Toshiba DP1600, DP2000, DP2500 SERVICE HANDBOOK

DIGITAL PLAIN PAPER COPIER

DP1600/2000/2500

File No. 31110004 R0111216700-TTEC Ver07_2002-06

TOSHIBA TEC CORPORATION

GENERAL PRECAUTIONS REGARDING THE INSTALLA TION AND SERVICE FOR DP1600/2000/2500 SERIES

The installation and service should be done by a qualified service technician.

1. Transportation

• When transporting/installing the copier, employ two persons and be sure to use the positions as indicated below . The copier is fairly heavy and weighs approximately 50 kg (110 lb), therefore pay full attention when handling it.

4 portions

2. Installation

• Be sure to use a dedicated outlet with AC 115 or 120V/15A (220V, 230V , 240V/10A) or more f or its power source.

• The copier must be grounded for saf ety. Never ground it to a gas pipe or a w ater pipe.

• Select a suitable place for installation. Avoid excessive heat, high humidity, dust, vibration and direct sunlight.

• Also provide proper ventilation as the copier emits a slight amount of ozone.

• To insure adequate working space for the copying operation, keep a minimum clearance of 80 cm (32") on the left, 80 cm (32") on the right and 10 cm (4") in the rear.

• After having installed the copier, be sure to push the carrying handles into the copier .

3. Service of Machines

• Basically, be sure to turn the main switch off and unplug the power cord during service.

• Be sure not to touch high-temperature sections such as the exposure lamp, the fuser unit, the damp heater and their periphery.

• Be sure not to touch high-voltage sections such as the chargers and the high-v oltage transformer .

• Be sure not to touch rotating/operating sections such as gears, belts, pulle ys , f ans, etc.

• When servicing the machines with the main switch turned on, be sure not to touch live sections and rotating/operating sections. A v oid exposure to laser r adiation.

• Use suitable measuring instruments and tools.

December 2000 © TOSHIBA TEC 1600/2000/2500 GENERAL PRECAUTIONS

• Av oid e xposure to laser r adiation during servicing.

– Av oid direct e xposure to beam. – Do not insert tools, parts, etc. that are reflective into the path of the laser beam. – Remove all watches , rings, bracelets, etc. that are reflective.

4. Main Service Parts for Safety

• The breaker, door s witch, fuse, thermostat, thermofuse, thermistor, etc. are particularly important for safety. Be sure to handle/install them properly.

5. Cautionary Labels

• During servicing, be sure to check the rating plate and the cautionary labels such as “Unplug the power cord during service”, “Hot area”, “Laser w arning label” etc. to see if there is an y dirt on their surface and whether they are properly stuck to the copier.

6. Disposition of Consumable Parts/Packing Materials

• Regarding the recovery and disposal of the copier, supplies, consumab le parts and packingm a terials, it is recommended to follow the rele v ant local regulations or rules.

7. When parts are disassembled, reassembly is basically the reverse of disassembly unless otherwise noted in this manual or other related documents. Be careful not to reassemble small parts such as screws, washer s, pins, E-rings, toothed washers in the wrong places.

8. Basically, the machine should not be operated with any parts removed or disassembled.

9. Precautions Against Static Electricity

• The PC board must be stored in an anti-electrostatic bag and handled carefully using a wristband,

because the ICs on it may become damaged due to static electricity.

Caution: Before using the wrist band, pull out the power cord plug of the copier and make

sure that there is no uninsulated charged objects in the vicinity.

Caution: Dispose of used batteries and RAM-ICs including lithium batteries according to the

manufacturer's instructions.

Attention: Se débarrasser de batteries et RAM-ICs usés y compris les batteries en lithium

selon les instructions du fabricant.

Vorsicht: Entsorgung des gebrauchten Batterien und RAM-ICs (inklusive der Lithium-Batterie)

nach Angaben des Herstellers.

1600/2000/2500 GENERAL PRECAUTIONS December 2000 © TOSHIBA TEC

1. ADJUSTMENT ITEMS ..................................................................................................1-1

1.1 Error Code List................................................................................................................... 1-1

1.2 Self-Diagnosis Modes ........................................................................................................1-7

1.2.1 Adjust mode (05)..................................................................................................... 1-9

1.2.2 System mode ........................................................................................................ 1-13

1.2.3 User test mode...................................................................................................... 1-19

1.2.4 Function test ......................................................................................................... 1-21

1.2.5 MAINTENANCE.................................................................................................... 1-39

1.2.6 SERVICE LIST......................................................................................................1-43

1.2.7 Country/Region code ............................................................................................ 1-49

1.2.8 Scanner parking mode..........................................................................................1-51

1.2.9 Speaker volume.................................................................................................... 1-51

1.2.10 Adjustment of document width sensor .................................................................. 1-52

1.3 Image Quality Control ......................................................................................................1-53

1.4 Copy Image Dimension Adjustment................................................................................. 1-54

1.4.1 Adjustment of paper aligning value ....................................................................... 1-55

1.4.2 Printer unit adjustment ..........................................................................................1-56

1.4.3 Scanner unit adjustment ....................................................................................... 1-61

1.5 Sharpness (HPF) Adjustment ..........................................................................................1-66

1.6 Gamma Slope Correction................................................................................................. 1-67

1.7 High-Voltage Adjustment..................................................................................................1-68

1.7.1 Adjustment ............................................................................................................ 1-68

1.7.2 Precautions ........................................................................................................... 1-71

1.8 Adjusting the Scanner Section ......................................................................................... 1-74

1.8.1 Installing glass ...................................................................................................... 1-74

1.8.2 Installing scanner motor........................................................................................ 1-76

1.8.3 Adjusting the carriage 1 ........................................................................................ 1-77

1.8.4 Installing carriage 2...............................................................................................1-79

1.8.5 CCD unit ...............................................................................................................1-82

1.9 Adjusting the main drive gear assembly........................................................................... 1-86

1.10 MAIN PWA replacement procedure ................................................................................. 1-90

1.11 Measurement of Transfer Guide Bias ............................................................................... 1-92

1.12 Distinction Between New and Old Process Units............................................................. 1-94

1.13 Adjustment of the doctor-sleeve gap................................................................................ 1-95

December 2000 © TOSHIBA TEC 1 DP1600/2000/2500 CONTENTS

01/12

2. PREVENTIVE MAINTENANCE (PM)............................................................................2-1

2.1 Maintenance Performed Every 81,000 (DP1600/2000 Ser ies) and

99,000 Copies (DP2500 Series) ........................................................................................ 2-1

2.2 Preventive Maintenance Check List .................................................................................... 2-1

2.3 PM Kit................................................................................................................................ 2-14

2.4 List of Adjustment Tools.....................................................................................................2-16

2.5 List of Grease.................................................................................................................... 2-16

3. PRECAUTIONS FOR ST ORING & HANDLING SUPPLIES.........................................3-1

3.1 Precautions for Storing TOSHIBA Supplies........................................................................ 3-1

3.2 Checking and Cleaning of the Pressure Roller .................................................................. 3-2

3.3 Checking and Cleaning of the Cleaning Roller................................................................... 3-2

3.4 Checking and Cleaning of the Heat Roller ......................................................................... 3-3

3.5 Checking and Replacing of the Transfer Guide Roller........................................................3-3

3.6 Checking and Cleaning of Photoconductive Drum (SRU type) .......................................... 3-4

3.7 Checking and Cleaning of Drum Cleaning Blade (SRU type) ............................................ 3-5

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

4.1 Troubleshooting Based on Error Code ............................................................................... 4-2

4.1.1 Transporting jam in the main body .......................................................................... 4-2

4.1.2 Paper feeding jam................................................................................................... 4-7

4.1.3 Transporting jam for the optional trays .................................................................. 4-13

4.1.4 Paper jam if some cover is opened .......................................................................4-18

4.1.5 Paper transporting jam at the ADF........................................................................ 4-22

4.1.6 Paper transporting jam at the RADF ..................................................................... 4-24

4.1.7 Paper jam in finisher ............................................................................................. 4-26

4.1.8 Drive system service call ...................................................................................... 4-30

4.1.9 Temporar y paper supply mechanism service call ................................................. 4-33

4.1.10 Optical system service call ...................................................................................4-39

4.1.11 Process system service call.................................................................................. 4-41

4.1.12 Fuser system service call ..................................................................................... 4-41

4.1.13 Communications system service call ....................................................................4-42

4.1.14 ADF or RADF system service call.........................................................................4-44

4.1.15 Other abnormal service call .................................................................................. 4-48

4.1.16 Laser optical system service call .......................................................................... 4-49

4.1.17 Finisher related service call .................................................................................. 4-50

4.1.18 Scanner related service call.................................................................................. 4-55

4.1.19 Printer related service call ....................................................................................4-56

4.1.20 Fax related service call ......................................................................................... 4-56

4.1.21 OCT system service call ....................................................................................... 4-57

4.1.22 Other service call .................................................................................................. 4-57

4.2 Troubleshooting of Image ................................................................................................. 4-58

DP1600/2000/2500 CONTENTS 2 December 2000 © TOSHIBA TEC

02/03

5. UPDA TING THE FIRMWARE ........................................................................................5-1

5.1 Outline................................................................................................................................ 5-1

5.2 Using the Recovery PWA................................................................................................... 5-2

5.2.1 Using main recovery PWA ...................................................................................... 5-2

5.2.2 Using the scanner recovery PWA ...........................................................................5-5

5.3 Using the Batch File ........................................................................................................... 5-8

5.3.1 Creating Download Disks........................................................................................ 5-8

5.3.2 Downloading ......................................................................................................... 5-13

5.4 Using the TOSHIBA Viewer.............................................................................................. 5-20

6. WIRE HARNESS CONNECTION DIAGRAMS ............................................................. 6-1

6.1 AC Wire Harness ............................................................................................................... 6-1

APPENDIX.......................................................................................................................... A-1

Appendix A. Specifications.........................................................................................................A-1

Appendix B. Accessories ...........................................................................................................A-5

Appendix C.Options ..................................................................................................................A-6

Appendix D. Replacement Units/Supplies ..................................................................................A-6

Appendix E. System List ............................................................................................................A-7

Appendix F. Power Supply Unit..................................................................................................A-8

December 2000 © TOSHIBA TEC 3 DP1600/2000/2500 CONTENTS

02/04

1. ADJUSTMENT ITEMS

2. PREVENTIVE MAINTENANCE (PM)

3. PRECAUTIONS FOR STORING & HANDLING SUPPLIES

4. TROUBLESHOOTING

5. UPDATING THE FIRMWARE

6. WIRE HARNESS CONNECTION DIAGRAMS

1. ADJUSTMENT ITEMS

1.1 Error Code List

While the error message or “Call for service” symbol is flashing, pressing the [CLEAR/STOP] key and

the [8] key on the digital keys at the same time shows one of the following error codes on the copy-

quantity indicator as long as those keys are pressed.

Classification Error code Machine status

Transporting jam in the main

body

Paper feeding jam

Transporting jam for the

optional trays

E01 Paper jam inside the machine

E02 Paper jam near the fuser unit

E03 Paper remaining inside the machine at power on (Except

for ADF/RADF)

E04 to E07 Reserved

E08 Transporting jam inside the ADU

E09 Time out error that occurs at the paper feeding sensor

E10 Reserved

E11 Paper feeding jam at the ADU

E12 Paper feeding jam at the SFB

E13 Cassette 1 feeding jam

E14 Cassette 2 feeding jam (PFU)

E15 Cassette 3 feeding jam (PFP)

E16 Cassette 4 (CM) feeding jam (DP2000/2500 series)

E17 to E18 Reserved

E19 LCF feeding jam (DP2000/2500 series)

E20 to E30 Reserved

E31 Paper not reach to feed sensor from cassette 2, so paper

jam inside the main unit during cassette 2 feed

E32 Paper not reach to feed sensor from cassette 3 or 4, so

paper jam inside the main unit during the feed

E33 Paper not reach to feed sensor from LCF cassette.

(DP2000/2500 series)

E34 Paper not reach to 2nd cassette feed sensor from cas-

sette 3 or 4. (Cassette 4 is DP2000/2500 series)

E35 Paper jam in cassette 4 transport path

(DP2000/2500 series)

E36 Paper jam in LCF transport path (DP2000/2500 series)

E37 to E40 Reserved

December 2000 © TOSHIBA TEC 1 - 1 1600/2000/2500 ADJUSTMENT ITEMS

Classification Error code Machine status

Paper jam if some cover is

opened

Paper transporting jam at the

ADF or RADF

Paper jam in the finisher

(DP2000/2500 series)

Life end

Other operator calls

E41 Copier front cover or side cover is opened during copying

(Copier front cover, side cover, or transport cover of job

separator/offset tray/bridge cover is opened during

copying)

E42 Side cover of cassette 2 or cassette 3 is opened during

copying

E43 ADU is opened during copying

E44 Reserved

E45 Side cover of LCF is opened during copying (DP2000/

2500 series)

E46 to E70 Reserved

E71 Original feeding jam at the feeding area of the ADF or

RADF

E72 Original transporting jam at the transporting area of the

ADF or RADF

E73 Original exiting jam at the exiting area of the ADF or RADF

E74 Original reversing jam at the reversing area of the RADF

E75 to EA0 Reserved

EA1 Paper transport delay jam

EA2 Paper transport stop jam

EA3 Paper remaining on the finisher transport path at power

EA4 Finisher is opened during copying

EA5 Finisher staple jam

EA6 Finisher early arrival jam

EA7 Set transport jam before stapling

EA8 to EAE Reserved

EAF Stapled set transport jam

EB1 to EZ9 Reserved

- Process unit life nearly end

- Toner is nearly empty

- No toner cartridge

- Toner empty

- No process unit

- Process unit life end

- Upper tray of the job separator is full

- Lower tray of the job separator is full

- Offset tray is full

- Finisher tray is full (DP2000/2500 series)

1600/2000/2500 ADJUSTMENT ITEMS 1 - 2 December 2000 © TOSHIBA TEC

Classification Error code Machine status

Other operator calls

- Internal tray full (when finisher bridge installed) (DP2000/

2500 series)

- No paper in the cassette 1

- No paper in the cassette 2

- No paper in the cassette 3

- No paper in the cassette 4 (DP2000/2500 series)

- No paper in the LCF (DP2000/2500 series)

- Cassette 1 is not ready

- Cassette 2 is not ready

- Cassette 3 is not ready

- Cassette 4 is not ready (DP2000/2500 series)

- LCF is not installed (DP2000/2500 series)

Front cover or side cover of the copier is open

Cover of the job separator is open

Cover of the off set catch tray is open

Cover of the bridge cover is open (DP2000/2500 series)

Cover of the ADU is open

Side cover of the cassette 2 is open

Side cover of the cassette 3 is open

CALL SERVICE from drive

system

Temporary paper supply

mechanism error

Side cover of the LCF is open (DP2000/2500 series)

Finisher joint is open (DP2000/2500 series)

No staples (displayed only when stapling is designated)

(DP2000/2500 series)

C01 Main motor drive error

C02 to C03 Reserved

C04 PFP main motor drive error

C05 Reserved

C06 LCF feed motor error (DP2000/2500 series)

C07 to C10 Reserved

C11 to C12 Reserved

C13 Cassette 1 error

C14 Cassette 2 error

C15 Cassette 3 error

C16 Cassette 4 error (DP2000/2500 series)

C17 Reserved

C18 LCF tray error (DP2000/2500 series)

C19 LCF feed motor abnormal (DP2000/2500 series)

C20 Reserved

December 2000 © TOSHIBA TEC 1 - 3 1600/2000/2500 ADJUSTMENT ITEMS

Classification Error code Machine status

CALL SERVICE from the

optical system

CALL SERVICE from the

process system

CALL SERVICE from fuser

area

CALL SERVICE from commu-

nication

C21 Carriage initialization error

C22 to C24 Reserved

C25 Scanner unit watch dog error

C26 Exposure lamp disconnection or peak detection error

C27 to C30 Reserved

C31 to C37 Reserved

C38 Replaced process unit error

C39 to C40 Reserved

C41 Abnormal thermistor or heater disconnection at power ON

C42 Reserved

C43 Warming up mode after disconnection judgment, or ab-

normal thermistor after ready

C44 Warming up mode after disconnection judgment, or heater

abnormal after ready

C45 Thermistor disconnection at the end part of heater

C46 to C50 Reserved

C51 to C55 Reserved

C56 Communication error between PFC and main unit

CALL SERVICE from ADF or

RADF

C57 Communication error between main unit and IPC

(DP2000/2500 series)

C58 Communication error between IPC and finisher (DP2000/

2500 series)

C59 to C70 Reserved

C71 Paper supply motor lock error

C72 Reserved

C73 EE-PROM initialization error

C74 Defective adjustment by the exit/reversal sensor detected

C75 to C80 Reserved

C81 Fan motor lock error

C82 Document aligning lower sensor (RADF)/Aligning sensor

(ADF) adjustment error

C83 Size length adjustment error

C84 to C89 Reserved

1600/2000/2500 ADJUSTMENT ITEMS 1 - 4 December 2000 © TOSHIBA TEC

Classification Error code Machine status

CALL SERVICE from others

CALL SERVICE from laser

optical system

CALL SERVICE from finisher

(DP2000/2500 series)

C90 Reserved

C91 SRAM abnormality (Lithium battery or SRAM chip are

abnormal.)

C92 to C94 Reserved

C95 Power supply unit fan motor abnormality

C96 Process unit fan motor abnormality

C97 Vacuum fan motor abnormality

C98 Clock IC abnormality

C99 PFC microcomputer abnormal

CA1 Polygon motor abnormal

CA2 HSYNC abnormal

CA3 to CB0 Reserved

CB1 Reserved

CB2 Exit motor abnormal

CB3 Reserved

CB4 Reserved

CB5 Staple motor abnormal

CB6 to CC2 Reserved

CC3 Set processing motor abnormal

Reserved

Scanner I/F

FAX unit

Offset catch tray

Reserved

CC4 to CC7 Reserved

CC8 Front aligning motor abnormal

CC9 Upper tray elevator motor abnormal

CCA Lower tray elevator motor abnormal

CCB Rear aligning motor abnormal

CCC to CD0 Reserved

F01 to F10 Reserved

F11 Scanner I/F error

F12 Write error at downloading the scanner unit program

F13 Download sector error of the scanner unit program

F14 Scanner unit F-ROM error

F15 to F20 Reserved

F31 Modem IC does not work normal

F32 to F40 Reserved

F41 Initial detection error of the offset catch tray

F42 to F99 Reserved

December 2000 © TOSHIBA TEC 1 - 5 1600/2000/2500 ADJUSTMENT ITEMS

01/05

1.2 Self-Diagnosis Modes

The self-diagnosis functions are used to make the settings for the various PPC functions. This document

describes the self-diagnosis functions.

For the FAX functions, refer to the SERVICE HANDBOOK (GD-1060).

For the method to enter each mode of the self-diagnosis functions, refer to the following chart.

Mode

Country/Region

code

Adjust mode

System mode

Scanner parking

mode

RAM clear

Service mode

How to enter

Turn the power on while

pressing the 0 and 2 keys.

Turn the power on while

pressing the 0 and 5 keys.

Turn the power on while

pressing the 0 and 8 keys.

Turn the power on while

pressing the 0 and 9 keys.

Turn the power on while

pressing the 1, 3, and * keys.

Press the PROGRAM key

while REDAY is indicated,

and then press the *, #, *,

then * keys.

Definition

Selects the country/region code.

Finely adjusts copy image quality.

Confirmation printing enabled by

pressing the INTERRUPT key.

Performs setups for the system,

maintenance, operations, printer,

scanner, etc.

Fixes the scanner carriage in place

when transporting the copier.

Clears values excluding the ones

set in 08-446/447 and in the Ad-

just mode (05).

Performs setups for FUNCTION

TEST and MAINTENANCE, and

prints the Service List.

How to clear

Turn the power off.

Press the

PROGRAM key,

and then press the

*, #, *, then * keys.

FUNCTION

TEST

MAINTENANCE

Service list

After entering the service

mode, select it on the screen.

This mode is selected by

turning the power on while

pressing the 1 and 3 keys.

After entering Service Mode,

select it on the screen.

After entering Service Mode,

select it on the screen.

Conducts OPE. PANEL TEST,

PRINT TEST, MODEM TEST, etc.

Performs setups for Memory Clear,

facsimile function, etc.

Prints PROTOCOL TRACE, Total

Error, FUNCTION LIST, etc.

Or turn the power

off.

Or press the

COPY key, or

press the MAIN

MENU key. *4

*1: After inputting the country/region code, the copier automatically enters the warm up mode.

*2: After the RAM clear, the machine automatically enters the warm up mode.

*3: In the SERVICE MODE, each function of the FUNCTION TEST, MAINTENANCE, or SERVICE LIST

in each test item of the TEST MODE (displayed by pressing the PROGRAM key), are added. When

the copier enters this mode, these functions are available.

*4 The copier enters into the service mode by pressing 1 and 3 keys while turning the power on. To exit

from the service mode, turn the power off.

1600/2000/2500 ADJUSTMENT ITEMS 1 - 6 December 2000 © TOSHIBA TEC

01/12

Power ON

"02"

Country/Region

code

Standby

"13*" "05"

RAM clear

"INT""INT"

Test printWarming up

"INT" : INTERRUPT key on.

Quick reference chart for self-diagnostic mode

"08" "13" "09"

System modeAdjust mode

Function test

Power OFF

Scanner parking mode

01-02-01

Note: Power ON Turn on the power switch.

Power OFF Turn on the power switch.

INT Press the INTERRUPT key.

C/S Press the CLEAR/STOP key.

Menu map

The menu below can be selected by pressing the program key. (However, the menu in the broken-dotted

box are displayed only when the copier enters the SERVICE MODE.)

01. DEFALT SETTINGS

02. LISTS

03. INITIAL SETUP

04. MENU LIST

05. TEST MODE

01. AUTO TEST

02. INDIVIDUAL TEST

03. TEST RESULT LIST

04. FUNCTION TEST

05. MENTENANCE

06. SERVICE LIST

Service mode

01. OPE PANEL TEST

02. PRINT TEST

01. MEMORY CLEAR

02. SET FUNCTION

01. PROTOCOL TRACE

02. TOTAL ERRORS

01-02-02

December 2000 © TOSHIBA TEC 1 - 7 1600/2000/2500 ADJUSTMENT ITEMS

01/12

1.2.1 Adjust mode (05)

0 5

Digital Keys

SET

START

Digital Keys

SET

START

Cancel

Power ON

Enter code

( C/S used to correct value)

Adjustment value

TEST MODE A MC=

205

Enter code

TEST MODE A MC=205

DT= 156

Adjustment value

1600/2000/2500 ADJUSTMENT ITEMS 1 - 8 December 2000 © TOSHIBA TEC

ADJUST MODE (05) ITEMS

Process unit adjustment

Code

205

210

220

221

233

234

235

261

Factor

Development

Charging

Transfer

Separation

Laser

Adjustment item (05)

Developer bias DC adjustment

Ž Increment/decrement by U/D (Up/Down) key

• Real-time high voltage output

• Developer bias DC ON

Grid voltage initial value adjustment