Manual Servicio Field

FrameMaker Ver5.5E(PC) COVER [FIELD] FOR CF1501/CF200118.01.2001

CF1501/CF2001

SERVICE MANUAL

[FIELD]

400-47991-11

FrameMaker Ver.5.5E(PC) PL/PS Standard Document Ver.0100.09.13

Safety Precautions for Inspection and Service

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

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

1. Always observe precautions.

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

3. Use the specified parts.

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

5. Be careful with the high-voltage parts.

6. Do not work with wet hands.

WARNING

• Parts requiring special attention in this product will include a label containing themark shown on the left plus precautionary notes. Be sure to observe the precau-tions.

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

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

• The product also contains parts that can jerk suddenly and cause injury.• If this product uses a laser, laser beam leakage may cause eye damage or

blindness.

• For replacement parts, always use the genuine parts specified in the manufac-turer’s parts manual. Installing a wrong or unauthorized part could cause dielec-tric breakdown, overload, or undermine safety devices resulting in possibleelectric shock or fire.

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

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

• Do not use a multiple outlet to which any other appliance or machine is con-nected.

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

• A part marked with the symbol shown on the left carries a high voltage. Touch-ing it could result in an electric shock or burn. Be sure to unplug the power cordbefore servicing this part or the parts near it.

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

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7. Do not touch a high-temperature part.

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

9. Do not remodel the product.

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

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

• Wait until these parts have cooled down before replacing them or any surround-ing parts.

• Be sure to connect the ground wire to the ground terminal even when perform-ing an inspection or repair. Without proper grounding, electrical leakage couldresult in an electric shock or fire.

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

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

• To promote safety and prevent product damage, make sure the harnesses arereturned to their original positions and properly secured in their clamps and sad-dles in order to avoid hot parts, high-voltage parts, sharp edges, or beingcrushed.

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

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1. Precautions for Service Jobs

2. Precautions for Servicing with Covers and Parts Removed

3. Precautions for the Working Environment

4. Precautions for Handling Batteries (Lithium, Nickel-Cadmium, etc.)

CAUTION

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

• When reassembling parts, make sure that the correct screws (size, type) areused in the correct places. Using the wrong screw could lead to strippedthreads, poorly secured parts, poor insulating or grounding, and result in a mal-function, electric shock or injury.

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

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

• Wherever feasible, keep all parts and covers mounted when energizing theproduct.

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

• Never place disassembled parts or a container of liquid on the product. Partsfalling into, or the liquid spilling inside, the mechanism could result in an electricshock or fire.

• Never use a flammable spray near the product. This could result in a fire.• Make sure the power cord is unplugged before removing or installing circuit

boards or plugging in or unplugging connectors.• Always use the interlock switch actuating jig to actuate an interlock switch when

a cover is opened or removed. The use of folded paper or some other objectmay damage the interlock switch mechanism, possibly resulting in an electricshock, injury or blindness.

• The product must be placed on a flat, level surface that is stable and secure.• Never place this product or its parts on an unsteady or tilting workbench when

servicing.• Provide good ventilation at regular intervals if a service job must be done in a

confined space for a long period of time.• Avoid dusty locations and places exposed to oil or steam.• Avoid working positions that may block the ventilation ports of the product.

• Replace a rundown battery with the same type as specified in the manufac-turer’s parts manual.

• Before installing a new battery, make sure of the correct polarity of the installa-tion or the battery could burst.

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

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

• When handling circuit boards, observe the “HANDLING of PWBs”.• The PC Drum is a very delicate component. Observe the precautions given in “HAN-

DLING OF THE PC DRUM” because mishandling may result in serious image problems.• Note that replacement of a circuit board may call for readjustments or resetting of partic-

ular items, or software installation.

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

• If removing this cover while the power is ON is unavoidable, be sure to wearprotective laser goggles that meet specifications.

• Make sure that no one enters the room when the machine is in this condition.• When handling the laser unit, observe the “Precautions for Handling Laser

Equipment.”

DANGERInvisible laser radiation when open.

AVOID DIRECT EXPOSURETO BEAM

0947-7127-01

1144D270AA

1167P001AA

Other Precautions

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ALL AreasCAUTION

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

GermanyVORSICHT!

Explosionsgefahr bei unsachgemäßem Austausch der Batterie.Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ.Entsorgung gebrauchter batterien nach Angaben des Herstellers.

FranceATTENTION

Ily a danger d’explosion s’ily a remplacement incorrec de la batterie.Remplacer uniquement avec une batterie du meme type ou d’un type équivalent recom-mande par le constructueur.Mettre au rebut les batteries usageés conformément aux instructions du fabricant.

DenmarkADVARSEL!

Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med bat-teri af samme fabrikat og type.Levér det brugte batteri tilbage til leverandøren.

NorwayADVARSEL

Eksplosjonsfare ved feilaktig skifte av batteri.Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

SwedenVARNING

Explosionsfara vid felaktigt batteribyte.Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-tillverkaren.Kassera använt batteri enligt fabrikantens instruktion.

FinlandVAROlTUS

Paristo voi räjähtää, los se on virheellisesti asennettu.Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä Käytetty paristovalmistajan ohjeiden mukaisesti.

Used Batteries Precautions

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Precautions for Service

When performing inspection and service procedures, observe the following precautions toprevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply.

• When the user is using a word processor or personal computer from a wall outlet of thesame line, take necessary steps to prevent the circuit breaker from opening due to over-loads.

• Never disturb the LAN by breaking or making a network connection, altering termination,installing or removing networking hardware or software, or shutting down networkeddevices without the knowledge and express permission of the network administrator orthe shop supervisor.

1. DIS/REASSEMBLY, ADJUSTMENT• To reassemble the product, reverse the order of disassembly unless otherwise specified.2. TROUBLESHOOTING• If a component on a PWB or any other functional unit including a motor is defective, the

text only instructs you to replace the whole PWB or functional unit and does not givetroubleshooting procedures applicable within the defective unit.

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

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

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

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

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

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

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

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

Precautions Before Service

How to Use this Book


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• Be sure to unplug the copier from the outlet before attempting to service the copier.• The basic rule is not to operate the copier anytime during disassembly. If it is absolutely

necessary to run the copier with its covers removed, use care not to allow your clothingto be caught in revolving parts such as the timing belt and gears.

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

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

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

• Never use flammable sprays near the copier.• A used battery should be disposed of according to the local regulations and never be dis-

carded casually or left unattended at the user’s premises.• When reassembling parts, make sure that the correct screws (size, type) and toothed

washer are used in the correct places.• If it becomes necessary to replace the thermal fuse or any other fuse mounted on a

board, be sure to use one of the rating marked on the blown fuse. Always note the ratingmarked on the fuse, as the rating and mounting site or number used are subject tochange without notice.

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

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

Precautions for Dis/Reassembly

Precautions for Circuit Inspection

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1. During Transportation/Storage:• During transportation or when in storage, new P.W. Boards must not be indiscriminately

removed from their protective conductive bags.• Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem-

perature.• When it becomes absolutely necessary to remove a Board from its conductive bag or

case, always place it on its conductive mat in an area as free as possible from static elec-tricity.

• Do not touch the pins of the ICs with your bare hands.• Protect the PWBs from any external force so that they are not bent or damaged.

2. During Inspection/Replacement:• Avoid checking the IC directly with a multimeter; use connectors on the Board.• Never create a closed circuit across IC pins with a metal tool.• Before unplugging connectors from the P.W. Boards, make sure that the power cord has

been unplugged from the outlet.• When removing a Board from its conductive bag or conductive case, do not touch the

pins of the ICs or the printed pattern. Place it in position by holding only the edges of theBoard.

• When touching the PWB, wear a wrist strap and connect its cord to a securely groundedplace whenever possible. If you cannot wear a wrist strap, touch a metal part to dis-charge static electricity before touching the PWB.

• Note that replacement of a PWB may call for readjustments or resetting of particularitems.

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

Handling of PWBs

Handling of Other Parts

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Only for Products Not Employing an Imaging Cartridge.1. During Transportation/Storage:• Use the specified carton whenever moving or storing the PC Drum.• The storage temperature is in the range between –20°C and +40°C.• In summer, avoid leaving the PC Drum in a car for a long time.

2. Handling:• Ensure that the correct PC Drum is used.• Whenever the PC Drum has been removed from the copier, store it in its carton or pro-

tect it with a Drum Cloth.• The PC Drum exhibits greatest light fatigue after being exposed to strong light over an

extended period of time. Never, therefore, expose it to direct sunlight.• Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger-

prints, and other foreign matter.• Do not scratch the surface of the PC Drum.• Do not apply chemicals to the surface of the PC Drum.• Do not attempt to wipe clean the surface of the PC Drum.

If, however, the surface is contaminated with fingerprints, clean it using the following proce-dure.

Handling of the PC Drum

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

1076D001

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

A. Turn the PC Drum so that the area of its surface onwhich the line of toner left by the Cleaning Blade ispresent is facing straight up. Wipe the surface inone continuous movement from the rear edge ofthe PC Drum to the front edge and off the surfaceof the PC Drum.

B. Turn the PC Drum slightly and wipe the newlyexposed surface area with a CLEAN face of theDust-Free Cotton Pad. Repeat this procedure untilthe entire surface of the PC Drum has been thor-oughly cleaned.

At this time, always use a CLEAN face of the dryDust-Free Cotton Pad until no toner is evident on theface of the Pad after wiping.

1076D002

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N O T E S• Even when the PC Drum is only locally dirtied, wipe the entire surface.• Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under

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

time.

Only for Products Employing an Imaging Cartridge.1. During Transportation/Storage:• The storage temperature is in the range between –20°C and +40°C.• In summer, avoid leaving the Imaging Cartridge in a car for a long time.

2. Handling:• Store the Imaging Cartridge in a place that is not exposed to direct sunlight.

3. Precautionary Information on the PC Drum Inside the Imaging Cartridge:• Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger-

prints, and other foreign matter.• Do not scratch the surface of the PC Drum.• Do not attempt to wipe clean the surface of the PC Drum.

3. Soak a small amount of either ethyl alcohol or iso-propyl alcohol into a clean, unused Dust-Free Cot-ton Pad which has been folded over into quarters.Now, wipe the surface of the PC Drum in one con-tinuous movement from its rear edge to its frontedge and off its surface one to two times.

Never move the Pad back and forth.

1076D003

4. Using the SAME face of the Pad, repeat the proce-dure explained in the latter half of step 3 until theentire surface of the PC Drum has been wiped.Always OVERLAP the areas when wiping. Twocomplete turns of the PC Drum would be appropri-ate for cleaning.

1076D004

Handling of the Imaging Cartridge

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FrameMaker Ver.5.5(PC) CF1501/CF200100.12.25

DIS/REASSEMBLY,ADJUSTMENT

SWITCHES ON PWBs,TECH. REP. SETTINGS

UNIT REPLACEMENTMANUAL

TROUBLESHOOTING

INSTALLATION

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INSTALLATION

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1 Installation

1.1 INSTALLATION CF1501 / CF2001 - - - - - - - - - - - - - - I-11.1.1 Unpacking the accessories - - - - - - - - - - - - - - - - - - - - - - - - I-1

1.1.2 Unpacking the Printer - - - - - - - - - - - - - - - - - - - - - - - - - - - I-1

1.1.3 Removing the protective tape and packing materials - - - - - - I-2

Paper Feed Section - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

1.1.4 Installing the Imaging Cartridges - - - - - - - - - - - - - - - - - - - - I-5

1.1.5 Installing the Oil-Coating Unit - - - - - - - - - - - - - - - - - - - - - - I-8

1.1.6 Filling the Toner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-11

1.1.7 If the copy desk, copy table or Large-capacity cabinetis to be used together with the copier stand - - - - - - - - - - - I-14

1.1.8 Connecting the Scanner - - - - - - - - - - - - - - - - - - - - - - - - - I-16

1.1.9 Installing the Manual Holder - - - - - - - - - - - - - - - - - - - - - - I-18

1.1.10 Checking the operation of the printer - - - - - - - - - - - - - - - - I-19

Loading Paper for a Test Print - - - - - - - - - - - - - - - - - - I-19

Connecting the Power Cord - - - - - - - - - - - - - - - - - - - - - 20

Turning On the Copier - - - - - - - - - - - - - - - - - - - - - - - - 21

Adjusting the Touch Panel Position - - - - - - - - - - - - - - - 22

Setting the CD and FD Magnification - - - - - - - - - - - - - - 23

Setting the Gradation Adjustment - - - - - - - - - - - - - - - - - 25

Making a Test Copy - - - - - - - - - - - - - - - - - - - - - - - - - - 27

Printing a copy of the test chart - - - - - - - - - - - - - - - - - - 27

1.1.11 Making System Settings - - - - - - - - - - - - - - - - - - - - - - - - - I-29

Specifying who performs replacements - - - - - - - - - - - - 29

Specifying the Serial Number - - - - - - - - - - - - - - - - - - - 30

Checking the Date Setting - - - - - - - - - - - - - - - - - - - - - - 31

Printing the List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

1.1.12 Loading Paper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-34

1st Drawer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34

2nd Drawer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

1.1.13 Turning Off the Copier - - - - - - - - - - - - - - - - - - - - - - - - - - I-36

1.1.14 Disconnecting the Power Cord - - - - - - - - - - - - - - - - - - - - I-37

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1.2 INSTALLATION AFR-16 - - - - - - - - - - - - - - - - - - - - I-381.2.1 Installing the Contents of the Duplexing Document Feeder Kit H

I-38

1.2.2 Unpacking the Duplexing Document Feeder - - - - - - - - - - I-41

1.2.3 Installing the Duplexing Document Feeder - - - - - - - - - - - - I-41

1.2.4 Checking for and correcting skewed feeding - - - - - - - - - - I-43

1.2.5 Checking and adjusting the scanning position of asingle-sided document I-44

1.2.6 Adjusting the scanning position of a single-sideddocument - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-45

1.2.7 Checking and adjusting the scanning position of adouble-sided document I-47

1.2.8 Adjusting the scanning position of a double-sideddocument I-48

1.2.9 Checking and adjusting the scanning position of amanually fed document - - - - - - - - - - - - - - - - - - - - - - - - - I-49

1.2.10 Adjusting the scanning position of a manually feddocument - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-50

1.2.11 Checking and adjusting the position of the fixeddocument guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-51

1.2.12 Checking and adjusting the position of the fixeddocument guide in the manual document feed slot - - - - - - I-52

1.2.13 Securing the stoppers - - - - - - - - - - - - - - - - - - - - - - - - - - I-53

1.3 INSTALLATION SCANNER - - - - - - - - - - - - - - - - - I-541.3.1 Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-54

1.3.2 Unpacking the Scanner - - - - - - - - - - - - - - - - - - - - - - - - - I-55

1.3.3 Removing the protective tape - - - - - - - - - - - - - - - - - - - - - I-55

1.3.4 Removing the packing materials - - - - - - - - - - - - - - - - - - - I-56

1.3.5 If the optional copier stand is used - - - - - - - - - - - - - - - - - I-58

1.3.6 If the Optional Sorter or Finisher Is To Be Used TogetherWith the Optional Copier Stand I-60

1.3.7 Connecting the Cables - - - - - - - - - - - - - - - - - - - - - - - - - I-61

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1.4 INSTALLATION COPY TABLE (CT-2)COPY DESK(CD-2M) I-621.4.1 Unpacking the Copy Table - - - - - - - - - - - - - - - - - - - - - - - I-62

1.4.2 Unpacking the Copy Desk - - - - - - - - - - - - - - - - - - - - - - - I-63

1.4.3 Installing the Copy Table/Copy Desk - - - - - - - - - - - - - - - - I-64

1.4.4 Adjusting the Adjusters - - - - - - - - - - - - - - - - - - - - - - - - - I-65

1.4.5 Attaching the paper feed unit to the copy table - - - - - - - - - I-65

1.4.6 Attaching the paper feed unit to the copy desk - - - - - - - - - I-66

1.4.7 If the Copy Desk or Copy Table Is To Be UsedTogether With the Copier Stand I-67

1.5 INSTALLATION JS-1002- - - - - - - - - - - - - - - - - - - - I-691.5.1 Unpacking the 10-Mailbin Sorter - - - - - - - - - - - - - - - - - - - I-70

1.5.2 Installing the Accessories - - - - - - - - - - - - - - - - - - - - - - - - I-71

1.5.3 Unpacking the Horizontal Transport Unit - - - - - - - - - - - - - I-74

1.5.4 Installing the Horizontal Transport Unit - - - - - - - - - - - - - - I-74

1.5.5 Adjusting the Tilt of the 10-Mailbin Sorter - - - - - - - - - - - - - I-76

1.5.6 Installing the shelves and connecting the hookup cord - - - I-77

1.5.7 Removing the Rail - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-77

1.6 Installation AD-14 - - - - - - - - - - - - - - - - - - - - - - - - I-781.6.1 Unpacking the duplex unit - - - - - - - - - - - - - - - - - - - - - - - I-78

1.6.2 Preparing to install the duplex unit - - - - - - - - - - - - - - - - - - I-79

1.6.3 Installing the duplex unit - - - - - - - - - - - - - - - - - - - - - - - - - I-81

1.6.4 Checking and adjusting the paper reference position - - - - I-83

1.7 INSTALLATION PF-118 - - - - - - - - - - - - - - - - - - - - I-851.7.1 Unpacking the paper feed unit - - - - - - - - - - - - - - - - - - - - I-85

1.7.2 Connecting the Optional Paper Feed Unit to the Copier - - I-86

1.7.3 Loading Paper into the Paper Feed Unit - - - - - - - - - - - - - I-90

1.7.4 Affixing the Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-91

1.7.5 Checking the Paper Reference Position - - - - - - - - - - - - - - I-91

1.7.6 Adjusting the Paper Reference Position - - - - - - - - - - - - - - I-93

1.8 INSTALLATION PF-117 - - - - - - - - - - - - - - - - - - - - I-951.8.1 Unpacking the large capacity cabinet - - - - - - - - - - - - - - - I-95

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1.8.2 Installing the stoppers - - - - - - - - - - - - - - - - - - - - - - - - - - I-97

1.8.3 Adjusting the Adjusters - - - - - - - - - - - - - - - - - - - - - - - - - I-97

1.8.4 Installing the Large Capacity Cabinet - - - - - - - - - - - - - - - I-98

1.8.5 If the Large Capacity Cabinet Is to be usedtogether with the Copier Stand I-101

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1.8.6 Specifying the Paper Size - - - - - - - - - - - - - - - - - - - - - - I-102

1.8.7 Checking and Adjusting the Paper Reference Position - - I-104

1.9 INSTALLATION FN-107 / 108 - - - - - - - - - - - - - - - I-1061.9.1 Before Setting Up the Finisher - - - - - - - - - - - - - - - - - - - I-106

1.9.2 Unpacking the Finisher - - - - - - - - - - - - - - - - - - - - - - - - I-107

1.9.3 Installing the accessoriesif the copier stand is not used I-109

1.9.4 Installing the AccessoriesIf the copier stand is used - - - - - - - - - - - - - - - - - - - - - - I-110

1.9.5 Unpacking the horizontal transport unit - - - - - - - - - - - - - I-112

1.9.6 Installing the horizontal transport unit - - - - - - - - - - - - - - I-112

1.9.7 Adjusting the height and tilt of the finisher - - - - - - - - - - - I-113

1.9.8 Connecting the Hookup Cord - - - - - - - - - - - - - - - - - - - - I-114

1.9.9 Affixing the Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-115

1.9.10 Installing the Tray and Protective Guide - - - - - - - - - - - - I-115

1.9.11 Checking the Hole-Punching Positions (FN-107 only) - - - I-116

1.9.12 Adjusting the Hole-Punching Positions (FN-107 only) - - - I-116

1.9.13 Removing the Rail - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-117

1.10 INSTALLATION INTERFACE KIT-E - - - - - - - - - - I-1181.10.1 UNPACKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-118

1.10.2 Installing the Circuit Board Assembly - - - - - - - - - - - - - - I-118

1.11 INSTALLATION INTERFACE KIT-I - - - - - - - - - - - I-1191.11.1 UNPACKING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I-119

1.11.2 Installing the Cooling-Air Duct - - - - - - - - - - - - - - - - - - - I-119

1.11.3 Installing the Circuit Board Assembly - - - - - - - - - - - - - - I-120

1.11.4 Install the Control Panel for the Internal Controller - - - - - I-121

1.12 INSTALLATION M128-2 (DIMM) - - - - - - - - - - - - - I-1231.12.1 Unpacking the Expansion Memory (DIMM) - - - - - - - - - - I-123

1.12.2 Installing the Expansion Memory - - - - - - - - - - - - - - - - - I-123

1.13 INSTALLING THE MECHANICAL COUNTER - - - I-125

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1 INSTALLATION

1.1 INSTALLATION CF1501 / CF2001

1.1.1 Unpacking the accessories

1. Remove the accessories from the box, and then check that the following areenclosed.

1) Imaging cartridges......................................42) Waste toner bottle ......................................43) Power cord *1.............................................14) LED cleaning tool *2...................................15) LED cleaning papers *2..............................56) Manual holder.............................................17) Operator’s Manual......................................18) Setup Instructions (this manual).................19) Quick Guide................................................110) Warranty card.............................................111) Power cord instruction *3 ...........................112) Paper size label..........................................1

*1 North America and Philipine only.

*2 The LED cleaning tool and its papers are not used during setup. Since theywill be needed when the imaging cartridge is changed or the printer is cleaned,keep them in a safe place for later use.

*3 Except North America, Taiwan and Saudi Arabia.

1.1.2 Unpacking the Printer

1. Remove the printer from the plastic bag.

2. Open the two handle covers, and then pull out the handles.

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3. Grasp the two handles on the right side of theprinter and the two grips on the left (as shownin the illustration), and then, while keeping theprinter level, remove it from its box.

NOTE

The printer weighs about 77 kg (169-3/4 lbs.).The printer must be lifted by at least two people.When lifting the printer, be careful not to strainyour back.

4. Carefully place the printer on a level andsturdy surface, such as a table.

1.1.3 Removing the protective tape and packing materials

Outside surface of the Printer

1. Remove the tape affixed to the outsidesurface of the printer.

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Inside of the Printer

2. Grasp the handle of the front door, and thencarefully swing the door open to the right asshown.

3. Pinch the release lever for an imagingcartridge.

4. Swing the release lever toward you.

5. Remove the packing material from theimaging cartridge slot.

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6. Remove the packing materials from the otherthree imaging cartridge slots as described insteps 3 through 5.

7. Carefully swing each of the release leversback up to their original positions, pushingthem in until they lock into place.

NOTE

If the release levers are not correctly positioned,the front door cannot be closed.

8. Carefully swing the front door closed, makingsure that it is securely shut.

1.1.3.1 Paper Feed Section

1. Pull out the paper drawer for the 1st drawer.

NOTE

Be careful not to touch the surface of the papertake-up roller with your hands. If the roller hasbeen touched, wipe it with a dry cloth.

2. Remove the 2 pieces of tape shown in theillustration from the paper-lifting plate.

3. Remove the 2 pieces of packing material fromthe paper-lifting plate.

4. Close the paper drawer.

Packing material

paper take-uproller

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5. Pull out the paper drawer for the 2nd drawer.

NOTE

Be careful not to touch the surface of the papertake-up roller with your hands. If the roller hasbeen touched, wipe it with a dry cloth.

6. Remove the tape affixed to the paper-liftingplate as shown.

7. Remove the packing material from the paper-lifting plate.


1.1.4 Installing the Imaging Cartridges

1. Grasp the handle of the front door, and thencarefully swing the door open to the right asshown.

2. Pinch the release lever for the yellow imagingcartridge. (The colors of the imagingcartridges are, from the left, yellow, magenta,cyan, and black.)

3. Swing the release lever toward you.

paper take-uproller

Packingmaterial

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4. Remove the yellow imaging unit from its boxand its protective plastic bag, and then placethe imaging unit on a stable, level surface,such as a table.

NOTE

The imaging unit can easily be damaged by light.Therefore, leave the imaging unit in its protectiveplastic bag until immediately before it is to beinstalled.When holding the imaging unit, be sure to hold itby its bottom cover. If the top imaging unit coveris held, it may fall off or the PC drum installed onthe imaging unit may become damaged, resultingin decreased image quality.

5. Remove the protective tape from the imagingunit.

6. Keeping the imaging unit level, pick it up bysupporting it on the bottom with your left handand on the bottom at the front with your righthand.

7. Keeping the imaging unit level, insert theimaging unit as far as possible into theimaging unit compartment. Be sure to insertthe imaging unit until the end of the bottomimaging unit cover contacts the back of theimaging unit compartment.

Protective tape

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NOTE

Do not insert the imaging unit into the compart-ment at an angle.

8. While keeping the bottom of the imagingcartridge supported with your left hand,carefully insert the imaging cartridge withyour right hand, as shown, until the cartridgesnaps into place.

9. Pull out the empty imaging cartridge cover.

10. Separate the top and bottom halves of theempty imaging cartridge cover.

NOTE

Since the bottom half of the imaging cartridgecover will be used when the imaging cartridge isreplaced again, store it in a safe place.

11. Carefully swing the release lever back up toits original position, pushing it in until it locksinto place.

Bottom cover

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12. Install the magenta, cyan, and black imagingcartridges in the same way (as described insteps 2 through 11).

NOTE

Be sure to install the imaging cartridges in theircorrect slots.

13. After all four imaging cartridges have beeninstalled, grasp the handle of the front door,and then carefully swing the door closed asshown.

1.1.5 Installing the Oil-Coating Unit

1. Pull up on the right-side door release lever toopen the right-side door.

NOTE

Do not to touch the surface of the image transferbelt at the bottom of the fusing unit; otherwise,decreased image quality may result.

2. Grasp the upper right-side door as shown,and then carefully open the door completelywhile making sure to support it.

Image transfer belt

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NOTE

Be sure to support the upper right-side door whilecarefully opening it; otherwise, it may becomedamaged.

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NOTE

Do not touch the metal terminals at the front ofthe fusing unit; otherwise, damage may occurdue to static electricity.

3. Remove the two pieces of tape from the locklevers of the oil-coating unit shown.

4. Remove the oil-coating unit from its box.

NOTE

When picking up the oil-coating unit, pick it up bythe two handles (one on each end of the unit) withboth hands.

5. Insert the oil-coating unit, making sure thatthe two pins (one on each end of the unit) fitinto the notches in the copier.

6. Swing the oil-coating unit up to install it.

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7. Secure the oil-coating unit by moving the twolock levers (one on each end of the unit)toward you.

8. Grasp the upper right-side door as shown,and then carefully close it.

9. Carefully close the right-side door.

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1.1.6 Filling the Toner

NOTE

Be careful not to spill toner inside the printer or get toner on your clothes and hands.If toner gets on your hands, wash them using water and a neutral soap. If toner getsin your eyes, immediately rinse them, and then consult a medical professional.

1. Grasp the toner hopper door as shown, andthen carefully swing the door up to open it.

2. Open the yellow toner hopper lid (leftmost) byswinging it toward you. (The toner hopper lidsare, from the left, yellow, magenta, cyan, andblack.)

3. Remove the yellow toner bottle from itspackaging. Hit the bottom of the bottle againsta strong surface, such as a desk or table, fouror five times from a height of about 10 cm(4in.). (Since the toner within the bottle mayhave become compacted, be sure to break itup by performing this step.)

NOTE

Be sure to hit the bottom of the toner bottleagainst the strong surface (the opening of thebottle should be pointing up).

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4. While holding the bottle securely, shake itwell in all directions to mix up the toner.

5. With the rounded side (marked with “”) ofthe bottle mouth facing towards you, placethe toner bottle on top of the hopper, and thenpress down on the bottle until it snaps intoplace.

6. Fully pull the toner hopper shutter out towardyou. Pulling out the toner hopper shutterallows the toner to begin filling the tonerhopper. Check that all of the toner hasemptied out of the toner bottle and into thehopper, which may take a while.

NOTE

Do not tap on the toner bottle while refilling thehopper; otherwise, the toner may spurt out.

7. Push the toner hopper shutter closed until itsnaps into place and closes the bottle.

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8. Tilt the toner bottle slightly backward, andthen pull the opening of the bottle up andtoward you to remove it.

9. Carefully close the yellow toner hopper lid.

10. Fill the magenta, cyan, and black toner in thesame way (as described in steps 2 through8).

NOTE

Be sure to fill the toner hoppers with the correctcolor of toner.

11. After all four toner hoppers are filled, graspthe toner hopper door as shown, and thencarefully swing the door down to close it.

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1.1.7 If the copy desk, copy table or Large-capacity cabinet is to be usedtogether with the copier stand

NOTE

If the optional copy desk, copy table or large-capacity cabinet is to be used togetherwith the optional copier stand, set up the copier stand as described below.For details on attaching the scanner to the copier stand, refer to the scanner’sUnpacking/Setup Instructions. In addition, for details on installing the copy desk,copy table or large-capacity cabinet, refer the corresponding manual.

1. Make sure that the supports for the optionalcopy desk and copy table are not installed. Ifthe supports are installed, remove them.

2. Position the scanner (attached to the copierstand) over the printer (attached to the copydesk, copy table or large-capacity cabinet).(The illustration shows the copy desk usedwith the copier stand.)

3. Turn the adjusters on the copier stand (one on each leg) until the four holes inthe copier stand align with the holes in the lower unit (large-capacity cabinet,copy desk, or copy table).

4. Attach the lower unit (copy table or copy desk) to the copier stand using the fourscrews supplied with the copier stand. Lightly tighten the screws.

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NOTE

If the large-capacity cabinet or copy table is installed, insert the two spacers(supplied with the copier stand) as shown.

5. Firmly tighten the four screws installed in step 4.

6. Install the five decorative covers supplied with the copier stand.

Spacer

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1.1.8 Connecting the Scanner

NOTE

Make sure that the scanner is completely set up. If the scanner is not set up, set itup according to the Unpacking/Setup Instructions supplied with the scanner.

1. If the copier stand is installed, pass one endof the interface cable under the frame of thecopier stand.

2. Insert the connector on the scanner’sinterface cable into the interface connector onthe printer.

NOTE

Be sure to insert the cable connectors straightinto the connectors on the units; otherwise, theconnectors may become damaged.

3. Tighten the two connector-securing screwsusing your fingers, and then firmly tighten thescrews using a screwdriver.

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4. Affix the cable clamp supplied with thescanner as shown. Then, secure the interfacecable with the cable clamp.

NOTE

Secure the interface cable so that the bend in theinterface cable is between 10 and 30mm(between 1/2 in. and 1-1/4 in.) from the bottom ofthe scanner.

5. If the copier stand is installed, pull the plug ofthe scanner’s power cord down, passing itbetween the printer and the copier stand.

6. Insert the plug on the scanner’s power cordinto the power cord socket on the printer.

Cable clamp

10mm - 30mm1/2 - 1-1/4 in.

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1.1.9 Installing the Manual Holder

1. Insert the tab on the bottom of the manualholder into the slot in the side of the printer.

2. Insert the tabs on the left and right sides ofthe manual holder into the correspondingslots in the side of the printer.

NOTE

If the optional copier stand is used, attach themanual holder to the copier stand at the positionshown, using the same procedure describedabove.

NOTE

If the optional finisher is used, attach the manualholder to the back of the finisher at the positionshown, using the same procedure describedabove.

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1.1.10 Checking the operation of the printer

1.1.10.1 Loading Paper for a Test Print

NOTE

Load paper that will be used in the procedure described in “Setting the GradationAdjustment”.

1. Prepare A3-size paper or 11 × 17-size paperof the recommended type.


3. Press down on the paper-lifting plate until itlocks into place.

4. Slide the adjustable paper guides to the A3paper size or 11 × 17 paper size.

5. Load the paper into the drawer so that thefront side of the paper (the side facing upwhen the package was unwrapped) faces up.

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NOTE

Do not load so much paper that the top of thestack is higher than the mark indicating themaximum paper capacity.

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7. Turn the paper type dial on the drawer to thesetting for normal paper.

1.1.10.2 Connecting the Power Cord

1. Make sure that the power switch is set to “O”.

2. If the copier stand is installed, pass the plugof the power cord between the printer and thecopier stand.

3. Insert the plug on the power cord into thepower cord socket on the printer.

If the copier stand is installed, connect thepower cord as shown.

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4. Insert the plug on the other end of the powercord into an electrical outlet.

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1.1.10.3 Turning On the Copier

1. Set the power switch to “I”.

2. While the copier warms up, the message“Warming up. Pre-program a job.” isdisplayed on the touch panel. Warming uptakes about five minutes. After warming up isfinished, the message “Ready to copy”appears on the touch panel.

NOTE

If the message “Ready to copy” does not appearon the touch panel after the copier has beenturned on, the copier has not been set upcorrectly or is malfunctioning. Perform the setupprocedure again from the beginning.

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1.1.10.4 Adjusting the Touch Panel Position

1. Check that the Basic screen appears in thetouch panel.

2. Display the Touch Panel Adj. screen.(For details about displaying the Touch PanelAdj. screen, refer to the Service Manual.)

3. Touch each of the four “+” marks displayed inthe touch panel.(The marks can be touched in any order.)

4. Touch [OK].

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1.1.10.5 Setting the CD and FD Magnification

1. Check that “Ready to copy” appears in theBasic screen displayed in the touch panel.

2. Display the Tech. Rep. Mode screen. (Fordetails about displaying the Tech. Rep. Modescreen, refer to the Service Manual.)

3. Touch [Machine Adjust].

4. Touch [IR Area].

5. Touch [CD-Mag].

6. Carefully place the 200 mm scale on theoriginal glass parallel to the document widthscale (in the CD direction).

NOTE

Be careful not to scratch the original glass;otherwise, decreased image quality may result.

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7. If the optional document cover is installed,close the document cover, and then press the[Start] key.

8. Check that the length of the copied imagemeets its standard length.Standard length: 200±1 mm

9. If the length of the copied image does notmeet its standard length, touch [ ] and [ ] inthe lower-right corner of the screen to adjustthe CD magnification. Repeat steps 6 through8, and then check that the length of thecopied image meets its standard length.

10. Touch [FD-Mag].11. Carefully place the 300 mm scale on the

original glass parallel to the document widthscale (in the FD direction).

NOTE

Be careful not to scratch the original glass;otherwise, decreased image quality may result.

12. If the optional document cover is installed,close the document cover, and then press the[Start] key.

13. Check that the length of the copied imagemeets its standard length.Standard length: 300±1.5 mm

14. If the length of the copied image does notmeet its standard length, touch [ ] and [ ] inthe lower-right corner of the screen to adjustthe FD magnification. Repeat steps 11through 13, and then check that the length ofthe copied image meets its standard length.

15. Touch [Menu] to return to the Machine Adjustscreen, touch [Menu] to return to the Tech.Rep. Mode screen, and then touch [Fin.Time].

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1.1.10.6 Setting the Gradation Adjustment



3. Touch [Gradation Adjust].

4. Press the [Start] key to print the test patternon A3 paper or 11 × 17 paper.

NOTE

It takes about three minutes to print the testpattern.

NOTE

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If the test pattern is not printed, the copier has not been set up correctly or ismalfunctioning. Perform the setup procedure again from the beginning.

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5. Position the printed test pattern face down on the original glass.

6. Place about ten sheets of blank A3-sizepaper or 11 × 17-size paper on top of theprinted test page. If the optional documentcover is installed, close it.

7. Press the [Start] key to begin scanning thetest pattern.

NOTE

Pressing the [Start] key only scans the image; apage is not printed.

8. After the image is scanned, the Tech. Rep.Mode screen re-appears on the touch panel.

9. Repeat steps 3 through 8 to scan the testpattern three times.

10. Touch [Menu], and then touch [Fin. Time].

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1.1.10.7 Making a Test Copy

Position the test copy document or test chart

1. Prepare the test chart for making a test copy.

NOTE

For more details about positioning the document,refer to the Operator’s Manual.

2. Position the test chart face down on theoriginal glass.

3. Align the corner of the test chart with thearrow marks on the document width scalesabove and to the left of the original glass.

4. If the optional document cover is installed,close it

1.1.10.8 Printing a copy of the test chart

NOTE

For more details about making copies, refer tothe Operator’s Manual.


2. Press the [Start] key to begin the test copy.

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3. The test copy is fed out into the copy outputtray.

NOTE

If the test chart is not copied, the copier has notbeen set up correctly or is malfunctioning.Perform the setup procedure again from thebeginning.

4. Check that there is no banding in the halftoneareas of the printed test copy. If the image isnot printed correctly, for example if there isbanding, refer to the section “IMAGEFAILURE” in the Troubleshooting chapter ofthe Service Manual.

Halftone bands

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1.1.11 Making System Settings

1.1.11.1 Specifying who performs replacements

NOTE

The message that appears a unit must be replaced can be changed to indicate thateither the user or the service representative must perform the replacement. Selectthe appropriate settings depending on the type of servicing being performed.


2. Touch [System Input].

3. Touch [Unit Change].

4. Touch [User] or [Service] to select whethereach unit should be replaced by the user orthe service representative

5. Touch [END].


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1.1.11.2 Specifying the Serial Number

NOTE

Be sure to specify the serial number.When the serial number is specified, the settings for each unit can be read by theprinter. If the serial number is not specified, a correctly adjusted image cannot beprinted.


2. Touch [System Input].

3. Touch [Serial # Input].

4. Make sure that [Printer] is selected. Using thekeypad, enter the printer’s serial number

5. Touch [IR]. Using the keypad, enter thescanner’s serial number.Repeat this step to enter the serial numbersfor [ADF], [LCC], [Sorter/FN], [Duplex], and

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[Vender].6. Touch [END].7. Touch [Menu], and then touch [Fin. Time].

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1.1.11.3 Checking the Date Setting

1. Display the Date/Time Input screen. (Fordetails about displaying the Date/Time Inputscreen, refer to the Service Manual.).

2. Check that the current date and time settingsare correct. If the settings are not correct, usethe keypad to enter the correct date and timein the upper row of the screen.Example) To specify April 1, 2001 15:30,press:[2], [0], [0], [1], [0], [4], [0], [1], [1], [5], [3], [0]

3. Touch [END].

4. Touch [Menu].

5. Check that the Basic screen appears on thetouch panel.

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1.1.11.4 Printing the List

1. Prepare about 20 sheets of A4-size or Letter-size plain paper.


3. If any A3-size paper or 11 × 17-size paper(used for the test copy) still remains in thedrawer, remove it.


5. Slide the adjustable paper guides to the A4(L)paper size or Letter(L) paper size.

6. Load the prepared A4(L)-size or Letter(L)-size plain paper into the paper drawer.


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8. Make sure that the paper type dial on thedrawer is turned to the setting for normalpaper.



11. Touch [List Output].

12. Touch [Image Processing].

13. Press the [Start] key to print out a list of allimage-related settings and each countervalue on A4-size paper (portrait orientation).


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1.1.12 Loading Paper

NOTE

For more details about loading paper, refer to the Operator’s Manual.

1.1.12.1 1st Drawer

1. Prepare paper that meets this product’sspecifications.



4. Slide the adjustable paper guides to fit thesize of paper to be loaded.

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NOTE

Do not load so much paper that the top of thestack is higher than the mark indicating themaximum paper capacity.Be careful not to touch the surface of the papertake-up roller with your hands. If the roller hasbeen touched, wipe it with a dry cloth.

6. Close the paper drawer.7. Turn the paper type dial on the drawer to the

setting for the type of paper loaded.

1.1.12.2 2nd Drawer

1. Prepare paper that meets this product’sspecifications.

2. Pull out the paper drawer for the 2nd drawer.


4. Slide the adjustable paper guides to fit thesize of paper to be loaded.

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NOTE

Do not load so much paper that the top of thestack is higher than the mark indicating themaximum paper capacity.Be careful not to touch the surface of the papertake-up roller with your hands. If the roller hasbeen touched, wipe it with a dry cloth.

6. Close the paper drawer.7. Affix the enclosed paper size label to the 2nd

drawer as shown.8. Affix the enclosed drawer number label as

shown.

1.1.13 Turning Off the Copier

1. Set the power switch to “O”.

2. Check that the copier stops running and thatthe touch panel and all indicators go off.

Paper size label

Drawer number label

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1.1.14 Disconnecting the Power Cord

1. Make sure that the power switch is set to “O”.

2. Remove the plug on the power cord from theelectrical outlet.

3. Remove the power cord plug from the powercord socket on the printer.

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1.2 INSTALLATION AFR-16

When attaching the duplexing document feeder to the CF1501/CF2001, use the en-closed kit H, containing the following accessories:1) Conductive glass ..................................12) Document width scale...........................13) Scale holder (front) ...............................14) Scale holder (rear) ................................15) Springs..................................................26) Screws (3 mm × 8 mm) .......................27) Setup Instructions (this manual) ...........18) Seal.......................................................1

1.2.1 Installing the Contents of the Duplexing Document Feeder Kit H

1. Remove the original cover, the documentwidth scale, and the hinge covers (right andleft).

2. Remove the original glass.

1 2

3

45 6

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3. Install the conductive glass, making sure thatthe right end of the glass is inserted into theholders on the right side.

NOTE

Check that the holders at the right-front and -back corners contact the upper surface of theconductive glass.Check that the glass does not hit the frame of thecopier.

4. Attach the seal at the center of the documentwidth scale bracket.

5. Install the springs at the positions in thedocument width scale bracket as shown inthe illustration at the left.

NOTE

Insert the springs as far down as possible.

Holders

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6. Install the document width scale, making sureto align the notches in the document widthscale with the springs installed in step 5.

7. Align the holes in the scale holders (front andback) with the pins on the document widthscale.Attach the scale holders to the documentwidth scale using the two screws (3 mm x 8mm).

8. Check that the document width scale movessmoothly.

NOTE

Check that part A of the document width scale(shown in the illustration for step 6) fits under theconductive glass.

9. Slide the glass toward the document widthscale, then toward the back of the copier.

NOTE

Check that the holders at the right-front and -back corners contact the upper surface of theconductive glass.

Notch

A

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1.2.2 Unpacking the Duplexing Document Feeder

Remove the duplexing document feeder from its box, and then check that the fol-lowing accessories are also enclosed:1) Output tray...................................... 12) Flat-head screw.............................. 43) Shoulder-head screws.................... 1

1.2.3 Installing the Duplexing Document Feeder

1. Insert an enclosed flat-head screw into eachof the two center holes, and use a screwdriverto tighten the screws securely.

2. Install the duplexing document feeder asshown in the illustration.

NOTE

To install the duplexing document feeder, hold itvertically, and then lower it into position.

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3. Attach the hinges using two of the enclosed flat-head screws, and then use ascrewdriver to tighten the screws securely.

NOTE

Make sure that the flat-head screws are securely tightened.

4. Remove all accessories attached with tape tothe duplexing document feeder, and thenremove the hookup cord from its plastic bag.

5. Attach the output tray.

6. Secure the output tray with the enclosedshoulder-head screw from the bottom of theduplexing document feeder.

OK

NG

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7. Connect the hookup cord from the duplexingdocument feeder to the copier.

1.2.4 Checking for and correcting skewed feeding

Checking for skewed feeding

1. Turn on the copier.

2. Insert a piece of paper between the documentwidth scale and the scale holders, so that thedocument scale is lower than the surface ofthe original glass.

3. Select the following settings:Auto Paper size settingSingle-Sided Original/Single-Sided Copysettings.

4. Load one sheet of an A4-size or Letter-sizedocument lengthwise into the document feedtray.

5. Press the start key, and then press the stopkey as soon as scanning begins.

6. Gently open the duplexing document feeder.

NOTE

If the duplexing document feeder is openedquickly, the paper may slide out of place.

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7. Check if the paper on the original glass isskewed. If so, determine in which direction,and then measure distance “a” or “b” on thescale.Maximum allowable skew: 1.0 mm on thedocument width scaleIf the paper is skewed more than themaximum allowed, follow the procedure in thenext section, “Correcting Skewed Feeding”,to correct it.

Correcting skewed feeding

1. Loosen the flat-head screw securing each ofthe two hinges, and then loosen the screwson both sides of the flat-head screw on theright hinge.

2. In the case of an “a” measurement, slide theduplexing document feeder toward the backof the copier. In the case of a “b”measurement, slide the duplexing documentfeeder toward the front of the copier. Then,tighten the screws loosened in step 1.

1.2.5 Checking and adjusting the scanning position of a single-sideddocument

Checking the scanning position of a single-sideddocumen1. Insert a piece of paper between the document

width scale and the scale holders, so that thedocument scale is lower than the surface ofthe original glass.

2. Select the following settings:Auto Paper size settingSingle-Sided Original/Single-Sided Copy

a

b

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settings.


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NOTE


6. Determine the direction (“c” or “d”) andmeasure the distance from the edge of thepaper on the original glass to the edge of thescale.Maximum allowable distance: 1.0 to 3.0 mmin direction “d” from the edge of the scale.

If the paper is further from the scale than themaximum allowed, follow the procedure in thenext section, “Adjusting the ScanningPosition of a Single-sided Document”, toadjust it.

1.2.6 Adjusting the scanning position of a single-sided document

1. Display the Tech. Rep. Mode screen.(For details about displaying the Tech. Rep.Mode screen, refer to the Service Manual.)

2. Touch “ADF Check”.

3. Touch “Tech. Rep. Choice”.

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4. Touch “Original Stop Position”.

5. Touch “1-Sided Set”.

6. Press the C (clear) key, and then use thekeypad to enter the adjustment value.To switch between the positive and negativesigns, press the ID key.Higher + value: Moves the paper in directionCHigher – value: Moves the paper in directionD.

7. Press the Panel Reset key to display theTech. Rep. Mode screen, and then touch“Fin. Time”.Repeat the procedure in the previous section,“Checking the Scanning Position of a Single-sided Document”, to recheck the scanningposition.

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1.2.7 Checking and adjusting the scanning position of a double-sideddocument

Checking the scanning position of a double-sided document

1. Insert a piece of paper between the documentwidth scale and the scale holders, so that thedocument width scale is lower than thesurface of the original glass.

2. Select the following settings:Auto Paper size settingDouble-Sided Original/Single-Sided Copysettings.

3. Load one sheet of an A4-size (or Letter-size)document crosswise into the document feedtray.

4. Press the start key, and then press the stopkey as soon as scanning of the second sidebegins.


NOTE


6. Determine the direction (“c” or “d”) andmeasure the distance from the edge of thepaper on the original glass to the edge of thescale.Maximum allowable distance: 1.0 to 3.0 mmin direction "d" from the edge of the scale.

If the paper is further from the scale than themaximum allowed, follow the procedure in the

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next section, “Adjusting the ScanningPosition of a Double-sided Document”, toadjust it.

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1.2.8 Adjusting the scanning position of a double-sided document





5. Touch “2-Sided Set”.6. Press the C (clear) key, and then use the

keypad to enter the adjustment value.To switch between the positive and negativesigns, press the ID key.Higher + value: Moves the paper in directionC.Higher – value: Moves the paper in directionD.

7. Press the Panel Reset key to display the

I-48CF1501/2001 Rev. 1.1/01.01

Tech. Rep. Mode screen, and then touch“Fin. Time”.Repeat the procedure in the previous section,“Checking the Scanning Position of a Double-sided Document”, to recheck the scanningposition.

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1.2.9 Checking and adjusting the scanning position of a manually feddocument

Checking the scanning position of a manually fed document

1. Insert a piece of paper between the documentwidth scale and the scale holders, so that thedocument width scale is lower than thesurface of the original glass.

2. Select the following settings:Auto Paper size settingSingle-Sided Original/Single-Sided Copysetting.

3. Load one sheet of an A4-size (or Letter-size)document lengthwise into the manualdocument feed slot. Make sure to feed thedocument straight and aligned with the fixeddocument guide.

4. Press the stop key as soon as scanningbegins after the document is automaticallyfed.


NOTE


6. Determine the direction ("c" or "d") andmeasure the distance from the edge of thepaper on the original glass to the edge of thescale.Maximum allowable distance: 1.0 to 3.0 mmin direction "d" from the edge of the scale

If the paper is further from the scale than themaximum allowed, follow the procedure in the

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next section, “Adjusting the ScanningPosition of a Manually Fed Document”, toadjust it.

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1.2.10 Adjusting the scanning position of a manually fed document





5. Touch "Single Feed Set".6. Press the C (clear) key, and then use the

keypad to enter the adjustment value.To switch between the positive and negativesigns, press the ID key.Higher + value: Moves the paper in directionCHigher – value: Moves the paper in directionD.

7. Press the Panel Reset key to display the

I-50CF1501/2001 Rev. 1.1/01.01

Tech. Rep. Mode screen, and then touch“Fin. Time”.Repeat the procedure in the previous section,“Checking the Scanning Position of aManually Fed Document”, to recheck thescanning position.

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1.2.11 Checking and adjusting the position of the fixed document guide

Checking the position of the fixed document guide

1. Select the following settings:Auto Paper size settingSingle-Sided Original/Single-Sided Copysettings.




NOTE


5. Measure the distance of the edge of thepaper to the edge of the scale.Standard distance: 4.0 mm from the edge ofthe scaleIf the measured distance does not meet itsstandard distance, follow the procedure in thenext section, “Adjusting the Position of theFixed Document Guide”, to adjust it.

Adjusting the position of the fixed document guide

1. Move the fixed document guide either towardthe back or the front of the copier so that theedge of the paper will meet its standarddistance.Less than 3.0 mm: Move toward the front ofthe copier.More than 5.0 mm: Move toward the back ofthe copier.

A

B 4±1mm

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1.2.12 Checking and adjusting the position of the fixed document guide inthe manual document feed slot

Checking the position of the fixed document guide in the manual document feed slot

1. Select the following settings:Auto Paper size settingSingle-Sided Original>Single-Sided Copysettings

2. Load one sheet of an A4-size or Letter-sizedocument lengthwise into the manualdocument feed slot. Make sure to feed thedocument straight and aligned with the fixeddocument guide.

3. Press the stop key as soon as scanningbegins after the


NOTE


5. Measure the distance of the edge of thepaper to the edge of the scale.Standard distance: 4.0 ± 1.0 mm from theedge of the scaleIf the measured distance does not meet itsstandard distance, follow the procedure in thenext section, “Adjusting the Position of theFixed Document Guide in the ManualDocument Feed Slot”, to adjust it.

Adjusting the position of the fixed document guide in the manual documentfeed slot

1. Move the fixed document guide either towardthe back or the front of the copier so that theedge of the paper will meet its standarddistance.Less than 3.0 mm: Move toward the front of

A

B 4±1mm

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the copier.More than 5.0 mm: Move toward the back ofthe copier.

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1.2.13 Securing the stoppers

1. Remove the screw for each stopper, and thenscrew it into the top hole.

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1.3 INSTALLATION SCANNER

1.3.1 Unpacking

1) Scanner power cord...............................................12) Interface cable .......................................................13) Unpacking/Setup Instructions (this manual) ..........14) Cable holder ..........................................................1

The cable holder will be used when setting up the printer engine; therefore, be care-ful not to lose it.

1 2

3 4

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1.3.2 Unpacking the Scanner

1. Remove the plastic bag from the scanner.

2. Two people must lift the scanner as shown inthe illustration, and then, while keeping itlevel, remove it from its box.

NOTE

The scanner weighs about 23.0 kg (50-3/4 lbs.).It must be picked up by at least two people. Whenlifting the scanner, be careful not to strain yourback.

3. Carefully place the scanner on a levelsurface, such as a table.

NOTE

If the copier stand is not being used, be sure toinstall the five rubber feet (sold separately).

1.3.3 Removing the protective tape

1. Remove the tape affixed to the outsidesurface of the scanner.

2. Remove the two pieces of tape and theprotective material from the original glass

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1.3.4 Removing the packing materials

1. Turn the optical-unit-securing screw on theleft side of the scanner counterclockwise.

2. Remove the securing screw from the left.

3. Remove the two screws securing the right-side cover, and then remove the cover.

4. Remove the two screws securing the glassholders, and then remove the holde

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5. Remove the original glass.

NOTE

Make sure the original glass does not get dirty,for example from fingerprints; otherwisedecreased print quality may result.

6. Remove the four pieces of packing tape fromwithin the optical unit.

7. Remove the packing materials from within theoptical unit

NOTE

When removing the packing material from withinthe optical unit, be sure not to pull up on theharness connected to the top of the slider.If the harness is pulled up, push down on the areashown in the illustration to reposition the harness.

8. Install the original glass, making sure that theleft end of the glass fits under the documentwidth scale.

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9. Using the two screws, install the glassholders so that they secure the original glass.

NOTE

Make sure that the glass holders contact theback of the original glass.

10. Using the two screws, install the right-sidecover.

1.3.5 If the optional copier stand is used

NOTE

If the optional copier stand is used, install the scanner as described below.If the optional sorter or finisher is to be installed, perform the steps described in “3.If the Optional Sorter or Finisher Is To Be Used Together With the Optional CopierStand” before attaching the scanner to the copier stand.

1. Two people should lift the scanner.

2. While aligning the holes in the bottom of thescanner with the corresponding connectingpins on the copier stand, carefully place the

I-58CF1501/2001 Rev. 1.1/01.01

scanner on top of the stand.

NOTE

Be careful that your fingers are not caughtbetween the copier stand and the scanner.

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3. Install the two pipe ends supplied with thecopier stand.

4. Use the four screws supplied with the copierstand to secure the scanner.

5. Install the four covers supplied with the copierstand

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1.3.6 If the Optional Sorter or Finisher Is To Be Used Together With theOptional Copier Stand

NOTE

If the optional sorter or finisher is to be used together with the copier stand, set upthe copier stand as described below.

1. Remove the two screws securing the legextension of the copier stand.

2. Pull off the leg extension from the copierstand.

3. Remove the adjuster from the leg extension.

4. Install the adjuster removed in step 3 onto thecopier stand as shown.

5. Attach the scanner to the copier stand asdescribed in “2. If the Optional Copier Stand

I-60CF1501/2001 Rev. 1.1/01.01

Is Used”.

6. After the CF1501/CF2001 printer is set up,install the sorter or finisher.

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1.3.7 Connecting the Cables

1. Insert the connector on one end of theinterface cable into the interface connector onthe scanner.

NOTE

Be sure to insert the cable connector straight intothe connector on the scanner; otherwise, theconnectors may become damaged.

2. Tighten the two connector-securing screwsusing your fingers, and then firmly tighten thescrews using a screwdriver.

3. Insert the plug on the power cord into thepower cord socket on the scanner.

The scanner setup is now completed.

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Continue setting up the copier according to theinstructions in the Unpacking/Setup Instructionsfor the CF1501/CF2001 printer.

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1.4 INSTALLATION COPY TABLE (CT-2)COPY DESK(CD-2M)

1.4.1 Unpacking the Copy Table

If there are a total of four copier drawers and optional paper feed units, first installthe copy table, and then install the optional paper feed units.

1) Copy table..............................................................12) Stabilizers A...........................................................23) Stabilizer B.............................................................14) Stabilizers screws ..................................................35) Adjusters................................................................26) Fixing plates...........................................................47) Fixing plate screws ................................................48) Grounding plates (inside).......................................29) Grounding plate (right-front) ..................................110) Grounding plate screws .........................................311) Unpacking/Setup Instructions (this manual) ..........1

1

2 3

4

5 67

8 9 10

11

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1.4.2 Unpacking the Copy Desk

1) Copy desk ........................................................................ 12) Stabilizers A ..................................................................... 23) Stabilizer B ....................................................................... 14) Stabilizers screws............................................................. 15) Adjusters .......................................................................... 26) Fixing plates ..................................................................... 47) Fixing plate screws........................................................... 48) Grounding plates (inside) ................................................. 29) Grounding plate (right-front) ............................................. 110) Grounding plate screws.................................................... 311) Unpacking/Setup Instructions (this manual)..................... 1

1

2

43

5

67

11

8 910

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1.4.3 Installing the Copy Table/Copy Desk

NOTE

Be sure to attach the stabilizers; otherwise, theunit may become unbalanced and fall over,causing injuries.If the copier stand is used, do not install theadjusters and Stabilizers A and B; only install thegrounding plates.

1. Attach the three grounding plates (two insideand one at the right-front corner) to the copytable/copy desk at the positions shown in theillustrations at the left (using a groundingplate screw for each plate).

2. Using one screw for each stabilizers, attach the two stabilizers A and stabilizerB to the copy table or copy desk at the positions shown in the illustration below.

3. Attach the two adjusters to the copy table or copy desk at the positions shownin the illustration at the left.

Stabilizers A

Stabilizer B

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Adjusters

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1.4.4 Adjusting the Adjusters

1. With the wrench (1031-7809-01), adjust theheight of the adjusters (front and back) tostabilize the unit on the floor.

The wrench is not enclosed.

CAUTION

Be sure to set the adjusters as specified. Failureto set the adjusters correctly may cause the unitto become unbalanced and fall, possibly resultingin serious injuries.

1.4.5 Attaching the paper feed unit to the copy table

1. Place the paper feed unit on top of the copytable so that the rubber feet on the paper feedunit are correctly aligned on the copy table.

2. Using the four enclosed fixing plates and fixing plate screws, secure the paperfeed unit to the copy table as shown.

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This completes the setup of the copy table.For instructions on making connectionsto the copier, refer to “Connecting the Optional Paper Feed Unit to the Copier” inthe Setup Instructions for the paper feed unit.

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1.4.6 Attaching the paper feed unit to the copy desk

1. Place the paper feed unit on top of the copy desk so that the rubber feet on thepaper feed unit are correctly aligned on the copy desk.

2. Using the four enclosed fixing plates and fixing plate screws, secure the paperfeed unit to the copy desk as shown.

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1.4.7 If the Copy Desk or Copy Table Is To Be Used Together With theCopier Stand

NOTE

Make sure that supports A and B are not installed. If supports A and B are installed,remove them.

1. Position the scanner (attached to the copierstand) over the printer engine (attached to thecopy table or copy desk).(The illustration shows the copy desk usedwith the copier stand.)

2. Turn the adjusters on the copier stand (one on each leg) until the four holes inthe copier stand align with the holes in the lower unit (copy table or copy desk).

3. Attach the lower unit (copy table or copy desk) to the copier stand using the fourscrews supplied with the copier stand. Do not tighten the screws.

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Screw

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NOTE

If the copy table is installed, insert the two spacers (supplied with the copier stand)as shown.* If the copy desk is installed, the spacers are not needed.



Spacer

Decorative covers

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1.5 INSTALLATION JS-1002

In order to adjust the height of the copier to the height of the 10-mailbin sort-er, the copy desk, or the copy table and additional paper feed units, or thelarge-capacity cabinet must be installed.

1. Copier + Two paper feed units + Copy table

2. Copier + Large-capacity cabinet

3. Copier + Copy desk

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1.5.1 Unpacking the 10-Mailbin Sorter

1. Remove the 10-mailbin sorter from its box, and then check that the followingaccessories are also enclosed.

1) Rail guide...............................................................12) Rail.........................................................................13) Shelves..................................................................104) Stabilizing pin.........................................................15) Magnet...................................................................16) Flat-head screws ...................................................27) Thumbscrew ..........................................................18) Horizontal transport unit.........................................19) Setup Instructions (this manual) ............................1

2. Remove all tape and the packing board.

NOTE

1 23

4 56 7

89

Tape

Front Back

Packing board

I-70CF1501/2001 Rev. 1.1/01.01

Be sure to install the 10-mailbin sorter on a level surface.After installing the 10-mailbin sorter, do not to move the copier unnecessarily.If it is necessary to move the copier, follow the procedure described under“Removing the Rail” on page 8.After moving the copier, perform the operations described in “Installing theHorizontal Transport Unit” and “Installing the Stabilizing Pin and Rail”.

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1.5.2 Installing the Accessories

If the copier stand is not used

1. Fully slide the bar on the 10-mailbin sorter in the direction indicated by thearrows, and then secure it with the enclosed thumbscrew.

2. Peel off the seal covering the area where the stabilizing pin and magnet will beattached. Using the enclosed flat-head screws, attach the enclosed stabilizingpin and magnet to the left side of the copier as shown.

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3. Attach the rail guide to the left side of the copier as shown in the illustration.If the large-capacity cabinet, copy table or copy desk is installed, attach the railguide at the same location.

NOTE

Be sure to fit the correct side of the rail guide onto the copier, and make sure that itsnaps into place.

4. Insert one end of the rail into the rail guide on the copier.

NOTE

Be sure to fit the correct side of the rail guide onto the copier, and make sure that itsnaps into place.

5. Slide the other end of the rail installed in step 4 into the rail guide on the 10-mailbin sorter.

NOTE

Insert the rail until it snaps into place. At this time, the 10-mailbin sorter should stayattached to the copier, even if you try to pull it away.

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If the copier stand is used

1. Fully slide the bar on the 10-mailbin sorter in the direction indicated by thearrows, and then secure it with the enclosed thumbscrew.

2. Remove the scanner from the copier stand.

3. Remove the pipe from the left leg of the copier stand.

NOTE

If the large-capacity cabinet, copy desk, or copy table is attached to the copierstand, remove it from the copier stand before continuing with this procedure.

4. Attach the adjuster from the removed pipe to the shorter leg of the copier stand.

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6. Secure the lower unit (large-capacity cabinet, copy desk, or copy table) to thecopier stand using the four screws enclosed with the copier stand.

7. Attach the scanner to the copier stand.

Go to step 2 and continue with the installation.

1.5.3 Unpacking the Horizontal Transport Unit

Remove all packing materials and tape.

1.5.4 Installing the Horizontal Transport Unit

1. Place the horizontal transport unit on the paper output section of the copier, andmake sure that the plastic guide pin on the bottom of the horizontal transport unithooks into the bracket on the 10-mailbin sorter.

Tape

Packing materials

Tape

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2. Push the horizontal transport unit in.

NOTE

Make sure that the gears on the horizontal transport unit and on the 10-mailbinsorter are correctly aligned.When securing the horizontal transport unit and the 10-mailbin sorter, be sure toplace the horizontal transport unit on the paper output section of the copier beforeinstalling it.

3. Secure the horizontal transport unit with the lock.

NOTE

Make sure that the horizontal transport unit lock is securely attached to thehorizontal transport unit, and then secure the horizontal transport unit and the 10-mailbin sorter.

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1.5.5 Adjusting the Tilt of the 10-Mailbin Sorter

1. If the 10-mailbin sorter tilts toward the copier,check the following:Are distances a and b equal?

If a and b are not equal, adjust the tilt asfollows:

2. Lift the 10-mailbin sorter’s caster covers up,and then pull them off.

3. Loosen the thumscrews indicated in theillustrations, and then adjust the tilt of theadjusting bolts.

If a > b: Turn the adjusting bolts clockwise.If a < b: Turn the adjusting boltscounterclockwise

a

b

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4. After adjusting the tilt, tighten the thumb-screws on both sides to secure the adjustingbolts, and then re-install the caster covers.

1.5.6 Installing the shelves and connecting the hookup cord

1. Attach the 10 shelves to the 10-mailbin sorterstarting from the bottom.

2. Insert the connector of the top hookup cordinto the connector on the horizontal transportunit, and then insert the connector of thebottom hookup cord into the connector on thecopier.

1.5.7 Removing the Rail

1. Pinch together the rail stoppers on the leftside of the 10-mailbin sorter to release them.

2. Disconnect the two hookup cords.3. Remove the horizontal transport unit from the

10-mailbin sorter, and then place it on top ofthe copier.

4. Carefully pull the 10-mailbin sorter away from

1

2

2

3

1

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the copier.5. Slide the rail under the copier, and then

remove it from the right side of the copier.

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1.6 Installation AD-14

1.6.1 Unpacking the duplex unit

1. Remove the duplex unit from its box, and then check that the followingaccessories are also enclosed.

1) Flat-head screws ....................................... 22) Wiring cover............................................... 13) Spring ........................................................ 14) Setup Instructions (this manual) ................ 1

2. Remove all packing material from the duplex unit.

1 2

3

4

Tape

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1.6.2 Preparing to install the duplex unit

1. Turn off the copier, unplug the power cordand the interface cable from the copier.Then, open the manual bypass tray

2. Remove the wiring cover from the copier.

NOTE

The wiring cover removed from the copier will notbe installed again; however, it should be stored ina safe place in case it will be needed later fortransporting the copier.

3. Push up on the upper-right cover as shown inthe illustration, and then remove the cover.

4. Grasp the upper right-side door as shown,and then carefully open the door completelywhile making sure to support it.

NOTE

Be sure to support the door while carefullyopening it; otherwise, it may be damaged.

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5. Remove the two screws securing the paperoutput cover, and then remove the cover.

6. Remove the spring indicated in theillustration, and then replace it with theenclosed spring.

NOTE

Be sure to install the spring so that it is orientedas shown in the illustration.The area around the fusing unit is extremely hot.Touching any part other than those specified mayresult in burns.

7. Close the upper right-side door.8. Pull up the lock release lever to open the

right-side door.9. Open the upper right-side door.

10. Grasp the handle at the bottom of the fusingunit, and then pull out the fusing unit.

NOTE

Touching any part other than the specifiedhandle may result in burns.

11. Attach the hook at the right end of the paperoutput cover onto the frame of the copier.

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12. Lower the left end of the paper output cover.13. Check that the paper output cover is securely

attached to the frame of the copier

14. Using the two screws, secure the paperoutput cover.

15. Re-insert the fusing unit.16. Close the upper right-side door.17. Close the right-side door.

1.6.3 Installing the duplex unit

1. Align the three tabs on the duplex unit with the three holes in the copier, andthen install the duplex unit.

NOTE

While supporting the duplex unit, open the dooron the right side of the copier, and make sure thatthe tabs are secured within the holes in the copierdoor.

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2. Open the duplex unit, and then secure the duplex unit to the copier with theenclosed flat-head screws.Firmly tighten the screws with a coin or screwdriver.

3. Plug the two connectors from the duplex unitinto the connectors on the copier.

4. Secure the cable of the duplex unit with thecable holder as shown.

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5. Install the enclosed wiring cover.

1.6.4 Checking and adjusting the paper reference position

NOTE

Perform the procedure below after adjusting the paper reference positions for thepaper feed unit and the large-capacity cabinet.


2. Touch “Machine Adjust”.

3. Touch “PRT Area”.

4. Touch “Dup. Left Margin”.

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5. Touch “1st.”.

6. Press the Start key.A test page is printed.

7. Measure the width of loss for the test patternprinted on the back of the test page.

NOTE

Do not measure from the back of the test pattern.

If the measured width of loss does not meetits standard width, touch and in thelower-right corner of the screen to adjust thewidth.Print another test page and check the printedimage.

8. Adjust the paper reference positions for the2nd, 3rd and 4th drawers in the same way (byrepeating steps 5 through 7).

NOTE

The 4th drawer is only available if two optionalpaper feed units are installed.

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1.7 INSTALLATION PF-118

1.7.1 Unpacking the paper feed unit

1. Remove the paper feed unit from its box, and then check that the followingaccessories are also enclosed:

1) Fixing plates ..................................................................... 42) Flat-head screws .............................................................. 43) Bracket ............................................................................. 14) Round-head screws ......................................................... 25) Controller harness ............................................................ 16) Power supply harness 1 (for a 24 V connection).............. 17) Power supply harness 2 (for a 24 V extension)................ 18) Label................................................................................. 19) Setup Instructions (this manual) ....................................... 1

2. Remove all tape from the optional paper feedunit.

NOTE

When using the copy table, first attach the paperfeed unit to it, and then connect the paper feedunit to the copier.

1

2

3

4 5

6 7

8

9

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1.7.2 Connecting the Optional Paper Feed Unit to the Copier

1. Grasp the front and rear handles of the copier, and then place it on top of thepaper feed unit.

2. Slightly pull out the paper drawers of the copier’s paper feed unit and theoptional paper feed unit, and then secure the optional paper feed unit to thecopier using the enclosed fixing plates and flat-head screws.

3. Remove the connector cover from the copier.

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4. Remove the rear covers from the copier’spaper feed unit and the optional paper feedunit.

5. Remove the bracket from the copier’s paperfeed unit.

NOTE

Before removing the bracket from the copier’spaper feed unit, unplug the white connector of thepower supply harness from the paper feed unit.

6. Plug the connector on one end of theenclosed controller harness (A) into theconnector on the copier’s paper feed unit.

7. Plug the connector on the other end of theenclosed controller harness into theconnector (B) on the optional paper feed unit.If an additional optional paper feed unit is tobe installed, perform step 6, and then connectthe upper and lower units.

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8. With the cables moved to the left as shown below, install the brackets.

NOTE

Check that the cables are not visible through the hole (C).If the cables are visible, remove the bracket, adjust the cables, and then reinstallthe bracket.Make sure the bracket fits securely over the tabs.

9. Plug in the white connector of the powersupply harness into the connector on thecopier’s paper feed unit as shown at the left.

OK NGC

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10. Plug in the white connector of enclosedpower supply harness 1 as shown at the left.Secure the harness with the cable holder onthe bracket.Plug in the black connector of enclosedpower supply harness 1 as shown at the left.Secure the harness with the cable holder onthe copier near the connector.

NOTE

Be sure that power supply harness 1 passesthrough the notch as shown at the left.If there is slack in the connected power supplyharness, coil the harness, and then secure it withthe cable holders on the brackets

If only one paper unit is installed, skip to step 13.

If two paper feed units are installed

11. As explained in step 10, plug the whiteconnector of enclosed power supply harness1 into the connector on the other paper feedunit.

12. Plug the connector on one end of enclosedpower supply harness 2 into the blackconnector of power supply harness 1, andthen plug the other connector of power supplyharness 2 into the connector on the copier.

NOTE

Check that the connection between power supplyharnesses 1 and 2 passes between the two cableholders on the topmost paper feed unit.If there is too much slack in the connectedharnesses, remove the slack in the harnesses,for example, by winding the harnesses aroundthe cable holders.

13. Reinstall the rear cover of each unit.

Power supply harnessblack connector

cable holders

Power supply harnesswhite connector

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14. Reinstall the connector cover of the copier.

1.7.3 Loading Paper into the Paper Feed Unit

1. Pull out the paper drawer of the optional paper feed unit, and then press downon the paper-lifting plate until it locks into place.

2. Adjust the front/rear edge-guide-plates and the trailing-edge guide plate to thesize of the paper that will be loaded.

12

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3. Load the paper.

NOTE

Do not load so much paper that the top of thestack is higher than the mark.Be careful not to touch the surface of the papertake-up rollers. If they have been touched, wipethem with a soft, dry cloth.Be sure the paper is not curled when it is loaded.

4. Slide the front/rear edge-guide-plates againstthe edges of the paper.

1.7.4 Affixing the Labels

Affix the enclosed label for the paper size at theposition shown.

1.7.5 Checking the Paper Reference Position

1. Load A4-size paper into the paper drawer ofthe optional paper feed unit.



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5. Touch “Left Margin”

6. Touch the key for the paper drawer that is tobe adjusted, and then press the Start key.A test page is printed.

7. Measure margin a from the edge of the paperto the pattern printed in the test page, andthen check that the width of the measuredmargin meets its standard width.

Standard width of the margin: 3.0 mm ± 1.0mmIf the width of the measured margin does notmeet its standard width, follow the procedurein the next section, “Adjusting the PaperReference Position”, to adjust it.

a

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1.7.6 Adjusting the Paper Reference Position

1. Display the Tech. Rep. Mode screen.



4. Touch “Left Margin”.

5. Select the paper drawer that you wish toadjust, and then touch the up and downarrows in the lower-right corner of the screento enter the difference between the measuredwidth and the standard width.

6. Print a test page and check the paperreference position.If the width of the measure margin does notmeet its standard width, follow theinstructions described below.

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7. Open the paper drawer for the cassette thatneeds to be adjusted, and then remove all ofthe paper.

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8. Loosen the two screws on the guide plate atthe bottom of the paper drawer.

9. Adjust the guide plate to the appropriateposition on the scale inside the paper drawer.

10. Tighten the two screws loosened in step 8.

11. Repeat the procedure in the previous section,“Checking the Paper Reference Position”.

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1.8 INSTALLATION PF-117

1.8.1 Unpacking the large capacity cabinet

1. Remove the large-capacity cabinet from its box, and then check that thefollowing accessories are also enclosed.

1) Fixing plates.................................... 42) Flat-head screws ............................ 43) L-shaped stopper ............................ 14) Stoppers ......................................... 45) Stopper covers................................ 26) Thumbscrews (short) ...................... 47) Thumbscrews (long) ....................... 28) Power supply harness .................... 19) Setup Instructions (this manual) ..... 1

2. Remove all protective tape from the large-capacity cabinet.

1 2 3

4 5 6

78 9

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3. Pull out the paper drawer of the large-capacity cabinet, and remove the packingmaterial.


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1.8.2 Installing the stoppers

NOTE

If the copier stand is used, do not install the stoppers or the L-shaped stopper.

1. Using the thumbscrews (short), attach the four enclosed stoppers at thelocations shown in the illustration.

2. Attach the stopper covers to the two stoppersinstalled at the front of the large-capacitycabinet.

3. Using the two thumbscrews (long), attach theenclosed L-shaped stopper to the right-rearcorner of the large-capacity cabinet.

1.8.3 Adjusting the Adjusters

To stabilize the large-capacity cabinet, adjust theheight of the two adjusters at the front of the

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cabinet.

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1.8.4 Installing the Large Capacity Cabinet

1. Before installing the large-capacity cabinet, make sure that the harness issecured with the harness clamp on the cabinet as shown in the illustration.

2. Grasp the handles of the copier, and then place it on top of the large-capacitycabinet so that the rubber feet on the copier align with the positioning pins of thecabinet.

3. Pull out the paper drawers of the copier’s paper feed unit and the large-capacitycabinet, and then secure the large-capacity cabinet to the copier with theenclosed fixing plates and flat-head screws.

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4. Remove the connector cover from the copier.

5. Remove the rear cover and bracket from the paper feed unit.

NOTE

Before removing the bracket from the copier’s paper feed unit, unplug the powersupply harness (white connector) on the paper feed unit.

6. Plug the connector on the large-capacitycabinet’s controller harness into theconnector on the copier’s paper feed unit asshown.

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7. With the cables moved to the left as shown below, install the bracket.

NOTE

Check that the cables are not visible through the hole (C).If the cables are visible, remove the bracket, adjust the cables, and then reinstallthe bracket.Make sure the bracket fits securely over the tabs.

8. Plug the white connector of the power supplyharness from the paper feed unit into theconnector shown in the illustration.

9. Plug the connector on the power supplyharness from the large-capacity cabinet intothe connector on the copier as shown in theillustration.Secure the harnesses with the cable holders

OK NGC

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on the brackets.10. Reinstall the rear cover of the paper feed unit.11. Reinstall the connector cover of the copier.

Cable holders

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1.8.5 If the Large Capacity Cabinet Is to be used together with the CopierStand

NOTE

Make sure that the stoppers and the L-shaped stopper are not installed. If they areinstalled, remove them.

1. Position the scanner (attached to the copierstand) over the printer engine (attached to thelarge-capacity cabinet)

2. Turn the adjusters on the copier stand (one on each leg) until the four holes inthe copier stand align with the holes in the large-capacity cabinet.

3. Attach the large-capacity cabinet to the copier stand using the four screwssupplied with the copier stand. Do not tighten the screws. Then, insert the twospacers (supplied with the copier stand) as shown.

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1.8.6 Specifying the Paper Size

(Except U.S.A. and Canada) The default paper size setting is “A4C”.

1. Remove the screw on the left side guide andthe screw on the right side guide, and thenremove the two side guides.

2. Install the side guides while adjusting them tothe desired paper size, and then secure theguides with the screws.

3. Move the slides at the bottom of the cabinetfully in the direction of the arrows.

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4. Remove the screw on the front guide plate and the screw on the rear guideplate, and then lift up the two guide plates.

5. Insert the tabs on the bottom of the front and rear guide plates into the slots forthe desired paper size.

6. Insert the tabs on the top of the front and rear guide plates into the slots for thedesired paper size.

NOTE

Make sure that all tabs on both the front and rear guide plates are inserted into theslots for the same paper size.

7. Check that the tabs on the front and rearguide plates are securely inserted into thepaper size slots, and then secure the twoguide plates with the screws.

8. Move the slides at the bottom of the cabinet(moved in step 3) fully in the direction of thearrows until they contact the front and rearguide plates.

9. Remove the rear cover from the large-capacity cabinet.

A4LTRB5

A4LTRB5

A4LTRB5

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10. Set the dip switches to select the desiredpaper size.* Adjust the dip switches according to thefollowing chart.

11. Reinstall the rear cover of the large-capacitycabinet.

1.8.7 Checking and Adjusting the Paper Reference Position

1. Load A4-size (or Letter-size) paper into thepaper drawer of the large-capacity cabinet.



4. Touch “PRT Area”

5. Touch “Left Margin”.

SW 1 2 3 4

A4Y ON OFF OFF OFF

B5T OFF ON OFF OFF

ON

1 2 3 4

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6. Touch the key for the third paper drawer, andthen press the Start key

7. Measure the margin from the edge of thepaper to the pattern printed in the top-rightcorner of the test page.

Standard width (a):3.0 mm ±1.0 mm

Touch the up and down arrows in the lower-right corner of the screen to enter thedifference (in millimeters) between themeasured width and the standard width.

8. Print another test page and check the paperreference position.

a

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1.9 INSTALLATION FN-107 / 108

1.9.1 Before Setting Up the Finisher

In order to adjust the height of the copier to the height of the finisher, the copy desk,or the copy table and additional paper feed units, or the large-capacity cabinet mustbe installed.

1. Copier + Two paper feed units + Copy table

2. Copier + Large-capacity cabinet

3. Copier + Copy desk

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1.9.2 Unpacking the Finisher

1. Remove the finisher from its box, and then check that the following accessoriesare also enclosed.

1) Rail guide .............................................................. 12) Rail ........................................................................ 13) Stabilizing pin ........................................................14) Magnet ..................................................................15) Horizontal transport unit ........................................16) Tray ....................................................................... 17) Protective guide..................................................... 18) Labels....................................................................29) Screws...................................................................310) Setup Instructions (this manual)............................ 1

12

3

4

56

7 89

10

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2. Remove all tape and packing brackets.On the FN-107

NOTE

Be sure to install the finisher on a level surface.After installing the finisher, do not to move the copier unnecessarily.If it is necessary to move the copier, follow the procedure described under“Removing the rail” on page 9.After moving the copier, perform the operations described in “Installing theHorizontal Transport Unit” and “Installing the Stabilizing Pin and Rail”.

NOTE: Do not remoce this parts

Packing bracket

Tape

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1.9.3 Installing the accessoriesif the copier stand is not used

1. Peel off the seal covering the area where thestabilizing pin and magnet will be attached.

2. Attach the enclosed stabilizing pin andmagnet with the enclosed flat-head screws tothe left side of the copier as shown.

3. Attach the rail guide to the left side of thecopier as shown in the illustration.If the large-capacity cabinet, copy table orcopy desk is installed, attach the rail guide atthe same location.

NOTE

Be sure to fit the correct side of the rail guide ontothe copier, and make sure that it snaps into place.

4. Insert one end of the rail into the rail guide onthe copier.

NOTE

Insert the rail until imt snaps into place.

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5. Slide the other end of the rail installed in step 3 into the rail guide on the finisher.

NOTE

Insert the rail until it snaps into place.At this time, the finisher should stay attached to the copier, even if you try to pull itaway.

1.9.4 Installing the AccessoriesIf the copier stand is used

1. Remove the scanner from the copier stand.

2. Remove the pipe from the left leg of the copier stand.

NOTE

If the large-capacity cabinet, copy desk, or copy table is attached to the copierstand, remove it from the copier stand before continuing with this procedure.

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3. Attach the adjuster from the removed pipe to the shorter leg of the copier stand.


5. Secure the lower unit (large-capacity cabinet, copy desk, or copy table) to thecopier stand using the four screws enclosed with the copier stand.

6. Attach the scanner to the copier stand.

Go to step 1 on page 3 and continue with the installation.

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1.9.5 Unpacking the horizontal transport unit

Remove all packing materials and tape.

1.9.6 Installing the horizontal transport unit

1. Place the horizontal transport unit on the paper output section of the copier, andmake sure that the plastic guide pin on the bottom of the horizontal transport unithooks into the bracket on the finisher.

2. Push the horizontal transport unit in.

NOTE

Make sure that the gears on the horizontaltransport unit and on the finisher are correctlyaligned.When securing the horizontal transport unit andthe finisher, be sure to place the horizontaltransport unit on the paper output section of thecopier before installing it

Tape

Packing material

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3. Secure the horizontal transport unit with thelock.

NOTE

Make sure that the horizontal transport unit lockis securely attached to the horizontal transportunit, and then secure the horizontal transport unitand the finisher.

1.9.7 Adjusting the height and tilt of the finisher

1. If the finisher gradually tilts toward the copier,check the following:Are the stabilizing pin and the hole in thefinisher at the same height?Is the horizontal transport unit not extremelytilted?

If the finisher is not at the same height as thecopier, adjust the copier as follows.

2. Slide the finisher away from the copier, andthen remove the lower-front cover (twoscrews) of the finisher.

3. Lift the finisher’s two caster covers up, andthen pull them off.

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4. Without turning the adjusting bolt (lower bolt)on the caster, loosen the securing bolt (upperbolt), and then turn the adjusting bolt (lowerbolt) as indicated below to adjust the height ofthe finisher.

The two rear and front castersIf the stabilizing pin is too high:Turn the bolt clockwise

If the magnet is too low:Turn the bolt counterclockwise

5. If the finisher tilts toward the copier, check thefollowing:Are distances a and b equal?

If a and b are not equal, refer to step 4 aboveand turn the adjusting bolt (lower bolt) asindicated to adjust the tilt of the finisher.

6. After the adjustment is finished, withoutturning any of the adjusting bolts (lowerbolts), tighten the four securing bolts (upperbolts).

7. Re-install the caster covers and the lower-front cover (two screws).

1.9.8 Connecting the Hookup Cord

Insert the connector on one end of the hookupcord into the connector on the horizontal trans-port unit, and then insert the connector on theother end of the hookup cord into the connectoron the copier.

Securing bolt

Adjusting bolt

a

b

Securing bolt

Adjusting bolt

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1.9.9 Affixing the Labels

Affix the enclosed operation labels.Label

Label

1.9.10 Installing the Tray and Protective Guide

Install the enclosed tray and protective guide atthe positions shown in the illustrations.

for FN-107 for FN-108

for FN-107 for FN-108

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1.9.11 Checking the Hole-Punching Positions (FN-107 only)

NOTE

If the Fiery is installed, check and, if necessary,adjust the punched hole positions.

1. Unplug the power cord, and then turn off thecopier.

2. Load A4-size paper (in landscape orientation)into tray 1.


4. Touch “Machine Adjust”.5. Touch “Hole Punch”.6. Press the Start key.7. Fold the paper that is fed out in half, and

check that the punched holes are aligned.

Standard position: ±2mm

NOTE

If the punched holes are not at their standardpositions, adjust the hole-punching position.

1.9.12 Adjusting the Hole-Punching Positions (FN-107 only)

1. Open the upper cover, and then loosen thehole-punching guide securing screw.Move the green slider to adjust the hole-punching position.

2. Tighten the securing screw.

3. Close the upper cover.

4. Make another test print, and then check thatthe punched holes are aligned.

I-116CF1501/2001 Rev. 1.1/01.01

NOTE

If the punched holes are not at their standardpositions, adjust the hole-punching position.

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1.9.13 Removing the Rail

1. Pinch together the rail stoppers on the leftside of the finisher to release them.

2. Disconnect the two hookup cords.3. Remove the horizontal transport unit from the

finisher, and then place it on top of the copier.4. Carefully pull the finisher away from the

copier.5. Slide the rail under the copier, and then

remove it from the right side of the copier.

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1.10 INSTALLATION INTERFACE KIT-E

WARNING

Before setting up this unit, be sure to unplug the power cord of the copier.Keep all packing materials out of the reach of children.

1.10.1 UNPACKING

Check that the following are enclosed.1) Circuit board assembly ................... 12) Setup Instructions (this manual) .....1

1.10.2 Installing the Circuit Board Assembly

1. Remove the five screws of the copiercontroller circuit board cover, then removethe cover.

2. Insert the circuit board assembly at thelocation of the controller circuit board coverremoved in step 1, and then secure it with thescrews used to secure the controller circuit

1

2

I-118CF1501/2001 Rev. 1.1/01.01

board cover.

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1.11 INSTALLATION INTERFACE KIT-I

If Fiery X3e is installed, install I/F kit I

1.11.1 UNPACKING

Check that the following are enclosed.1) Control panel for the internal controller ......12) Cooling-air duct ..........................................13) Screws........................................................24) Setup Instructions (this manual) .................1

1.11.2 Installing the Cooling-Air Duct

Using the two screws, attach the cooling-air duct to the circuit board assembly asshown:

Circuit board assy

1 2

3 4

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1.11.3 Installing the Circuit Board Assembly

1. Remove the five screws of the copier controller circuit board cover, and thenremove the cover. (The screws will be needed later, so be sure to keep them ina safe place.) Check that the hookup cord is visible at the side of the copier:

2. As shown, partly insert the circuit boardassembly at the location of the controllercircuit board cover removed in step 1.

3. Connect the hookup cord from the side of thecopier to the cooling-air duct harness.

4. While holding the harness pushed down sothat it will not be pinched, slowly insert thecircuit board assembly.

NOTE

Hookup cord

Controller circuit board cover

I-120CF1501/2001 Rev. 1.1/01.01

If the cooling-air duct harness is too long, secureit with a cable holder so that the harness will notbe caught on anything.

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5. Secure the circuit board assembly with thescrews used to secure the controller circuitboard cover.

1.11.4 Install the Control Panel for the Internal Controller

1. Open the front door and the toner hopperdoor.

2. Remove the screw and the cover shown inthe illustration.

3. Pull out the connector shown in theillustration.

NOTE

Be careful not to disconnect other connectorsaccidentally.

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4. Insert the connector mentioned in step 3 intothe connector on the back of the control panelfor the internal controller.

5. Install the control panel for the internalcontroller in place of the cover removed instep 2.

6. Secure the control panel for the internalcontroller with the screw used to secure thecover.

7. Close the front door and the toner hopperdoor.

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1.12 INSTALLATION M128-2 (DIMM)

1.12.1 Unpacking the Expansion Memory (DIMM)

1. Check that the following are enclosed.

(1) Expansion memory.......................................... 1(2) Unpacking/Setup Instructions (this manual) .... 1

2. Remove the packing materials.

NOTE

The expansion memory (DIMM) is easily damaged by static electricity. Beforetouching the expansion memory (DIMM), be sure to touch a metal object todischarge any static electricity from your body and clothes.Be sure to only hold the expansion memory (DIMM) by its edges when removing itfrom the insulated bag. Do not touch any terminals or any other parts of the circuitboard.

1.12.2 Installing the Expansion Memory

NOTE

Always install the expansion memory (DIMM) as a set of two.

1. Turn off the copier, and then unplug both thepower cord and interface cable from it.

2. Remove the seven screws securing the rearcover to the back of the copier, and thenremove the rear cover.

1 2

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3. Remove the six screws securing the circuitboard cover, and then remove the circuitboard cover.

4. Align the notches in the expansion memory(DIMM) with the ribs in the sockets, and theninsert the expansion memory into the socket.Fully insert the expansion memory (DIMM)into the socket until the tabs, one on each endof the socket, lock to secure the expansionmemory.

NOTE

Check that the expansion memory (DIMM) is wellsecured by the tabs on both ends of it.

5. Insert the other expansion memory (DIMM)into the other socket in the same way.

6. Reattach the circuit board cover, then the rearcover.

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1.13 INSTALLING THE MECHANICAL COUNTER

WARNING

Before setting up this unit, be sure to unplug the power cord of the copier.Keep all packing materials out of the reach of children.

Check that the following are enclosed:

1) Mechanical counter ..............................12) Screw ...................................................13) Setup Instructions (this manual)........... 1

1. Turn off the copier, and then unplug its powercord from the electrical outlet.

2. Disconnect the ground wire.

NOTE

Be sure to unplug the power cord beforedisconnecting the ground wire.

3. Open the front door and the toner hopperdoor.

1 2

3

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4. Remove the screw and the cover shown inthe illustration.

5. Open the right-side door.

6. Remove the screw and the handle covershown in the illustration.

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7. Break out the section shown from the coverremoved in step 6.

8. Remove the cover shown in the illustration.

9. Using the enclosed screw, install themechanical counter at the position shown.

10. Insert the connector on the hookup cord intothe connector on the mechanical counter.

11. Install any removed covers, and close anyopened doors.

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I-128CF1501/2001 Rev. 1.1/01.01

FrameMaker Ver.5.5E(PC) CF1501/CF2001 DIS/REASSEMBLY, ADJUSTMENT00.12.25

DIS/REASSEMBLY, ADJUSTMENT

18605


i

CONTENTS1. SERVICE INSTRUCTIONS ............................................................................. D-1

1-1. IDENTIFICATION OF FUSES .................................................................D-11-2. PARTS WHICH MUST NOT BE TOUCHED ...........................................D-2

(1) Red Painted Screws ........................................................................D-2(2) Variable Resistors on Board ............................................................D-2

2. DISASSEMBLY/REASSEMBLY ......................................................................D-32-1. DOORS, COVERS, AND EXTERIOR PARTS:

IDENTIFICATION AND REMOVAL PROCEDURES ...............................D-32-2. REMOVAL OF CIRCUIT BOARDS AND OTHER

ELECTRICAL COMPONENTS ................................................................D-5(1) Removal of the CCD Unit ................................................................D-6(2) Removal of the Image Processing Board ........................................D-6(3) Removal of the IR PRIF Board ........................................................ D-9(4) Removal of the Scanner Motor Drive Board ....................................D-10(5) Removal of the Flat Cable ...............................................................D-10(6) Removal of DC Power Supply 2 ...................................................... D-11(7) Removal of the Paper Size Detecting Board ................................... D-13(8) Removal of the LED Board and ATDC Sensors Y, M, and C ..........D-13

2-3. MAINTENANCE SCHEDULE ..................................................................D-162-4. Guidelines for Life Specifications Values by Unit ....................................D-182-5. Removal of Units .....................................................................................D-20

(1) Removal of the Toner Hopper Unit ..................................................D-21(2) Removal of the LED Unit .................................................................D-22

2-6. Cleaning and Disassembly of the IR Unit ................................................D-25(1) Cleaning of the Scanner Rails .........................................................D-25(2) Cleaning of the Mirrors (1st/2nd/3rd) ...............................................D-25(3) Cleaning of the Lens ........................................................................D-25(4) Cleaning of the Original Glass .........................................................D-26(5) Removal of the Original Glass Cooling Fan Motor ..........................D-26(6) Removal of the Scanner Motor ........................................................ D-26(7) Removal of IR Cooling Fan Motor 2 ................................................D-27(8) Removal of IR Cooling Fan Motor 1 ................................................D-28(9) Removal of the Scanner Home Sensor ...........................................D-28(10) Removal of the Original Cover Detecting Sensor ............................D-29(11) Removal of Original Size Detecting Sensors FD1 and FD2 ............ D-29(12) Removal of Original Size Detecting Sensor CD1 ............................D-30(13) Removal of the Size Reset Switch ..................................................D-30(14) Removal of the Scanner Assy .........................................................D-30(15) Removal of the Exposure Lamp ...................................................... D-31(16) Removal of the Temperature Fuse ..................................................D-31(17) Removal of the Scanner Drive Cables ............................................D-32(18) Winding of the Scanner Drive Cables ..............................................D-33

2-7. CLEANING AND DISASSEMBLY OF THE ENGINE PARTS .................D-38(1) Cleaning of the Paper Take-Up Roll ................................................D-38(2) Cleaning of the Paper Separator Roll ..............................................D-38(3) Cleaning of the Synchronizing Rollers .............................................D-38


ii

(4) Cleaning of the Paper Dust Remover ..............................................D-39(5) Cleaning of the Transfer Belt Unit ...................................................D-39(6) Cleaning of the LED ........................................................................D-40(7) Cleaning of the Area around the Waste Toner Collecting Port ........D-40(8) Cleaning of the Fusing Entrance Guide Plate ................................. D-41(9) Removal of the Imaging Unit Motor C/M/Y/Bk ................................. D-41(10) Removal of the Main Motor .............................................................D-43(11) Removal of the Ozone Ventilation Fan Motor ..................................D-43(12) Removal of the Fusing Drive Motor .................................................D-43(13) Removal of the Fusing Pressure/Retraction Motor ..........................D-44(14) Removal of the 1st Image Transfer Pressure/Retraction Motor ......D-45(15) Removal of Toner Replenishing Motor C/Bk ................................... D-46(16) Removal of Toner Replenishing Motor Y/M ..................................... D-46(17) Removal of the Cleaning Web Drive Motor ..................................... D-46(18) Removal of the Power Supply Cooling Fan Motor ...........................D-47(19) Removal of Fusing Cooling Fan Motor 2 .........................................D-48(20) Removal of Fusing Cooling Fan Motor 1 .........................................D-48(21) Removal of the 2nd Image Transfer Pressure/Retraction Clutch ....D-50(22) Removal of the Synchronizing Roller Clutch ................................... D-50(23) Removal of the Manual Feed Paper Take-Up Clutch ......................D-51(24) Removal of the Paper Take-Up Clutch ............................................D-52(25) Removal of AIDC/Registration Sensor 1/2 ......................................D-53(26) Removal of the Temperature/Humidity Sensor ...............................D-54(27) Removal of the Toner Supply Door Sensor ..................................... D-54(28) Removal of the Manual Feed Paper Take-Up Sensor .....................D-54(29) Removal of the 1st Image Transfer Retraction Position Sensor ......D-55(30) Removal of the Double Feed Sensor ..............................................D-55(31) Removal of the Drawer Set Sensor and Drawer Paper

Near-Empty Sensor ......................................................................... D-56(32) Removal of the Left Door Switch .....................................................D-57(33) Removal of the Right Door Switch ...................................................D-57(34) Removal of the Front Door Switch ...................................................D-58(35) Removal of the Fusing Roller Rotation Detecting Sensor ...............D-58(36) Removal of the Fusing Retraction Position Sensor .........................D-58(37) Removal of the Exit Sensor .............................................................D-58(38) Removal of the 2nd Image Transfer Pressure Position Sensor ......D-59(39) Removal of the Synchronizing Roller Sensor ..................................D-59(40) Removal of the OHP Detecting Sensor ...........................................D-59(41) Removal of the CD Paper Size Detecting Sensor Assy ..................D-60(42) Removal of the Paper Take-Up Roll ................................................D-60(43) Removal of the Paper Separator Roll ..............................................D-61(44) Removal of High Voltage Unit 1 ...................................................... D-61(45) Removal of High Voltage Unit 2/3 ...................................................D-61(46) Removal of DC Power Supply 1 ...................................................... D-61(47) Removal of the Charge Neutralizing Relay ..................................... D-62(48) Removal of the Waste Toner Full Detecting Sensor .......................D-62(49) Removal of the Waste Toner Bottle Set Sensor ..............................D-62


iii

(50) Removal of the Toner Empty Switch (Y/M/C/Bk) .............................D-633. ADJUSTMENTS .............................................................................................. D-64

3-1. ADJUSTMENT JIGS AND TOOLS USED ...............................................D-643-2. ADJUSTMENT REQUIREMENTS LIST ..................................................D-653-3. ADJUSTMENT OF SWITCHES ...............................................................D-66

(1) Microswitches ..................................................................................D-663-4. ADJUSTMENT OF BELT TENSION ........................................................ D-67

(1) Adjustment of the Scanner Motor Timing Belt ................................. D-673-5. ELECTRICAL/IMAGE ADJUSTMENT .....................................................D-68

(1) Accessing the Tech. Rep. Mode ...................................................... D-68(2) Producing a Test Print .....................................................................D-68(3) Touch Panel Adj. ............................................................................. D-69(4) Top Margin ......................................................................................D-70(5) Left Margin .......................................................................................D-72(6) Dup. Left Margin ..............................................................................D-73(7) Paper Loop ......................................................................................D-74(8) Color Shift Correction ......................................................................D-75(9) Fuser Nip .........................................................................................D-78(10) Fuser Temp. ....................................................................................D-80(11) Fuser Speed ....................................................................................D-81(12) Left Image ........................................................................................D-82(13) Top Image .......................................................................................D-83(14) CD-Mag. ..........................................................................................D-84(15) FD-Mag. ...........................................................................................D-85(16) Org. Detect Sensor ..........................................................................D-86(17) Gradation Adjust ..............................................................................D-87(18) PRT Max Density ............................................................................. D-88(19) PRT Highlight ..................................................................................D-88(20) Background Voltage Margin ............................................................D-89

4. OTHER ADJUSTMENTS .................................................................................D-904-1. Adjustment of the Position of the Scanner and 2nd/3rd

Mirrors Carriage .......................................................................................D-90(1) Adjustment of the 2nd/3rd Mirrors Carriage Assy for Parallel

Alignment .........................................................................................D-915. MISCELLANEOUS ..........................................................................................D-93

5-1. INSTALLATION OF THE MECHANICAL COUNTER (OPTION) ............ D-935-2. MOUNTING OF THE ORIGINAL SIZE DETECTING SENSORS

(OPTION) .................................................................................................D-945-3. FLASH MEMORY ....................................................................................D-955-4. REMOUNTING RAM IC (IC5) ..................................................................D-97


D-1

1. SERVICE INSTRUCTIONS1-1. IDENTIFICATION OF FUSES

DC Power Supply 1 PU1 125 V 15 A (F1) 120 V 10 A (F2) 125 V 15 A (F3) 125 V 15 A (F4)

4004D101AB

4004D100AB

DC Power Supply 2 PU2 250 V 3 A (F1)


D-2

1-2. PARTS WHICH MUST NOT BE TOUCHED(1) Red Painted Screws

Purpose of Application of Red Paint• Red painted screws show that the assembly or unit secured can only be adjusted or set

at the factory and should not be adjusted, set, or removed in the field.• Note that when two or more screws are used on the part in questions, only one represen-

tative screw may be marked with red paint.

(2) Variable Resistors on Board

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


D-3

2. DISASSEMBLY/REASSEMBLY2-1. DOORS, COVERS, AND EXTERIOR PARTS:

IDENTIFICATION AND REMOVAL PROCEDURES

5

12 3

7

84

6

IR

Printer

4004D102AA

4004D103AA

4004D104AA

4004D105AA

2

4

5

6

7

9

1

8

10

3

FrameMaker Ver.5.5E(PC) CF1501/C00.12.25

IR

Printer

No. Name

1 Original Glass Remove theRemove onrear). → Re

2 IR Right Cover Remove tw

3 Control Panel Remove twscrews, unp

4 IR Front Cover Remove thePanel fixingSensor Ass→ Loosen ttwo lower sCover.

5 IR Lower Front Cover

Remove theStand. → R

6 IR Rear Upper Cover

Remove theUpper Cove

7 IR Rear Cover Disconnectscrews and

8 IR Left Cover Remove theRemove thr

No. Name

1 Rear Left Cover

Open the Lthe Ozone

2 Hopper Door Open the Ractuator of ring E type per Door in

3 Panel Door Open the Fscrew and t

4 Front Door Open the F

5 Hopper Left Cover

Open the Fscrew and l

6 Paper Output Cover

Open the Rscrews and

7 Rear Upper Cover

Remove theRemove thr

8 Rear Cover Remove se

9 Rear Right Cover

Open the RCover.

10 Front Right Cover

Remove theCover.

F2001 DIS/REASSEMBLY, ADJUSTMENT

Removal Procedure

IR Right Cover. → Remove the IR Rear Cover. → e screw and the Original Glass fixing brackets (front and move the Original Glass.

o screws and the IR Right Cover.

o covers below the Control Panel. → Remove two lug one connector, and remove the Control Panel.

Control Panel. → Remove one screw and two Control brackets. → Remove one screw and the Scanner Home y. → Remove the two upper joints from the Copier Stand. wo screws and remove the IR Front Cover. → Loosen crews and remove two upper screws and the IR Front

Control Panel. → Demount the IR Unit from the Copier emove two screws and the IR Lower Front Cover.

Original Cover. → Remove three screws and the Rear r.

the power cable and IR hookup cable. → Remove four the IR Rear Cover.

IR Front Cover. → Remove the IR Rear Upper Cover. → ee screws and the IR Left Cover.

Removal Procedure

eft Door. → Remove the Waste Toner Bottle. → Remove Filter. → Remove two screws and the Rear Left Cover.

ight Door. → Open the Upper Right Door. → Remove the the Toner Supply Door Sensor. → Snap off one retaining from the left hinge of the Hopper Door and slide the Hop- closed position to the right to take it off.

ront Door. → Open the Hopper Door. → Remove one

D-4

he Panel Door.

ront Door. → Lift the Front Door off the copier.

ront Door. → Open the Hopper Door. → Remove one ift the Hopper Left Cover upward to take it off.

ight Door. → Open the Upper Right Door. → Remove two the Paper Output Cover.

Paper Output Cover. → Remove the Rear Cover. → ee screws and the Rear Upper Cover.

ven screws and the Rear Cover.

ight Door. → Remove one screw and the Rear Right

Panel Door. → Remove one screw and the Front Right


D-5

2-2. REMOVAL OF CIRCUIT BOARDS AND OTHER

ELECTRICAL COMPONENTS• When removing a circuit board or other electrical component, refer to “Handling of

PWBs” and follow the corresponding removal procedures.• The removal procedures given in the following omit the removal of connectors and

screws securing the circuit board support or circuit board.• Where it is absolutely necessary to touch the ICs and other electrical components on the

board, be sure to ground your body.

IR

Symbol Name Removal Procedures

PWB-A CCD Sensor Board D-6

PWB-CImage Processing Board

D-6

PWB-D IR PRIF Board D-9

PWB-ICScanner Motor Drive Board

D-10

PWB-Z Flat Cable D-10

PU2 DC Power Supply 2 D-11

4004D106AC

PU2

PWB-C

PWB-IC

PWB-D

PWB-A

PWB-Z


D-6

(1) Removal of the CCD Unit

(2) Removal of the Image Processing Board

1. Remove the IR Right Cover and Original Glass.2. Remove eight screws and the optical cover.

4004D001AC

3. Remove three screws and the imaging process-ing lid on the right inside the IR.

4004D002AB

4. Unplug three connectors.5. Remove three screws and the CCD Unit.

4004D003AA

1. Remove the IR Right Cover, IR Front Cover, IR Lower Front Cover, and IR Rear Upper Cover.

2. Remove the Original Glass.3. Remove eight screws and the optical cover.

4004D001AC

4. Remove three screws and the imaging process-ing lid on the right inside the IR.

4004D002AB


D-7

5. Remove four screws and the metal bracket on the upper right of the IR.

4004D004AA

6. Unplug eight connectors on the Image Process-ing Board.

4004D005AA

7. Remove three screws that secure the Image Pro-cessing Unit on the right.

4004D006AA

8. Remove two screws and the image processing lid on the left inside the IR.

4004D007AA

9. Unplug four connectors on the Image Processing Board.

4004D008AA


D-8

Precautions for Removal/Reinstallation of the IR Hookup Cable• Be sure to hold onto the connector of the cable when removing or reinstalling the cable.

NEVER pull on the cable.• At reinstallation, make sure that the connector is not tilt.• When securing the connector, use a flat-blade screwdriver and tighten the connector

firmly.

10. Remove two screws that secure the Image Pro-cessing Unit on the left.

4004D009AA

11. Remove the IR hookup cable.

4004D010AA

12. Remove two screws and two washers.

4004D011AA

13. Remove nine screws and the Image Processing Unit protective guide.

4004D012AC


D-9

(3) Removal of the IR PRIF Board

14. Pull out the Image Processing Unit.

4004D013AA

15. Remove 11 screws and the Image Processing Board.

4004D014AA

NOTE• At reinstallation, make sure that the Image Pro-

cessing Board is properly connected to the IR PRIF Board.

4004D194AA

1. Pull out the Image Processing Board Unit. D-6 (steps 1 through 14)2. Remove five screws and the IR PRIF Board.

4004D195AA

NOTE• At reinstallation, make sure that the IR PRIF Board

is properly connected to the Image Processing Board.

4004D196AA


D-10

(4) Removal of the Scanner Motor Drive Board

(5) Removal of the Flat Cable

1. Remove the IR Rear Upper Cover and IR Rear Cover.2. Remove the Original Glass.3. Remove the Scanner Assy.

1. Remove the IR Right Cover, IR Rear Right Cover, IR Rear Upper Cover, and IR Rear Cover.

2. Remove two screws and the reinforcement frame.

4004D015AA

3. Unplug three connectors.4. Remove one screw. Then, remove the Scanner

Motor Drive Board from the PWB support.

4004D016AB

4. Remove two screws, unplug one connector, and remove the Scanner Assy Flat Cable.

4004D025AA

5. Unplug one connector and remove the harness from one wiring saddle.

6. Remove two screws and the Original Glass Cool-ing Fan Motor.

4004D018AB


D-11

(6) Removal of DC Power Supply 2

7. Remove one screw, unplug one connector, and remove the Flat Cable.

4004D019AA

1. Remove the IR Rear Cover.2. Remove two screws that secure the IR power

receptacle.

4004D020AB

3. Remove six screws, two harness holders, and the DC Power Supply 2 cover.

4004D021AA

4. Remove one screw that secures DC Power Sup-ply 2 in position.

4004D022AA

5. Unplug six connectors.6. Take off DC Power Supply 2 by sliding it to the

right.

4004D023AA


D-12

Printer

Symbol Name Removal Procedures

PWB-H MSC Board Remove the Rear Cover. → Remove the Rear Left Cover. → Remove the PWB Shield Cover. → Unplug two connec-tors and remove four screws and the MSC Board.

PWB-I Master Board Remove the Paper Output Cover. → Unplug 21 connectors and remove six screws and the Master Board.

PWB-I1 Paper Size Detecting Board

D-13

PWB-LK LED Board

D-13PWB-N1 ATDC Sensor Y

PWB-N2 ATDC Sensor M

PWB-N3 ATDC Sensor C

PWB-PIC PIC Board Remove the Rear Cover. → Remove the Rear Left Cover. → Remove the PWB Shield Cover. → Remove the MSC Board. → Unplug two connectors and remove 12 screws and the PIC Board.

PWB-S Paper Type Detection Board

Open the Front Door. → Remove one screw and the Paper Type Detection Board cover. → Unplug one connector and remove one screw and the Paper Type Detection Board.

PWB-T Tech. Rep. Setting Switches Board

Open the Front Door. → Remove the Right Front Cover. → Unplug one connector and remove one screw and the Tech. Rep. Setting Switches Board.

4004D183AA

PWB-T

PWB-S

PU1

PWB-N3

PWB-I

PWB-PIC

PWB-H

PWB-I1

PWB-N2

PWB-N1

PWB-LK


D-13

(7) Removal of the Paper Size Detecting Board

(8) Removal of the LED Board and ATDC Sensors Y, M, and C

NOTE• Whenever the Imaging Unit has been slid out of the copier, be sure to cover it with the

light blocking bag (black) or light blocking cloth for packing purposes and place it in a dark place. Avoid leaving it to stand for a long time.

1. Remove the LED Unit. D-22

Removal of the LED Assy Bk

1. Remove High Voltage Unit 1 and 2. D-56 (steps 1 through 8)2. Remove two screws, unplug one connector, and

remove the Paper Size Detecting Board.

4004D184AB

2. Remove two screws and the Right Guide.

4004D108AA

3. Remove two screws and the Right Guide for C.

4004D110AA

4. Remove two screws and the Left Guide.

4004D109AA


D-14

Removal of the LED Assy C

NOTE• At reinstallation, ensure that the front hook makes

positive engagement.

4004D197AA

5. Remove one screw and the holder.

4004D113AA

6. Remove four screws, unplug two connectors, and remove the LED Assy Bk.

4004D114AB

7. Remove two screws, unplug one connector, and remove the ATDC Sensor C.

NOTE• When the ATDC Sensor is replaced, the Imaging

Unit should also be replaced.

4004D115AA

8. Remove two screws and the Left Guide.

4004D117AA


D-15

NOTE• At reinstallation, ensure that the front hook makes

positive engagement.

4004D197AA

9. Remove one screw and the holder.

4004D118AA

10. Remove four screws, unplug two connectors, and remove LED Assy C.

11. Following the same procedure as when removing LED Assy C, remove LED Assemblies M and Y.

4004D119AB

12. Remove 23 screws and the LED Board Cover.

NOTE• The illustration shows only the representative

screw. Remove all (23 in total) LED Board Cover mounting screws.

4004D120AB

13. Unplug two connectors.14. Remove nine screws and the LED Board.

4004D121AB


2-3. MAINTENANCE S

• To ensure that the copier prodmended that the maintenance instructed.

PM Parts

Maint

Clean

Pap

er T

ake-

Up

Sec

tion

Paper Take-Up RollWhen

malfuncoccur

Separator Roll AssyWhen

malfuncoccur

IR S

ectio

n

Scanner RailWhen

malfuncoccur

Mirrors (1st, 2nd, and 3rd)When

malfuncoccur

LensWhen

malfuncoccur

Original Glass Upon c

Imag

e T

rans

fer

Sec

tion

Transfer Belt Unit (1)When

malfuncoccur

Transfer Roller Unit (1) —

Synchronizing Roller 60 K

Paper Dust Remover (1) 60 K

Waste Toner Bottle —

Around waste toner collecting port

Upon c

Dev

elop

ing

Sec

tion

Imaging Unit C/M/Y —

Imaging Unit Bk —

LED

Each timeach Ima

Unit isreplace

Ozone Filter (1) —

Fus

ing

Sec

tion

Fusing Unit —

Fusing Web Unit —

Oil Coating Unit —

Fusing Entrance Guide Plate

Whenmalfunc

occur


CHEDULE

uces good copies and to extend its service life, it is recom-jobs described in this schedule be carried out as

enance Cycle

Parts No. QtyRef. Page in This Manual

Ref. Page in Unit

Replacement Manual

Replace

tion s

200 K4004-3002-014658-3027-01

1 D-38

D-60—

tion s

200 K 4658-0151-01 1 D-38

D-61—

tion s

— — — D-25 —

tion s

— — — D-25 —

tion s

— — — D-25 —

all — — — D-26 —

tion s

121 K 4697-161 1 — P-26

121 K 4697-171 1 — P-26

— — — D-38 —

121 K 4004-0156-02 1 D-39 P-26

(2) 4697-101 1 — P-19

all — — — D-40 —

4562 M —1

each— P-11

7204 M — 1 — P-21

D-16

e ging d

— — — D-40 —

121 K 4004-0347-01 1 — P-26

102 (3)4697-111 (100 V)4697-121 (120 V)4697-131 (230 V)

1 — P-22

(4) 4697-141 1 — P-2

34 K or 325,000

sec4697-151 1 — P-6

tion s

— — — D-41 —


D-17

1: Replace the Transfer Belt Unit, Transfer Roller Unit, Paper Dust Remover, and Ozone Filter at the same time.

2: About 4.5 K after a waste toner near full condition has been detected. 3: Forced to a stop when 110 K is reached. 4: About 1 K after 17 K has been reached or a web near empty condition has been

detected.

NOTES• K = 1,000 copies• The contents of the above maintenance schedule are subject to change without notice.


D-18

2-4. Guidelines for Life Specifications Values by Unit

NOTES• The life specifications values represent the number of copies made or figures equivalent

to it when given conditions are met. They can be more or less depending on the copier operating conditions of each individual user.

• The initiation of a new copy cycle is inhibited upon 1 K after a near life condition has been detected for all units (except the Toner Bottle and Waste Toner Bottle).

M: minutes

UnitLife

Spec. Value

Copying Condition Description

Near Life Value Life Value

Toner Bottle — B/EAn approximate life value is 10 K under the specified conditions. — 10 K

Waste Toner Bottle 40 K B/C/D/E/F

A waste toner full condition is detected when about 4.5 K copies are made after a waste toner near-full condition has been detected.

— 40 K

Fusing Web Unit 17 K B/C/D/F

The life specifications value is based on A4C or Letter C. A near life condition is detected when a web empty condition is detected or a predetermined number of copies are made, whichever arrives ear-lier.

16 K 17 K

20-cpm copier Oil Coating Unit

33 K

A/B/C/D/F

The life specifications value is based on A4C or Letter C. A near life condition or a life condition is detected when the Oil Coating Roller has turned a predetermined period of time or a predetermined number of copies are made, which-ever arrives earlier.

33 K 34 K

15-cpm copier Oil Coating Unit

26 K 26 K 27 K

Fusing Unit 101 K B/C/D/F The life specifications value is based on A4C or Letter C. 101 K 1 102 K

Transfer Belt Unit 120 K A/B/C/D/F The life specifications value is

based on A4C or Letter C.

2 120 K

(17400 M)

2 121 K

(17545 M)

20-cpm copier Imaging Unit (C, M, and Y)

30 K

A/B/C/D/F

The near life and life time values are detected when the PC Drum has turned or the Developing Unit has been energized for a predeter-mined period of time, whichever arrives earlier.

3 4415 M(30 K)

3 4562 M(31 K)

15-cpm copier Imaging Unit (C, M, and Y)

27 K3

4415 M(27 K)

3 4562 M(28 K)

20-cpm copier Imaging Unit (Bk)

50 K3

6972 M(50 K)

3 7122 M(51 K)

15-cpm copier Imaging Unit (Bk)

47 K3

6972 M(47 K)

3 7122 M(48 K)


D-19

1: As a rule, the Fusing Unit is to be replaced at the same time that the Fusing Web Unit is replaced a sixth time (17 K × 6 = 102 K). If the Fusing Web Unit is replaced before 17 K is reached, there will be a discrepancy in the replacement cycle, resulting in a near life and life value ranging between 90 K and 110 K.

2: The life of the Transfer Belt Unit is controlled based on the number of copies made. The life counter gives a time value display.

3: The life of the Imaging Unit is controlled based on a time value. The life counter gives a time value display.

• Conditions for Life Specifications Values

Copying Conditions 20-cpm Copier 15-cpm Copier

Job Type A Making two copies per job

Paper Size B A4 or Letter

Color Ratio C C (color) to Bk (black) = 5 to 1 C (color) to Bk (black) = 2.5 to 1

CV/M D 6 K 3.5 K

Original Density E B/W = 5 % for each color

No. of Operating Days per Month

F 20 days (Power Switch turned ON and OFF 20 times per month)


D-20

2-5. Removal of Units• Note that replacement of a unit may call for recheck and readjustments of some items.

NOTE• For the removal of the Imaging Unit, Transfer Belt Unit, Fusing Unit, Fusing Web Unit,

and Oil Coating Unit, see the Unit Replacement Manual.

Transfer Belt Unit

4004D182AA

LED Unit

Hopper Unit

Imaging Unit

Oil Cleaning UnitFusing Web Unit

Fusing Unit


D-21

(1) Removal of the Toner Hopper Unit



1. Remove the Paper Output Cover.2. Open the Front Door.3. Remove the Toner Supply Door.4. Remove the Hopper Left Cover.5. Slide out the Imaging Unit (C/M/Y/Bk). Unit Replacement Manual

NOTES• After the Imaging Unit has been pulled out, place the Imaging Unit lock lever back into

the locked position.• When sliding the Imaging Unit back in, make sure that the shutter is opened if the Imag-

ing Unit Lower Cover is not to be used.

6. Remove two screws and the Right Front Cover.

4004D043AA

7. Remove two screws and the Front Door Switch Cover.

4004D044AA

8. Disconnect three terminals. Terminals: Blue, white, and green from top down

4004D045AA


D-22

(2) Removal of the LED Unit



1. Open the Front Door.2. Slide out the Imaging Unit (C/M/Y/Bk). Unit Replacement Manual

NOTES• After the Imaging Unit has been pulled out, place the Imaging Unit lock lever back into

the locked position.• When sliding the Imaging Unit back in, make sure that the shutter is opened if the Imag-

ing Unit Lower Cover is not to be used.

3. Open the Right Door and Rear Left Cover.4. Remove the Ozone Filter, Waste Toner Bottle, and Transfer Belt Unit.5. Remove the Rear Cover and Rear Left Cover.

9. Unplug three connectors.10. Remove five screws and the Toner Hopper Unit.

4004D046AB

6. Remove five screws and the cover.

4004D229AA

7. Remove one screw and unplug one connector on the PIC Board.

4004D047AA


4004D048A

4004D232A

A

B

4004D024A

NOTE• Make sure that all four hubs a


8. Unplug five connectors.

B

NOTE• When unplugging the connector, make sure that

connector A (on the copier side) is disconnected. Connector B (on the LED Unit side) should not be disconnected.

A

9. Lock the Imaging Unit (C/M/Y/Bk) drive hub.

NOTES• During the locking procedure, use care not to

touch the LED surface.• Should the LED surface be touched, clean it with

the LED Cleaning Jig. D-40

A

re locked in position.

D-23

4004D049AA


Precaution for Replacement of• When the LED Unit is to be rep

and remount it on the new oneThis step is not, however, nece

4004D050A

Precaution for Reinstalling th• The lever of the LED Unit mu

rear of the copier and anothe


the LED Unitlaced, remove the ATDC Sensor from the old LED Unit

.ssary if the Imaging Unit is replaced at the same time.

10. Remove two screws and slide out the LED Unit.

A

4004D051AALED Unit Lever

e LED Unitst be fit into the space between the metal bracket in the r lever as illustrated below.

D-24


2-6. Cleaning and Dis

(1) Cleaning of the Scanner

(2) Cleaning of the Mirrors (1

(3) Cleaning of the Lens

4004D198A

4004D199A

4004D001A

4004D200A


assembly of the IR Unit

Rails

st/2nd/3rd)

1. Remove the IR Right Cover and Original Glass.2. Using a soft cloth dampened with alcohol, wipe

the Scanner Rails clean of dirt.

NOTE• Apply lubricant after cleaning.

A

1. Remove the IR Right Cover and Original Glass.2. Using a soft cloth dampened with alcohol, wipe

mirrors clean of dirt.

A

1. Remove the IR Right Cover and Original Glass.2. Remove eight screws and the optical cover.

C

D-25

3. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt.

B


D-26

(4) Cleaning of the Original Glass

(5) Removal of the Original Glass Cooling Fan Motor

(6) Removal of the Scanner Motor

1. Using a soft cloth dampened with alcohol, wipe the Lens clean of dirt.

4004D201AA

1. Remove the IR Rear Upper Cover and IR Rear Cover.

2. Unplug one connector and remove the harness from one wiring saddle.

3. Remove two screws and the Original Glass Cool-ing Fan Motor.

4004D018AB

1. Remove the IR Rear Upper Cover, IR Rear Cover, and IR Rear Right Cover.

2. Remove the Original Glass Cooling Fan Motor.3. Remove two screws and the reinforcement

frame.

4004D015AA

4. Remove four screws and the hinge support in the rear of the IR.

4004D027AA


D-27

(7) Removal of IR Cooling Fan Motor 2

1. Remove the IR Right Cover.2. Remove the Original Glass.3. Remove the Control Panel.4. Remove the IR Lower Front Cover, IR Front Cover, and IR Rear Upper Cover.5. Remove the optical cover.

5. Remove the tension spring for the Scanner Motor timing belt.

4004D028AA

6. Remove the harness from one cord clamp and one edge cover.

7. Remove three screws and the Scanner Motor Assy.

4004D029AD

8. Remove two screws and the Scanner Motor.

4004D030AA

6. Remove three screws and the Imaging Process-ing Lid on the right inside the IR.

4004D002AB


D-28

(8) Removal of IR Cooling Fan Motor 1

(9) Removal of the Scanner Home Sensor

7. Remove four screws and the IR upper right metal bracket.

4004D004AA

8. Unplug one connector.9. Remove two screws and IR Cooling Fan Motor 2.

4004D032AD

1. Remove the IR Right Cover and Original Glass.2. Unplug one connector.3. Remove two screws and IR Cooling Fan Motor 1.

4004D034AB

1. Remove the Control Panel.2. Unplug one connector.3. Remove one screw and the Scanner Home Sen-

sor Assy.

4004D035AB

4. Remove one screw and the Scanner Home Sen-sor.

4004D036AB


D-29

(10) Removal of the Original Cover Detecting Sensor

(11) Removal of Original Size Detecting Sensors FD1 and FD2

1. Remove the IR Rear Upper Cover and IR Rear Cover.

2. Unplug one connector.3. Remove one screw and the Original Cover

Detecting Sensor Assy.

4004D037AA

4. Remove the sensor fixing bracket and the Origi-nal Cover Detecting Sensor.

4004D038AA

1. Remove the IR Right Cover and Original Glass.2. Unplug one connector.3. Remove one screw and Original Size Detecting

Sensor FD1.

4004D123AA

4. Unplug one connector.5. Remove one screw and Original Size Detecting

Sensor FD2.

4004D122AA


D-30

(12) Removal of Original Size Detecting Sensor CD1

(13) Removal of the Size Reset Switch

(14) Removal of the Scanner Assy

1. Remove the IR Right Cover and Original Glass.2. Unplug one connector.3. Remove one screw and Original Size Detecting

Sensor CD1.

4004D124AA

1. Remove the Control Panel and IR Front Cover.2. Unplug one connector.3. Remove one screw and Size Reset Switch.

4004D039AB

1. Remove the IR Right Cover and Original Glass.2. Move the Scanner Assy to the location shown

and remove one mounting screw each at the front and rear end.

4004D202AA

NOTE• Do not remove the Scanner Positioning Screw.

4004D203AA

Scanner mounting Screws

Scanner positioning Screws


D-31

(15) Removal of the Exposure Lamp

1. Remove the IR Right Cover and Original Glass.2. Remove the Scanner Assy. D-30

(16) Removal of the Temperature Fuse

1. Remove the IR Right Cover and Original Glass.2. Remove the Scanner Assy. D-30

3. Take out the Scanner Assy by turning it in the direction of the arrow shown.

NOTE• The Scanner Assy cannot be completely taken off

the copier as a Flat Cable is still connected to it at this time.

4004D017AB

4. Remove two screws, unplug one connector, and remove the Scanner Assy Flat Cable.

5. Remove the Scanner Assy.

4004D025AA

3. Remove the Exposure Lamp from the Lamp Ter-minals.

4. Remove the Exposure Lamp.

4004D040AB

3. Remove one screw and the fuse cover.

4004D041AA


D-32

(17) Removal of the Scanner Drive Cables

1. Remove the Control Panel.2. Remove the IR Right Cover, IR Lower Front Cover, IR Rear Upper Cover, and IR Rear

Cover.3. Remove the Original Glass.4. Remove the optical cover.5. Remove the Scanner Assy and Flat Cable. D-30, D-10

4. Remove two screws and the Temperature Fuse.

4004D042AB

6. Unhook the springs of the Scanner Drive Cables on the hook side, one each at the front and in the rear.

7. Remove the front and rear Scanner Drive Cables.

4002D110AB

8. Remove the Scanner Motor Assy. D-26 (steps 4 through 8)9. Remove one screw and then slide the front pulley

and bushing toward the rear.

4002D112AA

10. Remove one screw and then slide the rear pulley and bushing toward the front.

4002D113AA


D-33

(18) Winding of the Scanner Drive Cables

11. Remove the Scanner Drive Gear, pulleys and bushings at the front and rear, and the shaft.

4002D114AD

4002D001AA

Pulley A

Pulley D

Pulley E

Pulley B

Pulley F

Pulley C

1. Position the round bead of the Scanner Drive Cable in the pulley as shown.

NOTE• Make sure that the bead snugly rests in the slit in

the pulley.

Front

4002D002AA

2. Wind the fixed bead end of the cable around the pulley five turns clockwise, from the rear toward the front side.

4002D003AA


D-34

3. Wind the hook end of the cable around the pulley five turns counterclockwise, from the front toward the rear side.

NOTE• Make sure that no part of the cable rides on the

other.

4002D004AA

4. Slip the Cable Holding Jig onto the pulley to secure the cable in position.

4002D501AA

5. Position the round bead of the Scanner Drive Cable in the pulley as shown.

NOTE• Make sure that the bead snugly rests in the slit in

the pulley.

Rear

4002D002AA

6. Wind the fixed bead end of the cable around the pulley five turns clockwise, from the front toward the rear side.

4002D006AA

7. Wind the hook end of the cable around the pulley five turns counterclockwise, from the rear toward the front side.

NOTE• Make sure that no part of the cable rides on the

other.

4002D004AA


D-35

8. Slip the Cable Holding Jig onto the pulley to secure the cable in position.

4002D502AA

9. Mount the front and rear pulleys and bushings on the shaft and install the shaft to the Scanner Unit.

10. Mount the Scanner Drive Gear on the shaft and secure it in position with one screw.

4002D115AD

11. Install an Allen wrench into the holes in the shaft and the IR Base Plate.

4002D116AD

12. Slide the front pulley and bushing to the front and install one mounting screw.

4002D117AC

13. Slide the rear pulley and bushing to the rear and install one mounting screw.

4002D118AD


D-36

14. Wind the bead end of the cable around pulley C and pulley B, then hook the bead onto the Adjust-able Anchor.

Front

4002D008AAPulley B

Pulley C

15. Wind the hook end of the cable around pulley A and pulley B.

4002D009AAPulley A

Pulley B

16. Fit the hook end of the cable into the groove in the Cable Guide and hook the spring.

4002D119AB

17. Wind the bead end of the cable around pulley F and pulley E, then hook the bead onto the Adjust-able Anchor.

Rear

4002D010AAPulley E

Pulley F

18. Wind the hook end of the cable around pulley D and pulley E.

Pulley D

Pulley E

4002D011AA


D-37

20. Mount the Scanner Motor Assy.21. Remove the Cable Holding Jigs from the front and rear pulleys.22. Remove the Allen wrench.23. Mount the Scanner Assy and Flat Cable.24. Reinstall the optical cover.25. Reinstall the Original Glass.26. Reinstall the IR Right Cover, IR Lower Front Cover, IR Front Cover, IR Rear Upper

Cover, and IR Rear Cover.27. Reinstall the Control Panel.28. Adjust the position of the Scanner and 2nd/3rd Mirrors Carriage. D-90

NOTE• Whenever the Scanner Drive Cables have been removed, be sure to carry out the “FD-

Mag” adjustment procedure. D-85

19. Fit the hook end of the cable into the groove in the Cable Guide and hook the spring.

4002D120AB


D-38

2-7. CLEANING AND DISASSEMBLY OF THE ENGINE PARTS(1) Cleaning of the Paper Take-Up Roll

(2) Cleaning of the Paper Separator Roll

(3) Cleaning of the Synchronizing Rollers

1. Slide out the drawer.2. Using a soft cloth dampened with alcohol, wipe

the Paper Take-Up Roll clean of dirt.

4658D005AA

1. Remove the Paper Separator Roll Mounting Assy.

D-612. Using a soft cloth dampened with alcohol, wipe

the Paper Separator Roll clean of dirt.

4658D006AA

1. Open the Right Door.2. Remove two screws and the guide.

4004D204AB

3. Using a soft cloth dampened with alcohol, wipe the Synchronizing Rollers clean of dirt.

4004D205AC


D-39

(4) Cleaning of the Paper Dust Remover

(5) Cleaning of the Transfer Belt Unit

NOTES• If any solvent is to be used, select one from among the following:

IPA, ethyl alcohol, PPC Cleaner, and Solmix AP-7.• When the solvent has been used for cleaning, make 28 or more copies using A3 blank

sheets of paper to remove image noise.

1. Open the Right Door.2. Remove the Paper Dust Remover.

4004D206AB

3. Using a brush, whisk dust off the Paper Dust Remover.

4004D207AA

1. Remove the Transfer Belt Unit. Unit Replacement Manual2. Wipe the surface of the Transfer Belt with a dry

cloth.

NOTES• If the dry cloth is not effective in removing dirt,

dampen it with alcohol.• Do not use a cloth wet with water.4004D228AA


(6) Cleaning of the LED

NOTE• Whenever the Imaging Unit ha

light blocking bag (black) or ligdark place. Avoid leaving it to

1. Open the Front Door.2. Remove the Imaging Unit (C/3. Wipe the LED of the LED Ass

reciprocating cycles.

NOTE• Use the specified LED Cleanin

(7) Cleaning of the Area arou

4004D221A


s been slid out of the copier, be sure to cover it with the ht blocking cloth for packing purposes and place it in a stand for a long time.

M/Y/Bk).y with the LED Cleaning Jig clean by moving the jig three

g Jig only.

nd the Waste Toner Collecting Port

4004D223AB

1. Open the Rear Left Cover.

D-40

2. Remove the Waste Toner Bottle.

A


D-41

(8) Cleaning of the Fusing Entrance Guide Plate

(9) Removal of the Imaging Unit Motor C/M/Y/Bk



1. Remove the Rear Cover.2. Open the Upper Right Door.3. Remove the Rear Upper Cover.4. Open the Right Door.5. Remove the Rear Right Cover.6. Remove the Ozone Filter.7. Open the Left Door.8. Remove the Waste Toner Bottle.9. Remove the Rear Left Cover.

3. Wipe the areas around the Waste Toner Collect-ing Port clean of spilled toner and dirt using a soft cloth dampened with water or alcohol.

4004D222AB

1. Remove the Fusing Unit. Unit Replacement Manual2. Wipe the Fusing Entrance Guide Plate clean of

dirt using a waste cloth dampened with alcohol.

4004D208AA

10. Remove six screws and the MSC Cover.

4004D052AB


D-42

11. Remove two screws and the mounting bracket.

4004D053AA

12. Unplug two connectors of the 2nd Drawer.

4004D054AA

13. Remove two screws and the power line mounting bracket for the 2nd Drawer.

14. Remove the harness from two wiring saddles.

4004D055AA

15. Unplug eight connectors.16. Remove 11 screws and the MSC/PIC Board Box.

4004D056AB

17. Remove the LED Unit. D-2218. Unplug two connectors.19. Remove four screws and Imaging Unit Motor Y.

4004D057AB


D-43

(10) Removal of the Main Motor

(11) Removal of the Ozone Ventilation Fan Motor

(12) Removal of the Fusing Drive Motor

20. Remove the harness from the wiring saddle. Wiring saddle: Two for M/C; one for Bk21. Unplug two connectors each.22. Remove four screws each and Imaging Unit

Motor M/C/Bk.

4004D058AB

1. Remove the MSC/PIC Board Box. D-41 (steps 1 through 8)2. Unplug one connector.3. Remove four screws and the Main Motor.

4004D060AA

1. Remove the MSC/PIC Board Box. D-41 (steps 1 through 8)2. Unplug one connector.3. Remove four screws and the Ozone Ventilation

Fan Motor.

4004D061AC

1. Remove the MSC/PIC Board Box. D-41 (steps 1 through 8)2. Unplug one connector.3. Remove four screws and the Fusing Drive Motor.

4004D062AB


D-44

(13) Removal of the Fusing Pressure/Retraction Motor

1. Remove the MSC/PIC Board Box. D-41 (steps 1 through 8)2. Remove the Fusing Drive Motor.

3. Remove two screws and the harness holder.

4004D063AA

4. Unplug two connectors.5. Remove three screws and the Fusing Pressure/

Retraction Motor Assy.

4004D064AA

6. Snap off one E-ring and remove the gear and pin.

NOTE• Use care not to lose the pin.

7. Snap off one E-ring and remove the bushing.8. Remove two screws and the Fusing Retraction

Position Sensor mounting bracket.

4004D125AA

9. Remove the gear (black).

4004D209AA

10. Remove two screws and the Fusing Pressure/Retraction Motor.

4004D126AB


D-45

(14) Removal of the 1st Image Transfer Pressure/Retraction Motor

4004D065AB

Precaution for Reinstallation• When reinstalling the harness holder,

make sure that the protrusion on the backside of the holder fits into the hole in the metal bracket.

1. Remove the MSC/PIC Board Box. D-41 (steps 1 through 8)2. Unplug three connectors and remove two termi-

nals.3. Remove six screws and High Voltage Unit 2.

4004D066AA

4. Unplug one connector.5. Remove three screws and the Fusing Cooling

Fan Motor 2 Unit.

4004D067AB

6. Remove four screws and, sliding the board holder to the left, take it off.

4004D068AA

7. Unplug one connector.8. Remove two screws and the 1st Image Transfer

Pressure/Retraction Motor.

4004D069AA


D-46

(15) Removal of Toner Replenishing Motor C/Bk

(16) Removal of Toner Replenishing Motor Y/M

(17) Removal of the Cleaning Web Drive Motor

1. Remove the Toner Hopper. D-212. Remove the Upper Right Front Cover.3. Open the Right Door and Upper Right Door.4. Slid out the Fusing Unit.

1. Open the Front Door.2. Remove the Right Front Cover.3. Unplug one connector.4. Remove four screws and the Toner Replenishing

Motor C/Bk Assy.

4004D071AB

1. Remove the Toner Hopper. D-212. Remove two screws and the Front Door Switch

Assy.

4004D072AA

3. Unplug one connector.4. Remove four screws and the Toner Replenishing

Motor Y/M Assy.

4004D073AE

5. Remove three screws and the Upper Right Front Cover Guide.

4004D127AA


D-47

(18) Removal of the Power Supply Cooling Fan Motor

6. Unplug one connector.7. Remove two screws and the Cleaning Web Drive

Motor Assy.

4004D128AB

8. Remove two screws and the Cleaning Web Drive Motor.

4004D129AA

4004D130AA

Gear Assy Construction

1. Remove the Paper Output Cover, Rear Cover, and Rear Upper Cover.

2. Remove six screws and the DC Power Supply 1 Cover.

4004D074AA


D-48

(19) Removal of Fusing Cooling Fan Motor 2

(20) Removal of Fusing Cooling Fan Motor 1

4004D075AB

3. Unplug 15 connectors and remove the harness from 13 cord clamps and five wiring saddles.

4. Remove nine screws and DC Power Supply 1.

5. Remove two screws and the Power Supply Cool-ing Fan Motor.

4004D076AA

1. Remove the Paper Output Cover, Rear Cover, and Rear Upper Cover.

2. Unplug one connector.3. Remove two screws and Fusing Cooling Fan

Motor 2.

4004D077AC

1. Open the Right Door.2. Open the cover.3. Unplug one connector.

4004D078AA


D-49

4. Disengage the lock at the front.

4004D079AB

Lock

5. Disengage the lock in the rear and remove the 2nd Image Transfer Roller.

4004D080AB

Lock

6. Remove ten screws and the Right Door reinforce-ment frame.

4004D081AB

7. Remove two screws and the support.8. Remove four screws and the fan motor duct.

4004D082AC

9. Remove two screws and Fusing Cooling Fan Motor 1.

4004D083AA


D-50

(21) Removal of the 2nd Image Transfer Pressure/Retraction Clutch

(22) Removal of the Synchronizing Roller Clutch

1. Open the Right Door.2. Remove the 2nd Image Transfer Pressure/Retraction Clutch.3. Remove the 2nd Image Transfer Roller.

1. Open the Right Door.2. Unplug one connector.3. Snap off one C-clip and remove the 2nd Image

Transfer Pressure/Retraction Clutch.

4004D084AA

NOTE• When reinstalling the 2nd Image Transfer Pres-

sure/Retraction Clutch, make sure that it is installed correctly as shown.

4004D210AA

4. Unplug one connector of the Synchronizing Roller Clutch.

4004D085AA

5. Snap off one C-clip and remove the Synchroniz-ing Roller Clutch.

4004D086AC


D-51

(23) Removal of the Manual Feed Paper Take-Up Clutch

NOTE• When reinstalling the Synchronizing Roller Clutch,

make sure that it is installed correctly as shown.

4004D211AA

1. Remove the Rear Right Cover.2. Unplug one connector.3. Remove four screws and the Manual Bypass

Unit.

4004D087AB

4. Remove one screw and the ground plate.

4004D088AB

5. Unplug one connector.6. Snap off one C-clip and remove the Manual Feed

Paper Take-Up Clutch.

4004D089AA

NOTE• When reinstalling the Manual Feed Paper Take-Up

Clutch, make sure that it is installed correctly as shown.

4004D212AB


D-52

(24) Removal of the Paper Take-Up Clutch

1. Remove the Rear Cover and Rear Right Cover.2. Remove the MSC/PIC Board Box. D-41 (steps 1 through 14)3. Remove the Main Motor.

4. Unplug two connectors, disconnect three ground connections, and remove the harness from the wiring saddle.

5. Remove two screws and the hookup connector metal bracket.

4004D090AC

6. Remove two screws and the harness guide.7. Remove the harness from one edge cover.

4004D091AB

8. Remove one bearing.9. Snap off three E-rings and remove three bush-

ings.10. Remove nine screws and the Gear Assy Guide.

4004D092AB

11. Remove one gear.12. Snap off one E-ring and remove the Paper Take-

Up Clutch.

4004D093AC


D-53

(25) Removal of AIDC/Registration Sensor 1/2

NOTE• When reinstalling the Paper Take-Up Clutch, make

sure that it is installed correctly as shown.

4004D213AA

1. Open the Right Door.2. Remove four screws and the Synchronizing

Roller entrance guide.

4004D094AA

3. Remove four screws and the cover.

4004D230AA

4. Remove two screws, unplug one connector, and remove AIDC/Registration Sensor 1.

4004D095AA

5. Remove two screws, unplug one connector, and remove AIDC/Registration Sensor 2.

4004D096AA


D-54

(26) Removal of the Temperature/Humidity Sensor

(27) Removal of the Toner Supply Door Sensor

(28) Removal of the Manual Feed Paper Take-Up Sensor

1. Remove the Rear Right Cover.2. Remove the Manual Bypass Unit. D-513. Remove the ground plate. D-50

1. Remove the Synchronizing Roller entrance guide.

D-53 (steps 1 and 2)2. Remove one screw, two washers, and the cover.

4004D097AA

3. Remove one screw, unplug one connector, and remove the Temperature/Humidity Sensor.

4004D098AB

1. Remove the Toner Hopper. D-212. Unplug one connector.3. Remove the sensor fixing bracket and Toner

Supply Door Sensor.

4004D131AB

4. Unplug one connector.5. Remove the sensor fixing bracket and Manual

Feed Paper Take-Up Sensor.

4004D132AA


D-55

(29) Removal of the 1st Image Transfer Retraction Position Sensor

(30) Removal of the Double Feed Sensor

1. Remove the 1st Image Transfer Pressure/Retrac-tion Motor.

D-432. Remove four screws and the 1st Image Transfer

Retraction Position Sensor Assy.

4004D133AA

3. Unplug one connector.4. Remove the sensor fixing bracket and 1st Image

Transfer Retraction Position Sensor.

4004D134AA

1. Pressing the tabs of the right and left rails, slide out the drawer.

4004D135AA

4004D136AA

2. Unplug one connector.3. Remove one screw and the Double Feed Sensor.

4004D137AB


D-56

(31) Removal of the Drawer Set Sensor and Drawer Paper Near-Empty Sensor

1. Slide out the drawer.2. Remove the Rear Upper Cover, Rear Right Cover, Rear Left Cover, and Rear Cover.3. Remove the MSC/PIC Board Box. D-41 (steps 1 through 8)

4. Remove four terminals. Terminal colors: White, blue, red, and orange from

top down5. Remove two screws and the terminal harness

guide.

4004D138AB

6. Remove two screws and High Voltage Unit 1.7. Unplug two connectors.8. Remove the harness from one cord clamp and

one edge cover.

4004D140AB

9. Unplug three connectors.10. Remove the harness from one edge cover.11. Remove two screws and High Voltage Unit 1.

4004D139AA

12. Remove one screw and the sensor assy.13. Remove the harness from one edge cover and

unplug two connectors.

4004D141AB


D-57

(32) Removal of the Left Door Switch

(33) Removal of the Right Door Switch

14. Remove the sensor fixing bracket and take off the Drawer Set Sensor and Drawer Paper Near-Empty Sensor.

4004D142AA

1. Remove the power supply box. D-47 (steps 1 through 5)2. Remove two terminals.3. Remove one screw and the Left Door Switch.

4004D099AB

1. Remove the MSC/PIC Board Box. D-43 (steps 1 through 8)2. Remove two terminals.3. Remove one screw and the Right Door Switch

Assy.

4004D143AB

4. Remove one screw and the Right Door Switch.

4004D144AB


D-58

(34) Removal of the Front Door Switch

1. Open the Front Door.2. Open the Toner Supply Door.3. Remove the Hopper Left Cover.

(35) Removal of the Fusing Roller Rotation Detecting Sensor

1. Open the Right Door and Upper Right Door.2. Slide out the Fusing Unit.

(36) Removal of the Fusing Retraction Position Sensor

(37) Removal of the Exit Sensor

4. Remove two terminals.5. Remove two screws and the Front Door Switch.

4004D145AA

3. Unplug one connector.4. Remove two screws and the Fusing Roller Rota-

tion Detecting Sensor.

4004D146AA

1. Remove the Fusing Pressure/Retraction Motor Assy.

D-44 (steps 1 through 5)2. Remove the sensor fixing bracket and Fusing

Retraction Position Sensor.

4004D147AA

1. Open the Upper Right Door.2. Unplug one connector.3. Remove the sensor fixing bracket and Exit Sen-

sor.

4004D148AB


D-59

(38) Removal of the 2nd Image Transfer Pressure Position Sensor

1. Open the Right Door.2. Remove the 2nd Image Transfer Roller. D-48 (steps 1 through 3)

(39) Removal of the Synchronizing Roller Sensor

1. Open the Right Door.2. Remove the 2nd Image Transfer Roller. D-48 (steps 1 through 3)

(40) Removal of the OHP Detecting Sensor

3. Unplug one connector.4. Remove one screw and the 2nd Image Transfer

Pressure Position Sensor.

4004D151AA

3. Unplug one connector.4. Remove two screws and the Synchronizing

Roller Sensor.

4004D152AA

1. Open the Right Door.2. Remove the Paper Dust Remover Unit.

4004D153AA

3. Remove the 2nd Image Transfer Roller. D-48 (steps 1 through 3)4. Unplug one connector.5. Remove the sensor fixing bracket and OHP

Detecting Sensor.

4004D154AA


D-60

(41) Removal of the CD Paper Size Detecting Sensor Assy

1. Remove the LED Unit. D-222. Slide out the drawer. D-55 (step 1)

(42) Removal of the Paper Take-Up Roll

4004D156AA

Where Sensor Assy is Installed

Front

Rear

3. Pressing the portion indicated by the arrow of the CD Paper Size Detecting Sensor Assy, slide the assy to the right and take it off.

4004D506AB

4. Unplug two connectors.

4004D155AB

1. Slide out the drawer.2. Lock the Paper Lifting Plate into position.3. Snap off one C-clip from the Paper Take-Up Roll

Assy.4. Slide the Paper Take-Up Roll Assy to the rear

and take its shaft off the front bushing.

4658D008AA


D-61

(43) Removal of the Paper Separator Roll

(44) Removal of High Voltage Unit 1

D-45 (steps 1 through 2)

(45) Removal of High Voltage Unit 2/3


(46) Removal of DC Power Supply 1


5. Snap off one C-clip and remove the Paper Take-Up Roll.

4658D009AA

1. Slide out the drawer.2. Remove two screws and the Paper Separator

Roll mounting bracket assy.

4658D002AA

3. Take off the rubber stopper, shaft, spring, and guide plate to remove the Paper Separator Roll fixing bracket assy.

NOTE• At reinstallation, make sure that the rubber stopper

is on the rear side of the copier.

4658D003AA

4. Snap off one E-ring and the Paper Separator Roll Assy.

4658D004AA


D-62

(47) Removal of the Charge Neutralizing Relay

(48) Removal of the Waste Toner Full Detecting Sensor

(49) Removal of the Waste Toner Bottle Set Sensor

1. Remove the MSC/PIC Board Box. D-41 (steps 1 through 8)2. Remove four terminals.3. Remove one screw and the Charge Neutralizing

Relay.

4004D160AB

1. Remove the LED Unit. D-222. Remove one screw and the Waste Toner Full

Detecting Sensor Cover.

4004D161AA

3. Unplug one connector and remove the Waste Toner Full Detecting Sensor.

4004D162AB

1. Remove the LED Unit. D-222. Disengage two locking tabs and remove the

Waste Toner Bottle Set Sensor Assy.

4004D163AA


D-63

(50) Removal of the Toner Empty Switch (Y/M/C/Bk)

3. Unplug one connector.4. Remove one screw and the Waste Toner Bottle

Set Sensor.

4004D164AA

1. Open the Front Door.2. Remove six screws and the Toner Empty Switch

Cover.

4004D111AB

3. Unplug one connector each and remove the Toner Empty Switch.

4004D112AB


D-64

3. ADJUSTMENTS• The adjustment procedures must be carried out in the order of printer and IR.

3-1. ADJUSTMENT JIGS AND TOOLS USED

Scanner Positioning Jigs

Imaging Unit Pull-out Jig LED Cleaning Jig

LED Cleaning Jig Pad

4004D185AA 4004D186AA

4004D187AA

4002D503AA

Scanner Drive Cable Holding Jig

4004D510AA


D-65

3-2. ADJUSTMENT REQUIREMENTS LIST

Adjustment Item Requirements Ref. PageP

rinte

r

Touch Panel Adj. Automatically adjusted D-69

Top Margin 5.0 ± 1.0 mm D-70

Left Margin 3.0 ± 1.0 mm D-72

Dup. Left Margin 3.0 ± 1.0 mm D-73

Paper Loop Test print tilts ± 0. D-74

Color Shift CorrectionFD, CD, and tilt ± 0 with

reference to Bk. D-75

Fuser Nip 7 ± 0.5 mm D-78

Fuser Temp. — D-80

Fuser Speed — D-81

Gradation Adjust — D-87

PRT Max Density — D-88

PRT Highlight — D-88

Background Voltage Margin — D-89

IR

Left Image 0 ± 1.0 mm D-82

Top Image 10 ± 1.0 mm D-83

CD-Mag. 200 ± 1.0 mm D-84

FD-Mag. 300 ± 1.5 mm D-85

Org. Detect Sensor Automatically adjusted D-86


D-66

3-3. ADJUSTMENT OF SWITCHES(1) Microswitches

The following microswitches are used in various parts of this copier.

Requirement

Out-of-Adjustment (When the actuator is closed)• If the gap between the switch and actuator is too big, current dose not at times flow to NC

or NO.• If there is no gap between the switch and actuator, the actuator is bent or the switch can

be broken.

NC (Normally-Closed) : Current flows between NC and COM when the actuator is open.

NO (Normally-Open) : Current flows between NO and COM when the actuator is closed.

COM (Common) : Common contact for NC and NO.

Wiring for the NO Type Wiring for the NC Type

1136D007AA 1136D008AA

Yellow (NO)

Red (COM)

Blue (NC)

Red (COM)

1074D040AA

Actuator

COM NCNO0.1 mm to

0.5 mm

The gap between the switch and actuator should be 0.1 to 0.5 mm when the actuator is closed.


3-4. ADJUSTMENT O

Checks after Adjustment• Turn the timing belt and check• Each belt should flex a little wh

Reference• Since a given tension is applie

the tension of each timing belt,screw after it has been loosene

(1) Adjustment of the Scann

1. Remove the Original Glass C D-26

4004D188A

4004D231A


F BELT TENSION

that all the pulleys and grooves of the belt fit securely.en the belt is lightly pressed with a finger.

d by a tension spring to the Tension Lever that maintains adjustment is completed by re-tightening the mounting d.

er Motor Timing Belt

ooling Fan Motor.

2. Loosen the three screws that secure the Scanner Motor mounting bracket.

C

3. With the Scanner Drive Gear mounting screw positioned on the motor side, move the Scanner Motor to the right and left three times.

4. Tighten the three screws that secure the Scanner Motor mounting bracket.

B

D-67


D-68

3-5. ELECTRICAL/IMAGE ADJUSTMENT(1) Accessing the Tech. Rep. Mode

1. Press the Utility key.2. Touch [Meter Count].3. Press the following keys in this order:

Stop → 0 → 0 → Stop → 0 → 1

(2) Producing a Test Print

1. Call the Tech. Rep. Mode to the screen.2. Touch [Test Print].3. Select the desired test pattern type.4. Make the necessary settings.5. Press the Start key. Press the Stop key to terminate the Test Print function.


D-69

(3) Touch Panel Adj.

NOTE• Make this adjustment if the Touch Panel is slow to respond to a pressing action.

1. Press the following keys: Stop → 0 → Stop → 3

2. Using the tip of a pen or similar object, touch the four crosses (+) on the screen in sequence.

NOTES• These crosses may be touched in any order; but

be sure to touch the center of each cross.• Use care not to damage the screen surface with

the tip of the pen.

1155D191CA

3. The cross touched changes into a grid marker that consists of a square with a cross superim-posed.

4. Touch [END].

1155D192CA


D-70

(4) Top Margin

Requirement

The leading edge erase width is set to 5 mm or 7 mm by “Erase” under “Administrator Mode.”

This adjustment must be made in any of the following cases:• The LED Unit has been replaced.• The paper type has been changed.• The image on the copy deviates in the FD direction.• A faint image occurs on the leading edge of the image.• A misfeed occurs at the 2nd image transfer section.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “PRT Area” → “Top Margin.”3. Load the 1st Drawer with A3 plain paper.4. Select plain paper on the Paper Type Setting Dial.5. Press the Start key to let the copier produce a test pattern.6. Check the dimension of width A on the test pattern.

If width A is outside the specified range:7. Touch “Paper Send Position” and then change the setting using the Up/Down key.

Adjustment InstructionsIf width A is longer than the specifications, make the setting value smaller than the current one.If width A is shorter than the specifications, make the setting value greater than the current one.

8. Press the Start key to let the copier produce a test pattern.9. Check the dimension of width A on the test pattern.10. If width A is outside the specified range, change the setting again and make a check

again.11. If width A falls within the specified range, touch “MENU.”12. Following the same procedure, adjust for thick paper and OHP.13. Go back to the initial Tech. Rep. Mode screen.14. Touch “Test Print.”15. Select “Halftone Pattern.”

Specifications Adjustment Mode Setting Range

5.0 or 7.0 ± 1.0 mm Top Margin -2.0 mm to +2.0 mm

Width A on the test pattern produced should fall within the following range.

4004D511AA

Width A


D-71

16. Select “Cyan,” “SINGLE,” and “HYPER.”17. Press the Clear key to clear the density setting.18. Enter “255” from the 10-Key Pad.19. Press the Start key to let the copier produce a test pattern.20. Check to see if the image on the leading and trailing edges of the test pattern is faint.

If the image is faint:21. Touch these keys in this order: “Machine Adjust” → “PRT Area” → “Top Margin.”22. Touch “2nd Transfer Timing” and then use the Down key to decrease the setting.

NOTE• Decreasing the setting makes transfer timing faster. An abnormally low setting could,

however, result in a paper misfeed.

23. Touch “MENU.”24. Produce a halftone test pattern again.25. Check the image on the leading and trailing edges of the test pattern.26. If the image on the leading and trailing edges of the test pattern is faint, change the set-

ting and make a check again.


D-72

(5) Left Margin

Requirement

This adjustment must be made in any of the following cases:• The LED Unit has been replaced.• A paper feed unit has been added.• The image on the copy deviates in the CD direction.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “PRT Area” → “Left Margin.”3. Load the 1st Drawer with A3 plain paper.4. Select plain paper on the Paper Type Setting Dial.5. Select the 1st Drawer.6. Press the Start key to let the copier produce a test pattern.7. Check the dimension of width A on the test pattern.

If width A is outside the specified range:8. Touch “1st” and then change the setting using the Up/Down key.



again.12. If width A falls within the specified range, touch “MENU.”13. Following the same procedure, adjust for all other paper sources.


3.0 ± 1.0 mm Left Margin -3.0 mm to +3.0 mm


4004D512AA

Width A


D-73

(6) Dup. Left Margin

Requirement

This adjustment must be made in any of the following cases:• The Duplex Unit has been set up.• The image on the backside of the 2-sided copy deviates in the CD direction.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “PRT Area” → “Dup. Left Margin.”3. Load the 1st Drawer with A3 plain paper.4. Select plain paper on the Paper Type Setting Dial.5. Select the 1st Drawer.6. Press the Start key to let the copier produce a test pattern.7. Check the dimension of width A on the test pattern.

If width A is outside the specified range:8. Touch “1st” and then change the setting using the Up/Down key.



again.12. If width A falls within the specified range, touch “MENU.”13. Following the same procedure, adjust for all other paper sources.


3.0 ± 1.0 mm Dup. Left Margin -3.0 mm to +3.0 mm


NOTE• Make this check with the backside of the test pat-

tern produced.

4004D512AA

Width A


D-74

(7) Paper Loop

Requirement

This adjustment must be made in any of the following cases:• The void image along the leading edge varies from one copy to another.• Paper skew occurs.• Paper is folded.• Paper misfeed occurs.

Adjustment Procedure1. Select the paper source, for which the adjustment is to be made.2. Call the Tech. Rep. Mode to the screen.3. Touch “Test Print.”4. Touch “Halftone Pattern.”5. Press the Start key and then immediately press the Stop key to let the copier produce

the test pattern.6. Fold the test pattern in half lengthwise to check for deviation in the pattern.

If there is any deviation in the pattern:7. Go back to the Tech. Rep. Mode initial screen.8. Touch “Machine Adjust.”9. Touch “Paper Loop.”10. Select the paper and paper source to be adjusted.11. Press the Clear key to clear the current setting.12. Enter the setting from the 10-Key Pad. Use the Access key to select the sign of + or -.

Setting InstructionsIf the test pattern deviates in the direction of A, decrease the setting.If the test pattern deviates in the direction of B, increase the setting.

13. Touch “MENU.”14. Let the copier produce a test pattern again.15. Check the test pattern for deviation.16. If there is any deviation, change the setting for Paper Loop and make a check again.17. If there is no deviation, use the same procedure to adjust for all other paper types and

sources.

Adjustment Mode Setting Range

Paper Loop -5 to +5

The test pattern produced should not deviate in the direction of either A or B.

4004D520AA

A B


D-75

(8) Color Shift Correction

This adjustment must be made in the following case:• Color shift occurs.

Adjustment Procedure1. Make the “Paper Loop” adjustment. D-742. Go back to the Tech. Rep. Mode initial screen.3. Touch these keys in this order: “Machine Adjust” → “Color Shift Correction.”4. Touch “Color Shift Correction (Bk).”5. Press the Start key to let the copier produce a test pattern.6. Fold the test pattern in half lengthwise.7. Check to see if the black cross at the location shown below deviates or not.8. If it deviates, change the setting using the Up/Down key.

If it does not deviate, go to step 12.

Setting Instructions

9. Press the Start key to let the copier produce a test pattern.10. Check to see if the cross on the test pattern deviates.11. If it deviates, change the setting and then make a check again.

If it does not deviate, go to step 12.12. Touch “MENU.”13. Touch “Color Shift Correction (C).”14. Press the Start key to let the copier produce a test pattern.15. Check to see if any of the cyan, magenta, and yellow crosses deviates with reference to

the black cross.

4004D509AB

If the cross deviates in the direction of A, decrease the setting.If the cross deviates in the direction of B, increase the setting.

Check Position

BA


D-76

If any of the crosses deviates:16. Touch the color of the deviated cross.17. Change the settings for X and Y using the Up/Down key.


4004D507AB

For X direction:

Check PositionBA


4004D508AB


For Y direction:

Check PositionB

A


D-77

18. Fold the test pattern in half lengthwise.19. Check to see if any of the cyan, magenta, and yellow crosses deviates with reference to

the black cross.

If any of the crosses deviates:20. Touch the color of the deviated cross.21. Change the setting for skew using the Up/Down key.


22. Press the Start key to let the copier produce a test pattern.23. Check to see if any of the cyan, magenta, and yellow crosses deviates with reference to

the black cross.24. If any of the crosses deviates, change the setting and make a check again.

4004D521AA


Check PositionBA


D-78

(9) Fuser Nip

Requirement

This adjustment must be made in any of the following cases:• Fusing performance is poor.• A misfeed occurs at the fusing section.• Gloss failure occurs.• Image problems relating to copies made on OHP transparencies occur.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “Fuse Nip.”3. Load the 1st Drawer with A4 crosswise paper.4. Select plain paper on the Paper Type Setting Dial.5. Press the Start key to let the copier produce a test pattern.6. Check the nip width on the test pattern.

If the nip width is outside the specified range:7. Slide out the Fusing Unit. Unit Replacement Manual8. Remove the front and rear covers from the Fusing Unit.


7.0 ± 0.5 mm Fuser Nip —

The nip width on the test pattern produced should fall within the following range.

4004D513AA

Nip Width

9. Turn the adjusting screws at the front and rear to adjust the nip width.

4004D217AB


D-79

Adjustment InstructionsIf the nip width on the test pattern is longer than the specifications, loosen the adjusting screws.If the nip width on the test pattern is shorter than the specifications, tighten the adjusting screws.

10. Reinstall the front and rear covers and the Fusing Unit in position.11. Close the Right Door and Upper Right Door.12. Produce a test pattern again.13. Check the nip width on the test pattern.14. If the nip width does not fall within the specifications, turn the adjusting screws as nec-

essary and then make a check again.


D-80

(10) Fuser Temp.

This adjustment must be made in the following case:• Fusing performance is poor or offset occurs when the paper type or environmental condi-

tions are changed.

As a general rule, the following settings should not be changed:• Plain (Lower)• OHP Film (Lower)• Thick 1 (Lower)• Thick 2 (Lower)

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “Fuse Temp.”3. Select the paper type.4. Press the Clear key to clear the current setting.5. Enter the new setting from the 10-Key Pad. Use the Access key to select the sign of + or -.

Adjustment InstructionsIf fusing performance is poor, increase the setting.If offset occurs, decrease the setting. The temperature does not change immediately when the setting is change. Wait a while

before performing the subsequent steps.

6. Touch “MENU.”7. Go back to the Basic screen.8. Make an ordinary copy using the paper type selected in step 3.9. Check the image on the copy to ensure that there are no image problems evident.10. If fusing performance is still poor or offset is evident, change the setting and make a

check again.


D-81

(11) Fuser Speed

This adjustment must be made in the following case:• Brush effect or blurred image is evident as a result of changes in environmental condi-

tions or degraded durability.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “Fuse Speed.”3. Select the paper type.4. Press the Clear key to clear the current setting.5. Enter the new setting from the 10-Key Pad. Use the Access key to select the sign of + or -.

Adjustment InstructionsIf brush effect is evident, decrease the setting.If a blurred image occurs, increase the setting.

6. Touch “MENU.”7. Go back to the Basic screen.8. Make an ordinary copy using the paper type selected in step 3.9. Check the image on the copy to ensure that there are no image problems evident.10. If brush effect or blurred image is still evident, change the setting and make a check

again.


D-82

(12) Left Image

Requirement

This adjustment must be made in any of the following cases:• The Original Glass has been replaced.• The Scanner Home Sensor has been replaced.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “IR Area.”3. Touch “Left Image.”4. Place a scale on the Original Glass so that it runs parallel with the Original Width Scale

and its leading edge is aligned with the Original Length Scale.5. Press the Start key to make a copy.6. Check the image on the copy produced.

If the image does not meet the specifications:7. Change the setting using the Up/Down key.

Adjustment InstructionsIf the 0-mm position on the sample copy is on the right side of the correct 0-mm position perpendicularly to the feeding direction (less than -1 mm), decrease the setting.If the 0-mm position on the sample copy is on the left side of the correct 0-mm position per-pendicularly to the feeding direction (exceeding 1 mm), increase the setting.

8. Press the Start key to make a copy.9. Check the image on the copy to see if the specifications are met.10. If it fails to meet the specifications, change the setting and make a check again.11. If it meets the specifications, touch “MENU.”


0 ± 1.0 mm Left Image -10.0 to +10.0

The position of 0 mm of the scale on the sample copy produced should fall within the following range.

4004D514AA

Scale 0-mm Position


D-83

(13) Top Image

Requirement

This adjustment must be made in any of the following cases:• The CCD Unit has been replaced.• The Original Glass has been replaced.• The Original Scale has been replaced.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “IR Area.”3. Touch “Top Image.”4. Place a scale on the Original Glass so that it runs parallel with the Original Length

Scale and its leading edge is aligned with the Original Width Scale.5. Press the Start key to make a copy.6. Check the image on the copy produced.


Adjustment InstructionsIf the 10-mm position on the sample copy is on the right side of the correct 10-mm position parallel to the feeding direction (less than 9 mm), decrease the setting.If the 10-mm position on the sample copy is on the left side of the correct 10-mm position parallel to the feeding direction (exceeding 11 mm), increase the setting.



10.0 ± 1.0 mm Top Image -5.0 to +5.0

The position of 10 mm of the scale on the sample copy produced should fall within the following range.

4004D515AA

Scale 10-mm Position


D-84

(14) CD-Mag.

Requirement

This adjustment must be made in any of the following cases:• The CCD Unit has been replaced.• The lens has been replaced.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “IR Area.”3. Touch “CD-Mag.”4. Place a scale on the Original Glass so that it runs parallel with the Original Width Scale

and its leading edge is aligned with the Original Length Scale.5. Press the Start key to make a copy.6. Check the image on the copy produced.


Adjustment InstructionsIf the specified width on the copy is less than 199 mm, increase the setting.If the specified width on the copy exceeds 201 mm, decrease the setting.



200 ± 1.0 mm CD-Mag. 0.990 to 1.010

The 200-mm width of the scale on the sample copy produced should fall within the following range.

4004D516AB

200 mm


D-85

(15) FD-Mag.

Requirement

This adjustment must be made in any of the following cases:• The Scanner Assy has been replaced.• The Scanner Motor has been replaced.• The Scanner Drive Cables have been replaced.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Machine Adjust” → “IR Area.”3. Touch “FD-Mag.”4. Place a scale on the Original Glass so that it runs parallel with the Original Length

Scale and its leading edge is aligned with the Original Width Scale.5. Press the Start key to make a copy.6. Check the image on the copy produced.


Adjustment InstructionsIf the specified width on the copy is less than 298.5 mm, increase the setting.If the specified width on the copy exceeds 301.5 mm, decrease the setting.



300 ± 1.5 mm FD-Mag. 0.990 to 1.010

The 300-mm width of the scale on the sample copy produced should fall within the following range.

4004D517AB

300 mm


D-86

(16) Org. Detect Sensor

This adjustment must be made in any of the following cases:• The Original Size Detecting Sensor has been replaced.• The optional Original Size Detecting Sensors have been added.• The copier fails to detect the size of the original correctly.

Adjustment Procedure1. Place a blank sheet of A3 paper on the Original Glass and lower the Original Cover.2. Call the Tech. Rep. Mode to the screen.3. Touch these keys in this order: “Machine Adjust” → “Org. Detect Sensor.”4. Press the Start key.

If the adjustment has been successfully made, it completes the adjustment procedure.If the adjustment has turned out to be unsuccessful, check the optional Original Size Detecting Sensors for correct installation and change the defective sensor or harness.


D-87

(17) Gradation Adjust

This adjustment must be made in the following case:• Color reproduction performance becomes poor.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch “Gradation Adjust.”3. Press the Start key to let the copier produce a test pattern.4. Place the test pattern produced on the Original Glass.5. Place ten blank sheets of A3 paper on the test pattern and then lower the Original

Cover.6. Press the Start key (to let the copier start scanning the original). When the copier completes scanning the data on the original, the “Tech. Rep. Mode” ini-

tial screen reappears.

7. Repeat steps from 2 to 6 twice (a total of three cycles).8. Touch “Gradation Adjust” and check the Conv. Value on the screen.

Results:If Max. falls within 0 ± 100 and Highlight within 0 ± 60, then it completes the adjustment procedure.If neither Max. nor Highlight falls outside the specified range, perform steps from 2 to 6.If the specifications are not met after another cycle of steps 2 to 6, make a copy and check the image.

9. For any image quality problem, take action by referring to TROUBLESHOOTING.


D-88

(18) PRT Max Density

This adjustment must be made in the following case:• An image quality problem is not corrected even after Gradation Adjust has been run.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Image Adjust” → “PRT Max Density.”3. Select the color to be adjusted.4. Press the Clear key to clear the current setting.5. Enter the new setting from the 10-Key Pad. Use the Access key to select the sign of + or -.6. When the adjustment has been made, touch “MENU” to go back to the “Image Adjust”

menu screen.7. Touch “Stabilizer.”8. Select “Stabilizer Mode.”9. Press the Start key to validate the adjustment value.

(19) PRT Highlight

This adjustment must be made in the following case:• An image quality problem is not corrected even after Gradation Adjust has been run.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Image Adjust” → “PRT Highlight.”3. Select the color to be adjusted.4. Press the Clear key to clear the current setting.5. Enter the new setting from the 10-Key Pad. Use the Access key to select the sign of + or -.6. When the adjustment has been made, touch “MENU” to go back to the “Image Adjust”



D-89

(20) Background Voltage Margin

This adjustment must be made in the following case:• Foggy background occurs.

Adjustment Procedure1. Call the Tech. Rep. Mode to the screen.2. Touch these keys in this order: “Image Adjust” → “Background Voltage Margin.”3. Select the color to be adjusted.4. Press the Clear key to clear the current setting.5. Enter the new setting from the 10-Key Pad. Use the Access key to select the sign of + or -.6. When the adjustment has been made, touch “MENU” to go back to the “Image Adjust”



D-90

4. OTHER ADJUSTMENTS4-1. Adjustment of the Position of the Scanner and 2nd/3rd

Mirrors Carriage

Requirement• With the Scanner Assy fixed to the Scanner Drive Cables, there should be no gap

between the Scanner/Mirrors Carriage Positioning Jig and the Scanner and also between the Scanner/Mirrors Carriage Positioning Jig and the 2nd/3rd Mirror Carriage.

This adjustment must be made in any of the following cases:• The Scanner Drive Cable has been replaced.• The Scanner Fixing Bracket has been removed from the Scanner Drive Cable.• The Scanner Drive Cable comes unwound.

Adjustment Procedure

1. Remove the IR Rear Upper Cover, IR Front Cover, IR Right Cover, and Original Glass.

2. Move the Scanner Assy so that the Scanner Positioning Screw is aligned with the hole in the upper frame.

3. Insert a screwdriver into the hole in the upper frame and loosen the Scanner Positioning Screw.

4004D218AA

NOTE• Do not remove the Scanner Positioning Screw.

4004D203AA

Scanner positioning Screws

4. Install the Scanner Positioning Jigs between the Scanner Assy and the 2nd/3rd Mirrors Carriage Assy.

4004D219AA


D-91

(1) Adjustment of the 2nd/3rd Mirrors Carriage Assy for Parallel Alignment

NOTE• When installing the Scanner Positioning Jigs, be

sure to fit the tabs on the jigs into the holes at the front and rear ends of the frame.

4004D220AC

5. Press the Scanner Assy and 2nd/3rd Mirrors Car-riage Assy tightly up against the Scanner Posi-tioning Jigs.

4004D522AA

6. Tighten the two Scanner Positioning Screws.

4004D224AA

1. Remove the Original Glass.2. Loosen one screw that secures the adjusting

plate.

4002D235AB

3. Turn the adjusting screw as necessary.

4002D236AA

a b

Adjusting Screw


D-92

Adjustment InstructionsIf there is a gap between the 2nd/3rd Mirrors Carriage Assy and the Scanner Positioning Jig at the front, turn the adjusting screw clockwise.If there is a gap between the 2nd/3rd Mirrors Carriage Assy and the Scanner Positioning Jig in the rear, turn the adjusting screw counterclockwise.

4. Lightly press the 2nd/3rd Mirrors Carriage Assy up against the Scanner Positioning Jigs and make sure there is no gap.

5. Tighten one screw to secure the adjusting plate in position.


D-93

5. MISCELLANEOUS5-1. INSTALLATION OF THE MECHANICAL COUNTER (OPTION)1. Open the Front Door.2. Open the Toner Supply Door.3. Remove the Panel Cover.4. Open the Right Door.5. Remove the Front Right Cover.

6. Cut out the knockout in the Front Right Cover.

C4004U267AA

7. Remove two screws and the Right Front Cover.

C4004U268AA

8. Secure the mechanical counter with one screw.

C4004U269AA

9. Connect one connector.

C4004U270AA


D-94

5-2. MOUNTING OF THE ORIGINAL SIZE DETECTING SENSORS

(OPTION)

NOTE• When an Original Size Detecting Sensor has been added, select “SET” in “Org. Detect

Option Sensor” of “System Input” available from the “Tech. Rep. Mode” and run “Org. Detect Sensor” of “Machine Adjust.”

D-86

1. Remove the IR Right Cover and Original Glass.2. Remove the optical cover.3. Install the harness.4. Mount the Original Size Detecting Sensor (option).

How the Harness should be Placed

4004D523CA

FD1Optional for the U.S.A.

FD3Optional for the Europe, U.S.A., Taiwan.

E

CD2Optional for the Europe, U.S.A., Taiwan.

G

4004D524CA


D-95

5-3. FLASH MEMORYSoftware has conventionally been upgraded by replacing ROM on each board.This copier employs flash memory for the system control IC mounted on the MSC Board. Its contents are reprogrammed easily by performing the following steps using the IC card (memory card), into which data has been previously downloaded.

NOTE• NEVER remove or insert the memory card with the copier power turned ON.

1. With the Power Switch in the OFF position, unplug the power cord from the power out-let.

2. Remove the Ozone Filter.3. Open the Left Door.4. Remove the Waste Toner Bottle.5. Remove the Rear Left Cover.

7. Plug the power cord into the power outlet and turn ON the Power Switch. Four different types of F/W appear on the Touch Panel.

9. Press the Start key. This starts the data rewriting sequence. (At this time, the Start key starts blinking red.)

Time Required for RewritingFour types at once: Approx. 13 min.Individual: MSC (approx. 1 min. 30 sec.), PRT (approx. 6 min.), IR (approx. 7 min.),

PIC (approx. 6 min.)

10. Check that the Touch Panel shows the message indicating that the data has been rewritten correctly (“Downloading Completed”). Check also the Check Sum value (“Check Sum XXXX”) shown on the Touch Panel. (The Start key blinks green.)

6. Insert the memory card into the slot.

4004D191AA

8. Select the particular type of F/W to be updated.

4004D519AB


D-96

11. Unplug the power cord from the power outlet.

NOTE• Do not turn OFF the Power Switch.

12. Remove the memory card from the slot and turn OFF the Power Switch.13. Check that the “ROM Version” of “Tech. Rep. Mode” matches the version marked on

the memory card.

Action When Data Transfer FailsIf “NG” appears on the Touch Panel, indicating that rewriting has been unsuccessful (in which case the Start key lights up red), take the following steps.

14. Perform the data rewriting procedure again.15. If the procedure is abnormally terminated, change the memory card for a new one and

try another rewriting sequence.16. If the procedure is still abnormally terminated, change the board that has caused “NG”

and carry out data rewriting procedure.


D-97

5-4. REMOUNTING RAM IC (IC5)

NOTE• If the MSC Board has replaced, be sure to remount RAM IC from the old to new board.• If the MSC Board has been replaced and RAM IC is not to be remounted, be sure to

record all data of User’s Choice and Tech. Rep. Choice functions and make entries again of these numeric values. Note that the RAM IC contains no data in this case.

1. Remove the MSC Board.2. Remove RAM IC from the new MSC Board.3. Remove RAM IC from the old MSC Board and remount it onto the new MSC Board.

4002D225AA

NOTE• Note the alignment notch (A) on RAM IC when

mounting it.

4002D255AB

A

FrameMaker Ver5.5E(PC) CF1501/CF2001 SWITCHES ON PWBs/TECH. REP. SETTINGS00.11.30

SWITCHES ON PWBs, TECH. REP. SETTINGS

17196


i

CONTENTS1. CONTROL PANEL KEYS AND TOUCH PANEL .............................................S-1

1-1. Control Panel Keys ..................................................................................S-11-2. Explanation of the Touch Panel ...............................................................S-3

(1) Basic Screen ...................................................................................S-3(2) Warning Screens ............................................................................. S-4

2. FUNCTION OF SWITCHES AND OTHER PARTS ON PWBs ........................S-62-1. PWB Location ..........................................................................................S-62-2. PWB-H (MSC Board) ............................................................................... S-62-3. PWB-T (Tech. Rep. Setting Switches Board) ..........................................S-7

(1) Clearing Procedures ........................................................................S-7(2) Data/Conditions Cleared by Reset Switches/Pins ...........................S-8

3. UTILITY MODE ................................................................................................ S-93-1. Utility Mode Selection Screen ..................................................................S-93-2. Utility Mode Function Tree .......................................................................S-93-3. Settings in the Utility Mode ......................................................................S-10

(1) User’s choice mode ......................................................................... S-10(2) Administrator Mode ......................................................................... S-13

4. Tech. Rep. Mode .............................................................................................S-174-1. Tech. Rep. Mode Menu Screen ...............................................................S-174-2. Tech. Rep. Mode Function Setting Procedure .........................................S-174-3. Tech. Rep. Mode Menu Function Tree ....................................................S-184-4. Setting in the Tech. Rep. Mode ...............................................................S-20

(1) Machine Adjust ................................................................................S-20(2) Image Adjust ....................................................................................S-22(3) System Input ....................................................................................S-23(4) Counter ............................................................................................S-25(5) State Confirm ...................................................................................S-28(6) ADF Check ......................................................................................S-30(7) ROM Version ...................................................................................S-30(8) RD Mode .........................................................................................S-31(9) Administrator # Input .......................................................................S-33(10) List Output .......................................................................................S-33(11) Test Print .........................................................................................S-35(12) Gradation Adjust ..............................................................................S-35

5. TOUCH PANEL CORRECTION MODE .......................................................... S-365-1. Touch Panel Correction Mode Screen .....................................................S-365-2. Touch Panel Correction Mode Setting Procedures ................................. S-36

6. SECURITY MODE ...........................................................................................S-376-1. Security Mode Screen ............................................................................. S-376-2. Security Mode Setting Procedures .......................................................... S-376-3. Settings in the Security Mode ..................................................................S-38

7. DATE/TIME INPUT MODE ..............................................................................S-397-1. Date/Time Input mode Screen .................................................................S-397-2. Date/Time Input Mode Setting Procedure ...............................................S-39


S-1

1. CONTROL PANEL KEYS AND TOUCH PANEL1-1. Control Panel Keys

Con

tras

t

Au

to C

olo

r

Fu

ll C

olo

r

Bla

ck

12

3

45

6

78

9

0C

Sta

rtS

top

Sc

an

Co

py

Ac

ce

ss

En

erg

y S

ave

r

Pan

el R

eset

Inte

rru

pt

Uti

lity

Jo

b R

ec

all

4004P008AA

1 2 3 4

5

6

7

8

9

101112

14

13


S-2

1. Access Mode Key• Press to enter the access number when

Copy Track of the Administrator mode available. Press the access Key.

2. Energy Saver Key• Press to set machine into the Energy

saver mode.3. Interrupt Key• Press to select the Interrupt mode.4. Panel Reset Key• Press to set the machine into the initial

mode, clearing all settings made on the control panel.

5. Clear Key• Clear the various numeric values.6. Stop Key• Stop a scanning cycle.7. Start Key• Start a print cycle.8. Auto Color/Full Color/Black Keys• Auto Color Key: Press to make copies

according to the type of the original being used.

• Full Color Key: Press to make full color copies.

• Black Key: Press to make black-and-white copies.

9. Touch Panel• Shows various screens and message.10. Job Recall Key• Press to display the Job Recall screen.11. Utility Key• Press to show the Utility Mode menu.12. Display Contrast Control Knob• Use to adjust the brightness of the Touch

Panel.13. 10-Key Pad• The number of copies to be made.• The various numeric values.14. Copy Key/Scan Key• Press to select the Scanner mode and the

Copy mode. The Scan mode is enabled when a printer

controller is mounted on the copier.


S-3

1-2. Explanation of the Touch Panel(1) Basic Screen

The Basic screen is the initial screen that appears when the copier is turned ON.

1. Supplementary Function Keys• Select the Auxiliary, Finishing, Orig. Copy, or Basics function.

2. Message Display• Shows the current copier status, operating instructions and precautions, and other data

including the number of copies selected.

3. Basic Display• Select the Text & Photo, Zoom, or Paper function.

4. Set Function Display• Shows graphic representations of the copying functions currently set for use.

4004P022CB

1

4

2

3


S-4

(2) Warning Screens

The Warning screen may be a malfunction display, error display, warning display, or a cau-tion display.

<Malfunction Display>Given when a malfunction occurs.E.g.: Malfunctions that can be identified

with a specific code.

<Error Display>Given when an error occurs.E.g.: Paper misfeed, door open, etc.

4004P023CB 4004P024CA

<Warning Display>Given when only a defective copy will be produced because of erroneous or illegal panel settings.E.g.: Unmatched paper size in Auto Paper.

<Caution Display>Given when, though further copier opera-tion will be possible, it could eventually result in a malfunction.E.g.: Toner near empty, etc.

4004P026CB4004P025CB


S-5

<Engine / IR Warning>

When the engine or IR develops a faulty condition, a mark appears at the lower left corner of the Basic screen. Touch this mark, and the display shows the details of the fault.

NOTE• For details, see TROUBLE SHOOTING.

4004P027CB 4004P028CA


S-6

2. FUNCTION OF SWITCHES AND OTHER PARTS ON

PWBs2-1. PWB Location

2-2. PWB-H (MSC Board)

Symbol Name Description

PJ2 Initialize Switch Resets a misfeed, malfunction, and erratic display.

TP1 Memory Clear Test Point Clears choice-related data.

NOTE• It does not, however, clear data of Electronic

Counters, Administrator, RD mode, Scanner Addr. Input, and IR backup data.

TP3 COM Test Point Ground used for memory clear.

4004S002AA

PWB-TPWB-H

PWB-H

COM TOTAL MEMORY

TP3 TP2 TP1

1 2

PJ6INI

4004S001AB


S-7

2-3. PWB-T (Tech. Rep. Setting Switches Board)

(1) Clearing Procedures

Initialize1. Turn ON the Power Switch.2. With the circuit across pins of PJ2 closed, turn OFF then ON the Power Switch.3. Open the circuit in about 5 seconds.4. Check that the message “Initialize Completed” is displayed on the Touch Panel and

then touch the “Enter” key.

Memory Clear1. Turn ON the Power Switch.2. With the circuit across TP1 and TP3 closed, turn OFF then ON the Power Switch.3. Open the circuit in about 5 seconds.4. Check that the message “Memory Clear Completed” is displayed on the Touch Panel

and then touch the “Enter” key.

NOTES• If the copier exhibits an erratic display or operation, reset and clear in the following order:

Initialize Memory Clear.• If Memory Clear has been performed, make settings of various functions once again.

Symbol Name Description

SW1 Trouble Reset Switch Resets the malfunction display.

PJ1

12

SW

1

PWB-T

4004S003AB


S-8

(2) Data/Conditions Cleared by Reset Switches/Pins

Clearing MethodFront Door Open/Close

Trouble Reset Switch SW1

Initialize PJ6

Memory Clear TP1

Data Cleared

Misfeed display – –

Malfunction display

Fusing/Optical Scanner ROM faults

– –

Others –

Erratic operation/display –

Job/Image – – –

User’s Choice – – –

Tech. Rep. Mode – – –

Security Mode – – –

Touch Panel Correction Mode

– – –

: Cleared –: Not cleared


S-9

3. UTILITY MODE• Utility Mode is used to make various settings according to the user’s need.

3-1. Utility Mode Selection Screen• Press the Utility key on the control panel

3-2. Utility Mode Function Tree

Displayed when “Mode 2, 3 or 4” is selected for “Peripheral Mode” available from the Service mode.

4004P044CB

Utility

Default Settings

Meter Count

Job Memory Input

Administrator Mode

Scanner Addr. Input

User’s ChoiceAdministrator Mode 1/2Administrator Mode 2/2

Administrator Mode 1/2Administrator Mode 2/2


S-10

3-3. Settings in the Utility Mode

(1) User’s choice mode

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

1. User’s Choice Function Setting Procedure<Procedure>1. Press the Utility key.2. Touch the “User’s Choice” key.3. Select the appropriate screen from the menu.4. Select the appropriate function.5. After the settings are complete, touch the “OK” key to validate the settings.

<Exiting the Mode>• Press the “OK” key.

Touch Panel Display

Setting

Default Settings Select the copying function settings established when the Power Switch is turned ON or the Panel Reset key is pressed.

NOTE• To designate the “Current Settings,” first make the necessary set-

tings on the control panel, then touch “Current Settings.”

Meter Count Displays the counts of various counters. Pressing the Start key will let the copier produce a printed page of the counts of various counters.

Job Memory Input Permits programming of various functions, including copying jobs.

User’s Choice User’s Choice is used to make various settings according to the user’s need.

Administrator Mode

The entry of the “Administrator #” set using the Tech. Rep. mode per-mits the settings of the following functions.

Scanner Addr. Input

Program the one-touch address for the Scanner mode.

Current Settings Factory Settings


S-11

2. User’s Choice Mode Function Tree

3. Settings in the User’s Choice Mode

Touch Panel Display Setting (The default is ).

Language Select the language of the Touch Panel messages.

2in1 copy zoom Select whether or not to set the default zoom ratio, ×0.647 for the inch areas and ×0.707 for the metric areas, when 2in1 is selected.

Intelligent Sort Select whether to enable or disable the function that automatically switches between Sort and Non-Sort according to the number of orig-inals and the number of copy sets to be made.Applicable when the system is equipped with a finishing option and using an ADF.

ACS Determination level Adjust

Set the mode evaluation level for the Auto Color mode.

Confirmation Beep Select whether to enable or disable the beep that sounds each time a key on the control panel is pressed or a function on the Touch Panel touched.

User’s Choice

User’s Choice 1/2

User’s Choice 2/2

Language selected2in1 copy zoomIntelligent sortingACS Determination level AdjustConfirmation BeepMail Bin Assignment

Auto Panel ResetEnergy Save ModeSleep Mode1st Drawer Paper Select

Highlighted

Metric Areas Inch Areas

GERMAN FRENCH FRENCH SPANISH

DUTCH ITALIAN SPANISH JAPANESE

PORTUGUESE DANISH NORWEGIAN

SWEDISH FINISH JAPANESE

ENGLISH ENGLISH

OFFON

Non-AutoAuto Select

std

Black 1 2 4 5 Full Color3

OFFON


S-12


Mail Bin Assignment

Select whether or not to designate specific bin or bins for the output via the PC when a Mailbin Finisher is mounted.

NOTE• When a specific bin is designated, that bin and subsequent bins are

assigned for the output via the PC.• Example: If the 7th Bin is designated

The 7th to 10th Bins will be assigned for the output via the PC and the 1st to 6th Bins usable only for copy bins.

Auto Panel Reset Select the time it takes the Auto Panel Reset function, which resets the panel settings when the set period of time elapses after a copy cycle has been completed or the last key operated, to be activated.Use the 10-Key Pad to set the time.

Energy Save Mode

Select the time it takes the copier to enter the Energy Saver mode after a copy cycle has been completed or the last key operated.Use the 10-Key Pad to set the time.

Sleep Mode Select the time it takes the Sleep function, which shuts down the copier when the set period of time elapses after a copy cycle has been completed or the last key operated, to be activated.

NOTE• The option of “OFF” becomes available on the screen if “Yes” is

selected for “Disable Sleep” of the “Administrator Mode” function.

1st Drawer Paper Select

Select the paper size setting method for the 1st Drawer.

Highlighted

2-10 Bin OFF

OFF 1 to 9 ( )5 min.

1 to 240 ( )15 min.

15 to 240 ( ) OFF15min.

Input SizeAuto Detect


S-13

(2) Administrator Mode

• The entry on the “Administrator #” set using the Tech. Rep. mode permits the settings of the following functions.

1. Administrator Mode Function Setting Procedure<Procedure>1. Press the Utility key.2. Touch the “Administrator Mode” key.3. Enter the Administrator number from the 10-Key pad.4. Select the appropriate function.5. After the settings are complete, touch the “Enter” key to validate the settings.

<Exiting the Mode>• Press the “OK” key.

2. Administrator Mode Function Tree

Available on the screen when the settings are made for “Mainte. Center” when a Data Terminal is mounted.

PRT Area (Top Margin)PRT Area (Left Margin)PRT Area (Dup. Left Margin)Thin Orig.

Expt. User’s Mode 1/2

Expt. User’s Mode

Administrator Mode 2/2

Administrator Mode

Thick Paper and OHP FilmImage DensityColor Shift Correction (C)Color Shift Correction (M)Color Shift Correction (Y)Color Shift Correction (Bk)Stabilizer

Expt. User’s Mode 2/2

Erase


Copy Track

Gradation Adjust

Disable Sleep Mode

User Send

Access # InputCounter CheckCounter ResetPermission LevelAccount Copy Limit set


S-14

3. Settings in the Administrator Mode


Administrator Mode

The entry on the “Administrator #” set using the Tech. Rep. mode per-mits the settings of the following functions.


Displays the various setting screens including Copy Track and Grada-tion Adjust.

Copy Track Functions

Select the number of accounts to be controlled.

Access # Input From the 10-Key Pad, enter the access number (ID), which can range 0001 to 9999.

Counter Check Check the counter value for the account.<Procedure>1. Place the required number of sheets of A4L or Letter L paper on

the 1st Drawer.2. Press the Start key to let the copier print the counter list.

Counter Reset Reset the counter value for the account.<Procedure>1. Using the or key, select the account number, for which the

counter is to be reset. Touch “All Accts” to reset the counters of all accounts.

2. Touch the “Cancel” key.3. Touch the “YES” key.4. Touch “OK” to reset the counter.

Permission Level Select whether to enable (“Permit”) or disable (“Prohibit”) copying according to the color or black mode for each account.<Procedure>1. Using the or key, select the account number for which Per-

mission Level is to be set.2. Select either Permit or Prohibit copying according to the color or

black mode.

Account Copy Limit set

Set the maximum number of copies to be made at one time for each account and copying mode using the 10-Key Pad.

<Procedure>1. Using the or key, select the account number for which Copy

Limit is to be set.2. Select either Common or Individual.3. Select whether to turn ON or OFF Copy Limit and then enter the

maximum number of copies to be made from the 10-Key Pad.

Highlighted

ON OFF

Account #Use or key to select the account number, for which an access number is to be programmed.

Access # Enter a 4-digit access number from the 10-Key Pad.

Common Copy limit is not set for each copying mode.

Individual Copy limit is set for each copying mode.


S-15


Gradation Adjust When an image failure occurs, run this function to automatically cor-rect the gamma curve. For details, see DIS/REASSEMBLY, ADJUSTMENT.

Disable Sleep Mode

Select whether to enable or disable the setting of the “Sleep” function available from User’s Choice.

Data Send Transmits various data to the Center when a Data Terminal is mounted.


Displays the various setting screens for Erase and Expert User’s Mode.

Erase Select the leading edge erase.

Expert. User’s Mode

Allows the image-related and paper passage-related functions to be set.

Expert. User’s Mode 1/2

Displays the image-related function adjustment screens.

Thick Paper and OHP Film Image Density

Correct the image density for copying on thick paper and OHP trans-parencies for each color.

Color Shift Correction (C)

Correct (fine-adjust) color shift of the cyan image in each of X, Y, and θ directions. For details, see DIS/REASSEMBLY, ADJUSTMENT.

Color Shift Correction (M)

Correct (fine-adjust) color shift of the magenta image in each of X, Y, and θ directions. For details, see DIS/REASSEMBLY, ADJUSTMENT.

Color Shift Correction (Y)

Correct (fine-adjust) color shift of the yellow image in each of X, Y, and θ directions. For details, see DIS/REASSEMBLY, ADJUSTMENT.

Color Shift Correction (Bk)

Correct (fine-adjust) color shift of the black image in the θ direction. For details, see DIS/REASSEMBLY, ADJUSTMENT.

Stabilizer If an image failure is not rectified even with Gradation Adjust, select “Reset and Stabilizer Mode.”

If “Reset and Stabilizer Mode” is run, run “Gradation Adjust” after the sequence has been completed.

Highlighted

Not displayed.

Yes Displayed.

No

7 mm5 mm

Lighter Darker

Reset and Stabilizer Mode Stabilizer Mode


S-16


Expert. User’s Mode 2/2

Displays the paper passage-related function adjustment screens.

PRT Area (Top Margin)

Adjust the image position for each paper source by varying the print start position of the printer in the sub scanning direction.

PRT Area (Left Margin)

Adjust the image position for each paper source by varying the print start position of the printer in the main scanning direction.

PRT Area (Dup. Left Margin)

Adjust the image position for each paper source in the 2-Sided Mode by varying the print start of the printer in the main scanning direction.

Thin Orig. Select whether or not to make the “Thin Orig.” option available in the Orig. Copy type selection screen.

Highlighted

Setting -2 mm ............................ ...........................+2 mm0

Setting -3 mm ............................ ...........................+3 mm0

Setting -3 mm ............................ ...........................+3 mm0

ON OFF


S-17

4. Tech. Rep. Mode• This mode is used by the Tech. Rep. to check, set, adjust, and/or program various ser-

vice functions.

4-1. Tech. Rep. Mode Menu Screen

4-2. Tech. Rep. Mode Function Setting Procedure<Procedure>1. Press the Utility key.2. Press the Meter Count key.3. Press the following keys in this order:

Stop 0 0 Stop 0 14. Select the desired Service Mode function.

<Exiting the Mode>• Press the “Fine. Time” key.

4004P030CB


S-18

4-3. Tech. Rep. Mode Menu Function Tree

Fuser NipFuser Temp.Fuser SpeedOrig. Detect SensorPRT AreaIR AreaLoop AdjustColor Shift CorrectionLPH RankStaple/Hole-Punch

PRT Max DensityPRT HighlightBackground VoltageATDC Level SettingAE AdjustStabilizerATDC Toner Supply

Marketing AreaOrig. Detect Option SensorSerial # InputTel. # InputFLS PaperBook Erase (Center)Peripheral ModeUnit Change

LifeJamTroubleWarningMaintenance

I/O CheckTable #Level History 1Level History 2Temp. & HumidityCCD CheckPaper PassageOption MemoryColor ShiftIU Lot No.

Machine Adjust

Image Adjust

System Input

Counter

State Confirm

Tech. Rep. Mode

~


S-19

Tech. Rep. ChoiceI/O CheckPaper Passage

Image ProcessingCounter

Gradation PatternHalftoneLattice PatternSolid PatternColor SampleIR Test Pattern8 Color Solid Pattern

ADF Check

List Output

Test Print

Service Mode

~

Gradation Adjust

ROM Version

RD Mode

Administrator #Input


S-20

4-4. Setting in the Tech. Rep. Mode(1) Machine Adjust

• These functions are used to make the various mechanical adjustments of the copier.

NOTE• For details, see DIS/REASSEMBLY, ADJUSTMENT or Option service manual.

Touch Panel Display

Setting

Fuser Nip Produces a sample copy for the check of the Fusing Roller nip width.

Fuser Temp. Set the temperature for fusing temperature control according to the operating environment and the type of paper used.

Fuser Speed Adjust the fusing speed.

Org. Detect Sensor

Automatically adjusts the threshold level of the Original Size Detect-ing Sensor.

PRT Area Displays the print area adjustment screen.

Top Margin Paper Send PositionVary the paper sending timing to adjust the image position in the sub-scanning direction.2nd Transfer TimingVary the second transfer timing to adjust the image transfer timing in the sub-scanning direction.

Left Margin Adjust the image position for each paper source by varying the print start position of the printer in the main scanning direction.

Dup. Left Margin Adjust the image position for each paper source in the 2-Sided Mode by varying the print start of the printer in the main scanning direction.

IR Area Left ImageAdjust the image position by varying the image reading position of the IR in the main scanning direction.Top ImageAdjust the image position by varying the image reading position of the IR in the sub scanning direction.CD-Mag.Adjust the zoom ratio in the crosswise direction by varying the num-ber of pixels to be read by the CCD.FD-Mag.Adjust the zoom ratio in the lengthwise direction by varying the scan speed of the Scanner.

Paper Loop Set the length of the loop to be formed in paper before the Synchro-nizing Rollers.


S-21

Touch Panel Display

Setting

Color Shift Correction

Color Shift Correction (C)Correct (fine-adjust) color shift of the cyan image in each of X, Y, and θ directions.Color Shift Correction (M)Correct (fine-adjust) color shift of the magenta image in each of X, Y, and θ directions.Color Shift Correction (Y)Correct (fine-adjust) color shift of the yellow image in each of X, Y, and θ directions.Color Shift Correction (Bk)Correct (fine-adjust) color shift of the black image in the θ direction.

LPH Rank This mode is for factory adjustment only and should NOT be used.It is confirmed that the numerical value is “0”.

Staple/Hole-Punch The staple position or the punch hole position is confirmed. The content changes by the installed exit option.


S-22

(2) Image Adjust

• These functions are used to make image adjustments.

NOTE• For details, see TROUBLE SHOOTING.

NOTE• If the image density has been adjusted in “PRT Max Density,” “PRT Highlight,” or “Back-

ground Voltage Margin,” select “Stabilizer Mode” in “Stabilizer” to run Stabilizer after the adjustment has been made. Or, turn OFF and ON the Power Switch.


PRT Max Density Adjust the image density by varying the maximum amount of toner sticking to paper.

PRT Highlight Adjust the image density of the highlighted area.

Background Voltage Margin

Adjust the fog level on the background.

ATDC Level Setting

Select the ATDC control level with the corresponding T/C ratio.

AE Adjust Adjust the AE Reference.

Stabilizer If an image failure is not rectified even with Gradation Adjust, select “Reset and Stabilizer Mode.”

If “Reset and Stabilizer Mode” is run, run “Gradation Adjust” after the sequence has been completed.

ATDC Toner Supply

If T/C is lower than the specifications: Only toner replenishing sequence is run.If T/C is higher than the specifications: Only developer agitation sequence is run (with no toner supplied).

Highlighted

Setting -10 ................................. ................................+10

Description Lighter Darker

0

Setting -10 ................................. ................................+10


0

Setting -5 ................................... ..................................+5

DescriptionFoggier Less

Foggy

0

Setting -2 -1 +1 +2


0

Setting 0 1 3 4

Description Foggy Less Foggier

2

Reset And Stabilizer Mode Stabilizer Mode


S-23

(3) System Input

• The function allows the Tech. Rep. to define the marketing area, and make settings.


Marketing Area Set the marketing area.

Org. Detect Option Sensor

Select “ON” when the optional Original Size Detecting Sensor is mounted.

After “Set” has been selected, run “Orig. Detect Option Sensor.”

Serial # Input Enter the serial number of each system component including options from the 10-Key Pad.

NOTE• This procedure must be performed to allow the adjustment data on

the IR side to be transmitted to the copier.• When the “END” key is touched after the IR serial number has been

input, data is transmitted to the copier.

Tel. # Input Enter the telephone number that will appear on the Touch Panel when a malfunction occurs in the copier.<Procedure>1. Enter the phone number from the 10-Key Pad. Use the Interrupt

key to enter a hyphen “-.”2. Touch “END” to validate the phone number setting.

FLS Paper Set the size for FLS.

Book Erase(Center)

Adjust the center erase width in Book copying.

Peripheral Mode Select the type of the external I/F operation when a printer controller is mounted.

Highlighted

MSJ MEMC

Set Unset

F: 330.2 mmC: 203.2 mm

F: 330.2 mmC: 215.9 mm

F: 330 mmC: 220 mm

F: 330 mmC: 210 mm

Setting +2 ................................. ................................+30

Description Smaller Greater

15

Mode 1 External I/F operation mode 1


External I/F operation mode 3



Mode 3


S-24


Unit Change Select who is to replace a unit when its replacement time arrives, either “User” or “Service.”Set the type of “Warning” message displayed on the Touch Panel when the replacement time arrives depending on the setting.

Example: TonerTo be replaced by “User”: A message that prompts the user to change the Toner Bottle appears.To be replaced by “Service”: A message that tells the user to call the Tech. Rep. appears.

Highlighted

Unit To be replaced by

Toner Service

Waste Toner Bottle User Service

Fusing Web Unit User Service

Oil Coating Unit User Service

Fusing Unit User Service

Transfer Belt Unit User Service

Imaging Unit User Service

User


S-25

(4) Counter

• Shows the number of copies made on each paper size or type.

<Clearing a Count>1. Open the counter menu screen.2. Select the counter to be cleared.3. Press the Clear key. Press the Stop key to undo the clearing operation, restoring the original count.4. Touch “END”.

Touch Panel Display

Setting

Life Counts the frequency of use of each of the different parts of the copier.

: It is not possible to clear the Life counter. It is automatically reset when a new unit has been installed.For “Fusing Web Unit,” however, it is possible to reset the counter and enter a count from the 10-Key Pad.

Display Description

Fusing UnitFusing Web UnitOil Coating Unit1st.2nd.3rd.4th.

No. of times a sheet of paper is fed throughNo. of times a sheet of paper is fed throughNo. of times a sheet of paper is fed throughNo. of sheets of paper fed from the 1st DrawerNo. of sheets of paper fed from the 2nd DrawerNo. of sheets of paper fed from the 3rd DrawerNo. of sheets of paper fed from the 4th Drawer

Display Description

ADF Feed

ADF Rev.

Sorter/FinisherStaplePunchLCC Parts1LCC Parts2

No. of sheets of paper fed through the ADF take-up sectionNo. of sheets of paper fed through the turnover unit ofthe ADFNo. of sheets of paper fed out of the SorterNo. of stapling sequences performedNo. of holes madeNo. of sheets of paper fed from the LCCNo. of sheets of paper fed from the LCC

Display Description

Cyan IU

Magenta IU

Yellow IU

Black IU

Transfer Belt UnitLPH(C)

LPH(M)

Period of time over which the Cyan Developing Unit has been used.Period of time over which the Magenta Developing Unit has been used.Period of time over which the Yellow Developing Unit has been used.Period of time over which the Black Developing Unit has been used.Period of time over which the Transfer Belt Unit has been used.Period of time over which the Cyan LPH has been used.Period of time over which the Magenta LPH has been used.


S-26

Touch Panel Display

Setting

Life

Jam Counts the number of misfeeds that have occurred at different loca-tions in the copier.

Trouble Counts the number of malfunctions that have occurred at different parts of the copier.

Display Description

LPH (Y)

LPH (Bk)

Period of time over which the Yellow LPH has been used.Period of time over which the Black LPH has been used.

Display Display

1st.2nd.3rd.4th.

ManualVertical Transport

Secondary Transfer

Fusing UnitExit

LCC FeedLCC Movement

Duplex TransportDuplex

Horizontal Transport

Display

Sorter/Finisher Trans.Sorter/Finisher Exit

StapleADF

Display Description

C0000/1C0010/1C0012/3C0014/5C0016/7C0040C0046C004C

Trans. MotorCyan PC MotorMagenta PC MotorYellow PC MotorBlack PC MotorSuction FanFuser Cooling FanExhaust Fan

Display Description

C004EC0060/1C0094C0096C0098C0200C0202C0204

Cooling FanFuser Motor2nd Transfer SeparationTransfer Belt SeparationFuser SeparationCyan PC ChargeMagenta PC ChargeYellow PC Charge


S-27

Touch Panel Display

Setting

TroubleDisplay Description

C0206C0400C0410C0500C0501C0510C0511C0520

Black PC ChargeExposure Lamp offExposure Lamp OnFuser (Upper)Fuser (Lower)Abnormal Low Temp. (Upper)Abnormal Low Temp. (Lower)Abnormal High Temp. (Upper)

Display Description

C0521C0650C0660C099XC0B0XC0B2XC0B3XC0B48X

Abnormal High Temp. (Lower)Home SensorOver RunLCCFinisher/Sorter Trans.Staple Unit. (CD direction)Finisher AlignmentFinisher Staple Transport (Exit)

Display Description

C0B4AC0B5C0B7C0B8C0BAXXC0F30/1/AC0F32/3/BC0F34/5/C

Finisher Staple Transport (Receipt)Staple Unit (Rotation)PunchShiftFinisher Elevator TrayCyan ATDC SensorMagenta ATDC SensorYellow ATDC Sensor

Display Description

C0F36/7/DC13C8C13CAC13CBC13CCC13D1C13D2C13D3

Black ATDC SensorNew Transfer Belt UnitNew Fusing UnitNew Fusing Web UnitNew Oil Coating UnitEEPROM Access (C)EEPROM Access (M)EEPROM Access (Y)

Display Description

C13D4C3310C37X0C3A00C3A01

EEPROM Access (Bk)CCD GainScanner Cooling FanPIC I/FPIC


S-28

(5) State Confirm

• These functions are used to confirm machine state.

Touch Panel Display

Setting

Warning Displays the number of warnings issued for different parts.

Maintenance Set different count values for the Maintenance Counter.When the preset count is reached, the maintenance call reminder message appear on the Touch Panel.<Procedure>1. Touch “Maint. Set”.2. Press the Clear key to clear the current value.

Press the Interrupt key to undo the clearing operation, restoring the original value.

3. Enter the value from the 10-Key Pad.4. Touch “END”.

Touch Panel Display

Setting

I/O Check • The following functions are used to locate the faulty spot.• Shows the states of the I/O ports when the copier is in the standby

state. For details, see TROUBLESHOOTING.

Table # Use this function to show the output values of the developing bias and grid voltage.

Display Display

AIDC Sensor (Front)AIDC Sensor (Back)

Cyan IUMagenta IUYellow IUBlack IU

S/P

CCD GainExp. Lamp Adjust

Color Shift Test PatternColor Shift Adjust

ATVC (C)ATVC (M)ATVC (Y)

Display

ATVC (Bk)ATVC (2nd)

Developing Bias Grid Voltage

Vb-CVb-MVb-YVb-Bk

Vg-CVg-MVg-YVg-Bk


S-29

Touch Panel Display

Setting

Level History 1 Displays ATDC, AIDC, and fusing temperatures.

Level History 2 Displays the AIDC adjustment values.

Temp. & Humidity Use this function to show the temperature and humidity inside the copier.

CCD Check Use this function to show the CCD data.

Paper Passage A check is made for paper passage performance.<Procedure>1. Select the paper source.2. Press the Start key to start the paper passage cycle.3. Press the Stop key to stop the paper passage cycle.

Optical Memory Displays the mounting of optional memories.

Color Shift Displays the amount of correction for color shift.

IU Lot No. Displays the lot number for each of C, M, Y, and Bk IUs.

Display Description

ATDC-CATDC-MATDC-YATDC-BkAIDC1AIDC2Temp-Upr.Temp-Lwr.

ATDC Sensor, cyan ratio (%)ATDC Sensor, magenta ratio (%)ATDC Sensor, yellow ratio (%)ATDC Sensor, black ratio (%)AIDC Sensor output value 1 (V)AIDC Sensor output value 2 (V)Upper Fusing Roller temperature (°C)Lower Fusing Roller temperature (°C)

Display Description

AIDC SensorAdjust Value 1AIDC SensorAdjust Value 2

Intensity adjustment value of AIDC background level (UN20)Intensity adjustment value of AIDC background level (UN21)

CLAMPRO RE GO GE BO BE

D/A values of clamp R, G, and B

GAINRO RE GO GE BO BE

D/A values of gain R, G, and B

Lamp Adjust Value


S-30

(6) ADF Check

• Allows the Tech. Rep. to make the various functional tests and adjustments of the (ADF). For details, see Option service manual.

(7) ROM Version

• Shows the ROM versions.

Touch Panel Display

Setting

Tech. Rep. Choice Displays the screens used to adjust.

Original Stop Position

Adjust the document stop position in each of the ADF modes.

Registration Loop Set the length of the loop to be formed in paper before the Registra-tion Rollers.

I/O Check The following functions are used to locate the faulty spot.Shows the states of the I/O ports when the copier is in the standby state.

Paper Passage Makes a paper passage check through the ADF.


S-31

(8) RD Mode

• Make the initial settings of the copier for the Data Terminal.

1. RD Mode Menu Function Tree

System Set

CT-ID

DT-ID

TEL. No.(Setting Modem)

Mail Address(Setting e-mail)

DT Setting

Mainte. RAM Clear

YES

NO

Mainte.Center

e-mail

Modem

CT-ID

DT-ID

TEL. No.(Setting Modem)

Mail Address(Setting e-mail)

Initial Transmission(Setting Modem)

DT Setting

Billing RAM Clear

YES

NO

Billing Center

ID Code

Call Completion

Common DT(Setting Modem)

Dial Mode

Tone

Pulse

Auto Receive

YES

NO

Date/Time

RD ModeInitial Transmission(Setting Modem)


S-32

2. Setting in the RD Mode


System Set Set the control system.

Billing Center Displays the various setting screens.

DT Setting Displays the setting screens for CT-ID, DT-ID, and telephone number.The mail address is also displayed if “e-mail” is set for System Set.

CT-ID Enter the ID number of the Center PC from the 10-Key Pad.

DT-ID Enter the ID number of the Data Terminal from the 10-Key Pad.

TEL No. Enter the telephone number of the modem connected to the Center PC.

Initial Transmission

Performs the initial transmission from the PPC to the Center to check for correct communication after the Data Terminal has been set up.

Billing RAM Clear Initializes the Data Terminal settings.

Mainte. Center Displays the various setting screens.

ID Code Enter the ID code.<Procedure>1. Touch the ID Code key.2. Enter the ID code from the 10-Key Pad.3. Touch the ID Code key. (This executes the transmission of

MAINT. START to the Center.)

DT Setting Displays the setting screens for CT-ID, DT-ID, and telephone number.The mail address is also displayed if “e-mail” is set for System Set.

CT-ID Enter the ID number of the Center PC from the 10-Key Pad.

DT-ID Enter the ID number of the Data Terminal from the 10-Key Pad.

TEL No. Enter the telephone number of the modem connected to the Center PC.

Initial Transmission

Performs the initial transmission from the PPC to the Center to check for correct communication after the Data Terminal has been set up.

Call Completion Transmits the signal of notifying the completion of service job to the Center.

Mainte. RAM Clear

Initializes the Data Terminal settings.

Highlighted

e-mail Modem

YES NO

YES NO


S-33

(9) Administrator # Input

• Set an ID number for opening the “Admin. Mode” screen of Utility Mode from the 10-Key Pad.

(10) List Output

• This function produces a list of the various Service mode data.

<Procedure>1. Check that A4L or Letter L paper is loaded.2. Select the desired function.3. Press the Start key.


Date/Time Set Set the date and time-of-day for Date Printing.

Common DT Displays the screens for communications settings.

Dial Mode Sets the type of telephone line of the user.

Auto Receive Sets the auto reception function.

Touch Panel Display

Setting

Image Processing Produces a list of image-related data.Produces a list of counter-related data.

Counter Produces a list of counter-related data.

Highlighted

Tone Pulse

YES NO


S-34

Details of List Output

Image Counter

Date/Time IR Area

OHP Speed ADF Original Position

Transfer Table Count Up Select

PC Action ATDC Sensor Volume

Fuser Action AIDC Level

PC PAT. PRT max Density

Paper Size PRT Highlight

Marketing Area Background Voltage

Serial # ATDC Level Setting

Fuser Oil Choice VB Shift

Fuser Oil Change AE Adjust

Fuser Speed Table #

AIDC Offset PC dev. Status

Transfer Output Bk Toner Sup. Status

Feed Motor Speed Temp & Humidity

PRT Area Top-Margin CCD Check

PRT Area Left-Margin ROM Version

PRT Area Dup. Left-Margin Gradation Adjust

Transfer Timing Stabilizer Trouble

Loop Adjust

Counter

Date/Time Jam Counter

Life Counter Warning Counter

Trouble Counter Meter Count


S-35

(11) Test Print

• Output the test pattern.

<Procedure>1. Select the test pattern type.2. Make the necessary settings according to the specific Test Print function (Color mode,

density, etc.).3. Press the Start key to start the output sequence. The test print is produced on paper of the maximum size among those loaded in the

drawers.

(12) Gradation Adjust

• Displays the Adj. Value and Conv. Value of Max. and Highlight for each color.• If an image failure occurs, this function can be run to let the copier automatically correct

the gamma curve. For details, see DIS/REASSEMBLY, ADJUSTMENT.

Touch Panel Display

Setting

Gradation Pattern Use to output a gradation pattern.Used to check for gradation reproduction on the engine side.

Halftone Use to output a halftone pattern.Used to check for uneven density, uneven pitch, and image noise on the engine side.

Lattice Pattern Use to output a lattice pattern.Used to check for fine line reproduction and toner scattering on the engine side.

Solid Pattern Use to output a solid pattern.Used to check for image density reproduction on the engine side.

Color Sample Use to output a color sample pattern.Used to check for reproduction of each color on the engine side.

IR Test Pattern Use to output a IR test pattern.Used to determine whether the engine or the IR is responsible for an image failure that has occurred.

8 Color Solid Pattern

Use to output a 8 color solid pattern.Used to check for reproduction and uneven density of each color on the engine side.


S-36

5. TOUCH PANEL CORRECTION MODE• Corrects deviation in the sensitive area of the Touch Panel.

5-1. Touch Panel Correction Mode Screen

5-2. Touch Panel Correction Mode Setting Procedures<Procedure>1. Press the following keys in this order. Stop 0 Stop 32. Sequentially touch the four points marked with + on the screen.

NOTE• Lightly touch the one dot portion at the exact center of the “+” marking using the tip of a

pen or similar object.

4004P031CA


S-37

6. SECURITY MODE• Allows the Tech. Rep. to set the various counters.

6-1. Security Mode Screen

6-2. Security Mode Setting Procedures<Procedure>1. Show the Tech. Rep. mode menu screen.2. Press the following keys in this order:

Stop 93. Select the particular function.

<Exiting the Mode>• Press the “Menu” key.

4004P032CA


S-38

6-3. Settings in the Security Mode


Size Counter Select the size of the paper to be counted by the Size Counter.

Total Counter Select the condition by which the Counter count is increased.

Vender Mode Set the initial screen according to the type of vender mounted on the copier.

Highlighted

No Count

A3/B4/11×17/Legal A3/B4/FLS/11×17/Legal

A3/11×17

1 Copy per 1 copy cycle

Mode 2Multiple count-up according to paper size 1/2-sided copying

Mode 1

<Count-up Table>

0: No count 1: 1 count 2: 2 counts 4: 4 counts

Copying 1-Sided 2-Sided

Size

Sizes Other than

those set

Set sizes

Sizes Other than

those set

Set sizes

TotalMode Mode Mode Mode

1 2 1 2 1 2 1 2

Total Counter 1 1 1 2 2 2 2 4

Size Counter 0 0 1 1 0 0 2 2

2-sided Total Counter 0 0 0 0 1 1 1 1

Set CardCoin

Unset


S-39

7. DATE/TIME INPUT MODE• This mode is used to set time-of-day and date.

7-1. Date/Time Input mode Screen

7-2. Date/Time Input Mode Setting Procedure<Procedure>1. Press the following keys in this order. Stop 1 1 4 4 Clear2. Enter year, month, day, hour, and minute, in that order, from 10-key Pad.3. Make sure that correct figures have been entered and then touch “OK.”

NOTE• When setting the month, day, hour, or minute, enter “0” first if the data one digit.

4004P033CA

FrameMaker Ver5.5E(PC) COVER [FIELD SERVICE] FOR CF1501/CF200100.12.25

FrameMaker Ver5.5E(PC) COVER [FIELD SERVICE] FOR CF1501/CF200100.12.25

Copyright2001 MINOLTA Co., Ltd.

Printed in Japan

Use of this manual should be strictly supervised to avoid disclosure of confidential information.

MINOLTA Co., Ltd. 4004-7991-11 01011200

CF1501/CF2001

SERVICE MANUAL

CF

1501/CF

2001 SE

RV

ICE

MA

NU

AL [F

IELD

SE

RV

ICE

]

[FIELD SERVICE]

FrameMaker Ver5.5E(PC) COVER [TROUBLESHOOTING] FOR CF1501/CF200100.12.20



Printed in Japan


MINOLTA Co., Ltd. 4004-7998-11 01011200

CF1501/CF2001

SERVICE MANUAL

CF

1501/CF

2001 SE

RV

ICE

MA

NU

AL [T

RO

UB

LES

HO

OT

ING

]

[TROUBLESHOOTING]

FrameMaker Ver.5.5(PC) CF1501/CF2001 TROUBLESHOOTING00.12.20

INDEX (TROUBLESHOOTING)

UNIT REPLACEMENT MANUAL

TROUBLESHOOTING


Safety Precautions for Inspection and Service

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

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

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

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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

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

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

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

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

1. Always observe precautions.

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

3. Use the specified parts.

WARNING

CAUTION

WARNING

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

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

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

• The product also contains parts that can jerk suddenly and cause injury.• If this product uses a laser, laser beam leakage may cause eye damage or

blindness.

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

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

P-1


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

5. Be careful with the high-voltage parts.

6. Do not work with wet hands.

7. Do not touch a high-temperature part.

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

9. Do not remodel the product.

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

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

• Do not use a multiple outlet to which any other appliance or machine is con-nected.

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

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

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

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

• Wait until these parts have cooled down before replacing them or any surround-ing parts.

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

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

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

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

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

P-2


1. Precautions for Service Jobs

2. Precautions for Servicing with Covers and Parts Removed

3. Precautions for the Working Environment

4. Precautions for Handling Batteries (Lithium, Nickel-Cadmium, etc.)

CAUTION

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

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

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

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

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

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

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

• Never use a flammable spray near the product. This could result in a fire.• Make sure the power cord is unplugged before removing or installing circuit

boards or plugging in or unplugging connectors.• Always use the interlock switch actuating jig to actuate an interlock switch when

a cover is opened or removed. The use of folded paper or some other object may damage the interlock switch mechanism, possibly resulting in an electric shock, injury or blindness.

• The product must be placed on a flat, level surface that is stable and secure.• Never place this product or its parts on an unsteady or tilting workbench when

servicing.• Provide good ventilation at regular intervals if a service job must be done in a

confined space for a long period of time.• Avoid dusty locations and places exposed to oil or steam.• Avoid working positions that may block the ventilation ports of the product.

• Replace a rundown battery with the same type as specified in the manufac-turer’s parts manual.

• Before installing a new battery, make sure of the correct polarity of the installa-tion or the battery could burst.

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

P-3


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

• When handling circuit boards, observe the “HANDLING of PWBs”.• The PC Drum is a very delicate component. Observe the precautions given in “HAN-

DLING OF THE PC DRUM” because mishandling may result in serious image problems.• Note that replacement of a circuit board may call for readjustments or resetting of partic-

ular items, or software installation.

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

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

• Make sure that no one enters the room when the machine is in this condition.• When handling the laser unit, observe the “Precautions for Handling Laser

Equipment.”

ANGRInvisible laser radiation when open.

AVOID DIRECT EXPOSURETO BEAM

0947-7127-01

1144D270AA

1167P001AA

Other Precautions

P-4


ALL AreasCAUTION

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

GermanyVORSICHT!

Explosionsgefahr bei unsachgemäßem Austausch der Batterie.Ersatz nur durch denselben oder einen vom Hersteller empfohlenen ähnlichen Typ.Entsorgung gebrauchter batterien nach Angaben des Herstellers.

FranceATTENTION

Ily a danger d’explosion s’ily a remplacement incorrec de la batterie.Remplacer uniquement avec une batterie du meme type ou d’un type équivalent recom-mande par le constructueur.Mettre au rebut les batteries usageés conformément aux instructions du fabricant.

DenmarkADVARSEL!

Lithiumbatteri - Eksplosionsfare ved fejlagtig håndtering Udskiftning må kun ske med bat-teri af samme fabrikat og type.Levér det brugte batteri tilbage til leverandøren.

NorwayADVARSEL

Eksplosjonsfare ved feilaktig skifte av batteri.Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten.Brukte batterier kasseres i henhold til fabrikantens instruksjoner.

SwedenVARNING

Explosionsfara vid felaktigt batteribyte.Använd samma batterityp eller en ekvivalent typ som rekommenderas av apparat-tillverkaren.Kassera använt batteri enligt fabrikantens instruktion.

FinlandVAROlTUS

Paristo voi räjähtää, los se on virheellisesti asennettu.Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hävitä Käytetty paristo valmistajan ohjeiden mukaisesti.

Used Batteries Precautions

P-5



When performing inspection and service procedures, observe the following precautions to prevent mishandling of the machine and its parts. Depending on the model, some of the precautions given in the following do not apply.

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

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

1. DIS/REASSEMBLY, ADJUSTMENT• To reassemble the product, reverse the order of disassembly unless otherwise specified.2. TROUBLESHOOTING• If a component on a PWB or any other functional unit including a motor is defective, the

text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedures applicable within the defective unit.

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

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

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

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

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

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

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

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

Precautions Before Service

How to Use this Book


P-6


• Be sure to unplug the copier from the outlet before attempting to service the copier.• The basic rule is not to operate the copier anytime during disassembly. If it is absolutely

necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears.

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

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

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

• Never use flammable sprays near the copier.• A used battery should be disposed of according to the local regulations and never be dis-

carded casually or left unattended at the user’s premises.• When reassembling parts, make sure that the correct screws (size, type) and toothed

washer are used in the correct places.• If it becomes necessary to replace the thermal fuse or any other fuse mounted on a

board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice.

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

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

Precautions for Dis/Reassembly

Precautions for Circuit Inspection

P-7


1. During Transportation/Storage:• During transportation or when in storage, new P.W. Boards must not be indiscriminately

removed from their protective conductive bags. • Do not store or place P.W. Boards in a location exposed to direct sunlight and high tem-

perature. • When it becomes absolutely necessary to remove a Board from its conductive bag or

case, always place it on its conductive mat in an area as free as possible from static elec-tricity.

• Do not touch the pins of the ICs with your bare hands.• Protect the PWBs from any external force so that they are not bent or damaged.

2. During Inspection/Replacement: • Avoid checking the IC directly with a multimeter; use connectors on the Board. • Never create a closed circuit across IC pins with a metal tool.• Before unplugging connectors from the P.W. Boards, make sure that the power cord has

been unplugged from the outlet.• When removing a Board from its conductive bag or conductive case, do not touch the

pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board.

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

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

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

Handling of PWBs

Handling of Other Parts

P-8


Only for Products Not Employing an Imaging Cartridge.1. During Transportation/Storage: • Use the specified carton whenever moving or storing the PC Drum. • The storage temperature is in the range between –20°C and +40°C. • In summer, avoid leaving the PC Drum in a car for a long time.

2. Handling: • Ensure that the correct PC Drum is used. • Whenever the PC Drum has been removed from the copier, store it in its carton or pro-

tect it with a Drum Cloth. • The PC Drum exhibits greatest light fatigue after being exposed to strong light over an

extended period of time. Never, therefore, expose it to direct sunlight. • Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger-

prints, and other foreign matter.• Do not scratch the surface of the PC Drum. • Do not apply chemicals to the surface of the PC Drum. • Do not attempt to wipe clean the surface of the PC Drum.

If, however, the surface is contaminated with fingerprints, clean it using the following proce-dure.

Handling of the PC Drum

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

1076D001

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

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

B. Turn the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thor-oughly cleaned.

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

1076D002

P-9


NOTES• Even when the PC Drum is only locally dirtied, wipe the entire surface.• Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under

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

time.

Only for Products Employing an Imaging Cartridge.1. During Transportation/Storage: • The storage temperature is in the range between –20°C and +40°C.• In summer, avoid leaving the Imaging Cartridge in a car for a long time.

2. Handling: • Store the Imaging Cartridge in a place that is not exposed to direct sunlight.

3. Precautionary Information on the PC Drum Inside the Imaging Cartridge:• Use care not to contaminate the surface of the PC Drum with oil-base solvent, finger-

prints, and other foreign matter.• Do not scratch the surface of the PC Drum. • Do not attempt to wipe clean the surface of the PC Drum.

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

Never move the Pad back and forth.

1076D003

4. Using the SAME face of the Pad, repeat the proce-dure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropri-ate for cleaning.

1076D004

Handling of the Imaging Cartridge

P-10

FrameMaker Ver.5.5E(PC) CF1501/CF2001 TROUBLESHOOTING00.12.20

TROUBLESHOOTING

18605


CONTENTS1. INTRODUCTION .............................................................................................T-1

1-1. Reading the Text .....................................................................................T-12. I/O CHECK ......................................................................................................T-1

2-1. Electrical Components Check Procedure ................................................T-12-2. I/O Check List ..........................................................................................T-32-3. How to Interpret “State Confirm” of “Tech. Rep. Mode” ...........................T-9

(1) Table # .............................................................................................T-9(2) Level History 1 .................................................................................T-10(3) Level History 2 .................................................................................T-10

2-4. Paper Misfeed ..........................................................................................T-112-5. Misfeed Detecting Sensor Layout ............................................................T-122-6. Types of Misfeed Detection and Detection Timing ..................................T-142-7. Misfeed Troubleshooting Procedures ...................................................... T-17

(1) Copier Paper Take-Up Misfeed .......................................................T-17(2) Manual Bypass Take-Up Misfeed ....................................................T-19(3) Copier Vertical Transport Misfeed ...................................................T-22(4) 2nd Image Transfer Misfeed ............................................................T-25(5) Exit Misfeed .....................................................................................T-27(6) PF-118 Paper Take-Up Misfeed ...................................................... T-29(7) PF-117 Paper Take-Up Misfeed ...................................................... T-32(8) Duplex Paper Take-Up Misfeed ...................................................... T-35

3. MALFUNCTIONS ............................................................................................T-373-1. Detection Timing by Warning Code .........................................................T-383-2. Detection Timing by Malfunction Code ....................................................T-403-3. Troubleshooting Procedures by Malfunction Code ..................................T-48

(1) C0000: Main Motor’s failure to turnC0001: Main Motor turning at abnormal timing ...............................T-48

(2) C0010: Imaging Unit Motor C’s failure to turnC0011: Imaging Unit Motor C turning at abnormal timingC0012: Imaging Unit Motor M’s failure to turnC0013: Imaging Unit Motor M turning at abnormal timingC0014: Imaging Unit Motor Y’s failure to turnC0015: Imaging Unit Motor Y turning at abnormal timingC0016: Imaging Unit Motor Bk’s failure to turnC0017: Imaging Unit Motor Bk turning at abnormal timing .............. T-49

(3) C0040: Fusing Cooling Fan Motor 1’s failure to turnC0046: Fusing Cooling Fan Motor 2’s failure to turnC004C: Ozone Ventilation Fan Motor’s failure to turnC004E: Power Supply Cooling Fan Motor’s failure to turn .............. T-51

(4) C0060: Fusing Drive Motor’s failure to turnC0061: Fusing Drive Motor turning at abnormal timing ...................T-53

(5) C0094: 2nd Image Transfer Roller pressure/retraction failure ........T-54(6) C0096: Image Transfer Belt pressure/retraction failure ...................T-55(7) C0098: Fusing Roller pressure/retraction failure .............................T-56(8) C0200: Cyan PC Drum Charge Corona malfunction

C0202: Magenta PC Drum Charge Corona malfunction

i


C0204: Yellow PC Drum Charge Corona malfunctionC0206: Black PC Drum Charge Corona malfunction ......................T-58

(9) C0400: Exposure Lamp’s failure to turn ONC0410: Exposure Lamp turning ON at abnormal timing ..................T-60

(10) C0500: Heating Roller warm-up failureC0501: Lower Fusing Roller Heater Lamp warm-up failureC0510: Heating Roller abnormally low temperatureC0511: Lower Fusing Roller Heater Lamp abnormally low temperatureC0520: Heating Roller abnormally high temperatureC0521: Lower Fusing Roller Heater Lamp abnormally high temperature

.............................................................................................T-61(11) C0650: Scanner Home Sensor malfunction

C0660: Scanner overrun failure .......................................................T-63(12) C0990: LCC Lift-Up Motor malfunction

C0991: LCC Lift 1 ascent motion failureC0995: LCC Transport Motor malfunctionC0999: LCC Lift 2 ascent motion failure ..........................................T-65

(13) C0F30: Abnormally low toner density detected by Cyan ATDC Sensor/C0F31: Abnormally high toner density detected by Cyan ATDC SensorC0F32: Abnormally low toner density detected by Magenta ATDC Sensor/C0F33: Abnormally high toner density detected by Magenta ATDC SensorC0F34: Abnormally low toner density detected by Yellow ATDC Sensor/C0F35: Abnormally high toner density detected by Yellow ATDC Sensor

.............................................................................................T-67(14) C0F36: Abnormally low toner density detected by Black ATDC Sensor/

C0F37: Abnormally high toner density detected by Black ATDC Sensor .............................................................................................T-69

(15) C0F3A: Cyan ATDC Sensor adjustment failureC0F3B: Magenta ATDC Sensor adjustment failureC0F3C: Yellow ATDC Sensor adjustment failureC0F3D: Black ATDC Sensor adjustment failure ..............................T-70

(16) C13C8: New Transfer Belt Unit resetting failureC13CA: New Fusing Unit resetting failureC13CB: New Fusing Web Unit resetting failureC13CC: New Oil Coating Unit resetting failure ................................T-71

(17) C13D1: Cyan IU EEPROM failureC13D2: Magenta IU EEPROM failureC13D3: Yellow IU EEPROM failureC13D4: Black IU EEPROM failure ...................................................T-72

(18) C3310: CCD clamp/gain adjustment failure ....................................T-73(19) C3700: IR Cooling Fan Motor 1 turning at abnormal timing

C3710: IR Cooling Fan Motor 2 turning at abnormal timingC3720: Original Glass Cooling Fan Motor turning at abnormal timing

.............................................................................................T-74(20) C3A00: PIC communication error

C3A01: PIC Board malfunctionC3FFF: ROM contents fault detected upon start .............................T-75

ii


3-4. Power Supply-Related Malfunctions ........................................................ T-76(1) Copier Does not Turned ON. ...........................................................T-76(2) No Control Panel Indicators Light up. ..............................................T-77(3) No Power is Supplied to Options. ....................................................T-78

4. IMAGE QUALITY PROBLEMS ........................................................................T-794-1. Troubleshooting Image Quality Problems ................................................T-794-2. Initial Check Items ...................................................................................T-794-3. Troubleshooting Procedure by a Particular Image Quality Problem ........T-82

(1) IR Scanner System: white lines in FD, white bands in FD, colored lines in FD, and colored bands in FD ..................................T-82

(2) IR Scanner System: white lines in CD, white bands in CD, colored lines in CD, and colored bands in CD ................................. T-83

(3) IR Scanner System: color spots ...................................................... T-84(4) IR Scanner System: fog ...................................................................T-85(5) IR Scanner System: blurred image, blotchy image .........................T-87(6) IR Scanner System: incorrect color image registration ...................T-88(7) IR Scanner System: moire ...............................................................T-89(8) IR Scanner System: skewed image .................................................T-90(9) IR Scanner System: distorted image ...............................................T-91(10) IR Scanner System: low image density, rough image .....................T-92(11) IR Scanner System: defective ACS .................................................T-93(12) IR Control System: blank copy, black copy ..................................... T-94(13) IR Control System: abnormal image ................................................T-95(14) Printer Monocolor: white lines in FD, white bands in FD,

colored lines in FD, colored bands in FD, white lines in CD, white bands in CD, colored lines in CD, colored bands in CD .........T-96

(15) Printer Monocolor: uneven density in FD ........................................T-98(16) Printer Monocolor: uneven density in CD ........................................T-100(17) Printer Monocolor: low image density ..............................................T-101(18) Printer Monocolor: gradation reproduction failure ...........................T-103(19) Printer Monocolor: foggy background ..............................................T-105(20) Printer Monocolor: void areas, white spots ......................................T-107(21) Printer Monocolor: colored spots .....................................................T-108(22) Printer Monocolor: blurred image ....................................................T-109(23) Printer Monocolor: blank copy, black copy ......................................T-110(24) Printer Monocolor: 0.5-mm-pitch uneven image ..............................T-111(25) Printer Monocolor: 2-mm-pitch uneven image ................................. T-112(26) Printer Monocolor: 94-mm-pitch uneven image ...............................T-113(27) Printer 4-Color: white lines in FD, white bands in FD,

colored lines in FD, and colored bands in FD ..................................T-114(28) Printer 4-Color: white lines in CD, white bands in CD,

colored lines in CD, and colored bands in CD ................................. T-116(29) Printer 4-Color: uneven density in FD .............................................T-118(30) Printer 4-Color: uneven density in CD .............................................T-119(31) Printer 4-Color: low image density ...................................................T-120(32) Printer 4-Color: poor color reproduction ..........................................T-122(33) Printer 4-Color: incorrect color image registration ...........................T-124

iii


(34) Printer 4-Color: void areas, white spots ...........................................T-126(35) Printer 4-Color: colored spots .......................................................... T-127(36) Printer 4-Color: oil lines, oil on copy ................................................T-129(37) Printer 4-Color: poor fusing performance, offset .............................T-130(38) Printer 4-Color: brush effect, blurred image ....................................T-131(39) Printer 4-Color: back marking .......................................................... T-132(40) Printer 4-Color: 75-mm-pitch uneven image,

200-mm-pitch uneven image ...........................................................T-133(41) Printer 4-Color: 94-mm-pitch uneven image ....................................T-134

4-4. Image Stabilizer Malfunction ....................................................................T-135(1) P-5: AIDC Sensor Failure (AIDC Sensor 2)

P-28: AIDC Sensor Failure (AIDC Sensor 1) ................................... T-135(2) P-6: Cyan Imaging Unit Failure

P-7: Magenta Imaging Unit FailureP-8: Yellow Imaging Unit FailureP-9: Black Imaging Unit Failure .......................................................T-135

(3) P-21: Color Shift Correction Failure (Test Pattern Failure) .............. T-136(4) P-22: Color Shift Correction Failure (Correction Amount Failure) ...T-136(5) P-23: Cyan 1st Image Transfer ATVC Failure

P-24: Magenta 1st Image Transfer ATVC FailureP-25: Yellow 1st Image Transfer ATVC FailureP-26: Black 1st Image Transfer ATVC FailureP-27: 2nd Image Transfer ATVC Failure .........................................T-136

(6) S-1: CCD Gain Adjustment Failure ..................................................T-137(7) S-2: Intensity Adjustment Failure .....................................................T-137

iv


1. INTRODUCTION1-1. Reading the Text

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

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

2. I/O CHECK2-1. Electrical Components Check Procedure

To allow the Tech. Rep. to easily and safely determine whether a particular electrical com-ponent is fully operational, this copier provides the following provision. Checking the data of the input port of the board IC with the copier in the standby state (including a misfeed, mal-function, and closure failure condition) allows the Tech. Rep. to determine whether signals are properly input to an electrical component.

<Procedure>1. When a misfeed or malfunction occurs, identify on the circuit diagram accompanying

the text the electrical component that is probably responsible for the problem.2. Select “State Confirm” from the “Tech. Rep. Mode” menu and then select “I/O Check.”

Then, from among the Sensors 1 to 7 screens, select the screen that contains the elec-trical component picked out in step 1 above. (See “Tech. Rep. Mode” contained in SWITCHES ON PWBs.)

3. Check the input data to determine if the signal is correctly input.

Pattern 1

Go to step 2 if you answered No.

Step Check Result Action

1 Is ..? YES Do this.

2

Pattern 2

Go to step 2 if it is checked okay.

Step Check Result Action

1 Is ..? YES Do this.

NO Check that.

2

T-1


<Electrical Component Check Procedure Through Checking Input Data>

ExampleWhen a paper misfeed occurs in the paper take-up section of the copier, the 2nd Drawer Paper Take-Up Sensor is considered to be responsible for it.<Procedure>1. Remove the sheet of paper misfed.2. From the I/O Check List that follows, it is known that the input signal of the 2nd Drawer

Paper Take-Up Sensor may be checked with the data of “Take-Up” of “2nd Drawer.”3. From the “Tech. Rep. Mode” menu, select “State Confirm” and then “I/O Check.” Then,

select the screen that contains “Take-Up” under “2nd Drawer.”4. Check that the data for “Take-Up” under “2nd Drawer” is “0” (sensor blocked).5. Move the actuator to unblock the 2nd Drawer Paper Take-Up Sensor.6. Check that the data for “Take-up” under “2nd Drawer” changes from “0” to “1” on the

screen.1: Sensor is operational. 0: Sensor is faulty.

T-2


2-2. I/O Check List

<I/O Check Screens>• These are only typical screens which may be different from what are shown on each indi-

vidual copier.

Previous Screen

Next Screen

Next Screen

Previous Screen

Next Screen

Previous Screen

Next Screen

Previous Screen

Next Screen

Previous Screen

Previous Screen

Next Screen

4004P047CA 4004P048CA

4004P049CA

4004P050CA

4004P051CA4004P052CA

4004P053CA

T-3


<I/O Check List>

Symbol Panel Display Part/Signal Name

Operation Characteris-tics/Panel Display Input

BoardIC

No.Port No.

CN/PJ No.

1 0

PC3 1st Drawer Set 1st Drawer Set Sensor

In position Out of position

Master Board

(PWB-I)

IC6 PG1 PJ17I-9A

PC6 Paper Empty

1st Drawer Paper Empty Sensor

Paper not present

Paper present

IC5 PI7 PJ3I-8A

PC4 Paper Near Empty

1st Drawer Paper Near-Empty Sensor

Blocked Unblocked IC6 PG0 PJ17I-6A

PC13 Double Feed

1st Drawer Double Feed Sensor

Paper present

Paper not present

IC6 PI0 PJ5I-8B

SW D 2nd Drawer

Set 2nd Drawer Set Switch


Control Board

(PWB-A)

IC1 PC0 PJ3A-4B

PC102 Paper Empty

2nd Drawer Paper Empty Sensor

Paper not present

Paper present

IC1 PB5 PJ3A-14A


2nd Drawer Paper Near-Empty Sensor

Blocked Unblocked IC1 PB6 PJ3A-11A

PC101 Take-Up 2nd Drawer Paper Take-Up Sensor

Paper present

Paper not present

IC1 PB7 PJ3A-5A

PC105 Double Feed

2nd Drawer Double Feed Sensor

Paper present

Paper not present

IC1 PC3 PJ3A-8A

SW D 3rd Drawer Set Drawer Set Switch In position Out of position

Control Board

(PWB-A)

IC1 PC0 PJ3A-4B

PC2 Paper Empty

Drawer Paper Empty Sensor

Paper not present

Paper present

IC1 PB5 PJ3A-14A


Drawer Paper Near-Empty Sensor


PC1 Take-Up Drawer Paper Take-Up Sensor

Paper present

Paper not present

IC1 PB7 PJ3A-5A

PC5 Double Feed

Drawer Double Feed Sensor

Paper present

Paper not present

IC1 PC3 PJ3A-8A

SW D 4th Drawer Set Drawer Set Switch In position Out of position

Control Board

(PWB-A)

IC1 PC0 PJ3A-4B

PC2 Paper Empty

Drawer Paper Empty Sensor

Paper not present

Paper present

IC1 PB5 PJ3A-14A


Drawer Paper Near-Empty Sensor


PC1 Take-Up Drawer Paper Take-Up Sensor

Paper present

Paper not present

IC1 PB7 PJ3A-5A

PC5 Double Feed

Drawer Double Feed Sensor

Paper present

Paper not present

IC1 PC3 PJ3A-8A

PC15 Manual Take-Up Manual Feed Paper Take-Up Sensor

Paper present

Paper not present

Master Board

(PWB-I)

IC6 PI5 PJ15I-7B

PC15 Set Manual Feed Paper Take-Up Sensor


IC5 PH4 PJ15I-10B

PC17 Paper Passage

Timing Roller

Synchronizing Roller Sensor

Paper present

Paper not present

IC1 P77 PJ14I-9B

PC10 Exit Exit Sensor Paper present

Paper not present

IC6 PI4 PJ3I-14A

PC19 Paper Passage

OHP Detect Sensor

OHP Detecting Sensor

OHP present

OHP not present

IC1 AN5 PJ14-2B

T-4


LS1 LCC Lift-Up 1 Lift-Up Sensor 1 At raised position

Not at raised

position

LCC Control Board

(PWB-A)

IC4 P74/ANI4

CN4A-6

LS2 Lift-Up 2 Lift-Up Sensor 2 At raised position

Not at raised

position

IC4 P73/ANI3

CN4A-9

RSEN Registration Registration Sensor Paper present

Paper not present

IC4 P22/INTP1

CN4A-2

S1 Paper Wait Paper Standby Position Sensor

At standby position

Not at standby position

IC4 P23/INTP2/

CI

CN3A-5

PPS0 Take-Up 1 LCC Paper Take-Up Sensor

Paper present

Paper not present

IC4 P24/INTP3

CN4A-11

PPS1 Take-Up 2 Paper Empty Sensor 1

Paper present

Paper not present

IC4 P25/INTP4/ASCK

CN3A-2

EMP Paper Empty

Paper Empty Sensor 2

Paper not present

Paper present

IC4 P72/ANI2

CN3A-8

RS1 Paper Near Empty 1

Paper Near Empty Sensor 1

Unblocked Blocked IC4 P75/ANI5

CN6A-12

RS2 Paper Near Empty 2

Paper Near Empty Sensor 2

Unblocked Blocked IC4 P76/ANI6

CN5A-5

PWB-A PI2

Duplex Set Duplex Unit Door Set Sensor (in PWB-A)

Duplex Control Board

- - PJ1A-3

PWB-A PI1

Paper passage 1

Duplex Unit Transport Sensor 1 (in PWB-A)

Paper present

Paper not present

- - PJ1A-12

PC1 Paper passage 2

Duplex Unit Transport Sensor 2

Paper present

Paper not present

- - PJ4A-3

PC1 Horizontal Trans. Unit

Horizontal Transport

Paper Sensor Paper not present

Paper present

Control Board

(PWB-A)

IC1IC1

P26P27

PJ15A-4PJ12-2

PC6 Rev. Empty Turnover Empty Detecting Sensor

Paper present

Paper not present

IC26IC1

PE3P22

PJ15A-12PJ13-2

PWB-B Mail Bin Sorter

Exit Section

Exit Sensor Board Paper present

Paper not present

IC1 P25 PJ6A-7

PWB-B 1st bin Empty

Non-Sort Bin Empty Sensor

Paper present

Paper not present

IC1 P40 PJ6A-5

PWB-D 2nd bin Empty

2nd Bin Empty Sensor

Paper present

Paper not present

IC1 P41 PJ7A-4A

PWB-D 3rd bin Empty

3rd Bin Empty Sensor

Paper present

Paper not present

IC1 P42 PJ7A-11A

PWB-D 4th bin Empty

4th Bin Empty Sensor

Paper present

Paper not present

IC1 P43 PJ7A-4B

PWB-D 5th bin Empty


Paper present

Paper not present

IC1 P44 PJ7A-11B

PWB-D 6th bin Empty


Paper present

Paper not present

IC1 P45 PJ8A-4A

PWB-D 7th bin Empty


Paper present

Paper not present

IC1 P46 PJ8A-11A

PWB-D 8th bin Empty


Paper present

Paper not present

IC1 P47 PJ8A-4B

PWB-D 9th bin Empty


Paper present

Paper not present

IC1 P23 PJ8A-11B

PWB-D 10th bin Empty


Paper present

Paper not present

P21 PJ9A-4

PWB-D



BoardIC

No.Port No.

CN/PJ No.

1 0

T-5


PWB-B Mail Bin Sorter

1st bin Full Non-Sort Bin Full Sensor

Blocked Unblocked Control Board

(PWB-A)

IC1 P70 PJ6A-4

PWB-D 2nd bin Full 2nd Bin Full Sensor Blocked Unblocked IC1 P71 PJ7A-1A

PWB-D 3rd bin Full 3rd Bin Full Sensor Blocked Unblocked IC1 P72 PJ7A-8A

PWB-D 4th bin Full 4th Bin Full Sensor Blocked Unblocked IC1 P73 PJ7A-1B


PWB-D 6th bin Full 6th Bin Full Sensor Blocked Unblocked IC1 P75 PJ8A-1A

PWB-D 7th bin Full 7th Bin Full Sensor Blocked Unblocked IC1 P76 PJ8A-8A



PWB-C 10th bin Full 10th Bin Full Sensor Blocked Unblocked IC1 P67 PJ9A-1

PC1 Finisher Exit (Non-sort)

1st Tray Exit Sensor Paper present

Paper not present

Control Board

(PWB-A)

IC26 PC4 PJ19A-6

PC3 Exit (Finisher)

Storage Sensor Paper present

Paper not present

IC26 PD0 PJ20A-3

PC4 Transport Upper

Upper Entrance Sensor

Paper present

Paper not present

IC26 PE6 PJ20A-9

PC2 Transport Lower

Lower Entrance Sensor

Paper present

Paper not present

IC26 PE7 PJ19A-8

PC6 Full (Non-sort)

1st Tray Full Detecting Sensor

Blocked Unblocked IC26 PC5 PJ19A-3

PC7 Full (Elev. Tray)

Elevator Tray Full Detecting Sensor

Blocked Unblocked IC26 PA7 PJ19A-12

PC5 Empty Finisher Tray Paper Detecting Sensor

Out of position

In position IC26 PD1 PJ25A-2

PWB-D Finisher Elevator Tray Upper Limit Sensor PQ

Paper present

Paper not present

IC26 PA6 PJ21A-2

PC8 Surface (Elev.)

Elevator Tray Paper Detecting Sensor

Blocked Unblocked IC26 PA5 PJ25A-9

PC9 Empty (Elev.)

CD Aligning Home Position Sensor

Blocked Unblocked IC26 PD2 PJ25A-6

PC14 Home (CD-Align)

Staple Home Position Sensor


PC12 Home (Stap. Unit)

Storage Roller Home Position Sensor


PC13 Hole (store roller)

Exit Rolls Home Position Sensor


- Home (Stapler 1)

Stapler Home 1 Blocked Unblocked IC1 P71, ANI1

PJ23A-2

- Empty St. 1 Needle

Stapler Empty 1 Blocked Unblocked IC1 P72, ANI2

PJ23A-4



BoardIC

No.Port No.

CN/PJ No.

1 0

T-6


- Finisher Self Priming S1

Stapler Self-Priming 1

Blocked Unblocked Control Board

(PWB-A)

IC1 P73, ANI3

PJ23A-3

- Home (Stapler 2)

Stapler Home 2 Blocked Unblocked IC1 P75, ANI5

PJ24A-2

- Empty St. 2 Needle

Staple Empty 2 Blocked Unblocked IC1 P76, ANI6

PJ24A-4

- Self Priming S2

Stapler Self-Priming 2

Blocked Unblocked IC1 P77, ANI7

PJ24A-3

S2S3

Elevate Tray

Raised/Lowered

Elevate Tray Raised/Lowered

ON OFF - - PJ4A-4

PC10 Home (Shift)

Shift Home Position Sensor


S4 Punch Hole Change

Hole Punch Position Switch

ON OFF IC28 PE2 PJ12A-3

PC15 Punch Speed

Punch Motor Pulse Sensor

Blocked Unblocked IC1 P21INPO

PJ13A-8

PC11 Shift Speed Shift Motor Pulse Sensor

Blocked Unblocked IC1 P24INPO

PJ25A-14

SW6 Dev. Cyan Toner Empty

Toner Empty Switch C

ON OFF Master Board

(PWB-I)

IC6 PH6 PJ5I-5A

SW7 Magenta Toner Empty

Toner Empty Switch M

ON OFF IC6 PH5 PJ5I-3A

SW8 Yellow Toner Empty

Toner Empty Switch Y

ON OFF IC6 PH4 PJ5I-1A

SW5 Black Toner Empty

Toner Empty Switch Bk

ON OFF IC6 PH7 PJ5I-5B

PC28 Transfer Belt

Transfer Unit

Separation

1st Image Transfer Retraction Position Sensor

Not Retracted

Retracted IC5 PI1 PJ17I-1A

- Set - In position Out of position

IC5 PE7 PJ4I-8

PC23 2nd Transfer

Transfer Unit

Separation

2nd Image Transfer Pressure Position Sensor

Not Retracted

Retracted IC5 PI2 PJ14I-6B

PC29 Toner Collect

Waste Toner

Waste Toner Full Detecting Sensor

Unblocked Blocked IC8 3Y PJ7I-7B

PC18 Toner Box Set

Waste Toner Bottle Set Sensor


IC5 PI4 PJ7I-5B

- Fusing Unit

Set Fusing Unit In position Out of position

IC5 PH5 PJ6I-7A

- Fusing Web Unit

Not used Not used Not used - - -

PC7 Fuser Roller Separation

Fusing Pressure Position Sensor

Pressed State other than pressed

IC5 PI6 PJ17I-3B

PC24 IR Home Sensor

Org. Detect Sensor At home Out of home

Image Process-

ing Board

(PWB-C)

- - PJ6C-2

SW10 Scanner Home Sensor

Org. Cover Size Reset Switch Lowered Raised - - PJ7D-2



BoardIC

No.Port No.

CN/PJ No.

1 0

T-7


PC25 Org. Detect Sensor

15 Degree Sensor

Original Cover Detecting Sensor

Less than 15°

15° or more

Image Process-

ing Board

(PWB-C)

- - PJ2C-2B

PC30 Org. Detect Sensor 1

Original Size Detecting Sensor FD1

Original loaded,

not mounted

Original not loaded

- - PJ7C-1



Original loaded,

not mounted

Original not loaded

- - PJ7C-7



Original loaded,

not mounted

Original not loaded

- - PJ7C-9



Original loaded,

not mounted

Original not loaded

- - PJ9C-3



Original loaded,

not mounted

Original not loaded

- - PJ9C-5


Original Size Detecting Sensor CD1

Original loaded,

not mounted

Original not loaded

- - PJ7C-12



Original loaded,

not mounted

Original not loaded

- - PJ7C-14



Original loaded,

not mounted

Original not loaded

- - PJ9C-10



BoardIC

No.Port No.

CN/PJ No.

1 0

T-8


2-3. How to Interpret “State Confirm” of “Tech. Rep. Mode”

Study the following to interpret data provided by “State Confirm” of “Tech. Rep. Mode.” Note, however, that the specific data given hereunder is only for reference.

(1) Table #

4004P054CA

Vb-C/-M/-Y/-BkOutput table value of each developing bias, representing data applicable during making copies.Though the minus sign is not displayed, all are negative values.Standard: Color (C, M, and Y): Around -400 V

Black (Bk): Around -800 VIf the image is light, the value becomes great.If the image is dark, the value becomes small.Used as a means of correcting image quality problems.

4004P055CA

4004P056CA

Vg-C/-M/-Y/-BkOutput table value of each PC Drum Charge Corona grid mesh, representing data appli-cable during making copies.Though the minus sign is not displayed, all are negative values.Standard: Color (C, M, and Y): Around -500 V

Black (Bk): Around -900 VIf the image is light, the value becomes great.If the image is dark, the value becomes small.Used as a means of correcting image quality problems.

T-9


(2) Level History 1

(3) Level History 2

ATDC-C/-M/-Y/-BkDisplays T/C ratios.The value is displayed in units of 0.01 %.Target value:Color (C, M, and Y) T/C: 5 ±1 %Black (Bk) T/C: 4.5 ±1 %AIDC1/2Displays the AIDC Sensor output values.The value is displayed in units of 0.01 V.Normally, the value should be around 4.5 V and the output can range from 0 V to 5 V.

Temp Upr./Lwr.Displays the temperatures of the Upper and Lower Fusing Rollers.The value is displayed in units of 5 °C.

4004P057CA

AIDC Sensor Adjust Value 1/2Displays the AIDC intensity adjustment val-ues.The values represent the intensity deter-mined through AIDC intensity control.The value is displayed in units of 1 step.Intensity range: 0 to 255

4004P058CA

T-10


2-4. Paper Misfeed

When a paper misfeed occurs in the copier, the misfeed message, misfeed location, and paper location are displayed on the Touch Panel.

<Misfeed Display Resetting Procedure>

Display Misfeed/Paper Location Ref. Item No.

1 ADF take-up

See relevant Option Service Manual.

2 ADF transport

3 ADF turnover/exit

4 Horizontal Unit

5Mailbin/Finishing option transport/Finishing option exit

6 Mailbins

7 Duplex Unit transport (8)

8 Fusing/Exit (5)

9 2nd Image Transfer (4)

10 Manual Bypass take-up (2)

11 Vertical Transport/Duplex Unit take-up (3)

12 1st Drawer take-up (1)

13 2nd Drawer take-up (1)

143rd Drawer take-up/LCC take-up/LCC Lift 2 to 1 paper transport

(6) (7)

15 4th Drawer take-up (6) (7)

Misfeed in copier Open the relevant door, clear the misfeed and remove paper left, and then close the door. (For the option, clear the misfeed and then install the option back up against the copier.)

Misfeed in option

3

2

1

4

512

13

14

15

10

11

11

11

6 11

9

8

7

4004P059CA

T-11


2-5. Misfeed Detecting Sensor Layout

• System Mounted with AD-14 and PF-117

Exit Sensor (PC10)

Duplex Unit Transport Sensor 1 (PI1)

Duplex Unit Transport Sensor 2 (PC1)

Manual Feed Paper Take-Up Sensor (PC15)

2nd Drawer Paper Take-Up Sensor (PC101)

LCC Registration Sensor (RSEN)

LCC Paper Take-Up Sensor (PPS0)

1st Drawer Double Feed Sensor (PC13)

2nd Drawer Double Feed Sensor (PC105)

Synchronizing Roller Sensor (PC17)

2/ OHP Detecting Sensor (PC19)

4011T055AA

T-12


• System Mounted with AD-14 and PF-118

Exit Sensor (PC10)

Synchronizing Roller Sensor (PC17)

Duplex Unit Transport Sensor 1 (PI1)

Duplex Unit Transport Sensor 2 (PC1)

Manual Feed Paper Take-Up Sensor (PC15)

2nd Drawer Paper Take-Up Sensor (PC101)

3rd Drawer Paper Take-Up Sensor (PC1)

4th Drawer Paper Take-Up Sensor (PC1)

OHP Detecting Sensor (PC19)

1st Drawer Double Feed Sensor (PC13)

2nd Drawer Double Feed Sensor (PC105)

3rd Drawer Double Feed Sensor (PC5)

4th Drawer Double Feed Sensor (PC5)

4011T056AA

T-13


2-6. Types of Misfeed Detection and Detection Timing

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

• The symbol “L” (for the leading edge) and “T” (for the trailing edge) given in ( ) indicate the particular edge of the paper detected by the sensor.

<Copier Paper Take-Up Misfeed>

<Manual Bypass Take-Up Misfeed>

<Copier Vertical Transport Misfeed>

Type Detection Start Detection

Paper take-up failure detection

1st Drawer Paper Take-Up Clutch energized

Synchronizing Roller Sensor (L)

2nd Drawer Paper Take-Up Clutch energized

2nd Drawer Paper Take-Up Sensor (L)

1st Drawer size error detection

Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

2nd Drawer size error detection


2nd Drawer Paper Take-Up Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

Detection of paper left in 2nd Drawer

Power Switch is turned ON, door or cover is opened and closed, misfeed or malfunction is reset

2nd Drawer Paper Take-Up Sensor activated


Bypass paper take-up failure detection

Manual Feed Paper Take-Up Sensor (L)


Manual bypass size error detec-tion

Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

Detection of paper left in Manual Bypass Table


Manual Feed Paper Take-Up Sensor activated


2nd Drawer paper take-up failure



T-14


<2nd Image Transfer Misfeed>

<Exit Misfeed>

<PF-118 Paper Take-Up Misfeed>


2nd Image Transfer mis-feed detection

Synchronizing Roller Sensor (L) Synchronizing Roller Sensor (T)

Exit Sensor (L)

Detection of paper left at 2nd Image Transfer


Synchronizing Roller Sensor activated, OHP Detecting Sensor activated


Exit misfeed Exit Sensor activated (L) Exit Sensor deactivated (T)

Exit Sensor deactivated (T) Duplex Unit Transport Sensor 1 (L)

Detection of paper left at exit


Exit Sensor activated


3rd Drawer size error detection

3rd Drawer Paper Take-Up Sensor (L)

3rd Drawer Paper Take-Up Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

4th Drawer size error detection

4th Drawer Paper Take-Up Sensor (L)

4th Drawer Paper Take-Up Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

Detection of paper left in 3rd Drawer


3rd Drawer Paper Take-Up Sensor activated

Detection of paper left in 4th Drawer


4th Drawer Paper Take-Up Sensor activated

T-15


<PF-117 Paper Take-Up Misfeed>

<Duplex Paper Take-Up Misfeed>


LCC misfeed detection

LCC paper take-up request LCC Exit signal ON

Lift 2 to 1 mis-feed detection

LCC Paper Take-Up Request LCC Paper Take-Up Sensor activated, LCC Paper Empty Sensor 1 activated, Paper Standby Position Sensor acti-vated

LCC vertical transport mis-feed detection

LCC Exit signal ON 2nd Drawer Paper Take-Up Sensor (L)

LCC size error detection


2nd Drawer Paper Take-Up Sensor (T)[When the paper size detected is ±20 mm or more of the size data fed from the controller]

Detection of paper left in LCC


LCC Registration Sensor Paper-Left Misfeed signal ON


Duplex paper take-up mis-feed detection

Duplex paper take-up start Synchronizing Roller Sensor (L), Man-ual Feed Paper Take-Up Sensor (L)

Duplex trans-port misfeed detection

Duplex Unit Transport Sensor 1 (L)

Duplex Unit Transport Sensor 2 (L)

Detection of paper left in Duplex


Duplex Unit Transport Sensor 1 acti-vated, Duplex Unit Transport Sensor 2 activated

T-16


2-7. Misfeed Troubleshooting Procedures

(1) Copier Paper Take-Up Misfeed

Relevant Electrical Parts

1st Drawer Paper Take-Up Clutch (CL1)2nd Drawer Paper Take-Up Clutch (CL101)Synchronizing Roller Sensor (PC17)Main Motor (M13)

2nd Drawer Paper Take-Up Motor (M101)Master Board (PWB-I)DC Power Supply 1 (PU1)2nd Drawer Control Board (PWB-A)

M13

PJ10512345678

PJ116

PC17

CL1

321

678

121

CN63

59 4

12 1

2112

CN55

PJ7PU1-4(DC24 V)PJ7PU1-5(GND)

PU1

PJ13I-7A(M13 LOCK)PJ13I-8A(M13 REM)

PJ13I-9A(M13 CLK)PJ13I-10A(DC5 V)PJ13I-11A(GND)PJ13I-12A(M13 CW/CCW)

PJ14I-7A(DC5 V)PJ14I-8A(GND)

PJ15I-10A(DC24 V)PJ15I-11A(CL1 REM)

PJ14I-9A(PC17 ON)

PWB-I

CL101

M101 321

14

CN61

23

21

CN1

12

4

PJ3A-13B(DC24 V)PJ3A-14B(CL101 REM)

PJ5A-4( – )

B

PJ5A-2( – )

APJ5A-3(B)

PJ5A-1(A)

PWB-A(2nd Tray) –

4004C16TAD

T-17


Copier Paper Take-Up Misfeed Troubleshooting Procedures

• Paper is not taken up at all.

Step Check Item Result Action

1 Paper meets product specifications. NO Change paper.

2 Paper is curled, wavy, or damp. YES Change paper. Instruct user in correct paper storage. Install Paper Dehumidifying Heater.

3 Edge Guide and Trailing Edge Stop are at correct position to accommodate paper.

NO Set as necessary.

4 Paper Take-Up Roll is deformed, worn, or dirty with paper dust or other foreign matter.

YES Clean or change.

5 Paper Lifting Plate is dirty, deformed, or scratched.


6 Separator Pad is deformed, worn, or dirty with paper dust or other foreign matter.


7 Separator Roll is deformed, worn, or dirty with paper dust or other foreign matter.


8 Paper take-up guide plate is dirty, deformed, or scratched.


9 Paper take-up guide plate is installed prop-erly.

NO Reinstall.

10 Paper Take-Up Roll turns when the Start key is pressed with the 1st Drawer selected.

NO Correct drive coupling (cou-pling engagement, position of drive transmitting pin).

11 1st Drawer Paper Take-Up Clutch operation when the Start key is pressed with the 1st Drawer selected: the voltage across PJ15I-11A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

YES Check for overload. Change clutch.

NO Change Master Board.

12 Paper Take-Up Roll turns when the Start key is pressed with the 2nd Drawer selected.


13 2nd Drawer Paper Take-Up Clutch opera-tion when the Start key is pressed with the 2nd Drawer selected: the voltage across PJ3A-14B on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.


NO Change Control Board.

T-18


(2) Manual Bypass Take-Up Misfeed


Manual Feed Paper Take-Up Sensor (PC15)Manual Feed Paper Take-Up Clutch (CL13)

Synchronizing Roller Sensor (PC17)Synchronizing Roller Clutch (CL21)Master Board (PWB-I)

PJ116

PC17

CL21

CL3

321

PJ40

PC15

123

678

121

CN63

5

267

71

CN65

2112

CN30

2112

CN41

1

9 4

12 1

334455

88

11

CN33

22DC24 V


PJ14I-7B(DC5 V)PJ14I-8B(GND)PJ14I-9B(PC17 ON)

PJ15I-9A(CL3 REM)PJ15I-7B(PC15 ON)PJ15I-8B(GND)PJ15I-9B(DC5 V)

PWB-I

4004C17AD

T-19


Manual Bypass Take-Up Misfeed Troubleshooting Procedures

• Paper is not detected.



1 I/O check for Manual Feed Paper Take-Up Sensor operation when the Manual Bypass Table is used: the voltage across PJ15I-7B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (paper present).

YES Change Master Board.

NO Correct actuator. Check sen-sor connector connection. Change sensor.




3 Guide plate is dirty with paper dust, deformed, or scratched.


4 Manual Bypass Take-Up Roll is dirty with paper dust, deformed, or worn.


5 Manual Bypass Take-Up Roll turns when the Start key is pressed with the Manual Bypass Table used.

NO Correct drive coupling (drive transmitting gear engage-ment).

6 Manual Feed Paper Take-Up Clutch opera-tion when the Manual Feed Paper Take-Up Sensor is blocked with the Manual Bypass Table used: the voltage across PJ15I-9A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



T-20


• Paper is at a stop at the vertical transport section.



2 Synchronizing Rollers are dirty with paper dust, deformed, or worn.


3 Paper Dust Remover is deformed or worn. NO Change Paper Dust Remover Unit.

4 Paper Dust Remover is installed properly. NO Reinstall Paper Dust Remover Unit.

5 An adequate length of loop is formed before the Synchronizing Rollers.

NO Adjust “Paper Loop.” (See ADJUSTMENT.)

6 I/O check for Synchronizing Roller Sensor operation when the Manual Bypass Table is used: the voltage across PJ14I-9B on Mas-ter Board and GND is DC 0 V when the sen-sor is unblocked (paper present) and DC 5 V when the sensor is blocked.


NO Correct actuator. Check sen-sor connector connection. Change sensor.

7 Synchronizing Rollers turn when the Start key is pressed with the Manual Bypass Table used.


8 Synchronizing Roller Clutch operation when the Manual Bypass Table is used: the volt-age across PJ15I-9A on Master Board and GND after the Manual Feed Paper Take-Up Clutch has been energized is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



9 Size error display after the misfeed display has been reset.

YES Check paper size.

T-21


(3) Copier Vertical Transport Misfeed


Synchronizing Roller Sensor (PC17)2nd Drawer Paper Take-Up Sensor (PC101)Synchronizing Roller Clutch (CL21)1st Drawer Paper Take-Up Clutch (CL1)2nd Drawer Paper Take-Up Clutch (CL101)

Main Motor (M13)2nd Drawer Paper Take-Up Motor (M101)Master Board (PWB-I)DC Power Supply 1 (PU1)2nd Drawer Control Board (PWB-A)

M13

PJ10512345678


PU1

PJ116

PC17

CL1

CL21

321

678

121

CN63

5

267

71

CN65

1

9 4

12 1

2112

CN55

2112

CN30

PJ14I-7A(DC5 V)PJ14I-8A(GND)



PJ14I-9A(PC17 ON)



PWB-I

PJ12

PC101

CL101

M101

321

321

14

CN61

23

21

CN1

12

4

PJ3A-3A(DC5 V)PJ3A-4A(GND)PJ3A-5A(PC101 ON)


PJ5A-4( – )

B

PJ5A-2( – )

APJ5A-3(B)

PJ5A-1(A)

PWB-A(2nd Tray) –

4004C18TAD

T-22


Copier Vertical Transport Misfeed Troubleshooting Procedures

• Paper is at a stop at the vertical transport section.


1 Synchronizing Rollers are deformed or worn.

YES Check type of paper being used.

2 Paper dust deposits on Synchronizing Roll-ers.

YES Clean Synchronizing Rollers. Check Paper Dust Remover for proper function.

3 Paper Dust Remover is deformed or worn. YES Change Paper Dust Remover Unit.

4 Paper Dust Remover is installed properly. NO Reinstall Paper Dust Remover Unit.

5 An adequate length of loop is formed before the Synchronizing Rollers.

NO Adjust “Paper Loop.” (See ADJUSTMENT.)

6 Vertical transport guide plate is dirty, deformed, or scratched.


7 I/O check for Synchronizing Roller Sensor operation: the voltage across PJ14I-9B on Master Board and GND is DC 0 V (paper present) when the sensor is unblocked and DC 5 V when the sensor is blocked.


NO Correct actuator. Check sen-sor connector for connection. Change sensor.

8 Synchronizing Rollers turn when the Start key is pressed with the 1st Drawer selected.


9 Synchronizing Roller Clutch operation when the 1st Drawer is used: the voltage across PJ14I-14A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



10 2nd Drawer Vertical Transport Roller 1 is dirty with paper dust, deformed, or scratched.


11 2nd Drawer vertical transport guide plate is dirty, deformed, or scratched.


12 Synchronizing Rollers turn when the Start key is pressed with the 2nd Drawer selected.


13 Synchronizing Roller Clutch operation when the 2nd Drawer is used: the voltage across PJ14I-14A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



T-23


14 2nd Drawer Paper Take-Up Motor turns when the Start key is pressed with the 2nd Drawer selected.

NO Correct drive coupling (cou-pling engagement, position of drive transmitting pin). Change motor. Change 2nd Drawer Control Board.


YES Check paper size. Check positioning of the Edge Guide and Trailing Edge Stop.


T-24


(4) 2nd Image Transfer Misfeed


Exit Sensor (PC10)Synchronizing Roller Sensor (PC17)Main Motor (M13)

Fusing Drive Motor (M14)Master Board (PWB-I)DC Power Supply 1 (PU1)

M13

PJ10512345678

M14

PJ10612345678


PU1


PJ13I-9A(M13 CLK)PJ13I-10A(DC5 V)PJ13I-11A(GND)PJ13I-12A(M13 CCM/CM)



PWB-I

PJ116

PC17

321

PJ133

PC10

321

678

121

CN63

312213

CN17

59 4

12 1


PJ3I-12A(DC5 V)PJ3I-13A(GND)PJ3I-14A(PC10 ON)

4004C20TAB

T-25


2nd Image Transfer Misfeed Troubleshooting Procedures

• Paper is at a stop at the 2nd Image Transfer section.


1 Vertical transport guide plate is dirty, deformed, or scratched.


2 Image Transfer Roller Unit is not installed properly.

YES Reinstall.

3 Pre-Image Transfer Guide Plate is dirty, deformed, or scratched.Seal is separated.

YES Clean or change Image Transfer Roller Unit.

4 Transfer Belt is driven when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Reinstall Transfer Belt Unit.

5 Transfer Belt is deformed or damaged. YES Change Transfer Belt Unit.

6 Transfer Roller turns when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Reinstall Transfer Roller Unit.

7 Transfer Roller is dirty with paper dust or other foreign matter, deformed, or worn.

YES Clean or change Image Transfer Roller Unit.

8 Fusing Rollers turn when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Correct the installed position of Fusing Unit.

9 Paper winds around Transfer Belt. YES Readjust Paper Separator Fingers. Readjust “Top Mar-gin.”

10 Paper winds around Transfer Roller. YES Change Transfer Roller Unit.

11 I/O check for Exit Sensor operation: the voltage across PJ3I-14A on Master Board and GND is DC 0 V (paper present) when the sensor is unblocked and DC 5 V when the sensor is blocked.



T-26


(5) Exit Misfeed


Exit Sensor (PC10)Fusing Drive Motor (M14)

Master Board (PWB-I)DC Power Supply 1 (PU1)

M14

PJ10612345678


PU1



PJ3I-12A(DC5 V)PJ3I-13A(GND)PJ3I-14A(PC10 ON)

PWB-I

PJ133

PC10

321 13

31

CN17

22

4004C21TAA

T-27


Exit Misfeed Troubleshooting Procedures

• Paper is at a stop at the 2nd Image Transfer section.


1 Fusing guide plate is dirty, deformed, or damaged.


2 Fusing Rollers are dirty, deformed, or scratched.

YES Clean or change Fusing Unit.

3 Fusing Paper Separator Fingers are dirty, deformed, or worn.

YES Clean, correct, or change.

4 Fusing Exit Roller is dirty, deformed, or scratched.


5 Fusing Rollers turn when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment). Correct installed posi-tion of Fusing Unit. Change Fusing Unit.

6 I/O check for Exit Sensor operation: the voltage across PJ3I-14A on Master Board and GND is DC 0 V (paper present) when the sensor is unblocked and DC 5 V when the sensor is blocked.



7 Exit Turnover Roller is dirty, deformed, or scratched.


8 Exit Turnover Roller turns when the Start key is pressed.

NO Correct drive coupling (roller position).

T-28


(6) PF-118 Paper Take-Up Misfeed


3rd Drawer Paper Take-Up Sensor (PC1)4th Drawer Paper Take-Up Sensor (PC1)3rd Drawer Paper Take-Up Clutch (CL1)4th Drawer Paper Take-Up Clutch (CL1)

3rd Drawer Paper Take-Up Motor (M1)4th Drawer Paper Take-Up Motor (M1)3rd Drawer Control Board (PWB-A)4th Drawer Control Board (PWB-A)

PJ12

PC1

CL1

M1

321

PJ12

PC1

CL1

M1

321

321

14

CN61

23

21

CN73

12

4

321

14

CN61

23

21

CN73

12

4



PJ5A-4( – )

B

PJ5A-2( – )

APJ5A-3(B)

PJ5A-1(A)

PWB-A(3rd Tray) –



PJ5A-4( – )

B

PJ5A-2( – )

APJ5A-3(B)

PJ5A-1(A)

PWB-A(4th Tray) –

4004C22TAB

T-29


PF-118 Paper Take-Up Misfeed Troubleshooting Procedures





3 Edge Guide and Trailing Edge Stop are at correct position to accommodate paper.

NO Set as necessary.

4 Paper Take-Up Roll is deformed, worn, or dirty with paper dust or other foreign matter.


5 Paper Lifting Plate is dirty, deformed, or scratched.




7 Paper take-up guide plate is dirty, deformed, or scratched.


8 Paper take-up guide plate is installed prop-erly.

NO Reinstall.

9 Paper Take-Up Roll turns when the Start key is pressed with the 3rd Drawer selected.


10 3rd Drawer Paper Take-Up Clutch opera-tion when the Start key is pressed with the 3rd Drawer selected: the voltage across PJ3A-14B on Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.


NO Change 3rd Drawer Control Board.

11 3rd Drawer Paper Take-Up Motor turns when the Start key is pressed with the 3rd Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment). Change motor. Change 3rd Drawer Control Board.

12 Paper Take-Up Roll turns when the Start key is pressed with the 4th Drawer selected.


13 4th Drawer Paper Take-Up Clutch opera-tion when the Start key is pressed with the 4th Drawer selected: the voltage across PJ3A-14B on Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.


NO Change 4th Drawer Control Board.

T-30


• Paper is at a stop at the Vertical Transport Rollers.

14 4th Drawer Paper Take-Up Motor turns when the Start key is pressed with the 4th Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment). Change motor. Change 4th Drawer Control Board.


1 Paper take-up guide plate or vertical trans-port guide plate is dirty or deformed.


2 Vertical Transport Rollers are dirty with paper dust, deformed, or worn.


3 I/O check for 3rd Drawer Paper Take-Up Sensor operation when the 3rd Drawer is used: the voltage across PJ3A-5A on Con-trol Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked.

YES Change 3rd Drawer Control Board.


4 Vertical Transport Roller 3 turns when the Start key is pressed with 3rd Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment, clutch spring opera-tion).

5 I/O check for 4th Drawer Paper Take-Up Sensor operation when the 4th Drawer is used: the voltage across PJ3A-5A on Con-trol Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked.

YES Change 4th Drawer Control Board.


6 Vertical Transport Roller 4 turns when the Start key is pressed with 4th Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment, clutch spring opera-tion).


YES Check paper size.


T-31


(7) PF-117 Paper Take-Up Misfeed


LCC Paper Take-Up Sensor (PPS0)Paper Standby Position Sensor (S1)LCC Registration Sensor (RSEN)LCC Paper Take-Up Clutch 1 (P1CL)LCC Paper Take-Up Clutch 2 (P2CL)

LCC Separator Clutch (BCL)LCC Registration Clutch (RCL)LCC Transport Motor (HMOT)LCC Control Board (PWB-A)

PJ10

S1123

PJ7

RSEN123

PJ4

PPSO

BCL

HMOT

RCL

P2CL

P1CL

123

PJ4123456

12

CN14

21

12

CN13

21

12

CN12

21

12

CN11

21

CN3A-6(S1 LED)CN3A-5(S1 ON)CN3A-4(DC5 V)

CN4A-3(RSEN LED)CN4A-2(RSEN ON)CN4A-1(DC5 V)

CN4A-12(PPSO LED)CN4A-11(PPSO ON)

CN7A-2(BCL ON)CN7A-1(DC24 V)

CN6A-6(HMOT CLK)CN6A-5(DC5 V)CN6A-4(HMOT SIG)CN6A-3(CTND)

CN6A-1(DC24 V)

CN7A-4(RCL ON)CN7A-3(DC24 V)

CN7A-6(P2CL ON)CN7A-5(DC24 V)

CN7A-8(P1CL ON)CN7A-7(DC24 V)

CN4A-10(DC5 V)

PWB-A(LCC Tray)

4004C23TAB

T-32


PF-117 Paper Take-Up Misfeed Troubleshooting Procedures

• Paper is not taken up at all. (Lift 1)

• Paper is not taken up at all. (Lift 2)




3 Lift is dirty, deformed, or damaged. YES Clean or change.

4 Paper Take-Up Roll 1 is dirty, deformed, or scratched.


5 Paper Take-Up Roll 1 turns when the Start key is pressed with Lift 1 used.

NO Correct drive coupling (drive transmitting gear engage-ment, spring operation, belt tension).

6 LCC Paper Take-Up Clutch 1 operation when the Start key is pressed with Lift 1 used: the voltage across CN7A-8 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.


NO Change LCC Control Board.




3 Lift is dirty, deformed, or damaged. YES Clean or change.

4 Paper Take-Up Roll 2 is dirty, deformed, or scratched.


5 Paper Take-Up Roll 2 turns when the Start key is pressed with Lift 2 used.

NO Correct drive coupling (drive transmitting gear engage-ment, spring operation, belt tension).

6 LCC Paper Take-Up Clutch 2 operation when the Start key is pressed with Lift 2 used: the voltage across PJ7A-6 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



T-33


• Paper is stationary at the Vertical Transport Roller.


1 Feed Roll is deformed, worn, or dirty with paper dust or other foreign matter.




3 Paper take-up guide plate is dirty, deformed, or damaged.


4 Vertical Transport Roller is dirty with paper dust, deformed, or worn.


5 Vertical transport guide plate is dirty or deformed.


6 I/O check for Paper Standby Position Sen-sor operation when the LCC Drawer is used: the voltage across PJ3A-5 on LCC Control Board and GND is DC 5 V when there is reflected light and DC 0 V when there is no reflected light.

YES Change LCC Control Board.

NO Check sensor connector for connection. Change sensor.

7 Feed Roll turns when the Start key is pressed with the LCC Drawer selected.

NO Correct drive coupling (drive transmitting gear engage-ment, belt tension).

8 Separator Roll turns when the Start key is pressed with the LCC Drawer selected.

NO Correct drive coupling (spring operation).

9 LCC Separator Clutch operation when the Start key is pressed with the LCC Drawer selected: the voltage across CN7A-2 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



10 I/O check for LCC Registration Sensor operation when the LCC Drawer is used: the voltage across CN4A-2 on LCC Control Board and GND is DC 5 V when there is reflected light and DC 0 V when there is no reflected light.


NO Check sensor connector for connection. Change sensor.

11 Vertical Transport Rollers turn when the Start key is pressed with the LCC Drawer selected.


12 LCC Registration Clutch operation when the Start key is pressed with the LCC Drawer selected: the voltage across CN7A-4 on LCC Control Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



T-34


(8) Duplex Paper Take-Up Misfeed


Duplex Unit Transport Sensor 1 (PI1)Duplex Unit Transport Sensor 2 (PC1)Manual Feed Paper Take-Up Sensor (PC15)Manual Feed Paper Take-Up Clutch (CL3)

Duplex Unit Transport Motor (M2)Switchback Motor (M1)Duplex Control Board (PWB-A)Master Board (PWB-I)

4004C24TAD

PJ3A-1( – )

B

PJ3A-3( – )

A

PJ2A-1( – )

B

PJ2A-3( – )

A

PJ40

PC15

CL3

M1

M2

123

PJ10

PC1

321

PI1

21

CN41

12334455

88

11

CN33

22

DC24 V

PJ15A-9A(CL3 REM)PJ15A-7B(PC15 ON)PJ15A-8B(GND)PJ15A-9B(DC5 V)

PJ4A-1(DC5 V)PJ4A-2(GND)PJ4A-3(PC1 ON)

PWB-I

PWB-APJ3A-2(B)

PJ3A-4(A)

PJ2A-2(B)

PJ2A-4(A)

4004C24TAD

T-35


Duplex Paper Take-Up Misfeed Troubleshooting Procedures

• Paper is at a stop in the Duplex Unit transport section.

• Paper is at a stop at the Manual Bypass take-up section.


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

2 Transport Roll is dirty, deformed, or worn. YES Clean or change.

3 Transport guide is dirty, deformed, or dam-aged.


4 Torn piece of paper left at the transport sec-tion.

YES Clean.

5 Duplex Unit Transport Roller 1 turns when the Start key is pressed with the Duplex Unit used.


6 Switchback Motor turns when the Start key is pressed with the Duplex Unit used.

NO Correct drive coupling. Change motor. Change Duplex Control Board.





9 Duplex Unit Transport Motor turns when the Start key is pressed with the Duplex Unit used.

NO Correct drive coupling. Change motor. Change Duplex Control Board.


1 I/O check for Manual Feed Paper Take-Up Sensor operation when the Manual Bypass Table is used: the voltage across PJ15I-7B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V (paper present) when the sensor is blocked.



2 Manual Bypass Paper Take-Up Roll is dirty with paper dust, deformed, or worn.


3 Manual Bypass Paper Take-Up Roll turns when the Start key is pressed with the Man-ual Bypass Table used.


4 Manual Feed Paper Take-Up Clutch opera-tion when Manual Feed Paper Take-Up Sensor is unblocked with the Manual Bypass Table used: the voltage across PJ15I-9A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.



T-36


3. MALFUNCTIONSThe copier’s CPU performs a self-diagnostics function that, on detecting a malfunction, gives the corresponding malfunction code and maintenance call mark on the Touch Panel.

Resetting a Malfunction• Press the Trouble Reset Switch on the Tech. Rep. Setting Switches Board to reset the

following malfunctions: IR-related malfunctions (except the following, i.e., C3310: CCD clamp gain adjustment failure; C3700: IR Cooling Fan Motor 1 turning at abnormal tim-ing; C3710: IR Cooling Fan Motor 2 turning at abnormal timing; C3720: Original Glass Cooling Fan Motor turning at abnormal timing) and fusing-related malfunctions.

• For any other malfunctions, open and close the Front Door or turn OFF and ON the Power Switch.

<Warning>

4004P060CA

If the maintenance call mark appears, touch it to view a screen (“State Confirm”) that shows data in greater details.

4004P045BA

4004P061CA

T-37


3-1. Detection Timing by Warning Code

• If an image stabilization or IR-related fault occurs, the corresponding warning code appears.

• Refer to the following table and take necessary action to remedy the faulty spot.

Code Fault Detection Timing

P-5 AIDC Sensor failure (AIDC Sensor 1)

• All readings of the detection points are 4.8 V or more or the selected reading is 1.0 V or less dur-ing AIDC Sensor intensity correction.

P-6 Cyan Imaging Unit failure • The results of converting the adjustment pattern reading to reflection density on paper fall short of the specified value during max. density adjustment (Vg/Vb adjustment).

• The ATDC Sensor output when 0 gradation mea-surement is taken is 253 (4.96 V) or more during γ correction.

• The result of converting the adjustment pattern reading to reflection density on paper is 0.4 V or less.

P-7 Magenta Imaging Unit fail-ure

P-8 Yellow Imaging Unit failure

P-9 Black Imaging Unit failure

P-21 Color Shift Correction fail-ure (test pattern failure)

• The calculated value of the CD color shift correc-tion amount is more or less than the specified value.

• The calculated value of the FD color shift correc-tion amount is more or less than the specified value.

P-22 Color Shift Correction fail-ure (correction amount fail-ure)

• The CD registration distance is greater than the specified range during registration correction.

• The FD registration distance is greater than the specified range during registration correction.

• Skew correction amount is more than the specified value.

P-23 Cyan 1st Image Transfer ATVC Failure

• The average value of voltage readings taken by the ATVC adjustment circuit is less than 0.5 V dur-ing ATVC adjustment.

• The average value of voltage readings taken by the ATVC adjustment circuit is 0.5 V or more and less than 0.6 V during ATVC adjustment. Or there are five consecutive adjustment sequences, each exceeding 4.6 V. (ATVC adjustment is made when power is turned OFF and ON. A warning is issued through a minimum of five sequences of turning power OFF and ON.)

P-24 Magenta 1st Image Trans-fer ATVC Failure

P-25 Yellow 1st Image Transfer ATVC Failure

P-26 Black 1st Image Transfer ATVC Failure

P-27 2nd Image Transfer ATVC Failure

P-28 AIDC Sensor failure (AIDC Sensor 2)

• All readings of the detection points are 4.8 V or more or the selected reading is 1.0 V or less dur-ing AIDC Sensor intensity correction.

T-38


S-1 Gain adjustment failure • Each gain adjustment value for R, G, or B is 240 or more when a gain adjustment is made after the Power Switch has been turned ON.

• Lamp adjustment value is 255 and, at the same time, the target value cannot be achieved through gain adjustment.

S-2 Intensity adjustment failure • Lamp voltage adjustment value Dx = 255 when a lamp voltage adjustment is made after the Power Switch has been turned ON and, at the same time, the target value cannot be achieved through the adjustment.

Code Fault Detection Timing

T-39


3-2. Detection Timing by Malfunction Code

Code Description Detection Timing

C0000 Main Motor’s failure to turn The Main Motor Lock signal remains faulty for a pre-determined continuous period of time while the Main Motor is turning.

C0001 Main Motor turning at abnormal timing

The Main Motor Lock signal remains faulty for a pre-determined continuous period of time while the Main Motor remains stationary.

C0010 Imaging Unit Motor C’s failure to turn

The Lock signal remains faulty for a continuous 1-sec. period after the motor rotation has stabilized and before the motor starts decelerating.

C0011 Imaging Unit Motor C turn-ing at abnormal timing

The Lock signal remains faulty for a continuous 1-sec. period after the motor has completely stopped and before the motor starts accelerating.

C0012 Imaging Unit Motor M’s failure to turn


C0013 Imaging Unit Motor M turn-ing at abnormal timing


C0014 Imaging Unit Motor Y’s fail-ure to turn


C0015 Imaging Unit Motor Y turn-ing at abnormal timing


C0016 Imaging Unit Motor Bk’s failure to turn


C0017 Imaging Unit Motor Bk turning at abnormal timing


C0040 Fusing Cooling Fan Motor 2’s failure to turn

A Fusing Cooling Fan Lock signal is detected for a continuous 3-sec. period while Fusing Cooling Fan Motor 2 is turning.

C0046 Fusing Cooling Fan Motor 1’s failure to turn

A Fusing Cooling Fan Lock signal is detected for a continuous 3-sec. period while the Fusing Cooling Fan Motor is turning.

C004C Ozone Ventilation Fan Motor’s failure to turn

An Ozone Fan Lock signal is detected for a continu-ous 3-sec. period while the Ozone Ventilation Fan Motor is turning.

C004E Power Supply Cooling Fan Motor’s failure to turn

A Power Supply Cooling Fan Lock signal is detected for a continuous 3-sec. period while the Power Sup-ply Cooling Fan Motor is turning.

T-40


C0060 Fusing Drive Motor’s fail-ure to turn

A Fusing Drive Motor Lock signal remains faulty for a predetermined continuous period of time while the Fusing Drive Motor is turning.

C0061 Fusing Drive Motor turn-ing at abnormal timing

The Fusing Drive Motor Lock signal remains faulty for a predetermined continuous period of time while the Fusing Drive Motor remains stationary.

C0094 2nd Image Transfer Roller pressure/retraction failure

• The 2nd Image Transfer Pressure Position Sensor is not activated (retracted position) within 1 sec. after the 2nd Image Transfer Roller has started its retracting motion.

• The 2nd Image Transfer Pressure Position Sensor is not deactivated (not the retracted position) within 1 sec. after the 2nd Image Transfer Roller has started its pressing motion.

C0096 1st Image Transfer Roller pressure/retraction failure

• The 1st Image Transfer Retraction Position Sen-sor is not activated (retracted position) within 3 sec. after the 1st Image Transfer Pressure/Retrac-tion Motor has started turning.

• The 1st Image Transfer Retraction Position Sen-sor is not deactivated (pressed position) within 1.5 sec. after the 1st Image Transfer Pressure/Retrac-tion Motor has started turning.

C0098 Fusing Roller pressure/retraction failure

• No change is observed in the encoder pulse even after the lapse of 0.5 sec. after the Fusing Pres-sure/Retraction Motor has started turning for retraction direction during retraction control.

• No change is observed in the encoder pulse even after the lapse of 0.5 sec. after the Fusing Pres-sure/Retraction Motor has started turning for pres-sure direction during pressure control.

• The Fusing Pressure Position Sensor is not acti-vated (pressed position) even when 31 motor encoder pulses have been counted after the Fus-ing Pressure/Retraction Motor has started turning for pressure direction during pressure control.

C0200 Cyan PC Drum Charge Corona malfunction

The SCD signal remains inactive for a continuous 1-sec. period while charge corona is being output (i.e., the Remote signal is being turned ON).

C0202 Magenta PC Drum Charge Corona malfunction


C0204 Yellow PC Drum Charge Corona malfunction


C0206 Black PC Drum Charge Corona malfunction



T-41


C0400 Exposure Lamp’s failure to turn ON

A Lamp-Out Detection signal is ON after the lapse of 5 sec. after the Exposure Lamp has been turned ON.

C0410 Exposure Lamp turning ON at abnormal timing

CCD Sensor outputs are written in line RAM at the end of a scan job and the average of these readings exceeds a predetermined value.

C0500 Heating Roller warm-up failure(Fusing Thermistor 1)

• Fusing Thermistor 1 does not detect a predeter-mined temperature and the warm-up cycle is not completed within the period of 9 min. 10 sec. after the warm-up cycle has been started.

• The temperature of Fusing Thermistor 1 does not rise to a level more than the predetermined output value within 30 sec. after the warm-up cycle has started.

C0501 Lower Fusing Roller Heater Lamp warm-up fail-ure(Fusing Thermistor 2)

• The temperature of Fusing Thermistor 2 does not reach 100 °C within 180 sec. after the warm-up cycle has started.

• The temperature of Fusing Thermistor 1 does not rise to a level more than the predetermined output value within 130 sec. after the warm-up cycle has started.

C0510 Heating Roller abnormally low temperature(Fusing Thermistor 1)

• The temperature of Fusing Thermistor 1 remains below 120 °C for 1 sec. or more in the standby state.

• The temperature of Fusing Thermistor 1 remains below 130 °C for 1 sec. or more during a print cycle.

• The temperature of Fusing Thermistor 1 remains below 90 °C for 1 sec. or more in the Energy Saver mode.

C0511 Lower Fusing Roller Heater Lamp abnormally low temperature(Fusing Thermistor 2)

• The temperature of Fusing Thermistor 2 remains below 100 °C for 1 sec. or more in the standby state.

• The temperature of Fusing Thermistor 2 remains below 100 °C for 1 sec. or more during a print cycle.

• The temperature of Fusing Thermistor 2 remains below 100 °C for 1 sec. or more in the Energy Saver mode.

C0520 Heating Roller abnormally high temperature(Fusing Thermistor 1)

The temperature of Fusing Thermistor 1 remains above 220 °C for 1 sec. or more at all times.

C0521 Lower Fusing Roller Heater Lamp abnormally high temperature(Fusing Thermistor 2)

The temperature of Fusing Thermistor 2 remains above 190 °C for 1 sec. or more at all times.


T-42


C0650 Scanner Home Sensor malfunction

• The Scanner Home Sensor fails to detect the Scanner at its home position though the Scanner is so located.

• The Scanner Home Sensor fails to detect the Scanner though the motor has been energized to move the Scanner over the maximum distance.

• The Scanner Home Sensor detects the Scanner at its home position though the Scanner has moved 5 mm away from the home position.

C0660 Scanner overrun failure The Scanner Home Sensor detects the Scanner at its home position during a period from when the prescan command and scan preparation command have been executed to when home return command is executed.

C0990 LCC Lift-Up Motor mal-function

See the relevant Option Service Manual.

C0991 LCC Lift 1 ascent motion failure

C0995 LCC Transport Motor mal-function

C0999 LCC Lift 2 ascent motion failure

C0B00 Finishing option transport drive malfunction

C0B20 Stapling Unit CD drive malfunction

C0B30 Finishing option Paper Aligning Bar moving mech-anism malfunction

C0B48 Finishing option Exit Roll pressure/retraction failure

C0B4A Finishing option Storage Roller pressure/retraction failure


T-43


C0B50 Finishing option stapling mechanism 1

See the relevant Option Service Manual.

C0B54 Finishing option stapling mechanism 2

C0B73 Finishing option punch cam motor mechanism malfunction

C0B78 Finishing option punch selector motor mecha-nism malfunction

C0B80 Finishing option Shift Motor mechanism mal-function

C0BA0 Finishing option Elevator Tray drive failure

C0F30 Abnormally low toner den-sity detected by Cyan ATDC Sensor

Toner density that is 2 % or more lower than the tar-get level is detected ten consecutive times during a print cycle, ATVC, or image stabilization sequence.

C0F31 Abnormally high toner density detected by Cyan ATDC Sensor

Toner density that is 4 % or more higher than the tar-get level is detected ten consecutive times during a print cycle, ATVC, or image stabilization sequence.

C0F32 Abnormally low toner den-sity detected by Magenta ATDC Sensor


C0F33 Abnormally high toner density detected by Magenta ATDC Sensor


C0F34 Abnormally low toner den-sity detected by Yellow ATDC Sensor


C0F35 Abnormally high toner density detected by Yellow ATDC Sensor


C0F36 Abnormally low toner den-sity detected by Black ATDC Sensor


C0F37 Abnormally high toner density detected by Black ATDC Sensor


C0F3A Cyan ATDC Sensor adjustment failure

Cyan ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.

C0F3B Magenta ATDC Sensor adjustment failure

Magenta ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.

C0F3C Yellow ATDC Sensor adjustment failure

Yellow ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.


T-44


C0F3D Black ATDC Sensor adjustment failure

Black ATDC Sensor adjustment does not function properly, failing to adjust to an appropriate value.

C13C8 New Transfer Belt Unit resetting failure

The output from the new unit detecting terminal remains HIGH and the copier does not recognize that a new unit has been installed.1. After an image stabilization sequence is com-

pleted, the fuse blowout signal of the new unit is set to a blowout state.

2. After the lapse of 2 sec. after step 1, the fuse blowout signal is brought to a state where no new units are installed.

3. After the lapse of 0.1 sec. after step 2, a new unit check sequence is carried out.

A total of three cycles of steps 1 to 3 are carried out and, if the copier fails to detect a new unit a third time, a malfunction condition results.

C13CA New Fusing Unit resetting failure

The output from the new unit detecting terminal remains HIGH and the copier does not recognize that a new unit has been installed.1. The fuse blowout signal of the new unit is set to a

blowout state.2. After the lapse of 0.5 sec. after step 1, the fuse

blowout signal is brought to a state where no new units are installed.


A total of two cycles of steps 1 to 3 are carried out and, if the copier fails to detect a new unit a second time, a malfunction condition results.

C13CB New Fusing Web Unit resetting failure







T-45


C13CC New Oil Coating Unit resetting failure






C13D1 Cyan IU EEPROM failure EEPROM access error:When EEPROM access control is executed, setting 1 “Start Flag” of GA register does not become ready even after the lapse of a predetermined period of time.

C13D2 Magenta IU EEPROM fail-ure

EEPROM access error:When EEPROM access control is executed, setting 1 “Start Flag” of GA register does not become ready even after the lapse of a predetermined period of time.

C13D3 Yellow IU EEPROM failure EEPROM access error:When EEPROM access control is executed, setting 1 “Start Flag” of GA register does not become ready even after the lapse of a predetermined period of time.

C13D4 Black IU EEPROM failure EEPROM access error:When EEPROM access control is executed, setting 1 “Start Flag” of GA register does not become ready even after the lapse of a predetermined period of time.

C3310 CCD clamp/gain adjust-ment failure

• When clamp adjustment is made:(AVE1 - AVE2) =< 4

• When gain adjustment is made:The average of CCD Sensor output values is 1 or less.Dgain = 0Dgain = 255

C3700 IR Cooling Fan Motor 1 turning at abnormal timing

A Lock signal is detected ten consecutive times when it is monitored at 0.01-sec. intervals while a Fan Motor ON signal is being output and, at the same time, after the lapse of 2 sec. or more after the output of the Fan Motor ON signal has been started.


T-46


C3710 IR Cooling Fan Motor 2 turning at abnormal timing


C3720 Original Glass Cooling Fan Motor turning at abnormal timing


C3A00 PIC communication error • A sampling lock is not received after the lapse of a predetermined period of time after IREQ has been received during AIDC sampling of image stabiliza-tion sequence or registration adjustment.

• There is an open-circuit in the communication har-ness between the PIC Board and Master Board.

• Either the PIC Board or Master Board is faulty.

C3A01 PIC Board malfunction The PIC Board is faulty.

C3FFF ROM contents fault detected upon start

The system fails to rewrite flash memory during updating.


T-47


3-3. Troubleshooting Procedures by Malfunction Code

(1) C0000: Main Motor’s failure to turn

C0001: Main Motor turning at abnormal timing

C0000: Main Motor’s failure to turn

C0001: Main Motor turning at abnormal timing


Main Motor (M13) Master Board (PWB-I)DC Power Supply 1 (PU1)


1 Main Motor turns when the Start key is pressed.

NO Check connector for connec-tion. Correct drive coupling (drive transmitting gear engagement).

2 Main Motor rotation when the Start key is pressed: the voltage across PJ13I-7A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.

YES Change motor.


3 Main Motor rotation when the Start key is pressed: the voltage across PJ7PU1-4 on DC Power Supply 1 and GND is DC 0 V when the motor is deenergized and DC 24 V when the motor is energized.

NO Change DC Power Supply 1.


1 Main Motor rotation while it is being ener-gized: the voltage across PJ13I-7A on Mas-ter Board and GND remains DC 0 V.


NO Change motor.

M13

PJ10512345678


PU1



PWB-I

4004C01TAA

T-48


(2) C0010: Imaging Unit Motor C’s failure to turn

C0011: Imaging Unit Motor C turning at abnormal timing

C0012: Imaging Unit Motor M’s failure to turn

C0013: Imaging Unit Motor M turning at abnormal timing

C0014: Imaging Unit Motor Y’s failure to turn

C0015: Imaging Unit Motor Y turning at abnormal timing

C0016: Imaging Unit Motor Bk’s failure to turn

C0017: Imaging Unit Motor Bk turning at abnormal timing


Imaging Unit Motor C (M17)Imaging Unit Motor M (M16)Imaging Unit Motor Y (M15)

Imaging Unit Motor Bk (M18)Master Board (PWB-I)DC Power Supply 1 (PU1)

PJ12I-6B(Speed CHG)

CL11

CL12

CL14

CL13

PJ8PU1-4(DC5V)PJ8PU1-3(GND)PJ7PU1-2(DC24 V)PJ7PU1-6(GND)

PJ1Y-1(DC5V)PJ1Y-2(GMD)

PJ1Y-3(DC24 V)PJ1Y-4(GND)

PU1

PJ12I-4A(M15 REM)PJ12I-3A(M15 LOCK)PJ12I-2A(Speed CHG)PJ12I-1A(CL11 REM)

PJ2Y-1(M15 REM)PJ2Y-2(M15 LOCK)

PJ2Y-3(Speed CHG)PJ2Y-4(CL11 REM)

PWB-I


PJ1M-1(DC5V)PJ1M-2(GMD)

PJ1M-3(DC24 V)PJ1M-4(GND)

PU1

PJ12I-8A(M16 REM)PJ12I-7A(M16 LOCK)PJ12I-6A(Speed CHG)PJ12I-5A(CL12 REM)

PJ2M-1(M16 REM)PJ2M-2(M16 LOCK)

PJ2M-3(Speed CHG)PJ2M-4(CL12 REM)

PJ1C-1(DC5V)PJ1C-2(GND)

PJ1C-3(DC24 V)PJ1C-4(GND)

PJ2C-1(M17 REM)PJ2C-2(M17 LOCK)

PJ2C-3(Speed CHG)PJ2C-4(CL13 REM)

PWB-I


PU1

PJ12I-4B(M17 REM)PJ12I-3B(M17 LOCK)PJ12I-2B(Speed CHG)PJ12I-1B(CL13 REM)

PWB-I

PJ1K-1(DC5V)PJ1K-2(GND)

PJ1K-3(DC24 V)PJ1K-4(GND)

PJ2K-1(M18 REM)PJ2K-2(M18 LOCK)

PJ2K-3(Speed CHG)PJ2K-4(CL14 REM)


PU1

M15

M16

M17

M18

PJ12I-8B(M18 REM)PJ12I-7B(M18 LOCK)

PJ12I-5B(CL14 REM)

PWB-I

M15

M16

M17

M18

4004C02TAD

T-49


C0010, C0012, C0014, C0016

C0011, C0013, C0015, C0017


1 Imaging Unit Motor turns when the Start key is pressed.

NO Correct drive coupling (drive transmitting gear engage-ment, coupling engagement). Check that the LED Assy is locked in position.

2 Imaging Unit Motor rotation when the Start key is pressed:Cyan: the voltage across PJ12I-3B on Mas-ter Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.Magenta: the voltage across PJ12I-7A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.Yellow: the voltage across PJ12I-3A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.Black: the voltage across PJ12I-7B on Mas-ter Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.

YES Change motor.



1 Imaging Unit Motor rotation while it is being energized:Cyan: the voltage across PJ12I-3B on Mas-ter Board and GND remains DC 0 V.Magenta: the voltage across PJ12I-7A on Master Board and GND remains DC 0 V.Yellow: the voltage across PJ12I-3A on Master Board and GND remains DC 0 V.Black: the voltage across PJ12I-7B on Mas-ter Board and GND remains DC 0 V.


NO Change motor.

T-50


(3) C0040: Fusing Cooling Fan Motor 1’s failure to turn

C0046: Fusing Cooling Fan Motor 2’s failure to turn

C004C: Ozone Ventilation Fan Motor’s failure to turn

C004E: Power Supply Cooling Fan Motor’s failure to turn

C0040


Fusing Cooling Fan Motor 1 (M23)Fusing Cooling Fan Motor 2 (M24)Ozone Ventilation Fan Motor (M22)

Power Supply Cooling Fan Motor (M21)High Voltage Unit 3 (HV3)Master Board (PWB-I)DC Power Supply 1 (PU1)


1 Fusing Cooling Fan Motor 1 turns when the Start key is pressed.

NO Check connector for connec-tion. Check fan for overload.

2 Fusing Cooling Fan Motor 1 rotation when the Start key is pressed: the voltage across PJ14I-13A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.


NO Change motor.

4004C03TAC

PJ14I-3A(M24 LOCK)PJ14I-2A(GND)PJ14I-1A(M24 ON)

PJ14I-13A(M23 LOCK)PJ14I-12A(GND)PJ14I-11A(M23 ON)

PJ10I-14(M22 ON)PJ10I-15(M22 LOCK)

CN2HV3-2(GND)CN2HV3-3(M22 LOCK)

CN2HV3-1(M22 ON)

PJ13PU1-2(GND)PJ13PU1-3(M21 LOCK)

PJ13PU1-1(DC24 V)

PJ6PU1-8(GND)PJ6PU1-9(GND)

PJ6PU1-2(DC24 V)PJ6PU1-1(DC24 V)

PJ1I-4PJ1I-5

PJ1I-3PJ1I-2

M24

CN80123

321

M23

M22

M21

CN31123

321

CN77123

321

67

54

CN65123

321

4567

CN1HV3-1(M22 LOCK)CN1HV3-2(M22 ON)

HV3

PU1PWB-I

4004C03TAC

T-51


C0046

C004C

C004E


1 Fusing Cooling Fan Motor 2 turns when the Start key is pressed.


2 Fusing Cooling Fan Motor 2 rotation when the Start key is pressed: the voltage across PJ14I-3A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.

YES Change motor.



1 Ozone Ventilation Fan Motor turns when the Start key is pressed.


2 Ozone Ventilation Fan Motor rotation when the Start key is pressed: the voltage across PJ10I-15 on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.


3 Ozone Ventilation Fan Motor rotation when the Start key is pressed: the voltage across CN2HV3-3 on High Voltage Unit 3 and GND is DC 5 V when the motor is deener-gized and DC 0 V when the motor is ener-gized.

YES Change motor.

NO Change High Voltage Unit 3.


1 Power Supply Cooling Fan Motor turns when the Start key is pressed.


2 Power Supply Cooling Fan Motor rotation when the Start key is pressed: the voltage across PJ13PU1-3 on DC Power Supply 1 and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.

YES Change motor.


T-52


(4) C0060: Fusing Drive Motor’s failure to turn

C0061: Fusing Drive Motor turning at abnormal timing

C0060

C0061


Fusing Drive Motor (M14) Master Board (PWB-I)DC Power Supply 1 (PU1)


1 Fusing Drive Motor turns when the Start key is pressed.

NO Check connector for connec-tion. Correct drive coupling (drive transmitting gear engagement).

2 Fusing Drive Motor rotation when the Start key is pressed: the voltage across PJ13I-1A on Master Board and GND is DC 5 V when the motor is deenergized and DC 0 V when the motor is energized.

YES Change motor.


3 Fusing Drive Motor rotation when the Start key is pressed: the voltage across PJ7PU1-4 on DC Power Supply 1 and GND is DC 0 V when the motor is deenergized and DC 24 V when the motor is energized.



1 Fusing Drive Motor rotation while it is being energized: the voltage across PJ13I-1A on Master Board and GND remains DC 0 V.


NO Change motor.

4004C0

PJ13I-2A(M14 REM)

PJ13I-3A(M14 CLK)PJ13I-4A(DC5 V)PJ13I-5A(GND)PJ13I-6A(M14 CCW/CW)

PJ13I-1A(M14 LOCK)

PJ7PU1-5(GND)PJ7PU1-4(DC24 V)

M14

PJ106

21

89

34567

PU1

PWB-I

4004C04TAA

T-53


(5) C0094: 2nd Image Transfer Roller pressure/retraction failure

C0094


2nd Image Transfer Pressure Position Sen-sor (PC23)2nd Image Transfer Pressure/Retraction Clutch (CL15)

Master Board (PWB-I)


1 While the 2nd Image Transfer Pressure/Retraction Clutch is supposed to be deener-gized during timing of pressure/retraction operation: the voltage across PJ14I-9A on Master Board and GND is DC 24 V when the clutch is deenergized and DC 0 V when the clutch is energized.

YES Check connector for connec-tion. Check for overload. Change clutch.


2 I/O check for 2nd Image Transfer Pressure Position Sensor operation during pressure/retraction operation: the voltage across PJ14I-6B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (pressed position).



CN1412

21

CN6512

7

7

1

6

CN631

5 84

6 7

1

9

PJ108

PC23

321

PJ122 4

1

32

PJ14I-4B(DC5 V)PJ14I-5B(GND)


PJ14I-6B(PC23 ON)

PWB-I

CL15

12

12

4004C05TAB

T-54


(6) C0096: Image Transfer Belt pressure/retraction failure

C0096


1st Image Transfer Retraction Position Sen-sor (PC28)1st Image Transfer Pressure/Retraction Motor (M11)



1 1st Image Transfer Pressure/Retraction Motor turns during pressure/retraction oper-ation.

NO Check connector for connec-tion. Correct drive coupling (drive transmitting gear engagement). Change motor. Change Master Board.

2 I/O check for 1st Image Transfer Retraction Position Sensor operation during pressure/retraction operation: the voltage across PJ17I-1A on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (retracted position).



PJ16I-2B(DC24 V)PJ16I-3B(DC24 V)PJ16I-4B(M11 A1)PJ16I-5B(M11 B1)PJ16I-6B(M11 A3)PJ16I-7B(M11 B3)

PJ17I-1A(PC28 ON)PJ17I-2A(DC5 V)PJ17I-3A(GND)

PWB-I

PJ109

CN46

PC28

321

654321

123456

M11

4004C06TAA

T-55


(7) C0098: Fusing Roller pressure/retraction failure


Fusing Pressure Position Sensor (PC7)Fusing Retraction Position Sensor (PC8)

Fusing Pressure/Retraction Motor (M8)Master Board (PWB-I)

40


PJ14I-4A(M8 -)PJ14I-5A(M8 +)


PWB-I

PJ12021

PJ136

PC7

321

PJ134

PC8

321

M8

CN4123

123

45

45

24 24

4004C07TAC

T-56


C0098


1 Fusing Pressure/Retraction Motor rotation when the Fusing Roller is retracted: the voltage across PJ14I-4A on Master Board and GND is DC 0 V when the motor is deenergized and DC 24 V when the motor is energized.

YES Check motor connector for connection. Change motor.


2 I/O check for Fusing Pressure Position Sen-sor when the Fusing Roller is retracted: the voltage across PJ6I-11B on Master Board and GND is DC 0 V when the sensor is unblocked (retracted position) and DC 5 V when the sensor is blocked.


NO Check sensor installation. Correct detecting plate. Check sensor connector for connection. Change sensor.

3 Fusing Pressure/Retraction Motor rotation when the Fusing Roller is pressed: the volt-age across PJ14I-5A on Master Board and GND is DC 0 V when the motor is deener-gized and DC 24 V when the motor is ener-gized.


4 I/O check for Fusing Pressure Position Sen-sor when the Fusing Roller is pressed: the voltage across PJ6I-11B on Master Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (pressed position).



5 I/O check for Fusing Retraction Position Sensor operation while the Fusing Pres-sure/Retraction Motor is turning: the voltage across PJ17I-3B on Master Board and GND remains DC 0 V when the sensor is unblocked or remains DC 5 V when the sensor is blocked while the motor remains stationary, and alternates between DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked while the motor is turning.



T-57


(8) C0200: Cyan PC Drum Charge Corona malfunction

C0202: Magenta PC Drum Charge Corona malfunction

C0204: Yellow PC Drum Charge Corona malfunction

C0206: Black PC Drum Charge Corona malfunction


Imaging Unit CImaging Unit MImaging Unit YImaging Unit Bk

High Voltage Unit 1 (HV1)Master Board (PWB-I)DC Power Supply 1 (PU1)

PJ9I-6(D.C REM-Y)PJ9I-7(D.C SCD-M)PJ9I-8(D.C REM-M)PJ9I-9(D.C SCD-C)

PJ9I-12(D.C REM-K)

PJ9I-10(D.C REM-C)

PJ9I-1(G CNT-K)PJ9I-2(G CNT-C)PJ9I-3(G CNT-M)PJ9I-4(G CNT-Y)PJ9I-5(D.C SCD-Y)

PJ9I-11(D.C SCD-K)

PWB-I


PU1

PJ17-12PJ17-11

PJ16-1(DC 24V)PJ16-2(GND)

PJ17-10PJ17-9PJ17-8PJ17-7PJ17-6PJ17-5PJ17-4PJ17-3PJ17-2PJ17-1

HV1

4004C08TAB

T-58


C0200, C0202, C0204, C0206


1 Imaging Unit contact failure YES Correct or clean Imaging Unit contact.

2 High Voltage Unit 1 contact failure YES Correct or clean High Voltage Unit 1 contact.

3 After corona output has been turned ON:Cyan (C0200):The voltage across PJ9I-10 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON.Magenta (C0202):The voltage across PJ9I-8 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON.Yellow (C0204):The voltage across PJ9I-6 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON.Bk (C0206):The voltage across PJ9I-12 on Master Board and GND is DC 24 V when the output is turned OFF and DC 0 V when the output is turned ON.

YES Change High Voltage Unit 1.


T-59


(9) C0400: Exposure Lamp’s failure to turn ON

C0410: Exposure Lamp turning ON at abnormal timing

C0400/C0410


Exposure Lamp (LA1)Flat Cable (PWB-Z)

Temperature Fuse (F4)DC Power Supply 2 (PU2)Image Processing Board (PWB-C)


1 Exposure Lamp conduction NO Change Exposure Lamp.

2 Temperature Fuse conduction NO Change Temperature Fuse.

3 Flat Cable conduction NO Check for correct installation or change.

4 The problem has been eliminated through the checks of steps up to 3.


5 Exposure Lamp turns ON and OFF cor-rectly after DC Power Supply 2 has been replaced.

NO Change Image Processing Board.

PJ8

PJ7

PJ1Z-1

PJ1Z-3

PWB-Z PWB-Z PU2F4

LA1

12 PJ2Z-5

PJ2Z-3

PJ2PU2-1(DC0 V)

PWB-CPJ2C-11BPJ2C-10BPJ2C-9BPJ2C-8BPJ2C-7B

PJ2PU2-3(DC70 V)

PJ3PU2-5(Lamp CNT)PJ3PU2-4(Lamp Down)PJ3PU2-3(Lamp REM)


4004C09TAB

T-60


(10) C0500: Heating Roller warm-up failure

C0501: Lower Fusing Roller Heater Lamp warm-up failure

C0510: Heating Roller abnormally low temperature

C0511: Lower Fusing Roller Heater Lamp abnormally low temperature

C0520: Heating Roller abnormally high temperature

C0521: Lower Fusing Roller Heater Lamp abnormally high temperature


Fusing Unit DC Power Supply 1 (PU1)Master Board (PWB-I)

PJ6I-1B(TH1 ON)PJ6I-2B(GND)PJ6I-3B(TH2 ON)

PJ4PU1-2(N H1)PJ4PU1-1(L)

PJ4PU1-3(N H2)PJ4PU1-4(N H3)

PJ6I-4B(GND)

PJ2I-8(H3 ON)PJ2I-9(H2 ON)

PJ2I-10(H1 ON)

PJ12PU1-2(H1 ON)PJ12PU1-3(H2 ON)PJ12PU1-4(H3 ON)

PWB-I

PU1

CN41

12

1

1213 13

141514

15

17 1718 18

16 16

24 24

FUSINGUNIT

4004C27TAC

T-61


C0500, C0510

C0520

C0501, C0511

C0521


1 Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is infinity with CN4 (2P) disconnected.

YES Change Fusing Unit.


2 Heating Roller Heater Lamps turn ON. YES Change DC Power Supply 1. Change Master Board.

NO Change Fusing Unit.


1 Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is 0 Ω (or close to 0) with CN4 (2P) discon-nected.




1 Fusing Unit condition: the resistance across CN4-17 and 18 on the Fusing Unit end is infinity with CN4 (2P) disconnected.



2 Lower Fusing Roller Heater Lamp turns ON. YES Change DC Power Supply 1. Change Master Board.



1 Fusing Unit condition: the resistance across CN4-15 and 16 on the Fusing Unit end is 0 Ω (or close to 0) with CN4 (2P) discon-nected.



T-62


(11) C0650: Scanner Home Sensor malfunction

C0660: Scanner overrun failure


Scanner Home Sensor (PC24)Scanner Motor (M1)

Scanner Motor Drive Board (PWB-IC)DC Power Supply 2 (PU2)Image Processing Board (PWB-C)

4004C11TAA

PJ26

PC24

321

M1

PJ38123

PJ6C-1(GND)PJ6C-2(DC24V)PJ6C-3(DC 5V)

PJ3IC-1(U)PJ3IC-2(V)PJ3IC-3(W)

PJ2IC-6PJ2IC-5PJ2IC-4PJ2IC-3PJ2IC-2PJ2IC-1

PJ1IC-4PJ1IC-3PJ1IC-2PJ1IC-1

PJ6PU2-6(GND)PJ6PU2-7(DC24 V)PJ6PU2-4(GND)PJ6PU2-2(DC5 V)

PJ2IC-7PJ2IC-8

PJ2C-4A(HOLD)PJ2C-5A(M1 CRNT SW1)PJ2C-6A(M1 CRNT SW2)PJ2C-7A(ENABLE)PJ2C-8A(RESET)PJ2C-9A(GND)

PJ2C-2A(CW/CCW)PJ2C-1A(CLK)

PWB-IC

PWB-C

PU2

4004C11TAA

T-63


C0650, C0660


1 Scanner can be moved manually. NO Correct drive coupling (Scan-ner Belt tension, pulley opera-tion, drive cable tension)

2 Scan motion: initial scan motion after the Power Switch has been turned ON or Front Door has been opened and closed.

NO Carry out misfeed/malfunction troubleshooting procedures.

3 Connectors are connected properly on Scanner Motor Drive Board: PWB-IC PJ1IC, PJ2IC, and PJ3IC.

NO Check connectors for connec-tion.

4 Scanner Motor turns when the Start key is pressed.

NO Check connectors for connec-tion. Change motor. Change Scanner Motor Drive Board.

5 I/O check for Scanner Home Sensor: the voltage across PJ6C-2 on Image Process-ing Board and GND is DC 0 V (home posi-tion) when the sensor is blocked and DC 5 V when the sensor is unblocked.

YES Change Image Processing Board.

NO Check sensor for installation. Correct detecting plate. Check sensor connector for connection. Change sensor.

6 “IR Area” check:Malfunction when Power Switch is turned ON after “Top Image” has been set to 0 and “FD-Mag.” to 1.000.

NO Adjust “IR Area” data.

T-64


(12) C0990: LCC Lift-Up Motor malfunction

C0991: LCC Lift 1 ascent motion failure

C0995: LCC Transport Motor malfunction

C0999: LCC Lift 2 ascent motion failure


LCC Set Sensor (FRONT)Lift-Up Sensor 1 (LS1)Lift-Up Sensor 2 (LS2)

LCC Transport Motor (HMOT)LCC Lift-Up Motor (EMOT)LCC Control Board (PWB-A)

CN4A-6(LS1 ON)CN4A-5(GND)CN4A-4(DC5 V)

CN4A-9(LS2 ON)CN4A-8(GND)CN4A-7(DC5 V)

CN5A-2(E MOT/CCW)CN5A-1(E MOT/CW)

CN6A-6(H MOT CLK)CN6A-5(DC5 V)CN6A-4(H MOT SIG)CN6A-3(GND)

CN6A-1(DC24 V)

PWB-A

LS2

LS1

PJ3123

PJ6123

CN6A-9(FRONT ON)CN6A-8(GND)CN6A-7(DC5 V)FRONT

PJ1123

PJ5123

456

CN17

21

12

H MOT

E MOT

4004C12TAA

T-65


C0990

C0991

C0995

C0999


1 LCC Lift-Up Motor turns after the LCC Drawer has been slid into position while the LCC Drawer is being used.

NO Change motor. Change LCC Control Board.


1 Lift 1 ascends after the LCC Lift-Up Motor has been energized.

NO Correct drive coupling (one-way gear engagement, cou-pling engagement, spring operation, and belt tension).

2 I/O check for Lift-Up Sensor 1 operation: the voltage across CN4A-6 on LCC Control Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (during lifting motion detection).


NO Check sensor for installation. Check sensor connector for connection. Change sensor.


1 LCC Lift-Up Motor turns when the Start key is pressed while the LCC Drawer is being used.

NO Change motor. Change LCC Control Board.


1 Lift 2 ascends after the LCC Lift-Up Motor has been energized.

NO Correct drive coupling (one-way gear engagement, cou-pling engagement, spring operation, and belt tension).

2 I/O check for Lift-Up Sensor 2 operation: the voltage across CN4A-9 on LCC Control Board and GND is DC 0 V when the sensor is unblocked and DC 5 V when the sensor is blocked (during lifting motion detection).


NO Check sensor for installation. Check sensor connector for connection. Change sensor.

T-66


(13) C0F30: Abnormally low toner density detected by Cyan ATDC Sensor/

C0F31: Abnormally high toner density detected by Cyan ATDC Sensor

C0F32: Abnormally low toner density detected by Magenta ATDC Sensor/

C0F33: Abnormally high toner density detected by Magenta ATDC Sensor

C0F34: Abnormally low toner density detected by Yellow ATDC Sensor/

C0F35: Abnormally high toner density detected by Yellow ATDC Sensor


ATDC Sensor C (PWB-N3)ATDC Sensor M (PWB-N2)ATDC Sensor Y (PWB-N1)

Toner Replenishing Motor C/Bk (M9)Toner Replenishing Motor Y/M (M10)Master Board (PWB-I)

4004C13TAA

PJ7I-1A(TH1 OUT)PJ7I-2A(GND)PJ7I-3A(DC5 V)PJ7I-4A(UN33 REM)PJ7I-5A(TH2 OUT)PJ7I-6A(GND)PJ7I-7A(DC5 V)PJ7I-8A(UN34 REM)PJ7I-9A(TH3 OUT)PJ7I-10A(GND)PJ7I-11A(DC5 V)PJ7I-12A(UN35 REM)

PJ5I-2B(A-A3)

PJ5I-4B(B-B3)

PJ5I-1B(– A-A1)

PJ5I-3B(– B-B1)

PJ5I-8A(A-A3)

PJ5I-10A(B-B3)

PJ5I-7A(– A-A1)

PJ5I-9A(– B-B1)

PWB-ICN35

43

12

2314

CN50

1211

12

103948576675849310211112

CN36

43

12

2314

CN72

10

4

1

73829110

M10

M9

PWB-N3PJ90N3-4(TH3 OUT)

PJ90N3-3(GND)PJ90N3-2(DC5 V)

PJ90N3-1(UN35 REM)

PWB-N2PJ89N2-4(TH2OUT)


PJ89N2-1(UN34 REM)



PJ88N1-1(UN33 REM)

4004C13TAA

T-67


C0F30, C0F32, C0F34

C0F31, C0F33, C0F35


1 ATDC Sensor window is dirty. YES Clean.

2 ATDC Sensor spring moving part operates properly.

NO Correct.

3 Hopper supplies toner properly. NO Correct.

4 ATDC Sensor LED is dirty. YES Clean.

5 ATDC Sensor LED emits light properly. NO Check connector for connec-tion. Check harness.

6 Imaging Unit Shutter operates properly. NO Correct.





2 Bias voltage is properly applied to the ATDC Sensor window.

NO Check wiring.



T-68


(14) C0F36: Abnormally low toner density detected by Black ATDC Sensor/

C0F37: Abnormally high toner density detected by Black ATDC Sensor

C0F36

C0F37


Imaging Unit BkToner Replenishing Motor C/Bk (M9)



1 Image density is low. YES Check and correct Imaging Unit Bk Shutter.

2 The problem has been eliminated through the check of step 1.

NO Check and correct Hopper.




1 Imaging Unit Bk is installed correctly. NO Reinstall.

2 Each of Imaging Unit Bk contacts makes good contact.

NO Clean or correct.

3 ATDC Sensor harness is open-circuited. YES Change Imaging Unit Bk.

PWB-ICN36

43

12

2314

M9

PJ13I-4BPJ13I-3BPJ13I-5BPJ13I-6B

PJ5I-2B(A-A3)

PJ5I-4B(B-B3)

PJ5I-1B(– A-A1)

PJ5I-3B(– B-B1)

Imaging Unit(Bk)

4004C26TAB

T-69


(15) C0F3A: Cyan ATDC Sensor adjustment failure

C0F3B: Magenta ATDC Sensor adjustment failure

C0F3C: Yellow ATDC Sensor adjustment failure

C0F3D: Black ATDC Sensor adjustment failure


ATDC Sensor C (PWB-N3)ATDC Sensor M (PWB-N2)ATDC Sensor Y (PWB-N1)Imaging Unit Bk

Toner Replenishing Motor C/Bk (M9)Toner Replenishing Motor Y/M (M10)Master Board (PWB-I)

PWB-N3

CN50

1211

12

1039487

56

675843

910

211112

PJ13I-4BPJ13I-3BPJ13I-5B

PJ90N3-4(TH3 OUT)PJ90N3-3(GND)

PJ90N3-2(DC5 V)PJ90N3-1(UN35 REM)

Imaging Unit(Bk)

PWB-N2PJ89N2-4(TH2OUT)


PJ89N2-1(UN34 REM)



PJ88N1-1(UN33 REM)

PJ13I-6B

PJ7I-1A(TH1 OUT)PJ7I-2A(GND)PJ7I-3A(DC5 V)PJ7I-4A(UN33 REM)PJ7I-5A(TH2 OUT)PJ7I-6A(GND)PJ7I-7A(DC5 V)PJ7I-8A(UN34 REM)PJ7I-9A(TH3 OUT)PJ7I-10A(GND)PJ7I-11A(DC5 V)PJ7I-12A(UN35 REM)

PJ5I-2B(A-A3)

PJ5I-4B(B-B3)

PJ5I-1B(– A-A1)

PJ5I-3B(– B-B1)

PJ5I-8A(A-A3)

PJ5I-10A(B-B3)

PJ5I-7A(– A-A1)

PJ5I-9A(– B-B1)

PWB-ICN35

43

12

2314

CN36

43

12

2314

CN72

10

4

1

73829110

M10

M9

4004C25TAC

T-70


C0F3A, C0F3B, C0F3C

COF3D

(16) C13C8: New Transfer Belt Unit resetting failure

C13CA: New Fusing Unit resetting failure

C13CB: New Fusing Web Unit resetting failure

C13CC: New Oil Coating Unit resetting failure

C13C8, C13CA, C13CB, C13CC



2 Imaging Unit window for ATDC Sensor is dirty.

YES Clean.

3 LED retracting lever is locked in position. NO Slide out the Imaging Unit and then reinstall.


NO Check ATDC Sensor connec-tor. Change ATDC Sensor.

5 The problem is eliminated after the ATDC Sensor has been replaced.

NO Change Imaging Unit.

6 The problem is eliminated after the Imaging Unit has been replaced.



1 Malfunction code C0F3D is displayed. YES Change Imaging Unit.


NO Check harness. Check con-nector for connection. Change Master Board.


1 Each unit is installed properly in the copier (good contact connection).


NO Reinstall.

T-71


(17) C13D1: Cyan IU EEPROM failure

C13D2: Magenta IU EEPROM failure

C13D3: Yellow IU EEPROM failure

C13D4: Black IU EEPROM failure

C13D1, C13D2, C13D3, C13D4


1 Imaging Unit is installed properly. NO Reinstall.

2 Connector between the Imaging Unit and copier is dirty.

YES Clean.





T-72


(18) C3310: CCD clamp/gain adjustment failure

Clamp/Gain Adjustment Values

Clamp: Allowable up to ±100 of the above values. Gain: Allowable up to ±90 of the above values for R and B; allowable up to ±50 of the

above values for G. Exposure Lamp adjustment value: Allowable in the range between 64 and 192. A differ-

ence of up to 30 is allowed between RO and RE, between GO and GE, and between BO and BE.

C3310


Exposure Lamp (LA1)Flat Cable (PWB-Z)

CCD Sensor Board (PWB-A)Image Processing Board (PWB-C)

RO RE GO GE BO BE

Clamp 130 130 130 130 130 130

RO RE GO GE BO BE

Gain 160 160 170 170 160 160

Lamp Adjust-ment Value

135


1 Check that each of the values displayed on the screen falls within the above range.

2 There is a wide difference between the clamp and gain adjustment values, the value being close to “0” or “255.”

YES Make positive connection of the harness connectors between CCD Sensor Board and Image Processing Board.

3 Clamp adjustment value exceeds the allow-able range.

YES Reinstall covers, as extrane-ous light is the cause of the problem.

4 The lamp adjustment value or gain value exceeds the upper limit of the allowable range, being abnormally great.

YES Clean lens, mirrors, CCD sur-face, shading sheet, and related parts.

5 The lamp adjustment value or gain value falls short of the lower limit of the allowable range, being abnormally small.

YES Reinstall covers, as extrane-ous light is the cause of the problem.Change Scanner, as the reflectors are deformed.

T-73


(19) C3700: IR Cooling Fan Motor 1 turning at abnormal timing

C3710: IR Cooling Fan Motor 2 turning at abnormal timing

C3720: Original Glass Cooling Fan Motor turning at abnormal timing

C3700

C3710

C3720


IR Cooling Fan Motor 1 (M3)IR Cooling Fan Motor 2 (M4)Original Glass Cooling Fan Motor (M2)

Image Processing Board (PWB-C)DC Power Supply 2 (PU2)


1 IR Cooling Fan Motor 1 rotation: the voltage across PJ6C-6 on Image Processing Board and GND remains DC 0 V while the motor is turning.


NO Change motor.


1 IR Cooling Fan Motor 2 rotation: the voltage across PJ6C-9 on Image Processing Board and GND remains DC 0 V while the motor is turning.


NO Change motor.


1 Original Glass Cooling Fan Motor rotation: the voltage across PJ2C-6B on Image Pro-cessing Board and GND remains DC 0 V while the motor is turning.


NO Change motor.


PJ2C-5B(GND)PJ2C-6B(M2 LOCK)

PJ2C-4B(M2 REM)

M4

CN22123

321

M3

CN2123

321

PJ6C-5(GND)PJ6C-6(M3 LOCK)

PJ6C-4(M3 REM)

PJ6C-8(GND)PJ6C-9(M4 LOCK)

PJ6C-7(M4 REM)

PJ1C-1PJ1C-2

M2

CN3123

321

PWB-C

PU2

4004C19TAB

T-74


(20) C3A00: PIC communication error

C3A01: PIC Board malfunction

C3FFF: ROM contents fault detected upon start

C3A00

C3A01

C3FFF


1 Harnesses and connectors connecting PIC Board to Master Board are in good condi-tion.

NO Change harnesses. Recon-nect connectors.


NO Change PIC Board.

3 The problem is eliminated after the PIC Board has been replaced.



1 The same malfunction recurs even after the malfunction has been reset, Power Switch turned OFF and ON, and the power cord plugged out and back in.

YES Change PIC Board.


1 This malfunction occurs when an attempt is made to update firmware (rewriting of flash ROM).

YES Try downloading again.



T-75


3-4. Power Supply-Related Malfunctions

(1) Copier Does not Turned ON.


Power Switch (SW1)Upper Right Door Switch (SW9)

Master Board (PWB-I)DC Power Supply 1 (PU1)DC Power Supply 2 (PU2)


1 Correct wiring is made to the Power Switch terminal.

NO Rewire.

2 Correct wiring is made to the Upper Right Door Switch terminal.

NO Rewire.

3 Power source voltage is supplied to DC Power Supply 1.

NO Check wiring.

4 Power source voltage is supplied to the power outlet.

NO Secure power source voltage.

5 The 5-V line is inadvertently shorted. YES Turn OFF Power Switch, wait for a while, and then turn ON the Power Switch again.

4004C30TAD

PJ4I-1PJ4I-2

PJ21I-1

PJ21I-3

PJ3PU1-1

PJ3PU1-2

N BkW

L

R

R 3B

3A 1A2A2B1B

Bk

WW

Bk

BkWBkW

GY

GR

GY

PWB-I

PJ1PU1-1(L IN)PJ1PU1-3(N IN)PJ2PU1-3(N IN)PJ2PU1-1(L IN)

PU1

PU2

11

CN12CN88

CN1

2

21

2

SW9

SW1

PG1

PJ101

4004C30TAD

T-76


(2) No Control Panel Indicators Light up.


Control Panel (UN1) IR PRIF Board (PWB-D)Image Processing Board (PWB-C)


1 DC 24 V is output from PJ3D-9B on IR PRIF Board.

NO Change IR PRIF Board.

2 DC 24 V is input to PJ30UN1-6B on Control Panel.

NO Check or change harness.

3 Control Panel screen is displayed with 24 V being input.

NO Change Image Processing Board. Change IR PRIF Board.

4004C29TAA

PJ30UN1-1A(GND)PJ30UN1-2A(FLM)PJ30UN1-3A(GND)PJ30UN1-4A(CL1)

PJ30UN1-5A(GND)PJ30UN1-6A(CL2)

PJ30UN1-7A(GND)PJ30UN1-8A(LD0)




PJ30UN1-2B(DC5 V)PJ30UN1-3B(DC5 V)

PJ30UN1-4B(GND)PJ30UN1-5B(GND)

PJ30UN1-6B(DC24 V)PJ30UN1-7B(GND)

PJ30UN1-8B(SLEEP OUT)PJ30UN1-9B(PRE MOTE)PJ30UN1-10B(DIS POFF)

PJ30UN1-11B(DC5 V)PJ30UN1-12B(SD OUT)

PJ30UN1-13B(SD IN)PJ30UN1-14B(S CLK)

UN1PJ3D-1APJ3D-2APJ3D-3APJ3D-4APJ3D-5APJ3D-6APJ3D-7APJ3D-8APJ3D-9APJ3D-10APJ3D-11APJ3D-12APJ3D-13APJ3D-14APJ3D-13BPJ3D-12BPJ3D-11BPJ3D-10BPJ3D-9BPJ3D-8BPJ3D-7BPJ3D-6BPJ3D-5BPJ3D-4BPJ3D-3BPJ3D-2BPJ3D-1B

PWB-D

PJ6D

CN2PWB-C

4004C29TAA

T-77


(3) No Power is Supplied to Options.


DC Power Supply 1 (PU1) DC Power Supply 2 (PU2)


1 Power source voltage is applied to DC Power Supply 1.

NO Check wiring.

2 DC 24 V is output from DC Power Supply 1 and DC Power Supply 2.

NO Change DC Power Supply 1. Change DC Power Supply 2.

3 There is an open-circuit in the harness from DC Power Supply 1 and DC Power Supply 2 to option connector.

YES Change harness.

PJ5PU1-2(DC24 V) CN60-11CN60-5

CN62-2CN62-1

CN82-1CN83-1CN82-2CN83-2

CN5-11CN5-5

PJ5PU1-3(GND)


PJ5PU1-6(DC24 V)


PJ7PU1-5(GND)

PU1 Sorter

Duplex

Tray

ADFPU2

L

N

4004C28TAA

T-78


4. IMAGE QUALITY PROBLEMS4-1. Troubleshooting Image Quality Problems

• This chapter is divided into two parts: “Initial Check Items” and “Troubleshooting Proce-dure by a Particular Image Quality Problem.”

• When an image quality problem occurs, first go through the “Initial Check Items” and, if the cause is yet to be identified, go to “Troubleshooting Procedure by a Particular Image Quality Problem.”

4-2. Initial Check Items1. First determine which of the following three is responsible for the image quality prob-

lem: the input system (IR), interface system, or the output system (printer).When an image quality problem occurs, possible causes that are likely to be responsi-ble for it may be broadly grouped into the following three: those relating to the Scanner of the IR unit, the interface between the IR unit and printer, and the printer.As a procedure to isolate basic causes, you first let the printer produce test prints. If the image quality problem of the same sort is evident on the test patterns, then the printer is very likely to be responsible for it. If not, the cause is attributable to the Scanner of the IR unit or the interface.The next step to take to identify whether the problem is attributable to the IR Scanner or the interface is to produce IR test prints. If the problem of the same sort is evident on the test patterns, then the interface is probably responsible for it.If the same symptom does not occur on the test prints, then the IR Scanner is responsi-ble for the problem.

CCD Sensor

Printer Test print

IR Test printImage Processing Boad

PIC Board

I/F Cable

LED Drive

IR Area

I/F Area

Printer Area

4004T006CA

T-79


Step Symptom Check Result CauseRef. Page

1

Gradation fail-ure, density failure

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” “Gradation Pattern” “4 Color.”

YES Printer T-96

NO To step 2 –

Uneven den-sity, pitch noise, or image noise (lines, bands, spots, etc.)

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” “Halftone Pattern” “C M Y Bk” Enter “64” in “Density.” Select “Hyper.”

YES Printer T-96

NO To step 2 –

Foggy back-ground

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” “Halftone Pattern” “C M Y Bk” Enter “0” in “Den-sity.”

YES Printer T-96

NO To step 2 –

Color reproduc-tion failure

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” “Color Sample” Enter “255” in “Density.”

YES Printer T-96

NO To step 2 –

2Abnormal image

The faulty symptom occurs when a test print is produced with the following settings made: “Test Print” “IR Test Pattern.”

YES Interface T-93

NO IR T-82

T-80


2. If the output system (printer) is responsible for the image quality problem, determine if it occurs with a single color of Y, M, C, or Bk, or four colors.By rule of thumb, if the problem occurs with a single color, the corresponding Imaging Unit is very likely to be faulty. If the problem occurs with four colors, the Transfer Belt and/or Fusing Unit are probably defective.The same problematic symptom occurs with each of the four colors, then the Transfer Belt, Image Transfer Rollers, and/or the Fusing Unit are responsible for it.If the symptom occurs with a single color, each Imaging Unit is responsible for it.

Step Symptom Check Result CauseRef. Page

1

Gradation fail-ure, density failure

The faulty symptom occurs with each of the four colors when a test print is produced with the follow-ing settings made: “Test Print” “Gradation Pattern” “4 Color.”

YESPrinter 4 color

T-114

NOPrinter mono-color

T-96

Uneven den-sity, pitch noise, or image noise (lines, bands, spots, etc.)

The faulty symptom occurs with each of the four colors when a test print is produced with the follow-ing settings made: “Test Print” “Halftone Pattern” “C M Y Bk” Enter “64” in “Density.” Select “Hyper.”

YESPrinter 4 color

T-114


T-96

Foggy back-ground

he faulty symptom occurs with each of the four colors when a test print is produced with the follow-ing settings made: “Test Print” “Halftone Pattern” “C M Y Bk” Enter “0” in “Density.”

YESPrinter 4 color

T-114


T-96

4 colors

Mono color

4004T008CA

T-81


4-3. Troubleshooting Procedure by a Particular Image Quality

Problem(1) IR Scanner System: white lines in FD, white bands in FD, colored lines in FD,

and colored bands in FD

<Typical Faulty Images>

<Troubleshooting Procedure>

Section Step Check Item Result Action

Original 1 Original is damaged or dirty. YES Change original.

Original Cover

2 Original Pad is dirty. YES Clean.

Original Glass

3 Original Glass is dirty. YES Wipe the surface clean with a soft cloth.

Shading sheet

4 Shading sheet is dirty. YES Wipe the surface clean with a soft cloth.

Mirror, lens, Exposure Lamp, and reflectors

5 Mirror is dirty. YES Clean.

Lens is dirty. YES Clean.

Exposure Lamp is dirty. YES Clean.

Reflectors are dirty. YES Clean.

Left Image (Tech. Rep. function)

6 The Scanner starts reading the image at the position of 0 mm from the scale.

NO Adjust the image reading position in the range of ±10 mm.

IR 7 The white lines/bands or col-ored lines/bands are blurry.

YES Change Scanner Assy.

8 The white lines/bands or col-ored lines/bands are clear and distinct.

YES Change CCD Unit.

White lines in FD Colored lines in FDWhite bands in FD Colored bands in FD

4011T015AA 4011T020AA 4011T017AA 4011T023AA

T-82


(2) IR Scanner System: white lines in CD, white bands in CD, colored lines in CD,

and colored bands in CD





Original Cover


Original Glass


Flat cable 4 Flat cable terminal is con-nected properly.

NO Clean terminal. Reconnect. Change flat cable.

Top Image (Tech. Rep. function)

5 The Scanner starts reading the image at the position of 0 mm from the scale.

NO Adjust the image reading position in the range of ±10 mm.

IR 6 The problem has been elimi-nated through the checks of steps up to 5.

NO Change Scanner Assy.

7 The problem is eliminated after the Scanner Assy has been replaced.

NO Change CCD Unit.

White lines in CD White bands in CD Colored lines in CD Colored bands in CD

4011T016AA 4011T021AA 4011T018AA 4011T022AA

T-83


(3) IR Scanner System: color spots

<Typical Faulty Image>




Original Cover


Original Glass





NO Change CCD Unit.

C F

Color spots

4011T027AA

T-84


(4) IR Scanner System: fog




Warning display

1 Maintenance call mark S-2 (intensity adjustment failure) is displayed.

YES Carry out remedial action pro-cedures for S-2 as part of image stabilizer malfunction troubleshooting procedures.

2 Maintenance call mark S-1 (gain adjustment failure) is dis-played.



Original Cover


5 Original Cover does not lie flat. YES Change Original Cover if it is deformed or hinges are bro-ken.

Original Glass


Shading sheet







Exposure setting (panel set-ting)

9 The problem is eliminated after the exposure mode has been changed to Auto.

NO Change the exposure mode to Manual.

Fog

4011T004AA

T-85





NO Change CCD Unit.


T-86


(5) IR Scanner System: blurred image, blotchy image




Original Cover


Original Glass

2 Original Glass tilts. YES Position Original Glass cor-rectly. Check original loading position.

IR 3 Scanner is not aligned with the 2nd/3rd Mirrors Carriage.

YES Readjust with the Scanner/Mirrors Carriage Positioning Jigs.

4 The problem has been elimi-nated through the checks of steps up to 3.



NO Change CCD Unit.

Blurred image, blotchy image

4011T046AA

T-87


(6) IR Scanner System: incorrect color image registration




Original Cover


Slide rails 2 Foreign matter on rails. YES Clean.

Drive Cables

3 Cable kinks or is damaged. YES Correct or change.

Scanner Motor

4 Scanner Motor turns smoothly. NO Change belt. Change Scan-ner Motor.


NO Change CCD Unit.

C FC F

Incorrect color image registration

4011T039AA

T-88


(7) IR Scanner System: moire




Original 1 Moire distortions occur. YES Change original loading direc-tion.

Original 2 Moire distortions recur even after the orientation of original has been changed.

YES Change the original mode (select one other than that resulted in moire).

Mode change

3 Moire distortions recur even after the original mode has been changed.

YES Select “Gradation” (mode optimized for gradation) or “Resolution” (that optimized for resolution).


NO Change the zoom ratio.

4011T040AA

Moire

T-89


(8) IR Scanner System: skewed image




Original 1 Original is skew. YES Reposition original.

Original Glass

2 Original Glass is in positive contact with the flat spring without being tilt.

NO Reinstall the glass. Check the original loading position.

2nd/3rd Mirrors Car-riage

3 Scanner Assy is not properly aligned with 2nd/3rd Mirrors Carriage.





NO Change CCD Unit.

C F

Skewed image

4011T048AA

T-90


(9) IR Scanner System: distorted image




Installation 1 IR is installed on a level sur-face if mounted without any rack.

NO Reinstall.

Rack is installed on a level sur-face.

NO Reinstall.

Rack is tilt with a lot of play. YES Adjust rack legs.

2nd/3rd Mirrors Car-riage

2 Scanner Assy is not properly aligned with 2nd/3rd Mirrors Carriage.


Scanner Motor

3 Scanner Motor turns smoothly. NO Change belt. Change Scan-ner Motor.




NO Change CCD Unit.

Distorted image

4011T045AA

ABCDEABCDEABCDEABCDEABCDE

T-91


(10) IR Scanner System: low image density, rough image




Warning display

1 Maintenance call mark S-2 (intensity adjustment failure) is displayed.


2 Maintenance call mark S-1 (gain adjustment failure) is dis-played.


Original 3 Original sticks to Original Glass.

YES Reposition original.

Original Glass


Shading sheet







Exposure Lamp

7 The problem has been elimi-nated through the check of step 6.

NO Clean or change Exposure Lamp.

IR 8 The problem is eliminated after the Exposure Lamp has been changed.


9 The problem is eliminated after the Scanner Assy has been changed.

NO Change CCD Unit.

Low image density

4011T003AA

T-92


(11) IR Scanner System: defective ACS




ACS Deter-mination Level Adjust (User’s Choice function)

1 ACS failure occurs. YES Change ACS Determination Level Adjust function.

The problem persists even after the ACS Determination Level Adjust function has been changed.

YES Change the original loading direction. Make manual set-tings according to the type of original. (If the original con-tains a colored area in one of its corners, the copier may fail to properly detect the colored area.)

Defective ACS

ABCDECF

ABCDEABCDEABCDEABCDE

Colored Area of Original

Black-and-White Area of Original

4011T052AA

T-93


(12) IR Control System: blank copy, black copy




Cable con-necting IR and printer

1 Connector is connected prop-erly with no pins bent.

NO Reconnect.

Image Pro-cessing Board

2 Connectors on the Image Pro-cessing Board are connected properly.

NO Reconnect.

Connection between IR and printer

3 The problem has been elimi-nated through the check using IR test pattern.

NO Change I/F connection cable.


4 The problem is eliminated after the I/F connection cable has been changed.


PIC Board 5 The problem has been elimi-nated through the checks of steps up to 4.


Blank copy Black copy

4011T036AA 4011T035AA

T-94


(13) IR Control System: abnormal image




Cable con-necting IR and printer

1 Connector is connected prop-erly with no pins bent.

NO Reconnect.


2 Connectors on the Image Pro-cessing Board are connected properly.

NO Reconnect.

PIC Board 3 If the copy contains part of data on the previous page together with that on the cur-rent page, the expanded mem-ory (rim) is properly mounted to the PIC Board.

NO Reinstall expanded memory.

Connection between IR and printer

4 The problem has been elimi-nated as checked on IR test prints produced.

NO Change interface connection cable.


5 The problem is eliminated after the interface connection cable has been changed.


PIC Board 6 The problem is eliminated through the checks of steps up to 5.


ABCDEABCDEABCDEABCDEABCDE

Abnormal image

4011T053AA

CF

ABCDEABCDEABCDE

Abnormal image

Data on previous page

Data on current page

4011T063AA

T-95


(14) Printer Monocolor: white lines in FD, white bands in FD, colored lines in FD,

colored bands in FD, white lines in CD, white bands in CD, colored lines in CD,

colored bands in CD




Imaging Unit

1 The surface of the PC Drum is scratched.

YES Change Imaging Unit.

LED Assy 2 The surface of the lens array is dirty.

YES Clean with cleaning jig.

Imaging Unit

3 Dirty on the outside. YES Clean.

4 Connectors and contact termi-nals make good connection between each Imaging Unit and LED Assy.

NO Clean contact terminals. Reconnect.

5 Developing bias contact termi-nal makes good connection.

NO Clean contact terminal and check terminal position.



Transfer Belt Unit


NO Change Transfer Belt Unit.

White lines in FD White bands in FD Colored lines in FD Colored bands in FD


4011T015AA 4011T020AA 4011T017AA 4011T023AA

4011T016AA 4011T021AA 4011T018AA 4011T022AA

T-96


LED Assy 8 The problem is eliminated after the Transfer Belt Unit has been replaced.

NO Change LED Assy.


T-97


(15) Printer Monocolor: uneven density in FD




High image density original

1 Uneven density in FD occurs at a pitch of 40 mm to 50 mm when a multi-copy cycle is run using an original with high image density (50 % or more).

YES Feed 10 to 20 blank sheets of paper with no originals placed, as the Imaging Unit fails to keep up with a high demand for toner.

LED Assy 2 LED retracting lever is locked in position.

NO Slide out the Imaging Unit and reinstall.

Imaging Unit






Transfer Belt Unit

6 Cam gear operates properly. NO Change Transfer Belt Unit.

Imaging Unit


NO The problem is eliminated after the Imaging Unit has been replaced.

Transfer Belt Unit




NO Change LED Assy.

LED Unit 10 The problem is eliminated after the LED Assy has been replaced.

NO Change LED Unit.

PIC Board 11 The problem is eliminated after the LED Unit has been replaced.


Uneven density in FD Uneven density in FD

4011T031AA

4011T042AA

T-98


High Volt-age Unit 2

12 The problem of uneven density in CD is eliminated after the PIC Board has been replaced.



T-99


(16) Printer Monocolor: uneven density in CD






Imaging Unit






Transfer Belt Unit

5 Transfer Belt Unit makes posi-tive contact with plates on rails.

NO Check and correct contacts.


Imaging Unit



Transfer Belt Unit




NO Change LED Assy.


NO Change LED Unit.




12 The problem of uneven density in CD is eliminated after the PIC Board has been replaced.


Uneven density in CD Uneven density in CD

4011T032AA 4011T043AA

T-100


(17) Printer Monocolor: low image density




Level His-tory 1 (Tech. Rep. function)

1 ATDC data is within ±1 % of the target value.

NO Readjust.

2 AIDC output value is around 4.5 V.

NO Clean AIDC Sensor. Check Transfer Belt for damage.

3 Vg and Vb values are correct.Color Vb: Around 400 V

Vg: Around 500 VBlack Vb: Around 800 V

Vg: Around 900 V

NO Go to next step.

Level His-tory data check results

4 Low ATDC and low Vg and Vb YES Go to step 5.

Low ATDC and high Vg and Vb

YES Go to step 12.

ATDC falling within specified range and low Vg and Vb

YES Go to step 5.

ATDC falling within specified range and high Vg and Vb

YES Go to step 9.



Imaging Unit

6 Imaging Unit and LED Assy connectors are dirty.

YES Clean.




ATDC Sen-sor window

9 The color ATDC Sensor win-dow on the LED Assy is dirty.

YES Clean. Change ATDC. Change Imaging Unit.

Transfer Belt Unit

10 Transfer Belt Unit makes posi-tive contact with plates on rails.

NO Check and correct contacts.


Low image density

4011T003AA

T-101


Hopper Unit 12 Connectors are loose. YES Reconnect.

13 Gear is cracked. YES Change gear.

14 Toner empty lever and/or detecting switch are defective.

YES Change Hopper Unit.

Toner replenish-ing

15 Image is okay after T/C has been increased by 1 % through toner replenishing.

NO Go to next step.

Gradation Adjust (Tech. Rep. function)

16 Data after three cycles of Gra-dation Adjust falls within the specified range.Max: 0 ±100Highlight = 0 ±60

NO Run another cycle of Grada-tion Adjust. Go to next step if it does not still make data okay.

PRT Max Density (Tech. Rep. function)

17 After Max has been adjusted, run Stabilizer to reflect the adjustment in image stabiliza-tion.

NO Go to next step.

PRT High-light (Tech. Rep. func-tion)

18 After Highlight has been adjusted, run Stabilizer to reflect the adjustment in image stabilization.

NO Go to next step.

Reset + Stabilizer (Tech. Rep. function)

19 After the Reset + Stabilizer sequence has been com-pleted, run Gradation Adjust; if the problem persists, make the adjustments of PRT Max Den-sity and PRT Highlight. There-after, run Stabilizer again.

NO Go to next step.

ATDC Sen-sor


NO For color, change ATDC Sen-sor and Imaging Unit at once. For black, change Imaging Unit.

Imaging Unit



Transfer Belt Unit




NO Change LED Assy.


NO Change LED Unit.







T-102


(18) Printer Monocolor: gradation reproduction failure




Original mode

1 Original type and screen pat-tern are selected properly.

NO Change screen pattern.


YES Slide out the Imaging Unit and reinstall.

Imaging Unit


YES Clean.

Imaging Unit




ATDC Sen-sor window

6 The color ATDC Sensor win-dow on the LED Assy and the ATDC Sensor window on the Imaging Unit are dirty.

YES Clean.

Level His-tory 1 (Tech. Rep. Function)





NO Run another cycle of Grada-tion Adjust. If the specifica-tions are not met yet, go to next step.



NO Go to next step.

Gradation reproduction failure Gradation reproduction failure

4011T034AA 4011T029AA

T-103




NO Go to next step.



NO Go to next step.

Imaging Unit



LED Assy 13 The problem is eliminated after the Imaging Unit has been replaced.

NO Change LED Assy.


NO Change LED Unit.







T-104


(19) Printer Monocolor: foggy background





1 ATDC data is within ±1 % of the target value.

NO Readjust.



3 Vg and Vb values are correct.Color Vb: Around 400 V

Vg: Around 500 VBlack Vb: Around 800 V

Vg: Around 900 V

NO Go to next step.

Level His-tory data check results

4 High ATDC and low Vg and Vb YES Go to step 16.

High ATDC and high Vg and Vb

YES Go to step 5.

ATDC falling within specified range and low Vg and Vb

YES Go to step 20.

ATDC falling within specified range and high Vg and Vb

YES Go to step 5.



Imaging Unit


YES Clean.


ATDC Sen-sor window

8 The color ATDC Sensor win-dow on the LED Assy is dirty.

YES Clean. Change ATDC. Change Imaging Unit.


9 High Voltage Unit 2 connector is connected properly.

NO Reconnect.



NO Run another cycle of Grada-tion Adjust. Go to next step if it does not still make data okay.

Foggy background

4011T004AA

T-105


Back-ground Voltage Margin (Tech. Rep. function)

11 After Background Voltage Mar-gin has been adjusted, run Stabilizer to reflect the adjust-ment value in image stabiliza-tion.

NO Go to next step.



NO Go to next step.



NO Go to next step.



NO Go to next step.

Imaging Unit




NO Change LED Assy.


17 The problem is eliminated after the LED Assy has been replaced.


PIC Board 18 The problem is eliminated after High Voltage Unit 2 has been replaced.



T-106


(20) Printer Monocolor: void areas, white spots





1 Low ID. YES Take action for low ID.

Imaging Unit





Imaging Unit


Hopper Unit 5 Foreign matter or caked toner in the Hopper.

YES Remove foreign matter.

Imaging Unit




NO Change LED Assy.

Void areas White spots

4011T008AA

4011T030AA

T-107


(21) Printer Monocolor: colored spots




Imaging Unit

1 Developing bias contact termi-nal makes good connection.

NO Clean contact terminal and check terminal position.






Imaging Unit




NO Change LED Assy.

C F

Colored spots

4011T027AA

T-108


(22) Printer Monocolor: blurred image






2 The surface of the lens array is dirty.


3 LED Unit positioning pin is loose.

YES Change LED Assy.

Imaging Unit





NO Change LED Assy.

Blurred image

4011T046AA

T-109


(23) Printer Monocolor: blank copy, black copy




Imaging Unit

1 Coupling of Imaging Unit drive mechanism is installed prop-erly.

NO Check and correct drive trans-mitting coupling. Change Imaging Unit.

2 The PC Drum Charge Corona voltage contact or PC Drum ground contact of the Imaging Unit is connected properly.

NO Check, clean, or correct the contact.


3 Connector is connected prop-erly.

NO Reconnect.



PIC Board 5 The problem is eliminated after High Voltage Unit 2 has been replaced.


LED Unit 6 The problem is eliminated after the PIC Board has been replaced.

NO Change LED Unit.

Blank copy Black copy

4011T035AA 4011T036AA

T-110


(24) Printer Monocolor: 0.5-mm-pitch uneven image






Imaging Unit




NO Change LED Assy.


NO Change LED Unit.

0.5mm

0.5-mm-pitch uneven image

4011T060AA

T-111


(25) Printer Monocolor: 2-mm-pitch uneven image




Imaging Unit

1 The drive mechanisms for spent toner conveying and Imaging Unit are dirty.

YES Clean.



2 mm

2-mm-pitch uneven image

4011T059AA

T-112


(26) Printer Monocolor: 94-mm-pitch uneven image




Imaging Unit



2 94-mm-pitch uneven image occurs on the image.

YES Store the Imaging Unit in a dark place overnight.



Transfer Belt Unit

4 Transfer Belt Unit drive gear is intact.

NO Correct. Change Transfer Belt Unit.

Transfer Roller Unit

5 Transfer Roller is damaged. YES Change Transfer Roller Unit.

4011T047AD

94 mm 94 mm94 mm

94-mm-pitch uneven image 94-mm-pitch uneven image

4011T057AA 4011T058AA


T-113


(27) Printer 4-Color: white lines in FD, white bands in FD, colored lines in FD, and

colored bands in FD




Transfer Belt Unit

1 Fingerprints, oil, or other for-eign matter is evident on the Transfer Belt.

YES Clean with specified solvent. (See DIS/REASSEMBLY, ADJUSTMENT.)

2 Transfer Belt is dirty or scratched.

YES Clean dirty belt with a soft cloth. Change Transfer Belt Unit if belt is damaged.

3 Cleaning Blade is not effective in removing toner completely.

YES Clean or change Transfer Belt Unit.


4 Transfer Roller is dirty or scratched.

YES Change Transfer Roller Unit.

Paper path 5 There is foreign matter on paper path.


6 Image Transfer Paper Separa-tor Fingers are damaged or dirty.


7 Paper dust accumulates on Paper Dust Remover.

YES Clean.

Fusing Unit 8 Fusing Belt is dirty or scratched.


9 Fusing Entrance Guide Plate is dirty or damaged.


10 Fusing Paper Separator Fin-gers are dirty.

YES Clean.

Fusing Web Unit

11 Web is properly taken up. NO Change Fusing Web Unit.

Oil Coating Unit

12 Oil exudes more than appropri-ate.

YES Change Oil Coating Unit.

White lines in FD White bands in FD Colored bands in FDColored lines in FD

4011T015AA 4011T020AA 4011T017AA 4011T023AA

T-114




NO Change Transfer Roller Unit.

Transfer Belt Unit

14 The problem is eliminated after the Transfer Belt Cleaner has been cleaned.



NO Change LED Assy.


NO Change LED Unit.

Paper Dust Remover

17 The problem is eliminated after the LED Unit has been replaced.

NO Change Paper Dust Remover.

PIC Board 18 The problem is eliminated after the Paper Dust Remover has been replaced.



T-115


(28) Printer 4-Color: white lines in CD, white bands in CD, colored lines in CD, and

colored bands in CD




Transfer Belt Unit












Oil Coating Unit



Paper Dust Remover

7 Paper dust accumulates. YES Clean.




Transfer Belt Unit

9 The problem is eliminated after the Transfer Roller Unit has been replaced.



NO Change LED Assy.


NO Change LED Unit.


4011T016AA 4011T021AA 4011T018AA 4011T022AA

T-116


Paper Dust Remover

12 The problem is eliminated after the LED Unit has been replaced.


PIC Board 13 The problem is eliminated after the Paper Dust Remover has been replaced.



T-117


(29) Printer 4-Color: uneven density in FD




Transfer Belt Unit





3 Terminal is dirty. YES Clean.


4 Transfer Roller is installed properly.

NO Reinstall.





Transfer Belt Unit



Uneven density in FD Uneven density in FD

4011T031AA

4011T042AA

T-118


(30) Printer 4-Color: uneven density in CD




Transfer Belt Unit








NO Reinstall.





Transfer Belt Unit




8 The problem is eliminated after the Transfer Belt Unit has been replaced.


Uneven density in CD Uneven density in CD

4011T032AA 4011T043AA

T-119


(31) Printer 4-Color: low image density




Paper 1 Paper is damp. YES Change paper to one just unwrapped from its package. Install Paper Dehumidifying Heater.

Transfer Belt Unit








NO Reinstall.



Paper path 7 Charge Neutralizing Cloth is not separated and ground ter-minal is connected properly.

NO Correct or change.

AIDC Sen-sor

8 Sensor is dirty. YES Clean with blower brush.






NO Go to next step.

Low image density

4011T003AA

T-120




NO Go to next step.



NO Go to next step.




Transfer Belt Unit



LED Unit 15 The problem is eliminated after the Transfer Belt Unit has been replaced.

NO Change LED Unit.







T-121


(32) Printer 4-Color: poor color reproduction





Transfer Belt Unit








NO Reinstall.



AIDC Sen-sor

7 Sensor is dirty. YES Clean with blower brush.






NO Go to next step.



NO Go to next step.

Poor color reproduction

4011T050AA

T-122




NO Go to next step.




Transfer Belt Unit



LED Unit 14 The problem is eliminated after the Transfer Belt Unit has been replaced.

NO Change LED Unit.







T-123


(33) Printer 4-Color: incorrect color image registration




Warning display

1 Warning display of P-5 (AIDC Sensor 2 failure) or P-28 (AIDC Sensor 1 failure) is dis-played.

YES Carry out remedial action pro-cedures for P-5 or P-28 as part of image stabilizer mal-function troubleshooting pro-cedures.

Machine condition

2 Vibration is given to copier after Power Switch has been turned ON.

YES Turn OFF and ON Power Switch.



Transfer Belt Unit





6 Drive coupling to the copier is dirty.

YES Clean.

Imaging Unit





NO Reinstall.



Fuser Speed (Tech. Rep. function)


NO Take steps to eliminate brush effect or blurred image according to the type of paper. Readjust Fuser Speed.

C FC F

Incorrect color image registration

4011T049AA

T-124


Paper Loop (Tech. Rep. function)

11 If incorrect registration occurs in the main scanning (CD) or sub-scanning (FD) direction, it is evident on the first copy and onward.

YES Readjust Paper Loop.

Color Shift Correction (Tech. Rep. function)

12 Paper skews a lot. YES Adjust Color Shift Correction (Bk).After the correction has been made, adjust PRT Area (Top Margin, Left Margin, and Dup. Left Margin) and then check skew again.If the problem persists, repeat these steps.




Transfer Belt Unit

14 The problem is eliminated after the Transfer Belt Cleaner has been cleaned.



NO Change LED Assy.


NO Change LED Unit.




T-125


(34) Printer 4-Color: void areas, white spots




Transfer Belt Unit










5 Pre-Image Transfer Guide Plate is damaged or dirty.



YES Clean.

7 Charge Neutralizing Cloth is not separated and ground ter-minal is connected properly.

NO Correct or change.




Transfer Belt Unit



Paper Dust Remover



Void areas White spots

4011T008AA4011T030AA

T-126


(35) Printer 4-Color: colored spots




Imaging Unit



Transfer Belt Unit











YES Clean.



Fusing Web Unit





Transfer Belt Unit



Fusing Web Unit


NO Change Fusing Web Unit.

Oil Coating Unit

12 The problem is eliminated after the Fusing Web Unit has been replaced.

NO Change Oil Coating Unit.

C F

Colored spots

4011T027AA

T-127


Fusing Unit 13 The problem is eliminated after the Oil Coating Unit has been replaced.



T-128


(36) Printer 4-Color: oil lines, oil on copy




Oil Coating Unit



2 Oil Coating Roller is scratched. YES Change Oil Coating Unit.



Fusing Web Unit




Oil Coating Unit





Oil lines

4011T019AA

Oil on copy

4011T054AA

T-129


(37) Printer 4-Color: poor fusing performance, offset




Paper 1 Paper type is wrong. YES Change paper type.

Oil Coating Unit




Fusing Web Unit


Fuser Nip (Tech. Rep. function)

5 Nip width meets the specifica-tions: 7 ±0.5 mm.

NO Readjust.

Fuser Temp. (Tech. Rep. function)

6 Changing fusing temperature eliminates the problem of poor fusing performance and offset.

NO Go to next step.

Fusing Web Unit



Oil Coating Unit





C F

C F

Offset

4004T003AA

C F

Poor fusing performance

4004T002AA

T-130


(38) Printer 4-Color: brush effect, blurred image





2 Paper type is wrong. YES Change paper type.

Fusing Unit 3 Fusing Entrance Guide Plate is dirty.

YES Clean.

4 Fusing Belt is dirty or scratched.


Fusing Web Unit


Oil Coating Unit




Fuser Nip (Tech. Rep. function)

8 Nip width meets the specifica-tions: 7 ±0.5 mm.

NO Readjust.

Fuser Speed (Tech. Rep. function)

9 Brush effect or blurred image is evident on different types of paper.

YES Readjust.

Fusing Web Unit



Oil Coating Unit





Blurred imageBrush effect

4011T046AA4004T004AA

T-131


(39) Printer 4-Color: back marking





1 Transfer Roller is scratched or dirty.




Fusing Unit 3 Fusing Entrance Guide Plate is scratched or dirty.


4 Lower Fusing Roller is scratched or dirty.


Transfer Belt Unit






Transfer Belt Unit



Oil Coating Unit



Fusing Web Unit

9 The problem is eliminated after the Oil Coating Unit has been replaced.


Fusing Unit 10 The problem is eliminated after the Fusing Web Unit has been replaced.



11 The problem is eliminated after the Fusing Unit has been replaced.


4011T009AA

Back marking

C F

Back marking

4011T051AA

T-132


(40) Printer 4-Color: 75-mm-pitch uneven image, 200-mm-pitch uneven image




Oil Coating Unit

1 Oil Coating Roller is damaged when 75-mm-pitch uneven image occurs.


Fusing Unit 2 Fusing Belt is damaged when 200-mm-pitch uneven image occurs.



75 mm

200 mm

4011T062AA 4011T061AA

T-133


(41) Printer 4-Color: 94-mm-pitch uneven image




Imaging Unit



2 94-mm-pitch uneven image occurs on the image.

YES Store the Imaging Unit in a dark place overnight.



Transfer Belt Unit

4 Transfer Belt Unit drive gear is intact.

NO Correct. Change Transfer Belt Unit.


5 Transfer Roller is damaged. YES Change Transfer Roller Unit.


4011T047AD

94 mm 94 mm94 mm


4011T057AA 4011T058AA

T-134


4-4. Image Stabilizer Malfunction

(1) P-5: AIDC Sensor Failure (AIDC Sensor 2)

P-28: AIDC Sensor Failure (AIDC Sensor 1)

(2) P-6: Cyan Imaging Unit Failure

P-7: Magenta Imaging Unit Failure

P-8: Yellow Imaging Unit Failure

P-9: Black Imaging Unit Failure


1 AIDC Sensor Shutter operates properly. NO Correct.

2 The area on the Transfer Belt facing the AIDC Sensor is dirty.

YES Clean the dirty area with a soft cloth. If it is seriously con-taminated, use the specified solvent. (See DIS/REASSEM-BLY, ADJUSTMENT.)

3 The area on the Transfer Belt facing the AIDC Sensor is scratched.

YES Change Transfer Belt Unit.

4 AIDC Sensor is mounted at an inappropriate position or connectors are not connected properly.

YES Reinstall. Reconnect.

5 AIDC Sensor window is dirty. YES Clean.

6 Value changes when AIDC Sensor output value is varied.

NO Change AIDC Sensor.

YES Change PIC Board.


1 PRT Max Density (Tech. Rep. Function) is correct.

NO Readjust.

2 Density during γ correction is normal. NO Readjust.

3 Imaging Unit is being driven. NO Check and correct drive cou-pling.

4 T/C is unusually low as found through checking.

YES Check Hopper.

5 AIDC Sensor window is dirty. YES Clean.

6 Imaging Unit connector contact is dirty. YES Clean.





T-135


(3) P-21: Color Shift Correction Failure (Test Pattern Failure)

(4) P-22: Color Shift Correction Failure (Correction Amount Failure)

(5) P-23: Cyan 1st Image Transfer ATVC Failure

P-24: Magenta 1st Image Transfer ATVC Failure

P-25: Yellow 1st Image Transfer ATVC Failure

P-26: Black 1st Image Transfer ATVC Failure

P-27: 2nd Image Transfer ATVC Failure


1 Produce a test pattern.

-

Go to step 2 if the image on the Transfer Belt is correct. Go to step 4 if the image den-sity is low.

2 The area on the Transfer Belt facing the AIDC Sensor is dirty.

YES Clean the dirty area with a soft cloth. If it is seriously con-taminated, use the specified solvent. (See DIS/REASSEM-BLY, ADJUSTMENT.)

3 The area on the Transfer Belt facing the AIDC Sensor is scratched.

YES Change Transfer Belt Unit.


1 LED retracting lever is locked in position. NO Slide out the Imaging Unit and then reinstall.

2 AIDC Sensor is installed slantwise. YES Reinstall.

3 Vertical Transport Guide is installed slant-wise.

YES Correct.


1 Transfer Belt Unit contact makes positive contact with High Voltage Unit contact.

NO Clean or correct.




NO Change High Voltage Unit 2. Change Master Board.

T-136


(6) S-1: CCD Gain Adjustment Failure

Clamp/Gain Adjustment Values

Clamp: Allowable up to ±100 of the above values. Gain: Allowable up to ±90 of the above values for R and B; allowable up to ±50 of the

above values for G. Exposure Lamp adjustment value: Allowable in the range between 64 and 192.

(7) S-2: Intensity Adjustment Failure

RO RE GO GE BO BE

Clamp 130 130 130 130 130 130

RO RE GO GE BO BE

Gain 160 160 170 170 160 160

Lamp Adjustment Value 135


1 Check that each of the values displayed on the screen falls within the above range.

2 There is a wide difference between the clamp and gain adjustment values, the value being close to “0” or “255.”

YES Make positive connection of the harness connectors between CCD Sensor Board and Image Processing Board.

3 Clamp adjustment value exceeds the allow-able range only slightly.


4 The lamp adjustment value or gain value exceeds the upper limit of the allowable range, being abnormally great.

YES Clean lens, mirrors, CCD sur-face, shading sheet, and related parts.

5 The lamp adjustment value or gain value falls short of the lower limit of the allowable range, being abnormally small.



1 Original Glass, mirrors, CCD surface, and Main and Auxiliary Reflectors are dirty.Exposure Lamp is dirty or has discolored.

YES Clean or change; then, turn ON Power Switch.

NO Change Exposure Lamp. Change CCD Sensor Board.

T-137

FrameMaker Ver.5.5(PC) CF1501/CF2001 Unit Replacement Manual00.12.22

UNIT REPLACEMENT MANUAL

18605


i

CONTENTS1. The Unit Life Manual ........................................................................................ 1

2. The Indication of Replacement for CRU/TFU/FRU .......................................... 1

3. Unit Replacement Manual ............................................................................... 13-1. Unit Layout ............................................................................................... 13-2. Replacing the Units .................................................................................. 2

(1) Replacing the Fusing Web Unit ....................................................... 2(2) Replacing the Oil Coating Unit ........................................................ 6(3) Replacing the Imaging Unit (C, M, Y) .............................................. 11(4) Replacing the Waste Toner Bottle ................................................... 19(5) Replacing the Imaging Unit Bk ........................................................ 21(6) Replacing the Fusing Unit ............................................................... 22(7) Replacing the Paper Dust Remover, Image Transfer Roller Unit,

Image Transfer Belt Unit, and Ozone Filter ..................................... 26

1

1. The Unit Life ManualNOTES• The life specifications values represent the number of copies made or figures equivalent to it when given conditions are met. They can be more or less depending on the copier operating conditions

of each individual user.• The initiation of a new copy cycle is inhibited upon 1K after a near life condition has been detected for all units (except the Toner Bottle and Waste Toner Bottle).

M: minutes 1: As a rule, the Fusing Unit is to be replaced at the same time that the Fusing Web Unit is replaced a sixth time (17K × 6 = 102K). If the Fusing Web Unit is replaced before 17K is reached, there

will be a discrepancy in the replacement cycle, resulting in a near life and life value ranging between 90K and 110K. 2: The life of the Transfer Belt Unit is controlled based on the number of copies made. The life counter gives a time value display. 3: The life of the Imaging Unit is controlled based on a time value. The life counter gives a time value display.

• Conditions for Life Specifications Values

Unit Life Spec. Value Copying Condition Code Description Near Life Value Life Value

Toner Bottle – B/E An approximate life value is 10K under the specified conditions. – 10K

Waste Toner Bottle 40K B/C/D/E/FA waste toner full condition is detected when about 4.5K copies are made after a waste toner near-full condition has been detected. – 40K

Fusing Web Unit 17K B/C/D/FThe life specifications value is based on A4C or Letter C. A near life condition is detected when a web empty condition is detected or a predetermined number of copies are made, whichever arrives earlier.

16K 17K

20-cpm copier Oil Coating Unit 33K

A/B/C/D/F

The life specifications value is based on A4C or Letter C. A near life condition or a life condition is detected when the Oil Coating Roller has turned a predetermined period of time or a predetermined number of copies are made, whichever arrives earlier.

33K 34K

15-cpm copier Oil Coating Unit 26K 26K 27K

Fusing Unit 101K B/C/D/F The life specifications value is based on A4C or Letter C. 101K 1 102K

Transfer Belt Unit 120K A/B/C/D/F The life specifications value is based on A4C or Letter C.2 120K (17400M)

2 121K (17545M)

20-cpm copier Imaging Unit (C, M, and Y) 30K

A/B/C/D/FThe near life and life time values are detected when the PC Drum has turned or the Developing Unit has been energized for a predetermined period of time, whichever arrives earlier.

3 4415M (30K)

3 4562M (31K)

15-cpm copier Imaging Unit (C, M, and Y) 27K 3 4415M (27K)

3 4562M (28K)

20-cpm copier Imaging Unit (Bk) 50K3 6972M

(50K)3 7122M

(51K)

15-cpm copier Imaging Unit (Bk) 47k 3 6972M (47K)

3 7122M (48K)

Copying Condition CF2001 CF1501

Job Type A Making two copies per job

Paper Size B A4 or Letter

Color Ratio C C (color) : Bk (black) = 5 : 1 C (color) : Bk (black) = 2.5 : 1

CV/M D 6K 3.5K

Original Density E B/W = 5% for each color

No. of Operating Days per Month F 20 days (Power Switch turned ON and OFF 20 times per month)


2. The Indication of Replacement for CRU/TFU/FRU K=1,000 copies The contents of the this list are subject to change without notice. For details, see the unit life manual about the PM cycle.

No. Unit Name Maintenance Message DisplayPM Cycle CF2001/CF1501

Page No.

1.Imaging Unit (Bk)

7122 min (51K/48K)

P-21

2.Imaging Unit (C)

4562 min (31K/28K)

P-11

3.Imaging Unit (M)

4562 min (31K/28K)

P-11

1



Page No.

4.Imaging Unit (Y)

4562 min (31K/28K)

P-11

5. Fusing Unit 102K/102K P-22

6.Oil Coating Unit

34K/27K P-6

2



Page No.

7.Fusing Web Unit

17K/17K P-2

8.Waste Toner Bottle

40K/40K P-19

9.Image Transfer Belt Unit

17545 min (121K/121K)

P-26

3



Page No.

10.Image Transfer Roller Unit

Nothing to indicate 121K/121K P-26

11.Paper Dust Cleaner

Nothing to indicate 121K/121K P-26

12. Ozone Filter Nothing to indicate 121K/121K P-26

4


3. Unit Replacement Manual3-1. Unit Layout

Fusing UnitReplace every 102 K.

Fusing Web UnitReplace the web unit every 17 K prints, or about 1 K prints after WEB UNIT NEARLY EMPTY is detected.

Oil Coating UnitReplace every 34 K or 325,000 sec.

Paper Dust RemoverReplace every 121 K.

Image Transfer Roller UnitReplace every 121 K.

Replace the waste toner bottle about 4.5 K prints after WASTE TONER BOTTLE NEARLY FULL is detected.

Image Transfer Belt UnitReplace every 121 K.

Ozone FilterReplace every 121 K.

Imaging UnitC, M, Y: Replace every 4,562 M.Bk: Replace every 7,204 M.

4004D301AA

4004D351CA

1


3-2. Replacing the Units

(1) Replacing the Fusing Web Unit

Removal method

NOTE• Before replacing the fusing web unit, ensure that it is not hot.

1. Turn OFF the main switch, then wait for about 20 min-utes.

2. Open the Upper Right Door.

NOTE• When opening the upper

right door, be sure to sup-port it with your hand until it is in the fully open position. If you remove your hand from the upper right door, it may drop, and the resulting impact may cause the hinges to bend.

4004D352CA

3. Release the two blue lock levers.(➀: Push up, ➁: Rotate)

4004D305AA

➀

➁

➁

➀

2


4. Grasp the two blue lock levers, and remove the fusing web unit.

4004D306AA

NOTE• Do not touch the metal ter-

minals beneath the fusing web unit (on the fusing unit side). Failure to observe this pre-caution may cause an elec-trostatic discharge, resulting in a breakdown.

4004D307AA

Terminals (metal)

3


Installation method

1. Remove the fusing web unit from its box, and remove the packing mate-rial.

2. Grasp the two blue lock levers, and set the fusing web unit in place.

NOTE• When setting the fusing web

unit, align the mark on the fusing web unit with the mark on the fusing unit.

4004D308AA

3. Lock the two blue lock levers. (➀: Push, ➁: Rotate,

➂: Push down)

4004D309AA

➀

➁

➂ ➀

➁➂

4


4. Close the Upper Right Door.

4004D353CA

5


(2) Replacing the Oil Coating Unit

Removal method

NOTE• Before replacing the oil coating unit, ensure that it is not hot.• When placing the oil coating unit on a bench, for example, stand it upright.

1. Turn OFF the main switch, and wait for about 20 min-utes.




4004D352CA

6


3. Release the two green lock levers.

4004D312AA

4. Grasp the two green han-dles, and remove the oil coating unit.

4004D313AA

7


NOTE• Do not touch the metal ter-

minals beneath the fusing web unit (on the fusing unit side). Failure to observe this pre-caution may cause an elec-trostatic discharge, resulting in a breakdown.

4004D314AA

Terminal (metal)

8


Installation method

1. Withdraw the oil coating unit from its box, and remove the packing mate-rial.

2. Grasp the two green han-dles, and set the oil coat-ing unit in place.

4004D315AA

3. Lock the two green lock levers.

4004D316AA

9



4004D353CA

10


(3) Replacing the Imaging Unit (C, M, Y)

Removal method

1. Turn OFF the main switch.2. Unplug the power cord.3. Disconnect the grounding

cord.4. Open the Front Door.

4004D317AA

5. Release the lock lever of the imaging unit.

4004D318AA

11


6. Remove the removal jig of the imaging unit from the main unit.

4004D319AA

7. Set the removal jig of the imaging unit in place.

8. Slowly rotate the jig clock-wise until it is fixed.

4004D320AA

9. Install the bottom cover of the imaging unit.

NOTE• When installing the bottom

cover of the imaging unit, align it with the blue label on the lock lever.

4004D321AA

12


10. Grasp the removal jig of the imaging unit, then slowly withdraw the imag-ing unit while supporting the bottom cover with your hand.

NOTE• Do not remove the bottom

cover after removing the imaging unit.

4004D322AA

11. Remove the removal jig of the imaging unit, and return it to the main unit.

4004D323AA

13


Installation method

NOTE• To prevent damaging the imaging unit by exposure to light, keep the imaging unit in its

light-proof vinyl pouch until immediately before installing it.• When holding the Imaging Unit, be sure to hold it by its bottom cover.

If the Top Imaging Unit Cover is hold, it may full off or the PC Drum installed on the Imaging Unit may be damage, resulting in decreased image quality.

1. Remove the imaging unit from its box, then remove the light-proof vinyl pouch.

2. Tilt the imaging unit to the left, and shake it gently twice in the tilted direc-tion, then tilt the imaging unit to the right, and shake it gently twice in the tilted direction.

4004D324AA

3. Remove the protective tapes.

C4004U213AA

14


4. Remove the shipping cushion.

C4004U214AA

NOTE• When installing the imaging unit, ensure that the color of the mounting guide of the

imaging unit is the same as the color of the label at the mounting position on the main unit.

NOTE• Do not insert the Imaging Unit into its compartment at an angle.

5. Support the bottom of the imaging unit with your left hand, and the bottom front side with your right hand, hold the unit horizontally, then push it in until the front edge stops.

6. Confirm that the imaging unit is inserted to the posi-tion where the front edge of the bottom cover touches the main unit.

4004D325AA

15


7. Using your left hand, sup-port the bottom of the imaging unit, then using your right hand gently push in the part shown in the drawing of the unit.

NOTE• When installing the imaging

unit, insert it to the position where it clicks into place.

4004D326AA

8. Pull out the Imaging Unit Cover.

9. Make sure that the Imag-ing Unit is inserted as far as possible.

4004D327AA

10. Gently return the lock lever of the imaging unit so that the unit locks.

NOTE• When locking the imaging

unit, return the lock lever to the position where it clicks into place.

4004D328AA

16


11. Close the Front Door.

4004D329AA

12. Separate the top and bot-tom halves of the Imaging Unit Cover.

4004D330AA

17


13. Install the top cover on the imaging unit that you removed in step 10 on Page 13.

NOTE• The four claws of the top

cover must be engaged with the four claw holders.

14. Connect the grounding lead.

15. Connect the power cord.16. Turn ON the main switch.

4004D331AA

NOTE• The bottom cover of the imaging unit is needed the next time you replace the imaging

unit, so store it carefully.

18


(4) Replacing the Waste Toner Bottle

NOTE• If the paper exit system option is installed, remove it from the main unit before replac-

ing the waste toner bottle.• When removing the paper exit system option, support the horizontal transport unit with

your hand to prevent it from dropping.

1. Turn OFF the main switch.2. Open the Left Door.

4004D332AA

3. Grasp the handle, and remove the waste toner bottle.

4004D354CA

19


NOTE• Raise the waste toner bottle gently before removing it.• If scattered toner has accumulated in the vicinity of the toner collecting port, do not tilt

the waste toner bottle when removing it.• Do not leave the waste toner bottle in a tilted condition after removing it.

4. Remove the seals from the two toner collecting ports.

4004D337AA

5. Peel off the seals for blocking the two toner col-lecting ports, and place them over the toner col-lecting ports.

4004D334AA

20


Installation method

(5) Replacing the Imaging Unit Bk

For the method of replacing the imaging unit, refer to “(3) Replacing the Imaging Unit (C, M, Y)”. page 11

1. Remove the waste toner bottle from its box, and remove the packing mate-rial.

2. Grasp the handle, and set the waste toner bottle in place.

4004D355CA

3. Close the Left Door.4. Turn ON the main switch.

4004D336AA

21


(6) Replacing the Fusing Unit

Removal method

NOTE• Before replacing the fusing unit, ensure that it is not hot.

1. Turn OFF the main switch, then wait for about 20 min-utes.

2. Open the Right Door.

4004D356CA




4004D352CA

22


4. Grasp the blue lever, and remove the fusing unit.

4004D357CA

5. Grasp the two handles with the blue labels, and remove the fusing unit.

4004D338AA

23


Installation method

1. Remove the fusing unit from its box, and remove the packing material.

2. Grasp the two handles with the blue labels, and install the fusing unit.

NOTE• When installing the fusing

unit, align it with the posi-tioning pin on the main unit.

4004D339AA

3. Grasp the blue lever, and push in the fusing unit.

4004D358CA


4004D353CA

24


5. Close the Right Door.

NOTE• Ensure that both the front

and rear sides are locked.

4004D359CA

25


(7) Replacing the Paper Dust Remover, Image Transfer Roller Unit, Image Transfer

Belt Unit, and Ozone Filter

Removal method

NOTE• If the paper exit system option is installed, remove it from the main unit before replac-

ing the paper dust remover.• When removing the paper exit system option, support the horizontal transport unit with

your hand to prevent it from dropping.

1. Turn OFF the main switch.2. Open the Right Door.

4004D356CA

3. Remove the paper dust remover while pushing the hook with the gray label at the front to the rear.

4004D340AA

26


4. Release the two blue lock levers.5. Grasp the two blue lock levers, and remove the image transfer roller unit.

4004D341AA

6. Open the Left Door.

4004D332AA

27


7. Grasp the handle, and remove the waste toner bottle.

4004D354CA

NOTE• Raise the waste toner bottle gently before removing it.• If scattered toner has accumulated in the vicinity of the toner collecting port, do not tilt

the waste toner bottle when removing it.• Do not leave the waste toner bottle in a tilted condition after removing it.

NOTE• Do not attempt to pull out the image transfer belt unit when the right door is not open

because you may damage the belt.

8. Pull out the image transfer belt unit.

4004D360CA

28


9. Remove the ozone filter while grasping the hooks at both ends.

4004D343AA

29


Installation method

1. Install the Ozone Filter.

4004D344AA

NOTE• When installing the image transfer belt unit, wear the gloves packed with the unit.

(This is to prevent the possibility of a defective image due to finger marks adhering to the transfer film.)

• When inserting the image transfer belt unit, align the boss on the transfer belt unit with the part of the main unit guide section marked with the arrow.

• When installing the transfer belt, insert it until into clicks into place.

4004D361CA

Boss Boss

30


2. Insert the Image Transfer Belt Unit.

4004D346AA

3. Grasp the handle, and install the waste toner bot-tle.

4004D355CA

4. Close the Left Door.

4004D336AA

31


5. Grasp the two blue lock levers, and install the image transfer roller unit.6. Lock the two blue lock levers.

4004D347AA

7. Install the paper dust remover.

NOTE• Push in the hook with the

gray label until it clicks into place.

4004D348AA

32


8. Close the Right Door.

NOTE• Both the front and rear

sides must be locked.

9. Turn ON the main switch.

4004D359CA

33




Printed in Japan


MINOLTA Co., Ltd. 4004-7998-11 01011200

CF1501/CF2001

SERVICE MANUAL

CF

1501/CF

2001 SE

RV

ICE

MA

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