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DP4500/3500
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Copyright TOSHIBA CORPORATION 2001
ALL RIGHTS RESERVED
GENERAL PRECAUTIONS REGARDING THE INSTALLATION
AND SER VICE FOR THE COPIER DP4500/3500
The installation and service should be done by a qualified service technician.
1.T ransportation/Installation
• When transporting/installing the copier, employ two persons and be sure to use the positions as
indicated below .
The copier is quite heavy and weighs approximately 73kg (161lb), therefore pay full attention when
handling it.
• Be sure to use a dedicated outlet with AC 115V or 120V/15A (220V, 230V , 240V/10A) or more f or
its power source.
• The copier must be grounded for saf ety.
Never g round it to a gas pipe or a water pipe.
• Select a suitable place for installation.
Av oid 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.
• The socket-outlet shall be installed near the copier and shall be easily accessible.
2.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, high-voltage transformer, IH
control circuit, exposure lamp control inverter, inverter for the LCD backlight and power supply
unit. Especially, the board of these components should not be touched since the electirc charge
may remain in the condensers, etc. on them even after the power is turned OFF.
• Be sure not to touch rotating/operating sections such as gears, belts, pulleys, fan, etc.
• Be careful when removing the covers since there might be the parts with very sharp edges underneath.
• When servicing the machines with the main switch turned on, be sure not to touch live sections
and rotating/operating sections. Av oid exposure to laser radiation.
• Use suitable measuring instruments and tools.
• Av oid exposure to laser radiation during servicing.
− Av oid direct exposure to the 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.
3.Main Service Parts for Safety
• The breaker , door switch, fuse, thermostat, thermofuse, thermistor, etc. are particularly important
for safety. Be sure to handle/install them properly.
4.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 any dirt on their
surface and whether they are properly stuck to the copier.
5.Disposition of Consumable Parts/Packing Materials
• Regarding the recovery and disposal of the copier, supplies , consumable parts and packing materials, it is recommended to follow the relevant local regulations or rules.
6.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, washers, pins, E-rings, star washers in the wrong places.
7.Basically , the machine should not be operated with an y parts removed or disassembled.
8.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 wristband, pull out the power cord plug of the copier and make
sure that there are no uninsulated charged objects in the vicinity .
Caution :Dispose of used batteries and RAM-ICs including lithium batteri es
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.
V orsic ht :Entsorgung des gebrauchten Batterien und RAM-ICs (inklusive
der Lithium-Batterie) nach Angaben des Herstellers.
1. ERROR CODE AND SELFDIAGNOSIS
2. ADJUSTMENT
3. PREVENTIVE MAINTENANCE
(PM)
4. PRECAUTIONS FOR STORING
/ HANDLING SUPPLIES AND
PARTS
5. TROUBLESHOOTING
6. UPDATING THE FIRMWARE
7. WIRE HARNESS
CONNECTION DIAGRAMS
CONTENTS
1. ERROR CODE AND SELF-DIA GNOSIS ..................................................................................... 1- 1
One of the following error codes is displayed instead of the set number while the [CLEAR/STOP] key and the
digital key “8” are pressed simultaneously when the “CLEAR PAPER” or “CALL SERVICE” symbol is flashing.
Group
Paper transport jam inside theE01Leading edge of paper not reaching the exit sensor
copier (1)E02Trailing edge of paper not passing the exit sensor
Paper misfeedingE11ADU misfeeding
Paper transport jam inside theE20Paper fed from the upper cassette
copier (2)not reaching the registration sensor
E03Paper remaining inside the copier at power ON
E09HDD is abnormal
(paper not reaching the registration sensor)
E12Bypass misfeeding
(paper not reaching the registration sensor)
E13Upper cassette misfeeding
(paper not reaching the upper feed sensor)
E14Lower cassette misfeeding
(paper not reaching the lower feed sensor)
E15PFP upper cassette misfeeding
(paper not reaching the PFP upper feed sensor)
E16PFP lower cassette misfeeding
(paper not reaching the PFP lower feed sensor)
E19LCF misfeeding
(paper not reaching the LCF feed sensor)
E21Paper fed from the lower cassette
not reaching the registration sensor
E22Paper fed from the lower cassette
not reaching the upper feed sensor
E30Paper fed from the PFP upper cassette
not reaching the registration sensor
E31Paper fed from the PFP upper cassette
not reaching the upper feed sensor
E32Paper fed from the PFP upper cassette
not reaching the lower feed sensor
E33Paper fed from the PFP lower cassette
not reaching the registration sensor
E34Paper fed from the PFP lower cassette
not reaching the upper feed sensor
E35Paper fed from the PFP lower cassette
not reaching the lower feed sensor
E36Paper fed from the PFP lower cassette
not reaching the PFP upper feed sensor
E3CPaper fed from the LCF
not reaching the registration sensor
E3DPaper fed from the LCF
not reaching the upper feed sensor
E3EPaper fed from the LCF
not reaching the lower feed sensor
Machine Status
DP4500/3500 ERROR CODES AND SELF-DIAGNOSIS
Group
Cover open jamE40Jam access cover opened during printing
Transport jam (ADU and other area)E51ADU stack jam (paper not reaching the ADU entrance sensor)
Transport jam (RADF)E71Original feeding jam
Paper jam in finisherE91Leading edge of paper not reaching the relay unit transport
Paper transport jam inside theEB5Paper left on the transport path due to multiple feeding
copier (3)EB6Paper left on the transport path due to multiple feeding
Drive system related service callC0 1Main motor is abnormal
Error Code
E41Front cover opened during printing
E42PFP side cover opened during printing
E43ADU opened during printing
E44Side cover opened during printing
E45LCF side cover opened during printing
E48Relay unit opened during printing
E52ADU transport jam (paper not reaching the ADU exit sensor)
E55Paper remaining on the transport path when CRUN is OFF
E72Original transport jam
E73Original discharging jam
E74Original reversing jam
sensor-1
E92Trailing edge of paper not passing the relay unit transport sen-
sor-1
E93Leading edge of paper not reaching the relay unit transport
sensor-2
E94Trailing edge of paper not passing the relay unit transport sen-
sor-2
E9FPunching jam
EA1Finisher paper transport delay jam
EA2Finisher paper transport stop jam
EA3Paper remaining inside the finisher at power ON
EA4Finisher front door opened during printing
EA5Finisher stapling jam
EA6Finisher early arrival jam
EA7Stack transport jam before stapling
EA8Saddle stitcher stapling jam
EA9Saddle stitcher door opened during printing
EAAPaper remaining at the saddle stitcher at power ON
EABSaddle stitcher paper transport stop jam
EACSaddle stitcher paper transport delay jam
EADPrint end command time-out jam
EAEReceiving time time-out jam
EAFStapled stack transport jam
EB3Ready time time-out jam
Scanning system related service callC2 6Peak detection error
Fuser unit related service callC4 1Thermistor or heater is abnormal at power ON
Communication related service callC55ADF I/F is abnormal
RADF related service callC7 1ADF feed motor is abnormal
Laser optical unit related service callCA 1Polygonal motor is abnormal
Error Code
C0 4PFP motor is abnormal
(paper can be fed from cassettes other than PFP cassette)
C1 3Upper cassette tray is abnormal (paper can be fed from the
cassettes other than the copier cassettes)
C1 4Lower cassette tray is abnormal (paper can be fed from the
cassettes other than the copier cassettes)
C1 5PFP upper cassette tray is abnormal (paper can be fed from
the cassettes other than the PFP upper cassette)
C16PFP lower cassette tray is abnormal (paper can be fed from the
cassettes other than the PFP lower cassette)
C1 8LCF tray-up motor is abnormal
(paper can be fed from the cassettes other than the LCF
cassette)
C1ALCF end fence motor is abnormal
(paper can be fed from the cassettes other than the LCF
cassette)
C1BLCF motor is abnormal
(paper can be fed from the cassettes other than the LCF
cassette)
C2 7Carriage home position sensor not going OFF within a fixed
time
C28Carriage home position sensor not going ON within a fixed
time
C4 3Thermistor is abnormal after abnormality judgment
C4 4Fuser is abnormal after abnormality judgment
C45Side thermistor is abnormal after the copier has become ready
C4 7IH power voltage is abnormal/IH initialization error
C4 8IGBT high temperature
C4 9IH circuit or coil is abnormal
C5 7Communication error between main CPU and IPC board
C5 8Communication error between IPC board and finisher
F07Communication error between SYS board and LGC board
F11Communication error between SYS board and SLG board
Finisher related service callCB1Feed motor is abnormal
Service call for othersC 9 4Main CPU is abnormal
Error Code
CB2Delivery motor is abnormal
CB3Tray lift motor is abnormal
CB4Alignment motor is abnormal
CB5Staple motor is abnormal
CB6Stapler shift motor is abnormal
CB7Height sensor is abnormal
CB8Backup RAM data are abnormal
CB9Saddle stitcher paper pushing plate motor is abnormal
CBASaddle stitcher stitch motor (front) is abnormal
CBBSaddle stitcher stitch motor (rear) is abnormal
CBCSaddle stitcher alignment motor is abnormal
CBDSaddle stitcher guide motor is abnormal
CBESaddle stitcher paper folding motor is abnormal
CBFSaddle stitcher paper positioning plate motor is abnormal
CC 0Saddle stitcher sensor connector connection error
CC 1Saddle stitcher microswitch error
CC 2Communication error between finisher and saddle stitcher
CC 3Stack processing motor is abnormal
CC 4Swing motor is abnormal
CC 5Horizontal registration motor is abnormal
CC 6Punch motor is abnormal
CC 8Front jogging motor is abnormal
CC 9Upper stack tray lift motor is abnormal
CCALower stack tray lift motor is abnormal
CCBRear jogging motor is abnormal
Since this copier is designed to cope with multifunctions such as those of a network printer and DSS, there
are many setting items which are related to each other in the self-diagnosis modes.
Malfunctions such as machine locking can be caused by the internal structural problem of the program
when a normal operation is attempted by pressing [0] and [9] simultaneously or [C/S] on the control panel
subsequently to the adjustment.
Therefore, turn OFF the power after using the self-diagnosis mode for adjustment after unpacking, service
or prev entive maintenance , and then leav e the machine to the customer .
Mode
Whole control panel
items lighting mode
Test mode
Test print mode
Adjustment mode
Setting mode
List printing mode
Unit replacement
mode
Note: To enter the desired mode, turn ON the power while two digital keys designated to each mode (e.g. [0] and
[5]) are pressed simultaneously.
Keys to
pressexit
[0]+[1]+
[POWER]
[0]+[3]+
[POWER]
[0]+[4]+
[POWER]
[0]+[5]+
[POWER]
[0]+[8]+
[POWER]
[9]+[ST AR T]
+[ POWER]
[6]+[ST ART]
+[ POWER]
All LEDs on the control panel are lit, and all
the LCD pixels flash.
Checks the status of input/output signals.
Outputs the test patterns.
Adjusts various items.
Sets various items.
Prints out the lists for the codes 05 and 08.
Performs auto-toner adjustment and clears
the process counters.
Function
Keys to
[C/S]or
[0]+[9]
[0]+[9]
[0]+[9]
[0]+[9]
[0]+[9]
[POWER]
OFF
[POWER]
OFF
Display
100%C
TEST MODE
100%PA4
TEST PRINT
100%AA4
TEST MODE
100%D
TEST MODE
100%LA4
LIST PRINT
100%K
TEST MODE
<Operation procedure>
• Whole control panel items lighting mode (01):
[0] [1]
[POWER]
Notes: 1. The mode can be canceled only by pressing the [C/S] key during the key check.
2. Key CheckKeys with LED(Press to turn OFF the LED)
DP4500/3500 ERROR CODES AND SELF-DIAGNOSIS
(All control
panel LEDs lit)
Keys without LED(Press to display the message on the control panel)
• Test mode (03): Refer to “1.2.1 Input check (test mode 03)” and “1.2.2 Outpout check (test mode 03)”.
• Test print mode (04): Refer to “1.2.3 Test print mode (04)”.
• Adjustment mode (05): Refer to “1.2.4 Adjustment mode (05)”.
• List print mode
[9] [START]
[POWER]
(code)
101:05 adjustment mode
(List starts to be printed)
102: 08 setting mode
• Unit replacement mode
[6] [START]
[POWER]
(code)[POWER] OFF
1: Auto-toner adjustment
2: Drum life counter resetting (08-401)
3: Resetting of the copier running time counter (08-402) and fuser unit counter (08-403)
4: Resetting of the separation charger life counter (08-497)
[STA RT]
(Operation started)
• Setting mode (08): Refer to “1.2.5 Setting mode (08)”.
[POWER] ON
Warming up
Normal
[C/S]
Whole control
panel items lit
*2
[0][1] [0][3]
Test mode
[0][5]
Adjustment mode
[0][9][0][9]
Setting mode
[0][9]
[STA RT]
[0][8][0][4][9][S]
T est print mode
[0][9]
[POWER] OFF
List print mode
[6][S]
Unit replacement
mode
Standby
*1
[0][5]
[POWER] OFF
*3
To user
[S]:START key
[C/S]: CLEAR/STOP key
State transition diagram of self-diagnosis mode
*1Only when the copier is put into the adjustment mode by turning ON the power while the digital keys
[0] and [5] are pressed simultaneously and then becomes standby state by pressing [0] and [9]
simultaneously, it can go back to the adjustment mode by the pressing of [0] and [5] simultaneously.
*2In the “whole control panel items lighting mode”, copying is disabled. Enter the standby state by
pressing [0] and [9] simultaneously or [C/S] key to perform copying.
*3Turn OFF the power after using the self-diagnosis mode, and leave the copier to the user .
DBypass feed sensorPaper does not exist
EADU connectionNot connected
FADU opening/closing switchADU opened
GADU exit sensorThere is paper
HADU entrance sensorThere is paper
A—
B—
CPFP upper cassette paper-stock sensorPaper is almost finished
DPFP upper feed sensorThere is paper
EPFP connectionNot connected
FPFP side cover opening/closing switchCover opened
GPFP upper cassette paper-empty sensorNo paper
HPFP upper cassette tray-up sensorTray at upper limit position
ALCF tray bottom sensorTray at bottom position
BLCF paper mis-insertion detection sensorPaper not inserted properly
C—
D—
E—
F—
G—
HLCF feed side paper-stock sensorPaper is almost finished
A—
B—
CPFP lower cassette paper-stock sensorPaper is almost finished
DPFP lower feed sensorThere is paper
EPFP motor rotation condition (motor is being rotated in the output check (03)) Abnormal rotation
F—
GPFP lower cassette paper-empty sensorNo paper
HPFP lower cassette tray-up sensorTray at upper limit position
ALCF end fence home position sensorFence at home position
BLCF end fence stop position sensorFence at stop position
CLCF standby side paper-empty sensorNo paper
DLCF side cover opening/closing switchCover closed
ELCF motor rotation condition (motor is being rotated in the output check (03)) Abnormal rotation
FLCF tray-up sensorTray at upper limit position
GLCF feed sensorNo paper
HLCF feed side paper-empty sensorNo paper
A—
B—
C—
D—
EUpper feed sensorThere is paper
F—
GUpper cassette paper-empty sensorNo paper
HUpper cassette tray-up sensorTray at upper limit position
DIPC board connectionNot connected
E—
FPolygonal motor rotation condition (motor is being rotated in the output check (03)) Abormal rotation
GToner cartridge detection switchOFF
H24V power supplyOFF
ARegistration sensorThere is paper
BExit sensorThere is paper
CAuto-toner sensor connectionNot connected
DFront cover switchCover opened
E—
F—
GSide door switchSide cover opened
HMain motor rotation condition (motor is being rotated by in the output check (03)) Abormal rotation
A—
BKey copy counter connectionNot connected
CToner bag full detection sensorToner is full
DFuser unit connectionUnit connected
ERelay unit transport sensor-2No paper
FRelay unit opening/closing switchCover opened
G—
HRelay unit paper full detection sensorPaper not full
A—
B—
C—
D—
E—
F—
GRelay unit installationNot installed
HRelay unit transport sensor-1No paper
A—
B—
C—
D—
E—
FRADF connectionRADF connected
GPlaten sensorPlaten cover opened
HScanner carriage home position sensorHome position
Items in the adjustment code list on the following pages can be corrected or changed in this adjustment mode (05). Turn ON the power while the digital keys [0] and [5] are pressed sim ultaneously to
enter this mode.
- As the value increases, the sensor output increases correspondingly.
- The value starts changing
approx. 2 minutes after this adjustment was started and is automatically set in the range of 2.35
to 2.45V.
( chapter 2.2)
Adjustment value of auto-toner
sensor can be displayed.
As the value increases by “1”, output from the transformer increases
correspondingly. Remove the developer unit and install the service
jig to make adjustment. However,
the service jig is not necessary to
adjust the developer bias DC.
( chapter 2.5)
When the value increases by “1”,
the laser output increases correspondingly.
When the value increases by “1”,
the image shifts toward the leading
edge of paper by approx. 0.17mm.
When the value increases by “1”,
image shifts toward the rear side
of paper by approx. 0.0423mm.
Moves the carriages to the adjustment position.
( chapter 2.3.4)
When the value increases by “1”,
the reproduction ratio of the secondary scanning direction decreases by approx. 0.025%.
When the value increases by “1”,
the aligning amount increases by
approx. 0.5mm.
Perf orm the adjustment and initialization when the PC board or sensor of the RADF is replaced.
When the value increases by “1”,
the reproduction ratio of the secondary scanning direction on original fed from the RADF increases
by approx. 0.1%.
When the value increases by “1”,
the image of original fed from the
RADF shifts toward the rear side
of paper by approx. 0.0423mm.
When the value increases by “1”,
the copied image of original fed from
the RADF shifts toward the trailing
edge of paper by approx. 0.1mm.
When the value increases by “1”,
the reproduction ratio of the primary scanning direction increases
by approx. 0.07%. (approx.0.5mm/
4steps)
When the value increases by “1”,
the writing start position shifts to the
front side by approx. 0.0423mm.
When the value increases by “1”,
the reproduction ratio of the secondary scanning direction increases by approx. 0.055%.
(approx. 0.5mm/4steps)
When the value increases by “1”,
the blank area becomes wider by
approx. 0.0423mm.
When the value increases by “1”,
the image shifts toward the leading edge of paper by approx.
0.4mm.
When the value increases by “1”,
the aligning amount increases by
approx. 0.8mm.
<Paper length>
Long size:330mm or longer
Middle size: 220mm~329mm
Short size:219mm or shorter
When the value increases by “1”,
the aligning amount increases by
approx. 0.8mm.
<Paper length>
Long size:330mm or longer
Middle size: 220mm~329mm
Short size:219mm or shorter
When the value increases by “1”,
the aligning amount increases by
approx. 0.5mm.
When the value increases by “1”,
the aligning amount increases by
approx. 0.8mm.
When the value increases by “1”,
binding / folding position shifts toward the right page by 0.25mm.
When the value increases by “1”,
the image shifts toward the front
side by 0.0423mm.
When the value increases by “1”,
the image shifts toward the front
side by 0.0423mm.
When the value increases, the image of the center step density becomes darker.
When the value increases, the image of the “light” steps becomes
lighter.
When the value increases, the image of the “dark” steps becomes
darker.
When the value increases, the image becomes darker.
Set whether the value of the
background peak and text peak are
fixed or not.
If they are fixed, the range
correction is performed with
standard values.
The values of the background peak
and text peak affect the
reproduction of the background
density and text density respectively.
Background peakText peak
1:fixedfixed
2:variedfixed
3:fixedvaried
4:variedvaried
When the value increases, the image becomes darker.
The number of units: Enter one of
the following fixed values in the
copying mode.
1: Text/Photo 2: Photo 5: Text
The number of tens: intensity
0: default value
1 to 9: when the value increases,
the image becomes sharper.
• In case of Te xt/Photo mode (code
620),
2 1
Fixed value for the Text/
Photo mode
Enter a number (0 to 9)
Set whether the value of the
background peak and text peak are
fixed or not.
If they are fixed, the range
correction is performed with
standard values.
The values of the background peak
and text peak affect the
reproduction of the background
density and text density respectively.
Paper size for bypass
feed
Paper size for upper cas-
225
sette
226
Paper size for lower cassette
227
Paper size for PFP upper cassette
228
Paper size for PFP lower
cassette
ALL–13 digits
ALL0:EUR0~2
1:UC
2:JPN
ALL00~3
ALL00~1
ALL30~10
ALL110~15
ALL90~20
ALL00~4
ALLUNDEF0~255
ALLJPN:A40~255
UC: LT
EUR:A4
ALLJPN:A30~255
UC: LD
EUR:A3
ALL JPN:A4-R0~255
UC: LT-R
EUR:A4-R
ALLJPN:B40~255
UC: LG
EUR:A4
Setting mode (08)
Accept-
able
Value
Year / month / date / day / hour / minute / second
Example: 00 03 01 5 13 27 49
0:EUR 1:UC 2:JPN
0: External copy counter not used
1: Coin controller
2: Copy key card
3: Key copy counter
0: For factory shipment 1: For line
*Field: ‘0' must be selected
*Need to be checked when K-SRAM
was changed.
Timer to return the machine to the default
settings when the [START] key is not
pressed after the function and mode were
set.
0: Max. (150 sec.)
1 to 10: Set number X 15 sec.
Timer to automatically switch to the energy saving mode when the copier has
not been used.
0: Disabled 1: 30sec. 2: 60sec. 3: 90sec.
4: 120sec. 5: 150sec. 6: 3min. 7: 4min.
8: 5min. 9: 7min. 10: 10min. 11: 15min.
12: 20min. 13: 30min. 14: 45min. 15: 60min.
Timer to automatically turn OFF the power
when the copier has not been used.
0: 3min. 1: 5min. 2: 10min. 3: 15min.
4: 20min. 5: 25min. 6: 30min. 7. 40min
8. 50min. 9: 60min. 10: 70min. 11. 80min.
12. 90min. 13. 100min. 14. 110min.
15. 120min. 16. 150min 17. 180min.
18. 210min. 19. 240min. 20. Not used
0: Language1 1: Language2
2: Language3 3: Language4
4: Language5
Press the icon on the LCD to select the
size
Press the icon on the LCD to select the
size