER SENSOR............................................................3-8

3.4 SCANNER SECTION ................................................................................3-9

3.4.1 EXPOSURE GLASS.........................................................................3-9

Non-DF machines.................................................................................3-9

DF-equipped machines.........................................................................3-9

3.4.2 LENS BLOCK .................................................................................3-10

3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD ..........................3-10

3.4.4 SCANNER MOTOR........................................................................3-11

3.4.5 SCANNER HP SENSOR................................................................3-11

3.4.6 SCANNER ALIGNMENT ADJUSTMENT .......................................3-12

3.5 FUSING...................................................................................................3-13

3.5.1 FUSING UNIT.................................................................................3-13

3.5.2 EXIT SENSOR ...............................................................................3-13

3.5.3 HOT ROLLER STRIPPER PAWLS ................................................3-14

3.5.4 HOT ROLLER & FUSING LAMP ....................................................3-15

3.5.5 THERMOFUSE, THERMOSWITCH, AND THERMISTOR.............3-15

3.5.6 PRESSURE ROLLER.....................................................................3-16

3.6 PCU.........................................................................................................3-17

3.7 TONER SUPPLY CLUTCH .....................................................................3-18

3.8 PAPER FEED SECTION.........................................................................3-19

3.8.1 PAPER FEED ROLLER AND FRICTION PAD...............................3-19

3.8.2 PAPER END SENSOR...................................................................3-19

3.8.3 REGISTRATION SENSOR.............................................................3-20

3.8.4 BYPASS PAPER END SENSOR (B044 AND B046 ONLY) ...........3-20

3.8.5 BYPASS FEED ROLLER (B044 AND B046 ONLY) .......................3-21

3.8.6 BYPASS FEED CLUTCH (B044 AND B046 ONLY).......................3-22

3.8.7 BYPASS FRICTION PAD (B044 AND B046 ONLY).......................3-22

3.8.8 REGISTRATION CLUTCH .............................................................3-22

3.8.9 PAPER FEED CLUTCH .................................................................3-23

3.9 IMAGE TRANSFER.................................................................................3-24

3.9.1 IMAGE TRANSFER ROLLER ........................................................3-24

3.9.2 ID (IMAGE DENSITY) SENSOR ....................................................3-24

3.9.3 DISCHARGE PLATE......................................................................3-25

3.10 FUNCTION CONTROL UNIT (FCU) .....................................................3-25

3.11 LASER UNIT .........................................................................................3-27

3.11.1 LOCATION OF “CAUTION” DECAL ............................................3-27

3.11.2 PSU BRACKET ............................................................................3-28

3.11.3 LASER UNIT ................................................................................3-29

3.11.4 LD UNIT........................................................................................3-29

3.11.5 POLYGON MIRROR MOTOR ......................................................3-29

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3.12 OTHER REPLACEMENTS....................................................................3-30

3.12.1 QUENCHING LAMP.....................................................................3-30

3.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD ...............................3-30

3.12.3 PSU ..............................................................................................3-30

3.12.4 MAIN MOTOR ..............................................................................3-31

3.12.5 EXHAUST FAN ............................................................................3-31

3.13 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING .....................3-32

3.13.1 PRINTING ....................................................................................3-32

Registration - Leading Edge/Side-to-Side...........................................3-32

Blank Margin.......................................................................................3-33

Main-Scan Magnification.....................................................................3-33

3.13.2 SCANNING...................................................................................3-34

Registration: Platen Mode...................................................................3-34

Magnification.......................................................................................3-34

Standard White Density Adjustment ...................................................3-35

3.13.3 DF IMAGE ADJUSTMENT ...........................................................3-36

Registration and Blank Margin............................................................3-36

Sub-scan Magnification.......................................................................3-36

4 TROUBLESHOOTING ................................................................. 4-1

4.1 SERVICE CALL CONDITIONS .................................................................4-1

4.1.1 SUMMARY .......................................................................................4-1

4.1.2 SC CODE DESCRIPTIONS .............................................................4-2

4.2 ELECTRICAL COMPONENT DEFECTS ..................................................4-7

4.2.1 SENSOR/SWITCH OPEN ERRORS................................................4-7

4.3 BLOWN FUSE CONDITIONS ...................................................................4-7

4.4 DUMPING THE FUSER TEMPERATURE LOG........................................4-8

5 SERVICE TABLES....................................................................... 5-1

5.1 USING SERVICE PROGRAM MODE .......................................................5-1

Accessing SP Mode..............................................................................5-1

Accessing Copy Mode from within SP Mode ........................................5-1

How to Select a Program Number ........................................................5-2

To Input a Value or Setting ...................................................................5-2

5.1.1 SP MODE TABLES ..........................................................................5-3

SP1-XXX (Feed) ...................................................................................5-3

SP2-XXX (Drum)...................................................................................5-4

SP4-XXX (Scanner) ..............................................................................5-9

SP5-XXX (Mode) ................................................................................5-14

SP6-XXX (Peripherals) .......................................................................5-18

SP7-XXX (Data Log)...........................................................................5-19

5.1.2 TEST PATTERN PRINTING (SP5-902) .........................................5-23

5.1.3 INPUT CHECK (SP5-803)..............................................................5-24

Input Check Table...............................................................................5-24

5.1.4 OUTPUT CHECK (SP5-804)..........................................................5-25

Input Check Table...............................................................................5-25

5.1.5 SMC PRINTING (SP5-992) ............................................................5-26

5.1.6 MEMORY ALL CLEAR (SP5-801)..................................................5-27

5.1.7 FREE RUNS...................................................................................5-28

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5.1.8 PROGRAM UPLOAD/DOWNLOAD ...............................................5-29

Program Download (SP5-827)............................................................5-29

Program Upload (SP5-826) ................................................................5-31

5.1.9 SRAM DATA UPLOAD/DOWNLOAD.............................................5-32

SRAM Data Upload (SP5-824) ...........................................................5-32

SRAM Data Download (SP5-825).......................................................5-33

5.1.10 SERIAL NUMBER INPUT (SP5-811) ...........................................5-33

5.1.11 ID SENSOR ERROR ANALYSIS (SP2-221) ................................5-34

5.1.12 MEMORY READ/WRITE ..............................................................5-35

5.2 USER TOOLS .........................................................................................5-36

5.2.1 HOW TO ENTER AND EXIT USER TOOLS ..................................5-36

5.2.2 USER TOOLS TABLE ....................................................................5-36

System Settings Table........................................................................5-36

Copy Features Table ..........................................................................5-36

6 DETAILED SECTION DESCRIPTIONS ....................................... 6-1

6.1 OVERVIEW ...............................................................................................6-1

6.1.1 COMPONENT LAYOUT...................................................................6-1

6.2 PAPER PATH............................................................................................6-5

6.3 DRIVE LAYOUT ........................................................................................6-6

6.4 BLOCK DIAGRAM: PCBS AND COMPONENTS......................................6-7

6.5 MAIN PCBS...............................................................................................6-8

6.5.1 FCU (FUNCTION/FACSIMILE CONTROL UNIT).............................6-8

SPC2 ....................................................................................................6-9

VPL (Video Processing LSI) .................................................................6-9

CIOP (Communications and I/O Processing)........................................6-9

FROM (Flash ROM) – 2MB ..................................................................6-9

DRAM – 8MB.......................................................................................6-9

SRAM – 128K .......................................................................................6-9

3V/5V Converter ...................................................................................6-9

Energy-Save Switching.........................................................................6-9

Reset/Backup Circuit ..........................................................................6-10

SAF Backup........................................................................................6-10

Analog Processing Circuit...................................................................6-10

Modem................................................................................................6-10

Speaker Driver....................................................................................6-10

Heater Control ....................................................................................6-10

Video Processing Circuit.....................................................................6-10

Power Pack Control ............................................................................6-10

Scanner Driver....................................................................................6-10

Plotter Driver.......................................................................................6-10

6.5.2 SBU (SENSOR BOARD UNIT).......................................................6-11

Buffer ..................................................................................................6-11

CCD ....................................................................................................6-11

Amplifier..............................................................................................6-11

6.5.3 NCU (NETWORK CONTROL UNIT) ..............................................6-12

North America version ........................................................................6-12

Europe/Asia version............................................................................6-12

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6.6 COPY PROCESS OVERVIEW ...............................................................6-13

6.7 SCANNING..............................................................................................6-15

6.7.1 OVERVIEW ....................................................................................6-15

6.7.2 SCANNER DRIVE ..........................................................................6-16

6.8 IMAGE PROCESSING ............................................................................6-17

6.8.1 OVERVIEW ....................................................................................6-17

6.8.2 IMAGE PROCESSING PATH.........................................................6-18

6.8.3 ORIGINAL MODES ........................................................................6-19

Original Modes: Copying....................................................................6-20

6.8.4 IMAGE PROCESSING STEPS FOR EACH MODE .......................6-21

6.8.5 MODE ADJUSTMENTS .................................................................6-22

To customize... ...................................................................................6-22

Default plotter customization settings for each mode... ......................6-23

6.9 LASER EXPOSURE................................................................................6-24

6.9.1 OVERVIEW ....................................................................................6-24

6.9.2 LD SAFETY SWITCHES ................................................................6-25

6.10 PHOTOCONDUCTOR UNIT (PCU) ......................................................6-26

6.10.1 OVERVIEW ..................................................................................6-26

6.10.2 DRUM DRIVE...............................................................................6-27

6.11 DRUM CHARGE ...................................................................................6-28

6.11.1 OVERVIEW ..................................................................................6-28

6.11.2 CHARGE ROLLER VOLTAGE CORRECTION............................6-29

Correction for Ambient Environment...................................................6-29

6.11.3 CHARGE ROLLER CLEANING....................................................6-30

6.11.4 DETECTION OF A NEW PCU......................................................6-31

At time of copier installation................................................................6-31

When a replacement PCU is installed.................................................6-31

6.12 DEVELOPMENT ...................................................................................6-32

6.12.1 OVERVIEW ..................................................................................6-32

6.12.2 DEVELOPMENT BIAS .................................................................6-33

6.12.3 TONER SUPPLY..........................................................................6-34

Toner-Bottle Models (B044 and B046)................................................6-34

Toner Hopper Magazine (B045 and B049) .........................................6-35

6.12.4 TONER DENSITY CONTROL ......................................................6-36

Overview.............................................................................................6-36

Reference Voltage ..............................................................................6-36

Toner Density Sensor Initial Setting....................................................6-36

Toner Concentration Measurement ....................................................6-37

Vsp/Vsg Detection ..............................................................................6-37

Calculation of Vref ..............................................................................6-37

Toner Supply Determination ...............................................................6-37

Toner Clutch ON Time........................................................................6-37

6.12.5 TONER SUPPLY IF SENSOR READING IS ABNORMAL ...........6-38

ID Sensor............................................................................................6-38

TD Sensor...........................................................................................6-38

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6.12.6 DETECTION OF TONER NEAR END AND TONER END ...........6-38

Toner Near End detected when either of the following occurs............6-38

Toner End detected when any of the following occurs........................6-38

6.13 DRUM CLEANING AND TONER RECYCLING.....................................6-39

6.14 PAPER FEED........................................................................................6-40

6.14.1 OVERVIEW ..................................................................................6-40

6.14.2 PAPER FEED DRIVE MECHANISM ............................................6-41

From Paper Tray.................................................................................6-41

From 100-Sheet Bypass Tray (B044, B046).......................................6-41

From 1-Sheet Bypass Tray (B045, B049)...........................................6-41

6.14.3 PAPER FEED AND SEPARATION ..............................................6-42

6.14.4 PAPER LIFT MECHANISM ..........................................................6-42

PAPER END DETECTION .................................................................6-43

Main Tray............................................................................................6-43

100-Sheet Bypass Tray (B044, B046) ................................................6-43

6.14.5 PAPER REGISTRATION..............................................................6-43

6.15 IMAGE TRANSFER AND PAPER SEPARATION .................................6-44

6.15.1 OVERVIEW ..................................................................................6-44

6.15.2 IMAGE TRANSFER CURRENT TIMING......................................6-45

6.15.3 TRANSFER ROLLER CLEANING................................................6-46

6.16 IMAGE FUSING AND PAPER EXIT......................................................6-47

6.16.1 OVERVIEW ..................................................................................6-47

6.16.2 FUSING DRIVE AND RELEASE MECHANISM ...........................6-47

6.16.3 PRESSURE ROLLER...................................................................6-48

6.16.4 PRESSURE RELEASE ................................................................6-48

Separation ..........................................................................................6-48

6.16.6 FUSING TEMPERATURE CONTROL..........................................6-49

Overview.............................................................................................6-49

Fusing Temperature Control for Thick Paper......................................6-49

6.16.7 OVERHEAT PROTECTION .........................................................6-49

6.17 ENERGY SAVER MODES ....................................................................6-50

6.17.1 MODE TRANSITIONS..................................................................6-50

6.17.2 SYSTEM SETTINGS....................................................................6-51

6.17.3 LOW POWER MODE LEVELS.....................................................6-51

6.17.4 AUTO-OFF LEVEL .......................................................................6-51

6.17.5 TRANSITION OPERATION..........................................................6-51

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PAPER TRAY UNIT (B421)

1 OVERALL MACHINE INFORMATION...................................B421-1

1.1 MECHANICAL COMPONENT LAYOUT ............................................ B421-1

1.2 ELECTRICAL COMPONENT LAYOUT.............................................. B421-1

1.3 DRIVE LAYOUT ................................................................................. B421-2

1.4 OVERALL ELECTRICAL CIRCUIT .................................................... B421-2

1.5 DETAILED DESCRIPTIONS.............................................................. B421-3

1.5.1 PAPER FEED AND SEPARATION ........................................... B421-3

1.6 PAPER LIFT MECHANISM................................................................ B421-3

1.7 PAPER END DETECTION................................................................. B421-4

1.8 SIDE AND END FENCES .................................................................. B421-5

2 REPLACEMENT AND ADJUSTMENT...................................B421-6

2.1 FEED ROLLER AND FRICTION PAD................................................ B421-6

2.2 REMOVING THE PAPER TRAY UNIT FROM THE COPIER............. B421-6

If Optional Tray Heater Is Not Installed.......................................... B421-6

If Optional Tray Heater Is Installed ................................................ B421-6

2.3 SENSORS.......................................................................................... B421-7

2.4 DRIVE SECTION................................................................................ B421-8

2.4.1 DRIVE BLOCK .......................................................................... B421-8

2.4.2 PAPER FEED MOTOR.............................................................. B421-8

2.4.3 PAPER FEED CLUTCH ............................................................ B421-9

2.4.4 TRAY MAIN BOARD ( 2.4.1) ..................................................... B421-9

DOCUMENT FEEDER (B444)

1 OVERALL INFORMATION ....................................................B444-1

1.1 MECHANICAL COMPONENT LAYOUT ............................................ B444-1

1.2 ELECTRICAL COMPONENT LAYOUT.............................................. B444-2

1.3 DRIVE LAYOUT ................................................................................. B444-3

2 DETAILED SECTION DESCRIPTIONS .................................B444-4

2.1 PICK-UP AND SEPARATION ............................................................ B444-4

2.2 CLUTCH OPERATION....................................................................... B444-4

2.3 TRANSPORT AND EXIT.................................................................... B444-4

2.4 UNIT OPEN SWITCH AND GUIDE OPEN SENSOR......................... B444-5

2.5 OVERALL ELECTRICAL CIRCUIT .................................................... B444-5

3 REPLACEMENT AND ADJUSTMENT...................................B444-6

3.1 DF UPPER COVERS ......................................................................... B444-6

3.2 ORIGINAL TABLE .............................................................................. B444-6

3.3 FEED UNIT......................................................................................... B444-6

3.4 DF PICKUP ROLLER......................................................................... B444-7

3.5 DF FEED ROLLER............................................................................. B444-7

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3.6 DF SEPARATION ROLLER ............................................................... B444-8

3.7 DF MOTOR ........................................................................................ B444-9

3.8 DF FEED CLUTCH........................................................................... B444-10

3.9 SENSORS........................................................................................ B444-10

3.10 DF EXPOSURE GLASS................................................................. B444-11

3.11 DF CONNECTION BOARD............................................................ B444-11

SPECIFICATIONS

1 GENERAL SPECIFICATIONS..............................................................SPEC-1

2 MACHINE CONFIGURATION.............................................................. SPEC-5

3 OPTIONAL EQUIPMENT..................................................................... SPEC-6

ADF .................................................................................................. SPEC-6

PAPER TRAY UNIT ........................................................................... SPEC-6

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24 July, 2001 INSTALLATION REQUIREMENTS

1. INSTALLATION

!!!!

CAUTION

Before installing options, please do the following:

1. If there is a fax unit on the machine, print out all messages stored in the memory, all user-programmed items, and a system parameter list.

2. If there is a printer option on the machine, print out all data in the printer buffer.

3. Turn off the main switch and disconnect the power cord, the telephone line, and the network cable.

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

–Temperature and Humidity Chart–

Installation

Humidity

80%

54%

Operation range

15%

10°C

(50°F)

27°C

(80.6°F)

(89.6°F)

32°C

Temperature

B046I512.WMF

1. Temperature Range: 10°C to 32°C (50°F to 89.6°F)

2. Humidity Range: 15% to 80% RH

3. Ambient Illumination: Less than 1,500 lux (Do not expose to direct sunlight.)

4. Ventilation: Room air should turn over at least 3 times/hr/person

5. Ambient Dust Less than 0.1 mg/m

6. Do not install the machine where it will be exposed to direct sunlight or to direct airflow (from a fan, air conditioner , air clean er, etc .) .

7. Do not install the machine where it will be exposed to corrosive gas.

8. Place the machine on a firm and level base.

9. Do not install the machine where it may be subjected to strong vibration.

1-1

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INSTALLATION REQUIREMENTS 24 July, 2001

1.1.2 MACHINE LEVEL

Front to back: Within 5 mm (0.2") of level Right to left: Within 5 mm (0.2") of level

1.1.3 MINIMUM OPERATIONAL SPACE REQUIREMENTS

Place the machine near the power source, providing clearance as shown.

[C]

[D]

[B]

450 mm (17.7")

A: Front > 750 mm (29.6")

[A]

B: Left > 100 mm (3.9 ") C: Rear > 105 mm (4.1") D: Right > 230 mm (9.0")

468 mm (18.4")

B046I130.WMF

NOTE: 1) The 750-mm front space indicated above is sufficient to allow the paper

tray to be pulled out. Additional space is required to allow an operator to stand at the front of the machine.

2) Actual minimum space requirement for left, rear, and right sides is 10mm (0.4") each, but note that this will not allow room for opening of the bypass tray, right door, platen cover, or ADF unit.

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24 July, 2001 INSTALLATION REQUIREMENTS

1.1.4 POWER REQUIREMENTS

CAUTION

1. Make sure that the wall outlet is near the machine and easily accessible. After completing installation, make sure the plug fits firmly into the outlet.

2. Avoid multi-wiring.

3. Be sure to ground the machine.

Input voltage:

North America: 120 V, 60 Hz, 7 A Europe: 220 – 240 V, 50/60 Hz, 4 A

Image quality guaranteed at rated voltage ± 10%. Operation guaranteed at rated voltage ± 15%.

Installation

1-3

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COPIER 24 July, 2001

1.2 COPIER

1.2.1 ACCESSORY CHECK

Check that you have the accessories indicated below. Note that accessories vary according to model and location.

No. Description Q’ty

1 Copier Operating Instructio ns (-17, -26, -29) 1 2 EU safety sheet (-22, -24, -26, -27) 1 3 NECR (-17, -27, -29) 1 4 Paper-size decals 1 set 5 Energy Star seal (-26) 1 6 Branding plaques (-22) 1 set 7 Brand decals (-22) 1 set 8 Handset bracket (B046-17) 1

1.2.2 INSTALLATION PROCEDURE

CAUTION

Make sure that the copier remains unplugged during installation.

[A]

B046I101.WMF

[B]

B046I124.WMF

1. Remove the strips of tape.

2. Remove the bag [A] holding the included accessories.

3. Remove the spacing wedge [B].

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24 July, 2001 COPIER

4. Remove the 3 scanner lock pins. (A tag is hanging from each pin.) To remove: Grasp the base of the pin [A], turn 90 degrees, and pull down and out.

[B]

[A]

Installation

5. Remove the tags from the pins. Then break each pin off of its base [A], discard the pin part [B], and set each base [A] back into its original hole, turning it 90° to lock it into place. (Be sure to do this for all three pins.)

6. If installing a DF-equipped model (B046 or B049): Raise the DF upper guide [C] and remove the protective paper [D] at the feed unit. Then lower the guide.

7. Open the platen cover [E] and remove the protective paper [F] covering the exposure glass. Then close the platen cover.

B046I106.WMF

[E]

[C]

[D]

1-5

B046I107.WMF

[F]

Page 17

COPIER 24 July, 2001

8. Open the front door [A].

9. If installing a toner-bottle model

(B044 or B046):

• Lift lever [B], press in on latch [C]

[C]

and pull the bottle holder [D] out. (It is not necessary to pull it completely out of the machine, however.)

• Take a new bottle of toner, shake it several times, remove its outer

cap [E], and load as shown. Then push the bottle holder back into the machine, and press the latch

[B]

[D]

[A]

down to lock it.

B046I112.WMF

If installi ng a toner-hopper magazine model (B045 or B049):

• Shake the magazine several times, then peel off the paper [F] from a new THM [G], and load the THM into the machine.

[E]

B046I301.WMF

[F]

[G]

1-6

B046I114.WMF

Page 18

24 July, 2001 COPIER

10. Remove the foam cushion [A] and pull the tabbed strips [B] all the way out of the PCU. Then close the front door.

11. Pull open the paper tray, and remove the tape [C] securing the end fence in the compartment.

12. Push the bottom plate [D] down, load paper, and adjust the side fences. If loading paper shorter than A4, remove the end fence [E] from its compartment, set it into the tray, and adjust it to the correct length.

[B]

Installation

[A]

B046I104.WMF

[E]

[D]

[C]

B046I119.WMF

13. Push the tray back in.

14. Adhere the appropriate branding decal (not shown) to the center of the front

[F]

door [F], and adhere the tray number decal and appropriate paper- si ze decal to the front of the paper tray (at [G]) as shown.

15. Hong Kong only:

If installing model B046 or B049 in Hong Kong, you must change the

position of the TB1 jumpe r on the NCU. Turn to the fax service manual and carry out steps 4 to 8 of the installation

[G]

B046I515.WMF

procedure (fax service manual, section 1.2.2).

16. Plug in the machine and turn on the main switch.

17. Enter SP mode, and run SP7-825 to initialize the electrical total counter to 0.

NOTE:

1) After selecting SP7-825, enter "1" and then hold down the Original Type key and press the OK key to initialize the counter. If

initialization is successful, the screen displays "Action comp leted."

2) SP7-825 is effective only once, at time of machine installation .

1-7

Page 19

COPIER 24 July, 2001

18. Models B046 and B049 only: Access SP5-992 and select "2" to print out a full SMC report. Confirm that the report shows a "YES" for SP7-801-3.

19. Models B046 and B049 only: Press the On Hook key on the fax operation panel, and confirm that you hear a dial tone coming from the monitor speaker.

20. Program the required items, as indicated below.

Initial Programming: Faxless models (B044, B045)

Items to Program (Service Level – SP Mode)

Date and time 5-302 Language replacement (Fir mware download) 5-827

*1: See Section 5 for SP-mode usage instructions.

Items to Program (User Level)

Display contrast Energy saver level (low power mod e) Reception mode Other items, as necessary *2

User Tools

User Tools →

System Settings

*2: Refer to the Operating Instructions for details.

Initial Programming: Fax-equipped models (B046, B049)

Items to Program (Service Level – Serv i ce Functions)

Country code (System switch 0F) 01 Protocol requirements (G3 switch 0 B) - E U only 01 PM call (System switch 01 – bit 0) 01 Country code (NCU parameter 0 0) 07 Service station's fax number 09

Function No.

SP No.

*3: See Section 5.1.1 of the fax service manual for information abou t using

service functions.

1-8

Page 20

24 July, 2001 COPIER

Items to Program (Service Level – SP Mode)

SP No.

Machine's serial number 5-811 Language replacement (Fir mware download) 5-827 PSTN access code (RAM address 4000DB) PSTN access method (RAM address 4000CD)

7-955

Periodic service call (RAM addresses 40054F to 400553)

*4: See Section 5 for SP-mode usage instructions.

Items to Program (User Administrator Level)

Monitor volume Display contrast Date and Time Reception mode Fax Header/Own Name/Own No. (TTI/RTI/CSI) Reports on/off Country Code (except NA) Fusing power control during e nergy saver mode System

Language selection Language Other initial progr amming items *5

User Tools

Fax Features

→ Setup

Key Op. Tools

Settings

Installation

*5: Refer to the Operating Instructions for details.

1-9

Page 21

PAPER TRAY UNIT 24 July, 2001

1.3 PAPER TRAY UNIT

1.3.1 ACCESSORY CHECK

Confirm that you have the accessories indicated below.

No. Description Q’ty

1 Paper-size decals 1 sheet 2 Installation Procedure (for service person) 1 3 Installation Procedur e (for us er) 1

1.3.2 INSTALLATION PROCEDURE

CAUTION

Unplug the main machine's power cord before starting the following procedure.

1. Remove the tape at [A], and the tape and cardboard at [B].

2. Pull the paper tray part way out of the unit, remove the tape and cardboard at [C], and push the tray back in.

[B]

[C]

[A]

B046I516.WMF

1-10

Page 22

24 July, 2001 PAPER TRAY UNIT

3. Set the machine onto the paper tray unit.

Installation

B046I527.WMF

4. Remove the paper tray from the paper tray unit.

5. Load paper into the paper tray. Adjust the side and end fences as necessary. If loading 8

"x 14" paper, remove the end fence and set it into the special

1/2

compartment.

6. Set the paper tray back into the paper tray unit.

7. Stick on the appropriate tray-number decal and paper-size decal, at the locations indicated in the illustration.

B046I517.WMF

1-11

Page 23

PAPER TRAY UNIT HEATER 24 July, 2001

1.4 PAPER TRAY UNIT HEATER

1.4.1 ACCESSORY CHECK

Confirm that you have the accessories indicated below.

No. Description Q’ty

1 Grounding wire 1 2 Relay harness 1 3Clamps 2 4 Ferrite core 1 5 Heater fastening screws 2 6 PTU fastening screws 3 7 Grounding screw 1 8 Decal for copier 1 9 Decal for paper unit 1

10 Tie wrap 1

1.4.2 INSTALLATION PROCEDURE

6 7

B046I518.WMF

CAUTION

Unplug the main machine's power cord before starting the following procedure.

1. If the paper tray unit is already installed, uninstall it by lifting the copier off of it. (Refer to illustrations for Procedure 1.3.2, above.)

2. Remove both paper trays—the one from the copier, and the one from the paper tray unit.

1-12

Page 24

24 July, 2001 PAPER TRAY UNIT HEATER

3. Remove the ground screw [A] at the rear of the paper tray unit.

4. Fasten the heater [B] and the supplied ground wire [C] to the pa per tray unit with 3 screws as shown. Note that [A] is the grounding screw you removed at Step 3 (returned to its original hole), and [D] and [E] are the two supplied heater fastening screws. NOTE: Be sure to position the ground

wire [C] and heater harness [F] so that they will be out of the way of the copier when you set it onto the paper tray unit.

5. Set the copier onto the paper tray unit.

6. Screw the paper tray unit into place using three supplied PTU fastening screws.

[E]

[B]

[F]

[D]

[C]

[A]

Installation

B046I519.WMF

1-13

B046I500.WMF

Page 25

PAPER TRAY UNIT HEATER 24 July, 2001

7. Open the front door [A] and remove the copy tray [B] (!×1). Then close the front door.

8. Remove the rear cover [C] (! x 5).

[B]

[A]

B046I501.WMF

[C]

B046I502.WMF

9. Remove the FCU cover plate [D] (7 screws on faxless machines, 8 screws on fax-equipped machines) . NOTE: On fax-equipped machines, detach the NCU connector [E] first.

Faxless machines: Fax-equipped machines:

[E]

[D]

B046I503.WMF

B046I504.WMF

1-14

Page 26

24 July, 2001 PAPER TRAY UNIT HEATER

10. Pass the heater's harness through the hole [A] at the rear of the copier.

11. Pass relay harness [B] through the circular opening at [C] (at the rear of

[A]

the PSU board bracket), and then through the hole at [A]. Then connect

[B]

the relay harness to the heater's harness [D].

[C]

Installation

12. Pull the relay harness back into the copier. Then set the ferrite core [E] over the relay harness, and push it back so that it is over the heater's harness.

13. Wrap the heater's harness once around the core (see [F]). Adjust so that the core is located toward the rear of the copier (at position [E], behind the rear clamp). Secure the core into position using the supplied tie wrap [G].

14. Clip off the excess length of the tie wrap [H].

[G]

[H]

[E]

[K]

[D]

B046I520.WMF

[L]

[F]

[J]

B046I521.WMF

[I]

15. Connect the relay harness connector [I] to the large connector at the front center of the PSU board. Screw the ground wire [J] to the PSU board bracket, using the included grounding screw.

16. Attach the supplied clamps [K] to corresponding holes on the PSU board bracket, and set the heater harness though the clamps. Position the harness so that the front clamp is between the two bindings [L] on the harness. Then fasten the clamps.

1-15

Page 27

PAPER TRAY UNIT HEATER 24 July, 2001

17. Pull the excess length of the heater's harness out the hole at the rear [A]. NOTE: Be sure that the harness passes to

the side of the grounding plate [B] at the bottom of the hole. (The front of the grounding plate must remain clear.)

18. Arrange the excess harness length so that it sits beneath the FCU cover plate.

19. Attach the caution decals to the locations shown in the illustration.

[B]

[A]

B046I522.WMF

20. Reinsert the paper trays, and reattach the copy tray and the rear cover.

1-16

B046I523.WMF

Page 28

24 July, 2001 DOCUMENT FEEDER

1.5 DOCUMENT FEEDER

1.5.1 ACCESSORY CHECK

Confirm that you have the components and accessories indicated below.

No. Description Q’ty

1 DF connection board 1 2 DF body 1 3 Hex wrench 1 4Hex screws 4 5 DF original tab le 1 6 Wire harness 1 7 Phillips-head screws 5 8Bracket 1 – Installation Procedure 1

Installation

B046I524.WMF

1.5.2 INSTALLATION PROCEDURE

CAUTION

Unplug the main machine's power cord before starting the following procedure.

1-17

Page 29

DOCUMENT FEEDER 24 July, 2001

1. Unpack the ADF and remove the packing tape from the bottom of the ADF body.

[C]

2. Remove the platen cover [A]. To

[A]

remove: Lift the cover, unlatch the two latches [B] (press down on the tabs [C] and push the latch back), and detach the cover from the hook [D].

[B]

[D]

B046I505.WMF

3. Remove the left piece [E] of the copier's platen cover by pushing the piece to the left and then pulling it up and off.

4. Place the DF original table [F] flat onto the platen cover, so that the 3 latches go all the way into the openings and so that the contact area [G] around each latch is flush against the cover. Then push so that latch [1] locks into place, then latch [2], and then latch [3] (at the rear left). NOTE: The latches may break if you

try to push the table in at an angle.

[E]

[1]

[3]

B046I525.WMF

[F]

[2]

[G]

B046I526.WMF

1-18

Page 30

24 July, 2001 DOCUMENT FEEDER

5. Remove the rear cover [A] (! x 5).

[A]

B046I514.WMF

6. Remove the left scale plate [B] (! x 2).

[B]

Installation

7. Set the DF body [C] onto the copier in its correct position. Press the latch [D] to raise the top half of the body, and fasten to the copier with the 4 hex screws (using the included hex wrench).

B046I506.WMF

[D]

B046I528.WMF

[C]

1-19

Page 31

DOCUMENT FEEDER 24 July, 2001

[B]

8. Install the DF connection board [A] and DF board bracket [B]. (! x 5)

[D]

[C]

[A]

B046I513.WMF

9. Connect the four wire sets from the DF body to CN103, CN105, CN106, and CN107 on the DF connection board. (Not shown in illustration.)

10. Connect one end of the supplied wire harness [C] to CN101 and CN102 on the DF connection board, and connect the other end to connectors CN9 and CN10 on the FCU. Secure the wire harness into the clamp [D] located to the side of the DF board.

11. Reattach the rear cover and the platen cover.

12. Plug in the power cord, and turn on the main switch.

13. Make a full-size copy from the first tray using the ADF, and check the side-toside and leading edge registrations. If the registration is incorrect, adjust as necessary (☛ 3.13.3).

1-20

Page 32

24 July, 2001 DIMM

1.6 DIMM

1.6.1 INSTALLATION PROCEDURE

CAUTION

Unplug the main machine's power cord before starting the following procedure.

1. Remove the rear cover [A] (! x 5).

Installation

[A]

B046I508.WMF

2. Remove the FCU cover plate [B] (7 screws on faxless machines, 8 screws on fax-equipped machines) . NOTE: On fax-equipped machines, detach the NCU connector [C] first.

Faxless machines: Fax-equipped machines:

[C]

[B]

B046I509.WMF

B046I510.WMF

1-21

Page 33

DIMM 24 July, 2001

3. Insert the DIMM [A] at an angle into slot CN2 on the FCU.

4. Press the free end of the DIMM toward the FCU, so that the DIMM snaps into place parallel to the FCU.

5. Reinstall the FCU cover plate and the rear cover.

[A]

B046I105.WMF

1-22

Page 34

24 July, 2001 PM TABLES

2. PREVENTIVE MAINTENANCE SCHEDULES

2.1 PM TABLES

NOTE: 1) After carrying out PM, clear the PM counter (SP7-804).

2) PM intervals (45k, 90k) indicate the number of prints.

Key: AN: As necessary C: Clean R: Replace I: Inspect

Every

45k

OPTICS

Reflector C C Optics cloth 1st mirror C C Optics cloth 2nd mirror C C Optics cloth 3rd mirror C C Optics cloth Platen cover C C Dry cloth Exposure glass C C Dry cloth Toner shield glass C C Dry cloth

DRUM AREA

PCU R Transfer roller R

Discharge plate R

PAPER FEED

Paper feed roller R C Water or alcohol. Friction pad R C Dry cloth Bottom-plate pad C C Water or alcohol. Registration roller C C Water or alcohol.

Every

90k

AN NOTE

On B044 and B046: Als o cl ean toner-bottle holder.

Preventive

Maintenance

FUSING UNIT

Hot roller R Pressure roller R Hot roller bearings R Pressure-roller

bushings Inlet guide C Outlet guide C Hot roller stripper

pawls Thermistor C

2-1

Page 35

HOW TO CLEAR THE PM COUNTER 24 July, 2001

Every

90k

Separation roller R C Water or alcohol Pick-up roller R C Water or alcohol White plate C Water or alcohol DF exposure glass C Water Rollers R0, R1, R2 C Water or alcoho l

Every

120k

PAPER TRAY UNIT

Paper feed roller R Bottom-plate pad C Dry cloth Friction pad R

AN NOTE

2.2 HOW TO CLEAR THE PM COUNTER

After finishing PM, clear the PM counter as follows.

1. Access SP mode 7-804.

2. Hold down the Original Type key and press the OK key (or ! key) to reset the counter. If the reset is successful, the display shows “Action completed.” If the reset fails, the display shows “Error!!!”

2-2

Page 36

24 July, 2001 PRECAUTIONS

3. REPLACEMENT AND AD JUSTMENT

3.1 PRECAUTIONS

3.1.1 GENERAL

CAUTION Turn off the main power switch and unplug the machine before starting any of the replacement procedures described in this section.

But note that you should not turn off the main switch while mechanical parts are active, as this may cause parts to stop out of home position. Attempting to remove or install the PCU or other such units while parts are out of home position may result in damage. Wait for operation to stop before turning off the machine.

3.1.2 LITHIUM BATTERIES

CAUTION: Lithium Batteries Incorrect replacement of lithium battery(s) on the FCU poses risk of explosion. Replace only with the same type or with an equivalent type recommended by the manufacturer. Discard used batteries in accordance with the manufacturer’s instructions.

Adjustment

Replacement

3.1.3 PCU (PHOTOCONDUCTOR UNIT)

The PCU consists of the OPC drum, charge roller, development unit, and cleaning components. Observe the following precautions when handling the PCU.

1. Never touch the drum surface with bare hands. If the drum surface is dirty or if you have accidentally touched it, wipe it with a dry cloth, or clean it with wet cotton and then wipe it dry with a cloth.

2. Never use alcohol to clea n the drum. Alcohol will dissolve the drum surfac e.

3. Store the PCU in a cool dry place.

4. Do not expose the drum to corrosive gases (ammonia, etc.).

5. Do not shake a used PCU, as this may cause toner and developer to spill out.

6. Dispose of used PCU components in accordance with local regulations.

3.1.4 TRANSFER ROLLER

1. Never touch the surface of the transfer roller with bare hands.

2. Be careful not to scratch the transfer roller, as the surface is easily damaged.

3-1

Page 37

PRECAUTIONS 24 July, 2001

3.1.5 SCANNER UNIT

1. Use alcohol or glass cleaner to clean the exposure and scanning glass. This will reduce the static charge on the glass.

2. Use a blower brush or a water-moistened cotton pad to clean the mirrors and lenses.

3. Take care not to bend or crease the exposure lamp’s ribbon cable.

4. Do not disassemble the lens unit. Doing so will throw the lens and copy image out of focus.

5. Do not turn any of the CCD positionin g screws. Doing so will throw the CCD out of position.

3.1.6 LASER UNIT

1. Do not loosen or adjust the screws securing the LD drive board on the LD unit. Doing so will throw the LD unit out of ad justment.

2. Do not adjust the variable resistors on the LD unit, as these are permanently adjusted at the factory. If replacement of the LD drive board is necessary, replace the entire LD unit.

3. Keep the polygon mirror and toroidal lens free of dust. Laser performance is very sensitive to dust on these components.

4. Do not touch the shield glass, the lenses, or the surface of the polygon mirror with bare hands.

3.1.7 FUSING UNIT

1. After installing the fusing thermistor, make sure that it is in contac t with the hot roller and that the roller can rotate freely.

2. Be careful to avoid damage to the hot roller stripper pawls and their tension springs.

3. Do not touch the fusing lamp and rollers with bare hands.

4. Make sure that the fusing lamp is positioned correctly and that it does not touch the inner surface of the hot roller.

Adjustment

Replacement

3.1.8 PAPER FEED

1. Do not touch the surface of paper feed rollers.

2. To avoid misfeeds, the side and end fences in each paper tray must be positioned correctly so as to align with loaded paper size.

3-2

Page 38

24 July, 2001 SPECIAL TOOLS AND LUBRICANTS

3.1.9 IMPORTANT

1. The machine will automatically start toner agitation when you install a new PCU. Be sure to wait for initialization to finish before reopening the front cover or turning off the main switch.

2. If the optional anti-condensation heater (for the optional paper tray unit) is installed, keep the copier's power cord plugged in even while the main switch is off, so that the heater remains energized.

3.2 SPECIAL TOOLS AND LUBRICANTS

Part Number Description Q’ty Common with...

A1849501 Optics Adjustment Tools (2 pcs/set ) 1 set Skylark A2929500 Test Chart – S5S (10 pcs/set) 1 set Mojito A0299387 Digital Multimeter – F lu k e 87 1 Russian-C, Stinger-C N8036701 Flash Memory Card (4MB) 1 Russian-C, Stinger-C N8031000 Case for Flash Memory Card 1 Russian-C, Stinger-C A2579300 Grease Barrierta – S552R 1 Russian-C, Stinger-C

52039501 Silicone Grease G-501 1 Russian-C, Stinger-C

G0219350 Loop back connector 1 Russian-C, Stinger-C

Adjustment

Replacement

3-3

Page 39

EXTERIOR COVER AND OPERATION PANEL 24 July, 2001

[C]

3.3 EXTERIOR COVER AND OPERATION PANEL

3.3.1 PLATEN COVER

1. Lift the platen cover [A].

2. Unlatch the two latches [B]. NOTE: To unlatch, press down on the tabs [C] and then push the latch back.

3. Detach the cover from the hook [D]

[A]

[B]

[D]

Adjustment

Replacement

3.3.2 REAR COVER

1. Platen cover (☛ 3.3.1)

2. Rear cover [A] (! x 5)

B046R904.WMF

[A]

B046R903.WMF

3-4

Page 40

24 July, 2001 EXTERIOR COVER AND OPERATION PANEL

3.3.3 COPY TRAY

1. Open the front door [A].

2. Copy tray [B] (! x 1)

[B]

[A]

3.3.4 SCALE PLATE (B044 AND B045 ONLY)

1. Scale plate [A] (! × 2)

[A]

B046R912.WMF

Adjustment

Replacement

3-5

B046R551.WMF

Page 41

EXTERIOR COVER AND OPERATION PANEL 24 July, 2001

3.3.5 LEFT COVER

1. Rear cover (☛ 3.3.2)

2. Slide the left cover [A] toward the rear to remove it.

[A]

[B]

[C]

[E]

[D]

Adjustment

Replacement

[F]

[G]

B046R901.WMF

3.3.6 RIGHT COVER

1. Rear cover (☛ 3.3.2)

2. Remove the metal fitting [B], and the platen-cover arm [C].

3. Slide the right cover [D] toward the rear to remove it.

3.3.7 FRONT LEFT COVER AND OPERATION PANEL

1. Front left cover [E] (On B044/5: ! × 2) (On B046/9: ! × 2, " × 2) NOTE: The illustration shows B046/9.

2. Operation panel [F] (! × 4, " × 1)

3.3.8 FRONT RIGHT COVER

1. Operation panel (☛ 3.3.7)

2. Open the right door.

3. Front right cover [G]

3-6

Page 42

24 July, 2001 EXTERIOR COVER AND OPERATION PANEL

3.3.9 RIGHT DOOR

1. Open the right door [A].

2. Undo the strap [B].

3. Right door (" × 1)

3.3.10 BYPASS TRAY (B044 AND B046 ONLY)

1. Press the stopper rails [A] inward and remove the bypass tray [B].

[B]

[A]

B046R909.WMF

Adjustment

Replacement

3-7

[B]

[A]

B046R908.WMF

Page 43

EXTERIOR COVER AND OPERATION PANEL 24 July, 2001

3.3.11 PLATEN COVER SENSOR

1. Rear cover (☛ 3.3.2)

2. Platen cover sensor [A] (" × 1)

[A]

B046R931.WMF

Adjustment

Replacement

3-8

Page 44

24 July, 2001 SCANNER SECTION

3.4 SCANNER SECTION

3.4.1 EXPOSURE GLASS

[A]

[B]

Adjustment

Replacement

B046R005.WMF

Non-DF machines

1. Rear cover (☛ 3.3.2)

2. Scale plate (☛ 3.3.4)

3. Exposure glass [A]

DF-equipped machines

1. Rear cover (☛ 3.3.2)

2. Right cover (☛ 3.3.6)

3. Exposure glass [A]

NOTE: When reinstalling: Be sure that the marking on the glass is at the rear left

corner, and be sure the left edge of the glass is aligned flush against the support ridge [B] on the frame.

3-9

Page 45

SCANNER SECTION 24 July, 2001

3.4.2 LENS BLOCK

1. Exposure glass (☛ 3.4.1)

2. Unclamp four clamps [A], and take

[A]

the wire out of the clamps.

3. Lens block [B] (! × 4, 1 flat cable)

NOTE: 1) Do not loosen the paint-

locked screws holding the lens unit in place.

2) After installing a new lens block, carry out copy adjustments. (☛ 3.13)

3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD

1. Exposure glass (☛ 3.4.1)

2. Operation panel (☛ 3.3.7)

[E]

[B]

B046R003.WMF

[B]

Adjustment

Replacement

3. Slide the 1st scanner to a position where the lamp and scanner are clear of the metal lids.

4. Disconnect the lamp connector [A].

5. Remove either or both of the following:

• Exposure lamp [B] (1 screw at [C])

• Lamp stabilizer board [D] (2 screws

at [E], 1 flat cable)

[D]

[A]

[C]

B046R001.WMF

3-10

Page 46

24 July, 2001 SCANNER SECTION

3.4.4 SCANNER MOTOR

1. Right cover (☛ 3.3.6)

2. Scanner motor [A] (! × 4, 1 spring,

[A]

" × 1)

NOTE: When reinstalling: Fasten the

screws loosely, then set the spring in place, then tighten up the screws.

B046R923.WMF

3.4.5 SCANNER HP SENSOR

Adjustment

Replacement

1. Left cover (☛ 3.3.6)

2. If non-DF machine: Scale plate (☛ 3.3.4)

If DF-equipped machine: Press on the DF latch and open the DF.

3. Scanner HP sensor [A] (" × 1)

[A]

B046R020.WMF

3-11

Page 47

SCANNER SECTION 24 July, 2001

3.4.6 SCANNER ALIGNMENT ADJUSTMENT

1. Remove the rear cover (☛ 3.3.2), operation panel (☛ 3.3.7), and exposure glass (☛ 3.4.1).

2. Loosen the 2 screws holding the 1st and 2nd scanner belts in place.

Adjustment

Replacement

B046D002.WMF

3. Slide the 1st and 2nd scanners so that all four of the following are roughly aligned on both the front and back sides:

• The hole on the copier's lid

• The hole on the 1st scanner

• The corner right hole on the 2nd scanner

• The hole at the base of the scanner

[A]

4. Insert the two optics adjustment tools [A], and adjust the scanne rs as necessary so that the tools go through all four holes.

5. Tighten the two screws that you loosened at step 2 above, so that the belts are firmly clamped into place.

6. Remove the adjustment tools.

3-12

B046D003.WMF

Page 48

24 July, 2001 FUSING

3.5 FUSING

3.5.1 FUSING UNIT

CAUTION The fusing unit can become very hot. Be sure that it has cooled down sufficiently before handling it.

1. Turn off the main switch, and unplug the machine.

2. Copy tray (☛ 3.3.3)

3. Fusing unit [A] (! × 3, " × 3)

NOTE: When reinstalling the unit:

Replace the spacer [B] in the correct position, and remember to set the grounding wire [C] into place.

3.5.2 EXIT SENSOR

1. Fusing unit (☛ 3.5.1)

2. Exit sensor [A] (" × 1)

[B]

[A]

[C]

B046R501.WMF

Adjustment

Replacement

3-13

[A]

B046R508.WMF

Page 49

FUSING 24 July, 2001

3.5.3 HOT ROLLER STRIPPER PAWLS

[A]

[B]

B046R502.WMF

[E]

Adjustment

Replacement

[D]

B046R507.WMF

[C]

1. Fusing unit (☛ 3.5.1)

2. Separate the fusing unit into two sections: the hot roller section [A], and the pressure roller section [B]. (! × 2) NOTE: After removing the screws, lower the pressure roller section about

halfway and then slide it toward the front side to detach it.

3. Hot roller stripper pawls [C] (1 spring for each pawl) NOTE: 1) To remove the right pawl, first remove the plastic spacer at [D]

(! × 1).

2) When re installing the center p awl, be sure to set roller [E] back into place.

3-14

Page 50

24 July, 2001 FUSING

3.5.4 HOT ROLLER & FUSING LAMP

[A]

1. Hot roller stripper pawls (☛ 3.5.3)

2. Hot roller assembly [A] (! × 2) NOTE: 1) Each of the screws has a

washer.

2) After removing the screws, lift the hot roller assembly out from the rear side.

3. Fusing lamp [B]

B046R505.WMF

[B]

4. Hot roller [C] (2 C-rings, 1 spacer, 1 gear, 2 bus hings)

[B]

Adjustment

Replacement

[C]

3.5.5 THERMOFUSE, THERMOSWITCH, AND THERMISTOR

1. Remove the hot roller assembly from the hot roller section. (☛ 3.5.3)

2. Thermofuse [A] (! × 2).

3. Thermoswitch [B] (! × 2) NOTE: You must remove the

thermofuse first.

[B]

4. Thermistor [C] (! × 1)

B046R509.WMF

[C]

[A]

B046R506.WMF

3-15

Page 51

FUSING 24 July, 2001

3.5.6 PRESSURE ROLLER

1. Fusing unit (☛ 3.5.1)

2. Separate the fusing unit into two sections: the hot roller section and the pressure roller section (☛ 3.5.3, Step 2). Carry out the remaining steps on the pressure roller section.

3. Fusing entrance guide [A]

4. 2 springs ([B], [C])

5. 2 pressure arms ([D], [E]) NOTE: Manipulate each arm so

that it comes out through the slit in the casing.

6. 2 bushings ([F], [G])

[H]

[A]

[B]

[D]

B046R504.WMF

[C]

[E]

[G]

Adjustment

Replacement

7. Pressure roller [H]

[F]

B046R503.WMF

3-16

Page 52

24 July, 2001 PCU

3.6 PCU

[A]

[B]

Adjustment

Replacement

B046I109.WMF

1. Open the right door. NOTE: Do not forget to open the right door. The PCU may become stuck if

you try to remove it while the front door is closed.

2. Open the front door.

3. Remove the toner bottle holder or THM. NOTE: If working on a toner-bottle model, clean away all spilled toner from the

toner bottle area and from the inside of the front door.

4. Detach the connector [A] and pull out the PCU [B].

NOTE: 1) After installing the new PCU, be sure to remove the Styrofoam piece

and to pull off the two tags. (☛ 1.1.2, Step 10)

2) The machine will automatically detect the new PCU and begin toner initialization. (☛ 6.10.4)

3-17

Page 53

TONER SUPPLY CLUTCH 24 July, 2001

3.7 TONER SUPPLY CLUTCH

[C]

[A]

[B]

Adjustment

Replacement

B046R932.WMF

1. Remove the toner bottle or THM.

2. Copy tray (☛ 3.3.3)

3. Rear cover (☛ 3.3.2)

4. Disconnect the connector on C19 on the FCU.

5. Reach into to the machine and push the clutch coupler [A] toward the rear, and at the same time reach around the back and remove the clip ring [B].

6. Remove the cone and spring, then lift the toner supply clutch mech anism [C] out of its housing and remove it. NOTE: When removing, note how the wire goes through a clamp, and also

note where it passes through the rear of the machine.

3-18

Page 54

24 July, 2001 PAPER FEED SECTION

3.8 PAPER FEED SECTION

3.8.1 PAPER FEED ROLLER AND FRICTION PAD

1. Take out the paper tray.

2. Clip ring [A]

3. Pull the shaft back, and lift it out.

4. Remove either or both of the following:

• Paper feed roller [B]

• Friction pad [C]

3.8.2 PAPER END SENSOR

1. Take out the paper tray.

2. Open the right door.

[A]

[B]

[C]

B046R702.WMF

Adjustment

Replacement

3. PCU (☛ 3.5)

4. Paper end sensor [A] (" × 1)

NOTE: When installing the new sensor,

reach your left hand in through the front and your right hand in through the right side, and view from the right side.

B046R929.WMF

[A]

3-19

Page 55

PAPER FEED SECTION 24 July, 2001

3.8.3 REGISTRATION SENSOR

[C]

[A]

B046R926.WMF

1. Take out the paper tray.

2. Open the right door.

[B]

B046R927.WMF

Adjustment

Replacement

3. Black guide piece [A]

4. Registration sensor feeler [B]

5. Registration sensor [C] (" × 1)

3.8.4 BYPASS PAPER END SENSOR (B044 AND B046 ONLY)

1. Right door (☛ 3.3.9)

2. Detach the sensor compartment [A].

3. Bypass paper end sensor [B] (" × 1)

[A]

3-20

B046R924.WMF

[B]

Page 56

24 July, 2001 PAPER FEED SECTION

3.8.5 BYPASS FEED ROLLER (B044 AND B046 ONLY)

[B]

[A]

B046R938.WMF

[D]

[E]

[C]

[A]

[B]

B046R930.WMF

1. Right door (☛ 3.3.9)

2. Unscrew the feed roller frame [A] (! × 2) and rotate it about the feed roller shaft [B] so that it is upside down.

3. Detach the feed roller shaft [B] from the feed roller frame (unsnap the two snap pawls [C] and remove the spacer [D]).

4. Bypass feed roller [E]

Adjustment

Replacement

3-21

Page 57

PAPER FEED SECTION 24 July, 2001

3.8.6 BYPASS FEED CLUTCH (B044 AND B046 ONLY)

1. Rear cover (☛ 3.3.2)

2. Right door (☛ 3.3.9)

3. Detach the bypass feed clutch connector [A] from CN3 on the high-voltage power supply board.

4. Unscrew the bypass feed roller housing [B] (! × 2), and pull it out of the machine. NOTE: It is not necessary to remove

or disconnect the bypass paper end sensor.

5. Bypass feed clutch [C] (# × 1)

[B]

B046R925.WMF

[C]

3.8.7 BYPASS FRICTION PAD (B044 AND B046 ONLY)

[A]

Adjustment

Replacement

1. Right door (☛ 3.3.9)

2. Detach the roller housing [B] (! × 2) , and move it out of the way.

3. Bypass friction pad [A]

3.8.8 REGISTRATION CLUTCH

1. Rear cover (☛ 3.3.2)

2. High-voltage power supply board (☛ 3.12.2)

3. Ground plate [A] (!)

[A]

B046R937.WMF

[C]

4. Registration clutch [B] ($× 1, " × 1) NOTE: To free the clutch, pry clip

[C] gently away from it using a screwdriver.

3-22

[A]

[B]

B046R950.WMF

Page 58

24 July, 2001 PAPER FEED SECTION

3.8.9 PAPER FEED CLUTCH

[B]

[C]

[A]

Adjustment

Replacement

B046R920.WMF

[D]

[E]

1. Pull the paper tray part way out.

2. High-voltage power supply board (☛ 3.12.2)

3. Main motor (☛ 3.12.4)

4. Remove 1 screw [A] from the small cover plate.

B046R922.WMF

5. Open 3 clamps [B] on the large cover plate, and remove the wiring.

6. Detach two connectors [C] from the FCU.

7. Large cover plate [D] (! × 7, # × 2, 2 bushings)

8. Paper feed clutch [E]

3-23

Page 59

IMAGE TRANSFER 24 July, 2001

3.9 IMAGE TRANSFER

3.9.1 IMAGE TRANSFER ROLLER

[B]

1. Right door (☛ 3.3.9)

2. Raise the levers ([A], [B]) at the ends of the image transfer roller, and remove the roller [C].

NOTE: 1) Note the position of the

2 springs [D] at each end. When reinstalling the roller, be sure that the pegs on the plastic end pieces fit into the springs.

2) Do not touch the transfer roller surface with bare hands.

3.9.2 ID (IMAGE DENSITY) SENSOR

[A]

[D]

[C]

B046R915.WMF

[B]

Adjustment

Replacement

B046R913.WMF

1. Right door (☛ 3.3.9)

2. Push in the latches as shown, and pry off the entire section [A].

3. ID sensor [B] (" × 1)

3-24

B046R914.WMF

Page 60

24 July, 2001 FUNCTION CONTROL UNIT (FCU)

3.9.3 DISCHARGE PLATE

1. Right door (☛ 3.3.9)

[A]

2. Use a tweezers to remove the discharge plate [A].

B046R934.WMF

3.10 FUNCTION CONTROL UNIT (FCU)

NOTE: 1) Before starting replacement, use SP5-824 to save SRAM user data from

the existing FCU into a flash memory card. After finishing the replacement, use SP5-825 to reload the data from the card into the SRAM on the new FCU. For instructions, see Section 5.1.8.

2) Replacement FCUs ship with the battery jumper switch set to the OFF position. Be sure to change the jumper switch to the ON position before installing the replacem ent FCU.

Adjustment

Replacement

3-25

Page 61

FUNCTION CONTROL UNIT (FCU) 24 July, 2001

[A]

Faxless machine

B046R907.WMF

[B]

Fax-equipped machine:

B046R910.WMF

Adjustment

Replacement

[D]

B046R911.WMF

[C]

1. Rear cover (☛ 3.3.2)

2. FCU cover plate [A] (7 screws on faxless machines, 8 on fax-equipped machines)

NOTE: On fax-equipped machines, detach the NCU connector [B] first, then

unscrew the cover plate and remove the cover plate together with the NCU.

3. FCU [C] (all connectors, 2 flat cables, ! x 6) NOTE: If an optional DIMM is installed on the FCU, remove it and install it on

the new FCU. (☛ 1.6)

4. Before installing the new board, set the new board's TB1 battery jumper switch [D] to the ON position.

3-26

Page 62

24 July, 2001 LASER UNIT

3.11 LASER UNIT

WARNING The laser beam can cause serious eye damage. Be sure that the main power switch is off and that the machine is unplugged before accessing the laser unit.

3.11.1 LOCATION OF “CAUTION” DECAL

Adjustment

Replacement

B046I103.WMF

B046RLW.WMF

3-27

Page 63

LASER UNIT 24 July, 2001

3.11.2 PSU BRACKET

1. FCU (☛ 3.10) NOTE: After removing the copy tray, leave the front door open.

2. Remove the 4 screws at [A].

3. Unscrew the 6 screws securing the PSU bracket [B], and detach the 4 connectors. NOTE: Use a stubby screwdriver to

remove the 2 screws at [C].

4. Hold the PSU bracket at the rear (viewing from the front of the machine), pull the rear end out to the left slightly, then lift the bracket upward at the rear so that it comes free of the hooks [D] at the front.

5. Pull the PSU bracket out.

[C]

[B]

[A]

B046R905.WMF

B046R906

[D]

Adjustment

Replacement

3-28

Page 64

24 July, 2001 LASER UNIT

3.11.3 LASER UNIT

[A]

[B]

[D]

[C]

B046R101.WMF

B046I103.WMF

1. PSU bracket (☛ 3.11.2) NOTE: After removing the PSU bracket, leave the front door open.

2. Release the toner bottle holder (if model B04 4 or B04 6) or THM (if model B04 5 or B049), and pull it out slightly. (Illustration shows toner-bottle model.)

3. Laser unit [A] (! x 3, " x 2) NOTE: When reinstalling the laser unit, be sure that the wire at [B] passes

under the unit. In particular, be certain that the wire does not pass in front of the glass area on the unit.

3.11.4 LD UNIT

1. Laser unit (☛ 3.11.3)

2. Remove the harness ([C] in figure above) from the clamp [D].

3. Laser unit cover [E] (! x 2)

[F]

Replacement

[E]

Adjustment

4. LD unit [F] (! x 2) NOTE: The LD drive board itself is not

adjustable, and is not a replaceable part. You must replace the entire bracket.

3.11.5 POLYGON MIRROR MOTOR

1. Laser unit (☛ 3.11.3)

2. Remove the harness ([C] in figure above) from the clamp [D].

3. Laser unit cover [E] (! x 2)

4. Polygon mirror motor [G] (! x 4)

3-29

[D]

[G]

B046R102.WMF

Page 65

OTHER REPLACEMENTS 24 July, 2001

3.12 OTHER REPLACEMENTS

3.12.1 QUENCHING LAMP

1. PCU (☛ 3.1.3)

2. Quenching lamp [A] (" × 1)

[A]

3.12.2 HIGH-VOLTAGE POWER SUPPLY BOARD

1. Rear cover (☛ 3.3.2)

2. High-voltage power supply board [A] (! × 4, all connectors)

[A]

3.12.3 PSU

[A]

1. Copy tray

B046R928.WMF

B046R936.WMF

Adjustment

Replacement

2. PSU [A] (! × 6, all connectors)

B046R935.WMF

3-30

Page 66

24 July, 2001 OTHER REPLACEMENTS

3.12.4 MAIN MOTOR

1. Rear cover (☛ 3.3.2)

2. Main motor [A ] (! × 4, " × 1)

[A]

3.12.5 EXHAUST FAN

1. Rear cover (☛ 3.3.2)

2. Exhaust fan [A] (! × 2, " × 1)

[A]

B046R919.WMF

B046R918.WMF

Adjustment

Replacement

3-31

Page 67

COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 24 July, 2001

3.13 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING

NOTE: 1) You need to perform these adjustment after executing a Memory All

Clear, and after replacing or adjusting any of the following parts.

• First or second scanner

• Lens Block

• Scanner Motor

• Polygon Mirror Motor

• Paper Tray

2) For detailed explanations about how to access and use SP mode, see Section 5.

3.13.1 PRINTING

NOTE: 1) Make sure the paper is installed correctly in each paper tray before you

start these adjustments.

2) Use the Trimming Area Pattern (SP5-902, No.10) to print the test pattern fo r the printing adjus tments below.

3) Reset SP5-902 to 0 after completing these printing adjustments.

Adjustment

Replacement

Registration - Leading Edge/Side-to-Side

1. Check the leading edge registration [A] for each paper feed station, and adjust each of these registrations using SP1-001.

Tray SP mode Specification

Paper tray(s) SP1-001-1 100-sheet bypass 1-sheet bypass

SP1-001-2

0 ± 2 mm 0 ± 2 mm 0 ± 4 mm

2. Check the side-to-side registration [B] for each paper feed station, and adjust these registrations using SP1-

002. (Adjust the trays in order: the 1st tray first, then the 2nd tray [if installed], then the bypass).

Tray SP mode Specification

1st tray SP1-002-1 2nd tray SP1-002-2 100-sheet bypass 1-sheet bypass

SP1-002-5

0 ± 2 mm 0 ± 2 mm

0 ± 4 mm

A: Leading Edge Registration B: Side-to-side Registration

B046R552.WMF

3-32

Page 68

24 July, 2001 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING

Blank Margin

NOTE: If the leading edge or side-to-side registration cannot be adjusted to within

the specification, then adjust the leading-edge blank margin or the left-side blank margin.

1. Check the trailing edge an d righ t side edge blank margins, and ad just them using the following SP modes.

SP mode Specification

Trailing edge (except for 1-sheet bypass)

Trailing edge for 1sheet bypass

Right edge SP2-101-6 2 +2.5/-1.5 mm Leading edge (except

for 1-sheet bypass) Leading edge for 1-

sheet bypass Left edge

SP2-101-4

SP2-101-12

SP2-101-1

SP2-101-11

SP2-101-5

A: Trailing Edge Blank Margin B: Right Edge Blank Margin C: Leading Edge Blank Margin D: Left Edge Blank Margin

Main-Scan Magnification

3 ± 2 mm 5 ± 3 mm

2 ± 1.5 mm

B046R553.WMF

Adjustment

Replacement

1. Print the single-dot grid pattern (SP5-902-5).

2. Check the magnification (the grid size should be 2.7 x 2.7 mm), and if necessary use SP2-998 to adjust it. The specification is 100 ± 1% in both directions.

3-33

Page 69

COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 24 July, 2001

3.13.2 SCANNING

NOTE: 1) Before doing the following scanner adjustments, check and adjust the

printing leading-edge and side-to-side registrations and the printing blank margins (as described above).

2) Use an A4 test chart to perform the following adjustments.

Registration: Platen Mode

1. Place the test chart on the exposure glass and make a copy from one of the feed stations.

2. Check the leading edge registration [A], and adjust as necessary using SP4-010. (Specification is 0 ± 2mm.)

Magnification

[A]

B046R557.WMF

A: Main scan magnification B: Sub-scan magnification

Adjustment

Replacement

B046R555.WMF

Main Scan Magnification

1. Place the A4 test chart on the exposure glass and make a copy from one of the feed stations.

2. Check the magnification ratio. If necessary, adjust the magnification using the following SP mode.

SP mode Specification

Main Scan Magnification SP4-008

3-34

± 1.0%

Page 70

24 July, 2001 COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING

Sub-scan Magnification

1. Place the A4 test chart on the exposure glass and make a copy from one of the feed stations.

2. Check the magnification ratio. If necessary, adjust the magnification using the following SP mode.

SP mode Specification

Sub-scan magnification SP4-101

± 1.0%

Standard White Density Adjustment

This procedure adjusts the standard white density level. Carry out this adjustment after doing any of the following:

• After replacing the standard white plate.

• After replacing the FCU.

• After replacing the lens block.

• After performing a memory all clear (SP5-801).

Procedure:

1. Place 10 sheets of new A4 paper on the exposure glass, and close the platen cover.

2. Access SP4-908, enter "1", and press OK. The machine automatic all y adjusts the standard white density.

Adjustment

Replacement

3-35

Page 71

COPY IMAGE ADJUSTMENTS: PRINTING/SCANNING 24 July, 2001

3.13.3 DF IMAGE ADJUSTMENT

Registration and Blank Margin

A: Leading edge registration B: Side-to-side registration

B046R556.WMF

NOTE: Make a temporary test chart as shown above, using A4 / 8

B046R559.WMF

"x11" paper.

1/2

1. Place the temporary test chart on the DF and make a copy from one of the feed stations.

2. Check the registrations, and adjust as necessary using SP mode, as follows.

SP mode

Side-to-side registration SP6-006-1 Leading edge registration SP6-006-2

Blank margin for the t

railing edge SP6-006-3

Sub-scan Magnification

Adjustment

Replacement

B046R558.WMF

NOTE: Make a temporary test chart as shown above, using A4 / 8

A: Sub-scan magnification

"x11" paper.

1/2

1. Place the temporary test chart on the DF and make a copy from one of the feed stations.

2. Check the registration, and if necessary adjust it using SP6-007. The specification is ±1.0%.

3-36

Page 72

24 July, 2001 SERVICE CALL CONDITIONS

4. TROUBLESHOOTING

4.1 SERVICE CALL CONDITIONS

4.1.1 SUMMARY

There are two service-call levels, as follows.

Level Definition Reset Procedure

To prevent possible damag e t o t he machine, level-A servic e calls can be

cleared only by a serv ice represent ative The machine will not operate until the representative clears the call.

These SCs can be cleared by turning the main power switch off and o n.

Enter SP 5-810 (SC code reset) and select “1”. Then simultaneo usly press

Original Type

the !) key. (There is no need to turn the main switch off and on.).

Turn the main power switch o ff and on.

key and the OK (or

NOTE:

1) If a problem involves circuit boards: Before deciding to replace a circuit board, first see if you can solve the problem by disconnecting and then reconnecting all connectors.

2) If a problem involves a motor lock: Check the mechanical load first, before deciding whether to replace motors or sensors.

3) If working on a fax-equipped machine, keep in mind that switching power off and back on may in some cases cause loss of data stored in SAF memory.

Trouble-

shooting

4-1

Page 73

SERVICE CALL CONDITIONS 24 July, 2001

4.1.2 SC CODE DESCRIPTIONS

No. Definition

Code

Error Code

Level

Exposure Lamp Error101 1-04 B Insufficient white leve l detec ted

when scanning the white plate.

Scanner home position error 1120 9-93 B Scanner home position sensor

did not detect OFF condition during initialization or copying.

Scanner home position error 2121 9-92 B Scanner home position sensor

did not detect ON condition during initialization or copying.

Scanner home position error 3122 9-91 B Scanner home position sensor

did not detect OFF condition during book or ADF scan operation.

Symptom Possible Cause

• Exposure lamp defective

• SBU harness defective

• Bad connection

• Defect in optics system (dirty

scanner mirror, mirror out of position, etc.)

• Lamp stabilizer board (or connector) defective

• Incorrect start position or length for white plate scanning (☛ SP4-015)

• Scanner HP sensor out of position

• Forgot to remove one or more of

the scanner stoppers

• Scanner motor defective

• Scanner HP sensor (or connector)

defective

• FCU defective

• Scanner belt loose or detached

• Forgot to remove one or more of

the scanner stoppers

• Scanner motor defective

• Scanner HP sensor (or connector)

defective

• FCU defective

• Scanner belt loose or detached

• Forgot to remove one or more of

the scanner stoppers

• Scanner motor defective

• Scanner HP sensor (or connector)

defective

• FCU defective

• Scanner belt loose or detached

Scanner home position error 4123 9-90 B Scanner home position sensor

did not detect ON condition during book or ADF scan operation.

4-2

• Forgot to remove one or more of the scanner stoppers

• Scanner motor defective

• Scanner HP sensor (or connector)

defective

• FCU defective

• Scanner belt loose or detached

Page 74

24 July, 2001 SERVICE CALL CONDITIONS

No. Definition

Code

Error Code

Level

SBU auto-adjustment error192 1-05 B During SBU auto-adjustment

(☛ SP4-908), the detected white level was out of range.

Charge roller current leak302 9-17 B Current leak at the charge

roller was detected.

Polygon mirror motor error320 9-23 B Did not detect lock signal from

polygon mirror motor within 10 seconds after motor ON signal; or, lost lock signal for continuous 1.5 seconds after signal was detected.

Laser synchronization error322 9-20 B Detected LD error signal for

continuous 1.5 seconds whil e polygon mirror motor was running at constant speed.

TD sensor error390 9-73 B The TD sensor output less

than 0.33 V or greater than

2.64 V ten times in succession. Development bias leak391 9-29 B Development bias leak signal

was detected. Developer initia lization error392 9-74 B

Error reading ID sensor pattern during developer initialization.

Symptom Possible Cause

• SBU auto adjustment was not done correctly (☛ 3.13)

• Exposure lamp defective

• SBU harness defective

• Bad connection

• Defect in optics system (dirty

scanner mirror, mirror out of position. etc.)

• Defective stabilizer board (or connector)

• Incorrect start position or length for white plate scanning (☛ SP4-015)

• Scanner HP sensor out of position

• Charge roller damaged

• High voltage supply board defective

• Poor connection of the PCU

• Polygon mirror motor (or h arness)

defective

• FCU defective

• Synchronization detection mirror

defective

• LD unit defective

• FCU defective

• LD harness damaged

• THM not in place

• TD sensor defective

• Bad connection

• Development roller defective

• High voltage supply board defective

• Forgot to remove heat seal from

replacement PCU

• ID sensor defective

• TD sensor defective

• Drum is not turning

• Development roller is not turning

• Right door not closed firmly

Trouble-

shooting

4-3

Page 75

SERVICE CALL CONDITIONS 24 July, 2001

No. Definition

Code

Error Code

Level

Transfer roller leak error 1 ("+" leak)401 9-29 B A current leak signal for the

transfer roller was detected. (Current feedback signal was not detected for at least 200ms).

Transfer roller leak error 2 ("-" leak)402 9-29 B A current leak signal for the

transfer roller was detected. (Current feedback signal was not detected for at least 200ms).

Main motor lock error500 9-24 B Failed to detect main motor

lock signal for 7 checks in succession (total of 700ms) after main motor started to rotate, or after last lock signal was detected.

Fusing thermistor open541 9-22 A Thermistor generated

abnormal values immediately after 24V power on.

Fusing temperature warm-up error542 9-22 A During fusing warm-up, fusing

temperature failed to reach target range within 22 seconds (when starting at least 25°C below the target temperature).

(☛ 4.4)

Fusing overheat error543 9-22 A Detected fusing temperature remained above 230°C for 1

second. Fusing low temperature error544 9-22 A Detected fusing temperature

remained abnormally low for 1 second during fusing operation (below 140°C) or during standby mode.

Symptom Possible Cause

• Transfer roller damaged

• High voltage supply board defective

• Poor connection between transfer

unit and machine

• Transfer unit set incorrectly

• Transfer roller damaged

• High voltage supply board defective

• Poor connection between transfer

unit and machine

• Transfer unit set incorrectly

• Main motor defective

• Too much load on the drive

mechanism

• Motor driver damaged

(☛ 4.4)

• Fusing thermistor defective or disconnected

(☛ 4.4)

• Fusing lamp defective

• Fuse blown

• PSU defective

• Bad connection between fuser and

machine

• Fusing thermistor defective

• Fusing lamp defective

• Thermofuse blown

• PSU defective

• Bad connection between fuser and

machine

• Fusing thermistor defective

• PSU defective

(☛ 4.4)

• Fusing thermistor defective

• PSU defective

• Bad connection between fuser and

machine

(☛ 4.4)

4-4

Page 76

24 July, 2001 SERVICE CALL CONDITIONS

No. Definition

Code

Error Code

Level

Unstable fusing temperature546 9-22 A Detected that fusing

temperature changed more than ± 25°C/second two seconds in succession.

Symptom Possible Cause

• Fusing thermistor defective

• PSU defective

• Bad connection between fuser and

machine

(☛ 4.4)

Zero-cross detection error547 9-22 B Detection error (detection

overflow or busy) occurred 8 times in succession (at 20-ms intervals) while 24V power was on.

(☛ 4.4)

Fusing-temperature range violation (too high)548 9-22 A During paper transport, fusing

temperature moved above limit (200°C for plain paper, 210°C for thick paper) and remained above limit for 10 seconds.

• PSU defective

• FCU defective

• TRIAC short

• Fan not running

(☛ 4.4)

Fusing-temperature range violation (too low)549 9-22 A During paper transport, fusing

temperature fell below lo wer limit (155°C) and remained below limit for 6 seconds.

• Fusing thermistor defective

• PSU defective

(☛ 4.4)

Standby temperature error 1550 9-22 A Fusing temperature failed to

drop to expected level within a given time (15 seconds, 15 minutes, or 25 minutes, depending on mode) after entering standby or low-power mode.

Standby overheat551 9-22 A Temperature during standby or

low-power mode remained too high for a specified interval (10 seconds or 25 seconds, depending on the mode).

(☛ 4.4)

• TRIAC short

• Fan not running

• TRIAC short

(☛ 4.4)

Standby low temperature error552 9-22 A After reaching expected

temperature in low-power mode (level 1) or standby mode, temperature fell and remained below 155°C for 20 seconds.

(☛ 4.4)

• Fusing thermistor defective

• PSU defective

Trouble-

shooting

4-5

Page 77

SERVICE CALL CONDITIONS 24 July, 2001

No. Definition

Code

Error Code

Level

Communication error between FCU and printer controller692 9-49 B Printer failed to acknowledge

message from FCU within 1.2 seconds.

Electrical total counter error900 9-79 B The electrical total counter is

not working properly.

Mechanical total counter901 9-78 B The mechanical total counter is

not working properly. Printer controller self-diagnostic error2001 9-48 B Printer controller's power-on

self-diagnostic detected an error.

Printer controller: FGATE error2002 9-47 B Printer application returned

FGATE error notification to copier.

Symptom Possible Cause

• Printer controller defective

• FCU defective

• Poor connection between FCU and

printer controller

• SRAM defectiv e.

The only way to correct this error is to replace the FCU.

• Mechanical total counter disconnected

• Self-diagnostic error

• FGATE error

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Page 78

24 July, 2001 ELECTRICAL COMPONENT DEFECTS

4.2 ELECTRICAL COMPONENT DEFECTS

4.2.1 SENSOR/SWITCH OPEN ERRORS

Sensor or Switch CN Symptom

Registration Sensor Paper End Sensor FCU 29-2 Paper-end error when attempti ng t o fe ed from Bypass Paper End Sensor

(B044 and B046 only)

Exit Sensor FCU 28-2 "A" or "Y" paper jam reported.

Image Density (ID) Sensor FCU 32-1 Toner control process changes. Toner Density (TD) Sens or

Scanner HP Sensor

FCU 27-2

FCU 30-2 "Paper End" message when at t empting to feed

FCU 23-3

FCU 26-3

"A" or "Y" paper jam reported.

main tray. Fax key blin ks red. from bypass tray. .

"Reset PCU Correctly " mess age appears, and Caution indicator stays on.

SC120 is displayed.

Platen Cover Sensor FCU 26-5 ADF Guide Open Sensor DF 105-5 ADF Original Set Sensor DF 105-7 Fails to dete c t originals at ADF.

ADF Registration Sensor DF 105 2 "P" paper jam reported. Front/Right Door Switch FCU 14

Delays start of polygon motor by a few seconds. (Longer time for first copy.)

"Close ADF" message appears, and Caution indicator stays on.

"Close Front/Right Cover" message appears, and the Caution indicator stay s on.

4.3 BLOWN FUSE CONDITIONS

Fuse

Power Supply Board

FU1 12 A/125 V 6.3 A/250 V No response.

F2 1 A/250 V 1 A/250 V F3 4 A/250 V 2 A/250 V No response.

F201 5 A/250 V 5 A/250 V No response.

120 V 220 – 240 V

Rating

At main switch ON

Anti-condensation heater (option) does not turn on.

Trouble-

shooting

4-7

Page 79

DUMPING THE FUSER TEMPERATURE LOG 24 July, 2001

4.4 DUMPING THE FUSER TEMPERATURE LOG

The FCU monitors the fuser temperature and maintains a log of the most recent temperature values. If a heating-related SC error occurs (error code "9-22"; SCs 541 to 552), you may wish to print out a dump of the logged data before clearing the SC condition. The printout can then be submitted for analysis.

To dump the log, proceed as follows.

1. Before clearing the SC, use SP7-955 to write "02h" into address 40191C. This freezes the log data.

2. Clear the SC.

3. Use SP-992 setting "3" (☛ 5.1.5) to print out a dump of addresses 401900 to 410CFF.

4. Use SP7-955 to write "00h" into 40191C. This will restart temperature logging.

4-8

Page 80

24 July, 2001 USING SERVICE PROGRAM MODE

5. SERVICE TABLES

5.1 USING SERVICE PROGRAM MODE

Use the service program mode (SP mode) to check electrical data, change operating modes, and adjust values.

Accessing SP Mode

How to Enter SP Mode

1. Key in the following sequence.

• Hold the % key down for longer than 3 seconds.

2. The LCD displays a menu.

→ " →

→

[Service P-Mode] No._ 1 Copy 2 Fax 3 Printer

B046M001.WMF

NOTE: Installed applications appear on the menu as follows: “1.Copy”, “2.

Fax”, “3. Printer”. If an application is not installed, the corresponding item does not appear.

3. Press the number for the application mode you need. (For example, press “1” to select the copier application mode.) The selected SP mode display appears on the LCD, as shown.

SP H5557200 E1 class1 No.1 Feed

B046M002.WMF

Tables

Service

How to Exit SP Mode

Press ! or the Cancel key one or more times to return to the standby-mode display.

Accessing Copy Mode from within SP Mode

1. Press the & key.

2. Select the appropriate copy mode and make trial copies. NOTE: The User Tools LED flashes while you are using copy mode from within

SP mode.

3. To return to SP mode, press the ! key.

5-1

Page 81

USING SERVICE PROGRAM MODE 24 July, 2001

How to Select a Program Number

C1(1)Feed C2 No. 1

B046M003.WMF

Each SP number consists of two or three levels (“classes”). To select a program, you need to enter each class number in sequence.

1. Enter the first-class program number with the numeric keypad (or change the number using the Right or Left cursor key), and then press the ' key or the OK key.

2. Enter the second-class program number with the numeric keypad (or Right or Left cursor key), and press ' or OK.

3. To select a third-class program: select the second-class number and then use the Right or Left cursor key.

4. To return to the next higher class, press !.

To Input a Value or Setting

1. Enter the required program mode as explained above.

2. Enter the required setting using the numeric keys, and then press ' or the OK key.

NOTE:

1) If you forget to press ' or OK, the previous value remains in effect.

2) If necessary, use the ! key to select “+” or “–” when entering the value.

5-2

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24 July, 2001 USING SERVICE PROGRAM MODE

5.1.1 SP MODE TABLES

NOTE: 1) An asterisk (*) after the SP number means that this SP's value is stored

in the SRAM. If you do a RAM reset, all these SP settings will be returned to their factory defaults.

2) In the Function/[Setting] column:

• Comments are in italics.

• The setting range is enclosed in brackets, with the default setting

written in bold.

• DFU stands for Design/Factory Use only. Values marked DFU should not be changed.

• IAJ means that you should refer to Section 3.13 ("Replacement and

Adjustment – Copy Image Adjustments") for more information. IP means that you should refer to Section 6.7, (Detailed Descriptions – Image Processing").

SP1-XXX (Feed)

001*

002*

003*

Mode Number/Name Function/[Setting]

Leading Edge Registration

1 Paper tray (copy, fax) 2 Bypass (copy fax) 4 Paper tray (optional

printer)

5 Bypass (optional

printer)

Side-to-Side Registration

1 1st tray 2 2nd tray 5Bypass

Paper Feed Timing

1 1st tray 2 Other trays 3Bypass

Adjusts the plotter leading-edge registration from each paper feed station. Use the Trimming Area Pattern (SP5902, No.10) to make the adjustment.) [–9.0 ~ 9.0 / 0.0 / 0.1 mm/step] IAJ

• Specification: 0

• Use the ! key to select “+” or “–” when entering the

value.

Adjusts the printing side-to-side registration from each paper feed station. (Use Trimming Area Pattern (SP5-902, No.10) to make the adjustment.) The 2nd-tray adjustment is for the optional tray.

[–9.0 ~ 9.0 / 0.0 / 0.1 mm/step] IAJ

• Specification: 0

• Use the ! key to select “+” or “–” when entering the

value.

Adjusts the amount of buckle the paper feed clutch applies to the paper (by adjusting delay between triggering of the registration sensor and activation of registration clutch). A higher setting applies greater buckling. [0 ~ 10 / 5 / 1 mm/step]

2 mm

Tables

Service

Fusing Temperature Display106

1 Displays the fusing temperature.

Press ! to exit the display.

5-3

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USING SERVICE PROGRAM MODE 24 July, 2001

Mode Number/Name Function/[Setting]

Fusing Nip Band Check109

1 Checks the fusing nip band.

Auto-Restart Interval901

1 Sets the time interval between completion of one copy

AC Frequency Display902

1 Displays the fusing lamp power control frequency (as

SP2-XXX (Drum)

001* Charge Bias Adjustment

005 Charge Bias Correction

Mode Number/Name Function/[Setting]

1 Image area Adjusts the voltage applied to the charge roller when

2 ID sensor pattern Adjusts the voltage applied to the charge roller when

3 Manual

1 Vsdp min. Sets lower limit for application of charge-bias correction.

2 Vsdp max. Sets upper limit for application of charge-bias correction.

3 Correction step

[1 = No / 0= Yes] DFU

and automatic start of next copy. [0 ~ 9999 / 0 / 1 s] DFU

detected by the zero cross signal generator), in Hz.

printing. [–1800 ~ –1500 / –1650 / 1 V/step]

The actually applied voltage changes automatically as charge roller voltage correction is carried out. The value you set here becomes the base value on which this correction is carried out.

generating the ID sensor pattern. [0 ~ 400 / 200 / 1 V/step]

The actual charge-roller voltage is obtained by adding this value to the value of SP2-001-1.

Use this feature to adjust the voltage to the image area when diagnosing a problem . [-1900 ~ 0 / 0 / 1 V/step]

• The value is applied as an offset to the value set by SP2-001-001.

• This setting is lost at power-off.

[0 ~ 100 / 90 / 1%/step]

Correction is applied if Vsdp/Vsg is less than this value.

[0 ~ 100 / 95 / 1%/step]

Correction is applied if Vsdp/Vsg is greater than this value.

Sets the correction step (the amount of voltage added or subtracted for each correction). [0 ~ 200 / 50 / 1V/step]

5-4

Page 84

24 July, 2001 USING SERVICE PROGRAM MODE

101*

201*

Mode Number/Name Function/[Setting]

Erase Margin Adjustment

1 Leading edge Adjusts the leading edge erase margin.

[0.0 ~ 9.0 / 3.0 / 0.1 mm/step] IAJ

Does not apply to 1-sheet bypass feed.

4 Trailing Adjusts the trailing edge erase margin.

[0.0 ~ 9.0 / 4.0 / 0.1 mm/step] IAJ

Does not apply to 1-sheet bypass feed.

5 Left side Adjusts the left edge erase margin.

[0.0 ~ 9.0 / 2.0 / 0.1 mm/step] IAJ

6 Right side Adjusts the right edge erase margin.

[0.0 ~ 9.0 / 2.0 / 0.1 mm/step] IAJ

1-sheet bypass

leading edge

12 1-sheet bypass

trailing

Development Bias Adjustment

1 Image area Adjusts the voltage applied to the development roller

2 ID sensor pattern Adjusts the voltage applied to the development roller

Copies after Toner Near End213*

Adjusts the leading edge erase margin for 1-sheet bypass. [0.0 ~ 9.0 / 4.5 / 0.1 mm/step] IAJ Adjusts the trailing edge erase margin for 1-sheet bypass. [0.0 ~ 9.0 / 4.5 / 0.1 mm/step] IAJ

when printing. [–800 ~ 0 / –600 / 1 V/step]

• This can be adjusted as a temporary measure if faint copies are being produced due to an aging drum.

when generating the ID sensor pattern. [0 = N (200 V) / 1 = H (240 V) / 3 = HH (280 V) / 4 = LL (120V)]

The actual voltage applied is this setting – 600V.

Sets the number of copy/print/fax pages that can be made after toner near-end has been detected. [0 = 50 pages / 1 = 20 pages]

Reduce the number of pages if the user normally makes copies with a high image ratio.

Tables

Service

Initial Developer Running214

Initializes the developer (by forced churning). [0 = No / 1 = Yes]

• To start forced developer initialization, you must turn the machine off and back on.

• Since the machine automatically initializes the developer when a replacement PCU is installed, there is no need to carry out this SP when replacing the PCU.

• If the machine has not been used for a long period of time, prints may have a dirty background. In this case, use this SP to mix the developer.

5-5

Page 85

USING SERVICE PROGRAM MODE 24 July, 2001

301*

Mode Number/Name Function/[Setting]

TD Sensor Value Display220

1Displays:

a) Current TD sensor output value (Vt) b) Target TD output value [Vts corrected by ID sensor

output]

• The TD sensor output value changes every copy. If a > b, toner is supplied to the development unit.

• Press ! to exit the display.

ID Sensor Display221

1 Displays Vsg, Vsp, Vsdp, Vt, and the ID sensor's PWM

output. Use these values to check the operational status of the ID sensor. [0 = No / 1 = Yes]

• This machine has no SC code for ID sensor errors. If imaging problems occur (such as dirty background), use this SP to determine whether the problem is with toner density control.

• You can use SP7-911 to check the number of ID sensor errors that have occurred.

• (

☛

5.1.11)

Transfer Current

1 Normal paper

2 Thick/Thin paper Adjusts the current applied to the transfer roller when

4 Cleaning Adjusts the current applied to the transfer roller for roller

Adjusts the current applied to the transfer roller when feeding from a paper tray.

[0 = –2 µA / 1 = 0 µµµµA / 2 = +2 µA / 3 = +4 µA]

• Use a high setting if the user normally feeds relatively thick paper (within spec).

• (

☛

6.14.2, , "Image Transfer Current Timing")

feeding from the bypass tray. [0 = –2 µA / –1 = 0 µµµµA / 2 = +2 µA / 3 = +4 µA]

• Use a high setting (a) if the user normally feeds relatively thick paper, or (b) if waste toner is re-attracted from the drum (which can occur when using transparencies).

• (

☛

6.14.2, , "Image Transfer Current Timing")

cleaning. [–10 ~ 0 / –4 / 1 µA/step]

• Increase the current if toner remains on the roller after cleaning. (Remaining toner may cause dirty background on the rear side.)

☛

• (

6.14.2, "Image Transfer Current Timing")

5 Manual (Temporary)

DFU

5-6

Page 86

24 July, 2001 USING SERVICE PROGRAM MODE

906*

922* Toner Supply Time

Mode Number/Name Function/[Setting]

Tailing Correction

1 Shift value When printing multiple copies, the machine will shift the

2 Interval

Forced Toner Supply908

1 Forces the toner bottle (or toner hopper) to supply toner to

Polygon Mirror Motor Idling Time915*

1 Selects the polygon mirror motor idling time.

1 Adjusts the toner supply motor ON time.

image writing position by the specified amount after every n copies, where n is given by SP2-906-2.

[0.0 ~ 1.0 / 0.0 / 0.1 mm/step]

When making many copies of an original that contains vertical lines (such as in tables), the paper may not separate correctly. This can cause tailing images (ghosts of the vertical lines continuing past the bottom of the table). This SP corrects the problem by shifting the paper after every specified number of copies.

Changes the interval for the image shift specified by SP2906-1. [1 ~ 10 / 1 / 1 page/step]

If the setting is n, the machine executes the shift after the first n copies, then shifts back to standard position after the next n copies, and so on.

the toner supply unit. Press “1” to start. [0 = No / 1 = Yes]

The machine supplies toner over a total of 15 seconds (1.5 second on, 1.5 second off, repeated 5 times).

[0 = None / 1 = 15 s / 2 = 25 s]

To increase the speed of the first copy, the mirror motor begins idling when the user sets an original, touches a key, or opens the platen cover or DF. If this setting is left at the default (25 s), the motor will stop if the user does nothing for 25 s. If the setting is “0”, the motor will not switch off during standby. (Regardless of the setting, the motor will switch off when the machine enters low-power mode.)

[0.1 ~ 5.0 / 0.6 / 0.1 s/step]

• Raising this value increases the toner supply motor ON time. Set to a high value if the user tends to make many copies having high proportions of solid black image areas.

• (

☛

6.11.4, "Toner Density Control")

Tables

Service

926* Standard Vt

Adjusts Vts (the reference voltage used for new developer). The TD sensor output is adjusted to this value during the TD sensor initial setting process. [0.00 ~ 3.3 / 1.25 / 0.01 V/step] DFU

5-7

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USING SERVICE PROGRAM MODE 24 July, 2001

929* Vref Limits

Mode Number/Name Function/[Setting]

ID Sensor Control927* 1 Selects whether the ID sensor is or is not used for toner

Toner End Clear928

1 Clears the toner end condition without adding new toner.

1 Upper Adjust the upper Vref limit.

2 Lower Adjust the lower Vref limit.

density control. [0 = No / 1 = Yes]

This value should normally be left at “1”. If the value is “0”, dirty background may occur after long periods of non-use.

Select “1” then press the ' key to clear the condition. [0 = No / 1 = Yes]

Setting this to “1” will clear the following:

• Toner end and near-end indicator

• Toner near-end counter

• Toner end counter (sheets)

• Toner end counter (level)

This function should generally not be used. If you clear the toner end condition without adding new toner, there is a risk that the drum may eventually begin to attract carrier after toner runs out. This attracted carrier may damage the drum.

[0.50 ~ 3.50 / 1.80 / 0.01V/step]

[0.00 ~ 3.50 / 0.45 / 0.01V/step]

995* ID Detection Interval

1 Sets the interval after which ID detection will be carried

Main Scan Magnification (Printing)998*

1 Adjusts the magnification along the main scan direction,

out at start of printing (relative to previous ID detection). [0 ~ 999 / 480 / 1 minute/step]

Higher values increase the chance of dirty background. Lower values increase the frequenc y at which the machine makes ID sensor patterns, increasing the chance that the transfer roller (and rear side of paper) will become dirty.

for all print modes (copy, fax, printing). [–0.5 ~ +0.5 / 0.0 / 0.1%/step] IAJ

• Use the ! key to select “+” or “–” when entering the value.

5-8

Page 88

24 July, 2001 USING SERVICE PROGRAM MODE

SP4-XXX (Scanner)

Mode Number/Name Function/[Setting]

Main Scan Magnification (Scanner)008*

1 Adjusts the magnification along the main scan direction,

for scanning. [–0.9 ~ +9.0 / 0.0 / 0.1%/step] IAJ

• Use the ! key to select “+” or “–” when entering the value

Leading Edge Registration (Scanner)010*

1 Adjusts the leading edge registration for scanning in

platen mode. [–2.0 ~ +5.0 / 0.0 / 0.1 mm/step] IAJ

• (–): The image moves toward the leading edge.

• (+): The image moves toward the trailing edge.

• Use the ! key to select “+” or “–” when entering the

value

Side-to-side Registration (Scanner)011*

1 Adjusts the side-to-side registration for scanning in platen

mode. [–0.9 ~ 0.9 / 0.0 / 0.1 mm/step] IAJ

• Increasing the value shifts the image to the right

• Use the ! key to select “+” or “–” when entering the

value

Scanner Free Run013

Performs a scanner free run with the exposure lamp on. [0 = No / 1 = Yes]

• For details about free runs:

• After selecting “1”, press OK or ' twice to start the run.

Press % to stop.

☛

5.1.7.

Tables

Service

015*

White Plate Scanning

1 Start position

2 Scanning area Adjusts the end position of the white plate scan, in the

Sub-Scan Magnificati on ( Sc ann in g)101*

1 Adjusts the actual sub-scan scanning magnification. The

Adjusts the scanning start position on the white plate for auto-shading. [–3.0 ~ +6.0 / 0.0 / 0.1 mm/step]

• Positive settings move the position away from HP.

main scan direction. The scan begins at the start position [as set by SP4-015-1] and extends for the specified length. [–3.0 ~ +6.0 / 0.0 / 0.1 mm/step]

• The total scanning length (as determined by SP2-015-1 and SP2-105-2) must be at least 2.0mm.

higher the setting, the lower the scanner motor speed. [-0.9 ~ +0.9 / 0.0 / 0.1%/step]

5-9

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USING SERVICE PROGRAM MODE 24 July, 2001

921* Image Adjustment Selection

Mode Number/Name Function/[Setting]

Exposure Lamp ON902*

SBU Auto-Adjustment908

1 Performs auto scanner adjustment.

DF Shading Interval Time913*

1 Adjusts the interval used for shading processing in DF

Lets you turn the exposure lamp on and off.

[0 = Lamp Off / 1 = Lamp On]

• To turn the exposure lamp on, press “1”. To turn the lamp off, press "0". To exit, press

• The scanner moves to the shading position and remains there until you exit the SP.

• The display also shows the minimum and maximum white-plate values (updated every 0.5 sec.).

[0 = No (normal operation) / 1 = Yes (start adjustment)]

• Use this SP after replacing the white plate, FCU, or lens block, and after executing a Memory All Clear (SP5-

801).

• (

☛

IAJ, “Standard White Density Adjustment”.)

mode. [0 ~ 255 / 30 / 1s/step]

• Setting this value to 255 will switch off auto-shading between pages of DF copy jobs.

• Light and heat may affect scanner response. Reduce this setting if copy quality indicates that the white level is drifting during DF copy jobs.

Use this to select the processing mode (pattern) that you wish to set adjustment parameters for. After selecting the mode, you can set the adjustment parameters for that mode using SPs 4-922 to 4-966. IP

or Cancel to exit.

There are 11 modes ("Pattern 1" to "Pattern 11"), as follows.

1 = Text 1 7 = Special 3 2 = Text 2 8 = Fax Text 1 ("text sharp") 3 = Photo 1 9 = Fax Photo 1 "(photo smooth") 4 = Photo 2 10 = Fax Photo 2 ("photo normal") 5 = Special 1 11 = Fax Text 2 ("text dropout") 6 = Special 2

First use the right or left cursor key to select the mode ["Pattern 1" to "Pattern 11"], and then press "1" to enable adjustment for that mode. Then press OK, and then proceed to use SPs 4-922 to 4-966 to make adjustments.

• If you press "0" and then press OK, SPs 4-922 to 4-966 will not operate.

5-10

Page 90

24 July, 2001 USING SERVICE PROGRAM MODE

Mode Number/Name Function/[Setting]

Scanning Density Adjustment922*

Selects the gamma table used for linear adjustment by the mode selected by SP4-921.

[0 = Linear / 1 = 16-bit gray] IP

Notch Selection923*

Selects the value of the center ID adjustment notch for the ID adjustment LEDs. Applies only to the mode selected by SP4-921. [–1 = Light / 0 = Normal / +1 = Dark]

Normally the center notch is 3 (range 1–5). If –1 is selected, each notch shifts down (becomes lighter). If +1 is selected, each notch shifts up (becomes darker).

Sharpness Adjustment925*

Adjusts the image sharpness processing (MTF and smoothing coefficients) for the mode selected by SP4-

921.

[–2 ~ 2 / 0 / 1/step] IP

Higher values produce greater sharpness.

Texture Removal Threshold926*

Adjusts the texture removal threshold for the mode selected by SP4-921. IP

Line Width Correction927*

Independent Dot Erase928*

930 Binary Data Select

931* Uneven Dot Adjustment

[0 ~ 4 / 0], where: 0: The mode's default value is used.

1: Fixed threshold. 2: Varying threshold (low variance) 3: Varying threshold (medium variance) 4: Varying threshold (photo error diffusion)

Adjusts the line width correction algorithm for the mode selected by SP4-921. Positive settings produce thicker lines; negative settings produce thinner lines. [–2 ~ 2 / 0 / 1/step] IP

Selects the dot erase level for the mode selected by SP4-

921. Higher settings provide greater erasure.

[–2 ~ 2 / 0 / 1/step] IP

Not effective on this machine. DFU

Selects the bad-dot correction m ethod us ed b y the m ode selected by SP4-921. [0 = selected mode's default / 1 = off / 2 =1-dot correct / 3 = 2-dot correct / 4 = 3-dot correct / 5 = 4-dot correct]

DFU (Not effective on this machine.)

Tables

Service

5-11

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USING SERVICE PROGRAM MODE 24 July, 2001

932* Auto Density Adjustment

933* Blank-Page Sensor Level Adjus tment

963* Marking Image Density Setting

Mode Number/Name Function/[Setting]

[-2 ~ 2 / 0 / 1/step] DFU (Not effective on this machine.)

[-2 ~ 2 / 0 / 1] DFU (Not effective on this machine.)

Peak Setting934*

Sets adjustment the machine will use when setting white peak prior to start of scanning, for the mode selected by SP4-921. [–128 ~ 127 / 0 / 1/step]

• If AE tracking is enabled, the applied peak becomes: [(detected peak + this setting) x approx. 40%]

• If AE tracking is disabled, the applied peak becomes: [(detected peak + this setting)

AE Tracking Speed935*

Adjusts the white-peak tracking speed for the mode selected by SP4-921. [–2 ~ 2 / 0 / 1/step]

Negative settings reduce the speed; positive settings increase it.

Peak Offset Select936*

Sets the peak correction offset for the mode selected by SP4-921. [–2 ~ 2 / 0 / 1/step] IP

Negative settings produce better reproduction of lowcontrast originals. Positive settings provide better elimination of dirty background.

Plotter Mode Select961*

Selects the plotter mode used by the processing mode selected by SP4-921. IP

[0 = Selected processing mode's default / 1 = Normal (no correction) / 2 = Toner save / 3 = FCI

• The default varies according to the processing mode selected by SP4-241

Marking Image Density Conversion962*

Selects the image density conversion for the processing mode selected by SP4-921. [–2 ~ 2 / 0 / 1/step] IP

A setting of "0" sets conversion OFF. Negative settings reduce the black marking size, while positive values magnify it.

Sets the density adjustment type for the mode selected by SP4-921. IP [0 ~ 5 / 0 / 1/step], where: 0: The mode's default value is used. 1: Distortion prevention 2: Distortion prevention and edge correction 3: Normal 4: Light edge correction 5: Dense edge correction

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24 July, 2001 USING SERVICE PROGRAM MODE

964*

Mode Number/Name Function/[Setting]

Spot Dot Enhancement Select

Selects emphasis used for lone dots, for the mode selected by SP4-921. IP

[–2 ~ 2 / 0 / 1/step

Toner Save Level965*

Sets the toner save level for the mode selected by SP4-

921.

[0 ~ 4 / 0 / 1/step], where: 0: The mode's default value is used.

1: Thin lines 2: Mask 1 (with edge detect) 3: Mask 2 (no edge detect) 4: Mask 3 (with edge detect)

Smoothing Select966*

Selects whether smoothing is used for the mode selected by SP4-921. IP

[0 ~ 4 / 0 / 1/step], where:

0: The mode's default value is used. 1: OFF 2: ON

Tables

Service

5-13

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USING SERVICE PROGRAM MODE 24 July, 2001

SP5-XXX (Mode)

501*

Mode Number/Name Function/[Setting]

All Indicators On001

Sets on all indicators on the operation panel, and causes the display to blink (empty for five second, all pixels black for five seconds).

After checking , press ! or Cancel to exit.

Date/Time302*

Sets the date and time.

• For the year value, you can set the last two digits only. (The first two digits are fixed at "20".)

• You cannot set the seconds value directly. Instead, the seconds value automatically resets to 0 when you enter the setting for the minutes value.

• Use cursor keys (or OK) to move from field to field (the selected field flashes), and enter values with the numeric keys. Your new settings are saved only if you press OK while the minutes field is selected.

PM Alarm Mode

1 Interval Sets the base PM interval.

[1 ~ 255 / 45 / 1K copies/step]

This setting is meaningful only if SP5-501-2 is set to “1”.

2 On/Off Enables/disables the PM alarm for the total number of

prints, copies, and faxes. [0 = Disable / 1 = Enable ]

Memory All Clear801

Resets all SP/UP settings and values to their defaults, with the exception of plug-and-play settings (SP5-907), total print counters (SP7-003), and the serial number setting (SP5-811).

[0 = No / 1 = Yes]

• Before clearing the SRAM, be sure to output an SMC printout of all current SRAM content. (

• This SP mode should generally not be used.

(☛ 5.1.6)

☛

SP5-992).

Free Run802

Starts a free run of both the scanner and the printer. [0: = No / 1 = Yes]

☛

• For details about free runs:

• After selecting “1”, press the OK key (or the ' key)

twice to start the free run. Press % to stop the free run.

Input Check803

Displays the signals being received from a selected

☛

5.1.4)

(

☛

sensor or switch.

Press ! to exit the program.

Output Check804

Turns on a selected electrical component for test purposes. (

5.1.7.

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Mode Number/Name Function/[Setting]

SC Code Reset810

Resets all level-A service call conditions, such as fusing errors. [0 = No / 1 = Yes]

• After selecting “1”, hold down the Original Type key and press the OK key (or the ' key) to execute the reset. If the reset succeeds, the machine reboots. If it fails, the display shows “Error!!!”.

☛

• (

4.1, "Service Call Conditions")

Serial Number Input811*

Used to input the machine serial number (normally done at the factory). This is the serial number printed on SMC reports. (

Service Telephone Number812*

Use this to input the telephone number of the service representative. (This number is displayed when a service call condition occurs.)

• To input a dash, press !.

• Use % to delete the existing phone number or to delete

the last digit that you entered.

SRAM Data Upload824

Uploads SP and UP settings from the machine's SRAM to a flash memory card. [0 = No / 1 = Yes]

• This SP is effective only if a flash memory card has been plugged into the machine’s card slot.

SRAM Data Download825

Downloads SP mode data from a flash memory card to the machine's SRAM. [0 = No / 1 = Yes]

• This SP is effective only if a flash memory card has been plugged into the machine’s card slot.

Program Upload826

Uploads the system program from the machine's SRAM into the flash memory card plugged into the machine's card slot.

[0 = No / 1 = Yes]

• This SP is effective only if a flash memory card has been plugged into the machine’s card slot.

Program Download827

Downloads the system program from a flash memory card to the machine's SRAM. [0 = No / 1 = Download first 2MB / 2= Download last 2MB]

• This SP is effective only if you have booted the machine from a flash memory card.

☛

5.1.10)

(☛ 5.1.8)

(☛ 5.1.9)

(☛ 5.1.8)

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USING SERVICE PROGRAM MODE 24 July, 2001

Mode Number/Name Function/[Setting]

Program Checksums837

Displays checksums of the contents of the machine's SRAM.

• The screen shows three check sums: "SUM" (total checksum, "B" (boot sum), and "M" (main sum).

• If you have used SP-827 to download new firmware, be sure to reboot the software before running this SP. (If you don't reboot, the screen will show checksums for the previous firmware.)

Printer Free Run901

Starts a printer free run. [0 = No / 1 = Yes]

• For details about free runs:

• After selecting “1”, press the OK key (or the ' key)

twice to start the free run. Press % to stop the free run.

Test Pattern Print902 1 Exhaust-Fan Control Timer906* 1 Inputs the fan control time.

Plug & Play Setting907*

Prints a test pattern. (

[30 ~ 120 / 30 / 1 s/step]

The fan maintains existing speed for the specified time before slowing or stopping (after occurrence of an SC or following entry into warm-up, standby, or low-power mode).

Selects the brand name and production name for the Plug and Play function (for Windows 95 and up). These names are registered in the SRAM. If the SRAM becomes defective, these names should be re-registered.

• Use the Right or Left cursor key to scroll through the list of brand names. To select a brand name, press the Original Type key and the OK (or ') key at the same time. The LCD displays an asterisk (*) next to the number of the currently selected brand name.

• After displaying any of the brand names, you can view the corresponding production name by holding down the Darker key. (If the production name is too long to fit on the screen, you can view the rest of the name by holding down both the Darker and Lighter keys).

• To exit, press ! or the Cancel key.

☛

5.1.2)

☛

5.1.7.

908* C1a/C1b Select

1 Selects whether the machine identifies itself as a C1a

(B045/B059) or C1b (B044/B046) when reporting to firmware. [0 = no setting / 1 = C1a / 2 = C1b]

• You can visually identify the machine is C1a or C1b by its bypass. C1a machines have 1-sheet bypass; C1b machines have 100-sheet bypass.

• If the setting is "0", the machine automatically checks its own bypass type to determine how to report itself.

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24 July, 2001 USING SERVICE PROGRAM MODE

912*

Mode Number/Name Function/[Setting]

PCU Alarm

1 Alarm Displa y On/Of f Selects whether or not the mac hine will dis p lay a "Replace

PCU' warning when the PCU alarm counter reaches the interval set by SP912-2. [0 = Display / 1 = Do not display]

2 Interval Sets the PCU Alarm interval (count) at which a "Replace

PCU' warning occurs. [1 ~ 255 / 45 / 1000 sheets/step]

UP Mode Data Reset913

1 Resets the user tools settings (with the exception of the

copy user codes and copy user code counters). [0 = No / 1 = Yes]

• This operation is equivalent to executing a System Reset with the User Tools.

• After selecting “1”, hold down the Original Type key and press the OK key (or ' key) to execute the reset. If the reset is successful, the display shows “Action completed.” If the reset fails, the display shows “Error!!!”

Preset Small-Size Se tti ng956

1 Enables setting of small paper sizes.

[0 = No / 1 = Yes]

• Setting this value to "1" enables setting of the following standard small sizes, for both paper tray and bypass tray: B5 SEF, Executive SEF.

If you change the setting from "1" to "0" when on e of these sizes is set, the size sett ing changes to each tray's default.

Debug Monitor Mode991*

SMC Printing992

[0 ~ 3 / 0 / 1/step] DFU

☛

Prints out machine data. ( [0 = No / 1 = SP settings / 2 = All / 3 = Memory]

5.1.5)

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SP6-XXX (Peripherals)

006

Mode Number/Name Function/[Setting]

ADF Registration

1 Side-to-Side Adjusts the side-to-side registration for DF mode.

[–9.0 ~ +9.0 / 0.0 / 0.1 mm/step] IAJ

Use the ! key to select “+” or “–” when entering the value.

2 Leading Edge Adjusts the leading edge registration for DF mode.

[–5.0 ~ +5.0 / 0.0 / 0.1 mm/step] IAJ

0.1 mm/step

Use the ! key to select “+” or “–” when entering the value.

3 Trailing Edge Erase Adjusts the trailing edge erase margin for DF mode.

[–3.0 ~ +3.0 / –1.0 / 0.1 mm/step] IAJ

Use the ! key to select “+” or “–” when entering the value.

ADF Sub-scan Magnification007

1 Adjusts the actual magnification ratio in the sub-scan

direction, for DF mode. [–0.9 ~ +0.9 / 0.0 / 0.1%/step] IAJ

Use the ! key to select “+” or “–” when entering the value.

ADF Free Run009

Performs a DF free run . [0 = No / 1 = Yes]

• For details about free runs:

• After selecting “1”, press OK or ' twice to start the run.

Press % to stop.

ADF/Printer Free Run910

Performs a free run of the DF and printer. [0 = No / 1 = Yes]

• For details about free runs:

• After selecting “1”, press OK or ' twice to start the run.

Press % to stop.

☛

5.1.7.

☛

5.1.7.

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SP7-XXX (Data Log)

002*

003*

101*

204*

504*

Mode Number/Name Function/[Setting]

Total Original Counter

1 All Modes Displays the total number of scanned originals (total). 2 Copy Displays total number of scanned originals (copy mode

only).

3Fax

Total Print Counter

1 All Modes Displays the total number of prints (total). 2 Copy Displays the total number of prints (copier mode). 3 Fax Displays the total number of prints (fax mode). 4 Printer Displays the total number of prints (printer mode).

Copy Counter – Paper Size

1 A4 Displays the total number of copies by paper size. 2B5 3LG 4LT 5HLT 6 Others

Total Scan Counter201*

1 Displays the total number of scanned originals.

Copy Counter - Paper Tray

11st 2 2nd 3Bypass

Total ADF Counter205*

1 Displays the total number of originals fed by the DF.

Total SC Counter401*

1 Displays the total number of logged SC codes.

SC Type Counter402*

1 Displays the total number of each type of logged SC code.

Total Jam Counter501*

1 Displays the total number of jams (copy paper + original).

Total Paper Jam Counter502*

1 Displays the total number of copy paper jams.

Total Original Jam Counter503*

1 Displays the total number of original jams.

Jam Counter – by Location

1“A” jams 2“B” jams 3“C” jams 4“Y” jams 51st Tray 6 2nd Tray 7Bypass

Displays total number of scanned originals (fax mode only).

Displays the total number of sheets fed from each paper feed station.

Displays the total number of copy paper jams by location.

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801

808 Reset Counters

Mode Number/Name Function/[Setting]

ROM Versions and Option Connections

Note: SP7-801 cannot be accessed at the screen. This information appears on SMC printouts only. (Go to SP5-992 and select "2" to print out all data. The SP-801 information will appear in the "LOG DATA" section on the second page of the printout.

☛

5.1.5])

[

1 Firmware Version 2 No meaning (Fixed at "VER. 1") 3 Fax Unit ["Yes" = installed, "No" = Not installed] 4 Printer Unit ["Yes" = installed, "No" = Not installed] 5 ADF ["Yes" = installed, "No" = Not installed] 6 Optional Memory ["No" (None installed), "32MB", "40MB", "64MB"] 7 Paper Tray Unit ["Yes" = installed, "No" = Not installed] 8 Bypass Type ["1" = 1 sheet / "100" = 100-sheet] PM Counter Display803*

1 Displays the PM counter value (the count since the last

PM Counter Reset804

1 Resets the PM counter.

SC/Jam Counter Reset807

1 Resets the SC counter and all jam counters.

1 Resets all counters, except for the total counter (SP7-

Shows software versions and option connection statuses.

PM).

[0 = No / 1 = Yes]

After selecting “1”, hold down the Original Type key and press the OK key (or ' key) to execute the reset. If the reset is successful, the display shows “Action completed.” If the reset fails, the display shows “Error!!!”.

[0 = No / 1 = Yes]

003).

[0 = No / 1 = Yes]

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825 Total Counter Reset

Mode Number/Name Function/[Setting]

1 Resets the electronic total counter.

SC History Display901

1 Displays the codes of the last fifty errors that have

SC History Reset902

1 Clears the SC history.

PCU Counter Display908

PCU Counter Reset909

1 Resets the developer counter.

ID Sensor Error Counter Display911*

1 Displays the total number of logged ID sensor errors.

ID Sensor Error Counter Reset912

1 Resets the ID sensor error counter.

[0 = No / 1 = Yes]

• This reset is generally performed at installation. This SP mode is effective only once, while the counter still has a negative value. This SP cannot be used once the counter takes a positive value.

occurred. [0 = No / 1 = Yes]

On fax-equipped models, you can print out the last fifty error codes using fax service mode 04. For information, refer to the fax service manual.

[0 = No / 1 = Yes]

• Note that when executed on fax-equipped models, this operation will not clear the machine's service-report data.

Displays the number of prints made since the PCU was last replaced.

[0 = No / 1 = Yes]

After selecting “1”, press the Original Type key and the OK key (or ' key) at the same time to execute the reset. If the reset is successful, the display shows “Action completed.” If the reset fails, the display shows “Error!!!”.

For information about how to analyze these errors, see Section 5.1.11.

[0 = No / 1 = Yes]

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Ricoh S-C1 Service Manual

IMPORTANT SAFETY NOTICES

TABLE OF CONTENTS

1. INSTALLATION

1.1 INSTALLATION REQUIREMENTS

1.1.1 ENVIRONMENT

1.1.2 MACHINE LEVEL

1.1.3 MINIMUM OPERATIONAL SPACE REQUIREMENTS

1.1.4 POWER REQUIREMENTS

1.2 COPIER

1.2.1 ACCESSORY CHECK

1.2.2 INSTALLATION PROCEDURE

Initial Programming: Faxless models (B044, B045)

Initial Programming: Fax-equipped models (B046, B049)

1.3 PAPER TRAY UNIT

1.3.1 ACCESSORY CHECK

1.3.2 INSTALLATION PROCEDURE

1.4 PAPER TRAY UNIT HEATER

1.4.1 ACCESSORY CHECK

1.4.2 INSTALLATION PROCEDURE

1.5 DOCUMENT FEEDER

1.5.1 ACCESSORY CHECK

1.5.2 INSTALLATION PROCEDURE

1.6 DIMM

1.6.1 INSTALLATION PROCEDURE

2. PREVENTIVE MAINTENANCE SCHEDULES

2.1 PM TABLES

2.2 HOW TO CLEAR THE PM COUNTER

3. REPLACEMENT AND AD JUSTMENT

3.1 PRECAUTIONS

3.1.1 GENERAL

3.1.2 LITHIUM BATTERIES

3.1.3 PCU (PHOTOCONDUCTOR UNIT)

3.1.4 TRANSFER ROLLER

3.1.5 SCANNER UNIT

3.1.6 LASER UNIT

3.1.7 FUSING UNIT

3.1.8 PAPER FEED

3.1.9 IMPORTANT

3.2 SPECIAL TOOLS AND LUBRICANTS

3.3 EXTERIOR COVER AND OPERATION PANEL

3.3.1 PLATEN COVER

3.3.2 REAR COVER

3.3.3 COPY TRAY

3.3.4 SCALE PLATE (B044 AND B045 ONLY)

3.3.5 LEFT COVER

3.3.6 RIGHT COVER

3.3.7 FRONT LEFT COVER AND OPERATION PANEL

3.3.8 FRONT RIGHT COVER

3.3.9 RIGHT DOOR

3.3.10 BYPASS TRAY (B044 AND B046 ONLY)

3.3.11 PLATEN COVER SENSOR

3.4 SCANNER SECTION

3.4.1 EXPOSURE GLASS

Non-DF machines

DF-equipped machines

3.4.2 LENS BLOCK

3.4.3 EXPOSURE LAMP, LAMP STABILIZER BOARD

3.4.4 SCANNER MOTOR

3.4.5 SCANNER HP SENSOR

3.4.6 SCANNER ALIGNMENT ADJUSTMENT

3.5 FUSING

3.5.1 FUSING UNIT

3.5.2 EXIT SENSOR

3.5.3 HOT ROLLER STRIPPER PAWLS

3.5.4 HOT ROLLER & FUSING LAMP

3.5.5 THERMOFUSE, THERMOSWITCH, AND THERMISTOR

3.5.6 PRESSURE ROLLER

3.6 PCU

3.7 TONER SUPPLY CLUTCH

3.8 PAPER FEED SECTION

3.8.1 PAPER FEED ROLLER AND FRICTION PAD

3.8.2 PAPER END SENSOR

3.8.3 REGISTRATION SENSOR

3.8.4 BYPASS PAPER END SENSOR (B044 AND B046 ONLY)

3.8.5 BYPASS FEED ROLLER (B044 AND B046 ONLY)

3.8.6 BYPASS FEED CLUTCH (B044 AND B046 ONLY)

3.8.7 BYPASS FRICTION PAD (B044 AND B046 ONLY)

3.8.8 REGISTRATION CLUTCH

3.8.9 PAPER FEED CLUTCH