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SERVICEMANUAL

Published in July 2006 3KH70760

PF-700/710/PF-750DP-700/JS-700DF-720/DF-730FaxSystem(M)


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CAUTION

DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITHTHE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE OFUSED BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS.

ATTENTION

IL Y A DANGER DEXPLOSION SIL Y A REMPLACEMENT INCORRECT DE LA BATTERIE.REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MME TYPE OU DUN TYPE REC-OMMAND PAR LE CONSTRUCTEUR. METTRE AU RBUT LES BATTERIES USAGES CON-FORMMENT AUX INSTRUCTIONS DU FABRICANT.


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Revision history

Revision Date Replaced pages Remarks


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This page is intentionally left blank.


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Safety precautions

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


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Safety warnings and precautions

Various symb ols are used to prot ect our service personnel and customers fro m physic al danger andto pr event damage to their pr operty. These symbols are described below :

DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrectcompliance with warning messages using this symbol.

WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliancewith warning messages using this symbol.

CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrectcompliance with warning messages using this symbol.

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

General warning.

Warning of risk of electric shock.

Warning of high temperature.

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

General prohibited action.

Disassembly prohibited.

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

General action required.

Remove the power plug from the wall outlet.

Always ground the copier.


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1.Installation Precautions

WARNING

Do not use a power supply with a voltage other than that specified. Avoid multiple connections to

one outlet: they may cause fire or electric shock. When using an extension cable, always checkthat it is adequate for the rated current. .............................................................................................

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

CAUTION:

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

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

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

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

Allow sufficient space around the copier to allow the ventilation grills to keep the machine as coolas possible. Insufficient ventilation may cause heat buildup and poor copying performance. ...........

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

Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may causethe copier to move unexpectedly or topple, leading to injury. ...........................................................

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

Advice customers that they must always follow the safety warnings and precautions in the copiersinstruction handbook. .....................................................................................................................


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2.Precautions for Maintenance

WARNING

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

Always follow the procedures for maintenance described in the service manual and other relatedbrochures. .......................................................................................................................................

Under no circumstances attempt to bypass or disable safety features including safety mechanismsand protective circuits. .....................................................................................................................

Always use parts having the correct specifications. .......................................................................... Always use the thermostat or thermal fuse specified in the service manual or other related bro-

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

When the service manual or other serious brochure specifies a distance or gap for installation of apart, always use the correct scale and measure carefully. ................................................................

Always check that the copier is correctly connected to an outlet with a ground connection. ............. Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it

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

Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light maydamage eyesight. ...........................................................................................................................

Handle the charger sections with care. They are charged to high potentials and may cause electricshock if handled improperly. ............................................................................................................

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

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

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

Handle the fixing section with care to avoid burns as it can be extremely hot. .................................. Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause

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


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

Do not pull on the AC power cord or connector wires on high-voltage components when removingthem; always hold the plug itself. .....................................................................................................

Do not route the power cable where it may be stood on or trapped. If necessary, protect it with acable cover or other appropriate item. .............................................................................................

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

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

Run wire harnesses carefully so that wires will not be trapped or damaged. .................................... After maintenance, always check that all the parts, screws, connectors and wires that were

removed, have been refitted correctly. Special attention should be paid to any forgotten connector,trapped wire and missing screws. ...................................................................................................

Check that all the caution labels that should be present on the machine according to the instructionhandbook are clean and not peeling. Replace with new ones if necessary. ......................................

Handle greases and solvents with care by following the instructions below: ..................................... Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely. Ventilate the room well while using grease or solvents. Allow applied solvents to evaporate completely before refitting the covers or turning the power

switch on. Always wash hands afterwards.

Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly tofire in a furnace, etc. .......................................................................................................................

Should smoke be seen coming from the copier, remove the power plug from the wall outlet imme-diately. ............................................................................................................................................

3.Miscellaneous

WARNING

Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than thespecified refiner; it may generate toxic gas. .....................................................................................


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PF-700

PF-710


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3J4-1

CONTENTS

1-1 Specifications1-1-1 Specifications ..........................................................................................................................................1-1-11-1-2 Parts names............................................................................................................................................1-1-21-1-3 Machine cross section ............................................................................................................................1-1-3

1-2 Installation1-2-1 Installation environment ..........................................................................................................................1-2-11-2-2 Unpacking ...............................................................................................................................................1-2-21-2-3 Installing the cassette heater (option) .....................................................................................................1-2-3

1-3 Maintenance Mode1-3-1 Maintenance mode (fullcolor machine) ...................................................................................................1-3-1

(1) Executing a maintenance item ..........................................................................................................1-3-1(2) Contents of maintenance mode items...............................................................................................1-3-2

1-3-2 Maintenance mode (monochrome machine) ..........................................................................................1-3-3(1) Executing a maintenance item ..........................................................................................................1-3-3(2) Contents of maintenance mode items...............................................................................................1-3-4

1-4 Troubleshooting1-4-1 Paper misfeed detection .........................................................................................................................1-4-1

(1) Paper misfeed indication ...................................................................................................................1-4-1(2) Paper misfeed detection conditions ..................................................................................................1-4-1(3) Paper misfeeds .................................................................................................................................1-4-2

1-4-2 Self-diagnosis .........................................................................................................................................1-4-4(1) Self-diagnostic function .....................................................................................................................1-4-4(2) Self diagnostic codes ........................................................................................................................1-4-4

1-4-3 Electric problems ....................................................................................................................................1-4-61-4-4 Mechanical problems ..............................................................................................................................1-4-8

1-5 Assembly and Disassembly

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

1-5-2 Paper feed section ..................................................................................................................................1-5-2(1) Detaching and refitting the forwarding, paper feed and separation pulleys ......................................1-5-2(2) Replacing paper feeder paper width switch 1, 2 ...............................................................................1-5-5(3) Replacing paper feeder paper feed clutch 1/2 and paper feeder paper conveying clutch ................1-5-7(4) Adjusting the position of the rack adjuster.........................................................................................1-5-9

2-1 Mechanical construction2-1-1 Mechanical construction .........................................................................................................................2-1-1

2-2 Electrical Parts Layout2-2-1 Electrical parts layout..............................................................................................................................2-2-1

2-3 Operation of the PWBs2-3-1 Paper feeder main PWB .........................................................................................................................2-3-1

2-4 AppendixesList of maintenance parts........................................................................................................................2-4-1Periodic maintenance procedures ..........................................................................................................2-4-1Wiring diagram........................................................................................................................................2-4-3


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1-1-1

1-1 Specifications

1-1-1 Specif icat ions

Paper supply method......................Friction retard method (No. sheets: 500, 80 g/m 2, 2 caddettes)Paper size.......................................A3 to A5R, folio, 11" x 17" to 5 1/2 " x 8 1/2 "Supported paper............................. Weight: 60 to 105 g/m 2

Types: standard, recycled, color Power source..................................Electrically connected to the machine.

Dimensions .....................................585 (W) x 590 (D) x 315 (H) mm23 5/16 " (W) x 23 1/4 " (D) x 12 3/8 " (H)

Weight.............................................26 kg/57.2 lbs

NOTE: These specifications are subject to change without notice.


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1-1-2

1-1-2 Parts names

Figure 1-1-1

1. Cassette 32. Cassette 43. Left cover 3


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1-1-3

1-1-3 Machine cross section

Figure 1-1-2 Machine cross sectio n

Paper path


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1-1-4



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1-2-1

1-2 Installation

1-2-1 Installation environment

1. Installation location (Be based on the machine establishment place.) Avoid direct sunlight or bright lighting. Ensure that the photo-conductor will not be exposed to direct sunlight orother strong light when removing paper jams.

Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directedonto the machine.

Avoid dust and vibration.Choose a surface capable of supporting the weight of the machine.Place the machine on a level surface (maximum allowance inclination: 1 ).

Avoid air-borne substances that may adversely affect the machine or degrade the photo-conductor, such as mer-cury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.Select a room with good ventilation.


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1-2-2

1-2-2 Unpacking

Figure 1-2-1 Unpacking

Caution: Place the machine on a level surface.

1. Paper feeder 2. Retainer 3. CVM4 x 06 cross-head

binding screws4. Pins5. Stays6. M4 x 10 TP screws7. Outer case8. Bottom pads

9. Upper pad10. Stays11. Machine cover 12. Rear spacer 13. Plastic bag14. Bar code label15. Plastic bag16. Installation guide


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1-2-3

1-2-3 Installing the cassette heater (option)

Cassette heater installation requires the following parts:Cassette heater (P/N 302FB25060): for 220 to 240 V specifications onlyCassette heater (P/N 302FB25050): for 120 V specifications onlyTwo (2) M4 x 8 S tight screws (P/N B1304060)

Procedure1. Remove cassette 3 and 4.2. Remove the three screws holding the paper

feeder rear cover and then the cover.3. Pass the cassette heater cable to the

machine rear through the cable hole in themachine right.

4. Attach the cassette heater using the two M4x 8 S tight screws.

Figure 1-2-2

5. Insert the cassette heater connector intothe connector of the main harness.

6. Tidy up the desk dehumidifier cable usingthe wire saddle and route the cable while

clipping the wire saddles into the holes inthe rear frame.7. Refit the paper feeder rear cover.8. Refit cassette 3 and 4.

Figure 1-2-3

M4 x 8S tight screws

Cable hole

Cassette heater

Wire saddle Cable of paper feeder

Cable of cassette heater


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1-3-2

(2) Contents of maintenance mode items

Maintenance

item No. Description

U247 Checking the operation of paper feeder DescriptionTurns on motors and clutches of paper feeder.PurposeTo check the operation of motors and clutches of paper feed device.Method

1. Press the start key.

2. Select the item to be operated.When selecting the motor, the operation starts. To stop the operation, select the item again.When selecting the clutch, each clutch is turned on for 1 s.

CompletionPress the stop/clear key. The screen for selecting a maintenance item No. is displayed.

U901 Checking cop y counts by paper feed locationsDescriptionDisplays copy counts by paper feed locations.PurposeTo check the time to replace consumable parts.Method

1. Press the start key. The counts by paper feed locations are displayed.


Display Motor and clutches

DESK FEED Paper feeder drive motor (PFDM)

CLUTCH FEED Paper feeder feed clutch (PFFCL)

CLUTCH U Paper feeder paper feed clutch 1 (PFPFCL1)

CLUTCH L Paper feeder paper feed clutch 2 (PFPFCL2)

Display Description

BYPASS MP tray

CASSETTE 1 Cassette 1CASSETTE 2 Cassette 2

CASSETTE 3 Cassette 3


DUPLEX Duplex unit


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1-3-3

1-3-2 Maintenance mode (monochrome machine)

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

(1) Executing a maintenance item

Enter 10871087 usingthe numeric keys.

Enter 001 using the cursorup/down keys or numeric keys

and press the start key.

Enter the maintenance itemnumber using the cursor up/down keys

or numeric keys.

The selected maintenance item is run.

Press the stop key.

Press the start key.

Start

End

Maintenance mode is entered.

The maintenance item isselected.

Maintenance mode is exited.

Repeat the samemaintenance item?

Run another maintenanceitem?

No

No

Yes

Yes

Press the status key.


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1-3-4


Maintenance


U247 Setting the paper feed deviceDescriptionTurns on motors and clutches of paper feeder.PurposeTo check the operation of motors and clutches of paper feed device.Method

1. Press the start key.

2. Select the item to be operated.3. Press the start key. The operation starts.4. To stop operation, press the stop key.

CompletionPress the stop key. The screen for selecting a maintenance item No. is displayed.

U901 Checking/clearing co py counts by paper feed lo cationsDescriptionDisplays or clears copy counts by paper feed locations.PurposeTo check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts.MethodPress the start key. The counts by paper feed locations are displayed.

When an optional paper feed device is not installed, the corresponding count is not displayed.Clearing

1. Select the count to be cleared.To clear all counts, press the clear key.

2. Press the start key. The count is cleared.CompletionPress the stop key. The screen for selecting a maintenance item No. is displayed.


DESK FEED Paper feeder drive motor (PFDM)

CLUTCH FEED Paper feeder feed clutch (PFFCL)

CLUTCH U Paper feeder paper feed clutch 1 (PFPFCL1)

CLUTCH L Paper feeder paper feed clutch 2 (PFPFCL2)

Display Paper feed locations

MP TRAY MP tray




LCF Optional 3000-sheet paper feeder

DUPLEX Duplex section


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1-4-1

1-4 Troubleshooting

1-4-1 Paper misfeed detection

(1) Paper misfeed indication

When a paper misfeed occurs, the machine immediately stops copying and displays the jam location on the operationpanel.Paper misfeed detection can be reset by opening and closing the left cover 3 to turn left cover 3 switch off and on.

(2) Paper misfeed detection conditions

Figure 1-4-1

Section Jam code Conditions Specifiedtime

Paper feedsection

12No paper feed from cas-sette 3

Feed switch 3 (FSW3) does not turn on within the specifiedtime of paper feeder paper feed clutch 1 (PFPFCL1) turningon; the clutch is then successively turned off for 1 s and turnedback on, but the switch again fails to turn on within the speci-

fied time.

1828 ms

13No paper feed from cas-sette 4

The paper feeder feed switch (PFFSW) does not turn on withinthe specified time of paper feeder paper feed clutch 2(PFPFCL2) turning on; the clutch is then successively turnedoff for 1 s and turned back on, but the switch again fails to turnon within the specified time.

1828 ms

24Multiple sheets in cassette3 paper feed section

Feed switch 3 (FSW3) does not turn off within specified time ofits turning on.

3960 ms

25Multiple sheets in cassette4 paper feed section

The paper feeder feed switch 1 (PFFSW) does not turn offwithin specified time of its turning on.

3960 ms

PFPFCL1

PFFSW

FSW3

PFPFCL2


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1-4-2

(3) Paper mi sfeeds

Problem Causes/check procedures Corrective measures

(1) A paper jam in thepaper feed section is

indicated duringcopying (no paperfeed from cassette3).Jam code 12

Paper is extremely curled. Change the paper.

Check if the paper feed pul-

ley, forwarding pulley andseparation pulley of cas-sette 3 are deformed.

Check visually and replace any deformed pulleys.

Broken feed switch 3 actua-tor.

Check visually and replace switch.

Defective feed switch 3. Run maintenance item U031 and turn feed switch 3 on and offmanually. Replace the switch if indication of the correspondingswitch on the touch panel is not displayed in reverse.

Check if paper feeder paperfeed clutch 1 malfunctions.

Run maintenance item U247 and select paper feeder paper feedclutch 1 on the touch panel to be turned on and off. Check the sta-tus and remedy if necessary.

Electrical problem withpaper feeder paper feedclutch 1.

Check (see page 1-4-6 ).

(2) A paper jam in thepaper feed section isindicated duringcopying (no paperfeed from cassette4).Jam code 13


Check if the paper feed pul-ley, forwarding pulley andseparation pulley of cas-sette 4 are deformed.

Check visually and replace any deformed pulleys.

Broken paper feeder feedswitch actuator.


Defective paper feeder feedswitch.

Run maintenance item U031 and turn paper feeder feed switch onand off manually. Replace the switch if indication of the corre-

sponding switch on the touch panel is not displayed in reverse.Check if paper feeder paperfeed clutch 2 malfunctions.




(3) A paper jam in thepaper feed section isindicated duringcopying (multiple

sheets in cassette 3).Jam code 24

Broken switch actuator. Check visually and replace switch.


Defective paper feederpaper feed clutch 1.




Defective feed pulleys orfeed rollers.

Check visually and replace.


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1-4-3

(4) A paper jam in thepaper feed section isindicated duringcopying (multiplesheets in cassette 4).Jam code 25


Defective paper feeder feedswitch.

Run maintenance item U031 and turn paper feeder feed switch onand off manually. Replace the switch if indication of the corre-sponding switch on the touch panel is not displayed in reverse.









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1-4-4

1-4-2 Self-diagnosis

(1) Self-diagnostic function

This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled and the problem dis-played as a code consisting of C followed by a number, indicating the nature of the problem. A message is also displayedrequesting the user to call for service.

After removing the problem, the self-diagnostic function can be reset by turning cover switch off and back on.

(2) Self diagnostic codes

Code ContentsRemarks

Caus es Ch eck pro ced ur es/cor rect ive measu res

C0420 Paper feeder communication error A communication error from paperfeeder is detected 10 times in succes-

sion.

Poor contact in theconnector termi-nals.

Check the connection of connector YC33 onthe engine PWB and the connector YC1 onthe paper feeder main PWB, and the conti-

nuity across the connector terminals. Repairor replace if necessary.

Defective PWB. Replace the paper feeder main PWB orengine PWB and check for correct opera-tion.

C1030 Paper feeder lift motor 1 error When optional cassette 3 is inserted,paper feeder lift switch 1 does not turnon within 12 s of paper feeder lift motor 1turning on.The lift overcurrent protective monitorsignal is detected above 500 ms duringdriving the motor.However, the first 1 s after paper feederlift motor 1 is turned on is excluded fromdetection.


Check the connection of connector on theengine PWB and the connector on the paperfeeder main PWB, and the continuity acrossthe connector terminals. Repair or replace ifnecessary.

Broken gears orcouplings of paper

feeder lift motor 1.

Replace paper feeder lift motor 1.

Defective paperfeeder lift motor 1.

Check for continuity across the coil. If none,replace paper feeder lift motor 1.

Defective paperfeeder lift switch 1.

Check if YC1-5 on the paper feeder mainPWB goes low when paper feeder lift switch1 is turned off. If not, replace paper feeder l iftswitch 1.

C1040 Paper feeder lift motor 2 error When optional cassette 4 is inserted,paper feeder lift switch 2 does not turnon within 12 s of paper feeder lift motor 2turning on.

The lift overcurrent protective monitorsignal is detected above 500 ms duringdriving the motor.However, the first 1 s after paper feederlift motor 2 is turned on is excluded fromdetection.



Broken gears orcouplings of paperfeeder lift motor 2.

Replace paper feeder lift motor 2.






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1-4-5

C1900 Paper feeder EEPROM error When writing the data, the write data andthe read data is not continuously in

agreement three times.


Check the connection of connector on theengine PWB and the connector on the paperfeeder main PWB, and the continuity across

the connector terminals. Repair or replace ifnecessary.

Defective enginePWB.

Replace the engine PWB and check for cor-rect operation.

Defective paperfeeder.

Replace the paper feeder with another unitand check the operation. If the operation isnormal, replace or repair paper feeder.




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1-4-6

1-4-3 Electr ic problems

Problem Causes Check procedures/corrective measures

(1)The paper feederdoes not operatewhen the main powerswitch is turned on.

Poor contact in the connec-tor terminals.

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

Defective left cover 3switch. Check for continuity across the contacts. If none, replace the leftcover 3 switch.

(2)The paper feederdrive motor does notoperate.



Broken the gear. Check visually and replace the gear if necessary.

Defective paper feederdrive motor.

Run maintenance item U247 and check if the paper feeder paperconveying motor operates when YC4-3 on the paper feeder mainPWB goes low. If not, replace the paper feeder drive motor.

Defective paper feedermain PWB.

Run maintenance item U247 and check if YC4-3 on the paperfeeder main PWB goes low. If not, replace the paper feeder mainPWB.

(3)The paper feederpaper feed clutch 1/2or paper feederpaper conveyingclutch does not oper-ate.

Broken clutch coil. Check for continuity across the coil. If none, replace the clutch.




Run maintenance item U247 and check if following terminals onthe paper feeder main PWB goes low. If not, replace the paperfeeder main PWB.Paper feeder paper feed clutch 1: YC1-14Paper feeder paper feed clutch 2: YC1-13Paper feeder paper conveying clutch: YC2-1

(4)The paper feeder liftmotor 1/2 does notoperate.

Broken motor coil. Check for continuity across the coil. If none, replace the motor.

Poor contact in the connec-

tor terminals.

Reinsert the connector. Also check for continuity within the con-

nector cable. If none, remedy or replace the cable.

(5)The size of paper onthe cassette 3 is notdisplayed correctly.



Defective paper feederpaper length switch 1.

Check if YC3-7 on the paper feeder main PWB goes low when thepaper feeder paper length switch 1 is turned on. If not, replace thepaper feeder paper length switch 1.

Defective paper feederpaper width switch 1.

Check for continuity between YC3-9 and YC3-1, YC3-2, and YC3-3 on the paper feeder main PWB. If the continuity is unaffected bymovement of the width guides in the cassette 3 (i.e. eitherremains present or remains absent), then replace the paperfeeder paper width switch 1.

(6)The size of paper onthe cassette 4 is notdisplayed correctly.



Defective paper feederpaper length switch 2.

Check if YC3-8 on the paper feeder main PWB goes low when thepaper feeder paper length switch 2 is turned on. If not, replace thepaper feeder paper length switch 2.

Defective paper feederpaper width switch 2.

Check for continuity between YC3-10 and YC3-4, YC3-5, andYC3-6 on the paper feeder main PWB. If the continuity is unaf-fected by movement of the width guides in the cassette 4 (i.e.either remains present or remains absent), then replace the paperfeeder paper width switch 2.


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1-4-7

(7)The messagerequesting covers tobe closed is dis-played when the leftcover 3 is closed.

Poor contact of the leftcover 3 switch connectorterminals.


Defective left cover 3

switch.

Check for continuity across the contacts. If there is no continuity

when the left cover 3 switch is on, replace it.

(8)Others.

Wiring is broken, shorted ormakes poor contact.

Check for continuity. If none, repair.



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1-4-8

1-4-4 Mechanical problems


(1)No primary paper feed.

Check if the surfaces of the following rollersand pulleys are dirty with paper powder:forwarding pulley, paper feed pulley, separa-tion pulley, feed roller and feed pulley.

Clean with isopropyl alcohol.

Check if the paper feed pulley or separationpulley is deformed.

Replace (see page 1-5-2 ).

Check if the forwarding pulley is deformed. Replace (see page 1-5-2 ).

Electrical problem with the following electro-magnetic clutches: paper feeder paper feedclutches 1/2 and paper feeder paper convey-ing clutch.

See page 1-4-6 .

(2)Skewed paper feed.

Width guide in the cassette installed incor-rectly.

Check the width guide visually and remedyor replace if necessary.

Deformed width guide in the cassette. Check the width guide visually and remedyor replace if it is deformed.

(3)Multiple sheets of paperare fed at one time.

Check if the separation pulley is deformed. Replace the separation pulley if it is worn(see page 1-5-2 ).

Check if the paper is curled. Change the paper.

(4)Paper jams.

Check if the paper is excessively curled. Change the paper.

Deformed guides along the paper conveyingpath.

Check visually and remedy or replace anydeformed guides.

(5) Abnormal noise is heard.

Check if the pulleys, rollers and gears operatesmoothly.

Grease the bushings and gears.

Check if the paper feeder paper feed clutches1/2 and the aper feeder paper conveyingclutch are installed correctly.

Remedy.


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1-5-1


1-5-1 Precautions for assembly and disassembly

(1) Precautions

Before starting disassembly, press the Power key on the operation panel to off. Make sure that the Power lamp is offbefore turning off the main power switch. And then unplug the power cable from the wall outlet. Turning off the main powerswitch before pressing the Power key to off may cause damage to the equipped hard disk.

When handling PWBs (printed wiring boards), do not touch parts with bare hands. The PWBs are susceptible to staticcharge.Do not touch any PWB containing ICs with bare hands or any object prone to static charge.When replacing battery on a PWB, dispose properly according to laws and regulations.


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1-5-2

1-5-2 Paper feed section

(1) Detaching and refitting the forwarding, paper feed and separation pulleys

Replace the forwarding, paper feed and separation pulleys as follows.

Procedure

Removing the primary paper feed units1. Remove cassette 3 and 4.2. Remove the two screws holding the lower

front cover and then the cover.3. Remove the one screw from each of the pri-

mary paper feed units and then the units.

Figure 1-5-1

Removing th e forwarding pulley4. Remove the stopper and spring from the pri-

mary paper feed unit.5. Raise the forwarding pulley retainer in the

direction the arrow, and remove from the pri-mary paper feed unit.

Figure 1-5-2

Primary paper feed unit

Screws

Forwarding pulleyretainer

Stopper

Spring


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1-5-3

6. Remove the stop ring from the forwardingpulley retainer.Remove the forwarding pulley from the for-warding shaft.

Figure 1-5-3

Removing the paper feed pulley7. Remove two stop rings.8. Pull the paper feed shaft toward the rear of

the primary paper feed unit (in the directionof the arrow) and remove the paper feedpulley and gear.

Figure 1-5-4

Removing the separation pulley9. Remove the stop ring from the rear of the

primary paper feed unit.10. Pull the separation shaft toward the rear of

the machine (in the direction of the arrow)and remove the separation pulley.

Figure 1-5-5

Stop ring

Forwarding shaft

Forwarding pulley retainer

Forwarding pulley

Paper feed shaft Paper feed pulleyGear

Stop rings

Stop ring Separation shaft Separation pulley


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11. Replace the forwarding, paper feed andseparation pulleys.

12. Refit all removed parts.

Cautions:When fitting the forwarding pulley, orient itcorrectly as shown in figure 1-5-6.When fitting the paper feed pulley and gear,keep the blue end of the paper feed pulleyand the black end of the gear toward themachine rear.

Figure 1-5-6

Forwarding pulley

Machine front Machine rear


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1-5-5

(2) Replacing paper feeder paper wid th swi tch 1, 2

Replace paper feeder paper width switch 1 and 2 as follows.

Caution: After replacing paper feeder paper width switch, be sure to perform (4) Adjusting the position of the rack adjuster.

Procedure1. Remove the cassette.2. Remove two screws and 8-pin socket from

the rear of the drawer.3. Detach the 8-pin connector from the 8-pin

socket.4. Remove the three screws holding the rack

adjuster.5. While raising the cassette lift in the direction

of the arrow, remove the rack adjuster.

Figure 1-5-7

6. Remove two screws from the back of therack adjuster and then the paper feederpaper width switch.

Figure 1-5-8

Screws

Rack adjuster

Cassette lift

8-pin connector

Screws

8-pin socket

Screws

Paper feeder paper widthswitch


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7. Apply the specified grease to the printedsurface of the new paper feeder paper widthswitch (shaded area in the diagram) and fitthe switch to the rack adjuster.

Figure 1-5-98. Refit all removed parts.

Apply the specified grease.


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1-5-8

7. Remove the three screws holding the paperfeeder drive motor retainer and then theretainer.

Figure 1-5-12

8. Remove the connectors and then theclutches.

Figure 1-5-13

9. Replace the clutches.10. Refit all removed parts.

Caution:When fitting the clutches, be sure to refit thewhirl-stops.

Paper feeder drive motor retainer

Screws

Paper feeder paper feed clutch 1

Paper feeder paper conveying clutch

Connector

Connector

Connector

Paper feeder paper feed clutch 2


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Yes

No

Select [Center Adjust] and then select[Center (Feed 3)].

Press the interrupt key to output thetest pattern.

Enter maintenance mode.

Enter 034 using cursor up/down keysor numeric key and press the start key.

Exit maintenance mode.

Start

End

Is the image correct?

Deviation to the left or right:

1.5 mm or less

Loosen the three screws securing therack adjuster and change the positionof the adjuster.If the test pattern output examplelooks like 1, turn the adjusting screwclockwise, move the adjuster in thedirection of the black arrow ( ).If the test pattern output examplelooks like 2, turn the adjusting screw

counterclockwise, move the adjusterin the direction of the white arrow( ).Retighten the three screws securingthe rack adjuster.

(4) Adjusting t he position of the rack adjuster

Perform the following adjustment if there is a regular error between the center lines of the copy image and the original onthe paper fed from the cassette.

Procedure

Figure 1-5-14

Figure 1-5-15 Adjusting th e position of the r ack adjuster

Correct image Outputexample 1

Outputexample 2

Rack adjuster

Screws

Adjusting screw


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2-1-1

2-1 Mechanical construction

2-1-1 Mechanical construction

The paper feeder feeds paper from either of its two cassettes to the machine. When paper is fed from cassette 3 of thepaper feeder, the paper feeder paper conveying clutch (PFCCL) is operated to rotate the feed roller and pulley to carry thepaper into the machine.

Figure 2-1-1

(1) Forwarding pulley(2) Paper feed pulley(3) Separation pulley(4) Feed roller (5) Feed pulley(6) Cassette lift(7) Lift operating plate(8) Upper feed guide(9) Middle feed guide(10) Lower feed guide(11) Feed guide(12) Paper feeder paper feed clutch 1

(PFPFCL1)(13) Paper feeder paper feed clutch 2

(PFPFCL2)(14) Paper feeder paper conveying

clutch (PFCCL)

(15) Paper feeder paper switch 1(PFPSW1)

(16) Paper feeder paper switch 2(PFPSW2)

(17) Paper feeder feed switch (PFFSW)(18) Paper feeder lift switch 1

(PFLSW1)(19) Paper feeder lift switch 2

(PFLSW2)(20) Paper feeder paper length switch 1

(PFPLSW1)(21) Paper feeder paper length switch 2

(PFPLSW2)(22) Paper feeder paper width switch 1

(PFPWSW1)(23) Paper feeder paper width switch 2

(PFPWSW2)


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2-1-2

Figure 2-1-2

PFCCL

PFFSW

PFPFCL1

PFPSW1

PFPFCL2

PFLSW1PFMPWB

YC1-5

YC1-6YC1-14

YC2-1

YC1-7YC1-8YC1-13

YC2-7

PFPSW2 PFLSW2


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2-2 Electrical Parts Layout

2-2-1 Electrical parts layout

Figure 2-2-1 Layout of electrical parts

1. Paper feeder main PWB (PFMPWB)........... Controls electrical parts.2. Left cover 3 switch (LC3SW) ....................... Breaks the safety circuit when left cover 3 is opened, and resets paper

jam detection.3. Paper feeder paper switch 1 (PFPSW1)...... Detects the presence of paper in cassette 3.4. Paper feeder paper switch 2 (PFPSW2)...... Detects the presence of paper in cassette 4.5. Paper feeder lift switch 1 (PFLSW1)............ Detects the cassette lift of cassette 3 reaching the upper limit.6. Paper feeder lift switch 2 (PFLSW2)............ Detects the cassette lift of cassette 4 reaching the upper limit.7. Paper feeder paper length switch 1

(PFPLSW1).................................................. Detects the length of paper in cassette 3.8. Paper feeder paper length switch 2

(PFPLSW2).................................................. Detects the length of paper in cassette 4.9. Paper feeder paper width switch 1

(PFPWSW1) ................................................ Detects the width of paper in cassette 3.10. Paper feeder paper width switch 2

(PFPWSW2) ................................................ Detects the width of paper in cassette 4.11. Paper feeder feed switch (PFFSW) ............. Controls paper feeder paper feed clutch 2.12. Paper feeder drive motor (PFDM)................ Drives the paper feeder.13. Paper feeder lift motor 1 (PFLM1) ............... Drives the cassette lift of cassette 3.14. Paper feeder lift motor 2 (PFLM2) ............... Drives the cassette lift of cassette 4.15. Paper feeder paper feed clutch 1

(PFPFCL1)................................................... Primary paper feed from cassette 3.16. Paper feeder paper feed clutch 2(PFPFCL2)................................................... Primary paper feed from cassette 4.

17. Paper feeder paper conveying clutch(PFCCL)....................................................... Conveys paper to the machine.

18. Paper feeder cassette heater* (PFCH) ........ Dehumidifies paper.

*Optional.

2 11

17

15

12

164 6

97

1

13

10

18

8

14

3 5

Machine front Machine inside Machine rear


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2-3 Operation of thePWBs

2-3-1 Paper feeder main PWB

Figure 2-3-1 Paper feeder main PWB diagram

PFDM LC3SW

PFFSW

From the machine

PFMPWB

CPU(U1)

PFLM1PFLM2

PFPFCL1PFPFCL2PFCCL

PFPSW1PFPSW2PFLSW1PFLSW2PFPLSW1PFPLSW2PFPWSW1PFPWSW2


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2-3-2

Figure 2-3-2 Paper feeder main PWB si lk-screen di agram

Y C 5

1

1 0

YC611 7

1112

12

3

YC4

YC3

Y C 2

1 7

1 8

1 2

1 5

1 6

Y C 1

1 2


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Connector Pin No. Signal I/O Voltage DescriptionYC1 1 5V O 5 V DC 5 V DC supply for PFLSW1

Connectedto the paperfeeder paperswitch 1/2,paper feederlift switch 1/2 and paperfeeder paperfeed clutch1/2

2 5V O 5 V DC 5 V DC supply for PFPSW1

3 5V O 5 V DC 5 V DC supply for PFLSW2

4 5V O 5 V DC 5 V DC supply for PFPSW2

5 UCLLSW I 5/0 V DC PFLSW1: On/Off

6 UCPESW I 0/5 V DC PFPSW1: On/Off

7 LCLLSW I 5/0 V DC PFLSW2: On/Off

8 LCPESW I 0/5 V DC PFPSW2: On/Off

9 SGND - - Ground

10 SGND - - Ground

11 SGND - - Ground

12 SGND - - Ground

13 LFCL REM I 0/24 V DC PFPFCL2: On/Off

14 UFCL REM I 0/24 V DC PFPFCL1: On/Off

15 24VR O 24 V DC 24 V DC supply for PFPFCL1

16 24VR O 24 V DC 24 V DC supply for PFPFCL2

YC2 1 FCL REM I 0/24 V DC PFCCL: On/Off

Connectedto the paperfeeder paperconveyingclutch,paper feederfeed switchand paperfeeder lift

motor 1/2

2 24VR O 24 V DC 24 V DC supply for PFCCL

3 PGND - - Ground

4 LLM REM I 24 V DC PFLM2: On/Off

5 PGND - - Ground

6 ULM REM I 24 V DC PFLM1: On/Off

7 LFEED SW I 5 V DC PFFSW: On/Off

8 5V O 5 V DC 5 V DC supply for PFFSW

9 SGND - - Ground

10 NC - - Not used

11 NC - - Not used

12 NC - - Not used

13 SGND - - Ground

14 SGND - - Ground

15 UP SIG1 I ??? PFPSW1: On/Off

16 LO SIG1 I ??? PFPSW2: On/Off

17 UP SIG2 I ??? PFPSW1: On/Off

18 LO SIG2 I ??? PFPSW2: On/Off


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YC3 1 UP DIG0 I 0/5 V DC PFPWSW1: On/Off

Connectedto the paperfeeder paperlengthswitch 1/2and paperfeeder paperwidth switch1/2

2 UP DIG1 I 0/5 V DC PFPWSW1: On/Off

3 UP DIG2 I 0/5 V DC PFPWSW1: On/Off

4 LO DIG0 I 0/5 V DC PFPWSW2: On/Off



7 UPCLE SW I 0/5 V DC PFPLSW1: On/Off

8 LOCLE SW I 0/5 V DC PFPLSW2: On/Off

9 SGND - - Ground

10 SGND - - Ground

11 SGND - - Ground

12 SGND - - Ground

YC4 1 24VR O 24 V DC 24 V DC supply for PFDM

Connected

to the paperfeeder drivemotor

2 PGND - - Ground

3 ON O 0/5 V DC PFDM: On/Off 4 LOCK I 0/5 V DC PFDM lock signal

5 CLOCK O 0/5 V DC(pulse)

PFDM clock signal

YC5 1 UFEED SW

Connectedto themachine

2 READY

3 SDI

4 SDO

5 SCLK

6 5V

7 SGND - - Ground8 PGND - - Ground

9 SEL

10 24V

YC6 1 24VR I 24 V DC/0V LC3SW: On/Off

Connectedto the leftcover 3switch

2 NC - - Not used

3 24V O 24 V DC 24 V DC supply for LC3SW

Connector Pin No. Signal I/O Voltage Description


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2-4 Appendixes

List of maintenance parts

Periodic maintenance procedures

Maintenance part namePart No.

Al ternat ivepart No.

Fig.No.

Ref.No.Name used i n serv ice man ual Name used i n par ts l ist

Feed roller ROLLER,VERTICAL CONVEYING 302AR07421 2AR07421 6 10

Feed pulley RIGHT PULLEY,FEED 33906660 - 4,5 36

Paper feed pulley PULLEY,PAPER FEED 2AR07220 - 4,5 2

Separation pulley PULLEY,SEPARATION 2AR07230 - 4,5 3

Forwarding pulley PULLEY FEED A 2BJ06010 - 4,5 5

Paper feeder paper feed clutch 1 CLUTCH,FEED 32 303J444020 3J444020 6 9

Paper feeder paper feed clutch 1 CLUTCH,FEED 32 303J444020 3J444020 6 9

Paper feeder paper conveyingclutch

CLUTCH,FEED 32 303J444020 3J444020 6 9

Section Maintenancepart/location

Method Maintenance cycle Points and cautions Page

Paper con-veying sec-tion

Push paper sensor Cleaning Every time Air brush

Surface view sensor Cleaning Every time Air brush

Upper cover sensor Cleaning Every time Air brush

Paper conveying sensor Cleaning Every time Air brush

Adjusting hone positionsensor

Cleaning Every time Air brush

Exit sensor Cleaning Every time Air brushTray upper limit sensor Cleaning Every time Air brush

Tray lower limit sensor Cleaning Every time Air brush

Reverse sensor Cleaning Every time Air brush

Exit roller Cleaning Every time Wipe with cloth moistened withalcohol.

Paper conveying belt Cleaning Every time Wipe with cloth moistened withalcohol.

Paper conveying roller Cleaning Every time Wipe with cloth moistened withalcohol.

Paddle Cleaning Every time Wipe with cloth moistened withalcohol.

Front static eliminator Check Every time If paper powder or dust adheresto tip of brush, remove it.

Rear static eliminator Check Every time If paper powder or dust adheresto tip of brush, remove it.

Reverse staticeliminator

Check Every time If paper powder or dust adheresto tip of brush, remove it.

Push paper levercushion

Cleaning Every time Wipe with cloth moistenedwith alcohol.


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Wiring diagram

1 7

PFPWSW1

PFPWSW2

2 8 YC3 YC24 4 5 3 1 1 UP DIG0 FCL REM 1 1 3 3 6 4 2 2 UP DIG1 2 2 7 1 3 3 UP DIG2 24VR 2 2 1 1 8 2 9 9 SGND 10 105 5 4 6 11 11

3 5 12 12UP SIG2 17 17

PFPFCL1

PFPFCL2

1 SGND 13 13

2 UP SIG1 15 153 PGND 5 5

ULM REM 6 6

PFPLSW1

PFPLSW2

2 2 7 7 UPCLE SW1 1 11 11 SGND

1 7 LO SIG2 18 182 8 SGND 14 14

4 4 5 3 4 4 LO DIG0 LO SIG1 16 16 3 3 6 4 5 5 LO DIG1 PGND 3 3 2 2 7 1 6 6 LO DIG2 LLM REM 4 41 1 8 2 10 10 SGND5 5 4 6 LFEED SW 7 7

3 5 5V 8 8 SGND 9 9

123

2 2 8 7 UPCLE SW1 1 12 11 SGND

YC116 16 24VR14 14 UFCL REM

PFPSW1

PFLSW1

PFPSW2

PFLSW2

2 8 15 15 24VR1 1 1 7 13 13 LFCL REM2 2 4 6 2 2 5V3 3 3 5 6 6 UCPESW

6 4 10 10 SGND1 1 5 3 1 1 5V2 2 8 2 5 5 UCLL SW3 3 7 1 9 9 SGND

YC62 8 24VR 1 1

1 1 1 7 22 2 4 6 4 4 5V 24V 3

23

3 3 3 5 8 8 LCPESW6 4 12 12 SGND

1 1 5 3 3 3 5V YC52 2 8 2 7 7 LCL LSW UFEED SW 1 1 3 3 7 1 11 11 SGND READY 2 2

SDI 3 3YC4 SDO 4 4

1 1 1 1 24VR SCLK 5 52 2 2 2 PGND 5V 6 6

PFDM 3 3 3 3 ON SGND 7 74 4 4 4 LOCK PGND 8 85 5 5 5 CLOCK SEL 9 9

24V 10 10

PFCH

PFMPWB

1 12 2

3

21

321


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CONTENTS

1-1 Specifications1-1-1 Specifications ..........................................................................................................................................1-1-11-1-2 Parts names............................................................................................................................................1-1-21-1-3 Machine cross section ............................................................................................................................1-1-3

1-2 Installation1-2-1 Installation environment ..........................................................................................................................1-2-11-2-2 Unpacking ...............................................................................................................................................1-2-21-2-3 Installing the cassette heaters (option) ...................................................................................................1-2-3

1-3 Maintenance Mode1-3-1 Maintenance mode (fullcolor machine) ...................................................................................................1-3-1

(1) Executing a maintenance item ..........................................................................................................1-3-1(2) Contents of maintenance mode items...............................................................................................1-3-2

1-3-2 Maintenance mode (monochrome machine) ..........................................................................................1-3-3(1) Executing a maintenance item ..........................................................................................................1-3-3(2) Contents of maintenance mode items...............................................................................................1-3-4

1-4 Troubleshooting1-4-1 Paper misfeed detection .........................................................................................................................1-4-1

(1) Paper misfeed indication ...................................................................................................................1-4-1(2) Paper misfeed detection conditions ..................................................................................................1-4-1(3) Paper misfeeds .................................................................................................................................1-4-2

1-4-2 Self-diagnosis .........................................................................................................................................1-4-4(1) Self-diagnostic function .....................................................................................................................1-4-4(2) Self diagnostic codes ........................................................................................................................1-4-4

1-4-3 Electric problems ....................................................................................................................................1-4-61-4-4 Mechanical problems ..............................................................................................................................1-4-7


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

1-5-2 Paper feed section ..................................................................................................................................1-5-2(1) Detaching and refitting paper feeder separation roller 1 and 2 .........................................................1-5-2(2) Detaching and refitting the paper feeder paper conveying unit assembly.........................................1-5-3(3) Detaching and refitting paper feeder paper feed rollers 1 and 2 .......................................................1-5-3(4) Adjusting the position of the center adjuster (center line alignment).................................................1-5-4

2-1 Mechanical construction2-1-1 Mechanical construction .........................................................................................................................2-1-1

2-2 Electrical Parts Layout2-2-1 Electrical parts layout..............................................................................................................................2-2-1

(1) PWBs ................................................................................................................................................2-2-1(2) Switches and sensors .......................................................................................................................2-2-2(3) Other electrical components..............................................................................................................2-2-3

2-3 Operation of the PWBs2-3-1 Paper feeder main PWB .........................................................................................................................2-3-1

2-4 AppendixesList of maintenance parts........................................................................................................................2-4-1Periodic maintenance procedures ..........................................................................................................2-4-1Wiring diagram........................................................................................................................................2-4-3


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1-1-1

1-1 Specifications

1-1-1 Specif icat ions

Paper supply method......................Friction retard method (No. sheets: 3000, 80 g/m 2)Paper size.......................................11" x 8 1/2 ", A4Supported paper............................. Weight: 60 - 105 g/m 2

Types: standard, recycled, color Power source..................................Electrically connected to the machine

Dimensions .....................................23 5/16 " (W) x 23 5/8 " (D) x 12 3/8 " (H)585 (W) x 600 (D) x 314 (H)mm

Weight.............................................Approx. 50.6 lbs. / Approx. 23 kg

NOTE: These specifications are subject to change without notice.


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1-1-2

1-1-2 Parts names

Figure 1-1-1

1. Lifts2. Left cover 33. Cassette 34. Cassette front cover 5. Front and rear lateral size adjusters


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1-1-3 Machine cross section

Figure 1-1-2 Machine cross sectio n

Paper path


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1-2 Installation

1-2-1 Installation environment

1. Installation location (Be based on the machine establishment place.) Avoid direct sunlight or bright lighting. Ensure that the photo-conductor will not be exposed to direct sunlight orother strong light when removing paper jams.

Avoid extremes of temperature and humidity, abrupt ambient temperature changes, and hot or cold air directedonto the machine.

Avoid dust and vibration.Choose a surface capable of supporting the weight of the machine.Place the machine on a level surface (maximum allowance inclination: 1 ).

Avoid air-borne substances that may adversely affect the machine or degrade the photo-conductor, such as mer-cury, acidic of alkaline vapors, inorganic gasses, NOx, SOx gases and chlorine-based organic solvents.Select a room with good ventilation.


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1-2-2 Unpacking

Figure 1-2-1 Unpacking

Caution: Place the machine on a level surface.

1. 3000-sheet paper feeder 2. Outer case3. Lower front pad4. Lower rear pad5. Support6. Upper pad7. Stay8. Retainer

9. Pins10. CVM4 x 06 cross-head

binding screws11. M4 x 16 TP screws12. Machine cover 13. Plastic bag14. Plastic bag


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1-2-3 Installing the cassette heaters (option)

Cassette heater installation requires the following parts:Two (2) cassette heaters (P/N xxxxxxxxxx): for 220 - 240 V specifications onlyTwo (2) cassette heaters (P/N xxxxxxxxxx): for 120 V specifications onlyTwo (2) cassette heater retainers (P/N 5A707690)Six (6) M4 x 6 IT tap-tight (S-tight) screws (P/N 37611570)

Relay wire (P/N 5A707890)Ten (10) wire saddles (P/N M2109000)

Procedure1. Remove two screws from each of the right

cover and left cover 3 and then the covers.2. Remove three screws holding the paper

feeder rear cover and then the cover.3. Open the paper feeder.4. Remove two screws holding the paper con-

veying unit assembly and then the assem-bly.

Figure 1-2-2

5. Fit the cassette heaters to the cassette

heater retainers using two screws and wiresaddle for each.6. Fit the cassette heater retainers to the left

and right of the paper feeder using onescrew for each.

Figure 1-2-3

7. Pull the cassette heater cable out to themachine rear through the cable hole.

Screw

ScrewPaper conveying unit assembly

Machine left

Cassette heater

Wire saddle

Cassette heater retainer

Screws

Machine right

Cassette heater retainer

Cassette heater Screws

Wire saddle


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8. Detach the open connector from the con-nector of the main harness on the machinerear.

Figure 1-2-4

9. Insert the cassette heater connectors intothe relay wire connectors.

10. Insert the main harness connector into therelay wire connector.11. Tidy up the cassette heater cable and relay

wire using eight wire saddles and route thecable and wire while clipping the wire sad-dles into the holes in the rear frame.

12. Refit the paper feeder rear cover.13. Refit the right cover and left cover 3.

Figure 1-2-5

Open connector

Wire saddles

Wire saddles

Wire saddlesRelay wire

Wire saddle


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1-3-1

1-3 Maintenance Mode

1-3-1 Maintenance mode (fullcolor machine)







or numeric keys.


Press the stop/clear key.


Start

End






No

No

Yes

Yes


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Maintenance


U208 Setting t he paper size for the paper feeder DescriptionSets the size of paper used in 3000-sheet paper feeder.PurposeTo change the setting when the size of paper used in the paper feeder is changed.Setting

1. Press the start key.2. Select the paper size (A4, B5 or 11 x 8.5).

Initial setting: 11 x 8.5 (Inch specifications) A4 (Metric specifications)

3. Press the start key. The setting is set.CompletionPress the stop/clear key. The screen for selecting a maintenance item No. is displayed.

U247 Checking th e operation o f 3000-sheet paper feeder DescriptionTurns on motors and clutches of 3000-sheet paper feeder.PurposeTo check the operation of motors and clutches of paper feed device.Method

1. Press the start key..

2. Select the item to be operated.When selecting the motor, the operation starts. To stop the operation, select the item again.When selecting the clutch, each clutch is turned on for 1 s.


U901 Checking cop y counts by paper feed locationsDescriptionDisplays copy counts by paper feed locations.PurposeTo check the time to replace consumable parts.Method

1. Press the start key. The counts by paper feed locations are displayed.

When an optional paper feed device is not installed, the corresponding count is not displayed.CompletionPress the stop/clear key. The screen for selecting a maintenance item No. is displayed.


LCF FEED Paper feeder conveying motor (PFCM)

CLUTCH B Paper feeder conveying clutch (PFCCL)

CLUTCH P1 Paper feeder paper feed clutch 1 (PFPFCL1)


Display Description

BYPASS MP tray


CASSETTE 3 Cassette 3 (3000-sheet paper feeder)

CASSETTE 4 -

DUPLEX Duplex unit


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1-3-3

1-3-2 Maintenance mode (monochrome machine)







or numeric keys.


Press the stop key.


Start

End






No

No

Yes

Yes

Press the status key.


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1-3-4


Maintenance


U208 Setting t he paper size for the paper feeder DescriptionSets the size of paper used in optional 3000-sheet paper feeder.PurposeTo change the setting when the size of paper used in the paper feeder is changed.Setting

1. Press the start key.2. Select the paper size (A4, B5 or Letter).

Initial setting: Letter (Inch specifications)/A4 (Metric specifications)3. Press the start key. The setting is set.


U247 Setting the paper feed deviceDescriptionTurns on motors and clutches of 3000-sheet paper feeder.PurposeTo check the operation of motors and clutches of paper feed device.Method

1. Press the start key.r

2. Select the item to be operated.3. Press the start key. The operation starts.4. To stop operation, press the stop key.


U901 Checking/clearing co py counts by paper feed lo cationsDescriptionDisplays or clears copy counts by paper feed locations.PurposeTo check the time to replace consumable parts. Also to clear the counts after replacing the consumable parts.MethodPress the start key. The counts by paper feed locations are displayed.

When an optional paper feed device is not installed, the corresponding count is not displayed.Clearing

1. Select the count to be cleared.To clear all counts, press the clear key.

2. Press the start key. The count is cleared.CompletionPress the stop key. The screen for selecting a maintenance item No. is displayed.


LCF FEED Paper feeder conveying motor (PFCM)

CLUTCH B Paper feeder conveying clutch (PFCCL)



Display Paper feed locations

MP TRAY MP tray


CASSETTE 2 Cassette 2CASSETTE 3 Optional cassette 3

CASSETTE 4 Optional cassette 4

LCF 3000-sheet paper feeder

DUPLEX Duplex section


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(3) Paper mi sfeeds


(1) A paper jam in thepaper feed section is

indicated duringcopying (no paperfeed from cassette3).Jam code 12


Broken feed switch 3 actua-

tor.



Check if the clutch malfunc-tions.

Run maintenance item U247 and select following clutch on thetouch panel to be turned on and off. Check the status and remedyif necessary.Paper feeder paper feed clutch 1/2, paper feeder paper conveyingclutch

Electrical problem withclutch.


(2) A paper jam in thepaper feed section isindicated duringcopying (jam in 3000-sheet paper feederhorizontal paper con-veying section).Jam code 15


Check if the paper sideguides are deformed.


Defective paper path sen-sor 3.

With 5 V DC present at CN6-12 on the paper feeder main PWB,check if CN6-11 on the paper feeder main PWB remains low whenpaper path sensor 3 is turned on and off. If it does, replace paperpath sensor 3.



Electrical problem withpaper feeder paper feed

clutch 2.







With 5 V DC present at CN6-9 on the paper feeder main PWB,check if CN6-8 on the paper feeder main PWB remains low whenpaper path sensor 2 is turned on and off. If it does, replace paperpath sensor 2.






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With 5 V DC present at CN6-6 on the paper feeder main PWB,check if CN6-5 on the paper feeder main PWB remains low when

paper path sensor 1 is turned on and off. If it does, replace paperpath sensor 1.

Check if paper feeder paperconveying clutch malfunc-tions.

Run maintenance item U247 and select paper feeder paper con-veying clutch on the touch panel to be turned on and off. Checkthe status and remedy if necessary.

Electrical problem withpaper feeder paper convey-ing clutch.


(5) A paper jam in thepaper feed section isindicated during

copying (jam inoptional paper feedervertical paper con-veying section).Jam code 19

Broken feed switch 3 actua-tor.



(6) A paper jam in thepaper feed section isindicated duringcopying (multiplesheets in cassette 3).Jam code 24











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1-4-2 Self-diagnosis

(1) Self-diagnostic function

This unit is equipped with a self-diagnostic function. When a problem is detected, copying is disabled and the problem dis-played as a code consisting of C followed by a number, indicating the nature of the problem. A message is also displayedrequesting the user to call for service.

After removing the problem, the self-diagnostic function can be reset by turning cover switch off and back on.

(2) Self diagnostic codes



C0420 Paper feeder communication error A communication error from paperfeeder is detected 10 times in succes-sion.


Check the connection of connector YC33 onthe engine PWB and the connector YC1 onthe paper feeder main PWB, and the conti-nuity across the connector terminals. Repair

or replace if necessary.Defective PWB. Replace the paper feeder main PWB or

engine PWB and check for correct opera-tion.

C1100 Paper feeder lift motor 1 error A motor over-current signal is detectedcontinuously for 1 s or longer.



Paper feeder liftmotor 1 does notrotate correctly (the

motor is over-loaded).

Check the gears and remedy if necessary.

C1110 Paper feeder lift motor 2 error A motor over-current signal is detectedcontinuously for 1 s or longer.



Paper feeder liftmotor 2 does notrotate correctly (themotor is over-loaded).

Check the gears and remedy if necessary.

C1120 Paper feeder left lift position problemPaper feeder switch 2 does not turn onwithin 30 s of paper feeder lift motor 1turning on.







The paper feeder

left lift does not riseproperly.

Check the gears and belts, and remedy if

necessary.


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C1130 Paper feeder right lift position prob-lemPaper feeder switch 1 does not turn on

within 30 s of paper feeder lift motor 2turning on.


Check the connection of connector on theengine PWB and the connector on the paperfeeder main PWB, and the continuity across

the connector terminals. Repair or replace ifnecessary.





The paper feederright lift does notrise properly.

Check the gears and belts, and remedy ifnecessary.

C1900 Paper feeder EEPROM error When writing the data, the write data andthe read data is not continuously inagreement three times.



Defective enginePWB.

Replace the engine PWB and check for cor-rect operation.

Defective paperfeeder.

Replace the paper feeder with another unitand check the operation. If the operation isnormal, replace or repair optional paperfeeder.

C2600 Paper feeder paper conveying motorerror The lock signal of the motor is detectedavobe 450 ms.



Defective drivetransmission sys-tem.

Check if the rollers and gears rotatesmoothly. If not, grease the bushings andgears. Check for broken gears and replace ifany.

Defective PWB. Replace the paper feeder main PWB orengine PWB and check for correct opera-tion.

Defective paper

feeder paper con-veying motor.

Replace the paper feeder paper conveying

motor.




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1-4-3 Electr ic problems


(1)The paper feederdoes not operatewhen the main powerswitch is turned on.



(2)The paper feederpaper conveyingmotor does not oper-ate.



Broken the gear. Check visually and replace the gear if necessary.

Defective paper feederpaper conveying motor.

Run maintenance item U247 and check if the paper feeder paperconveying motor operates when CN2-2 on the paper feeder mainPWB goes low. If not, replace the paper feeder paper conveyingmotor.


Run maintenance item U247 and check if CN2-2 on the paperfeeder main PWB goes low. If not, replace the paper feeder main

PWB.(3)The lift motor 1/2does not operate.

Broken motor coil. Check for continuity across the coil. If none, replace the motor.




Check if CN7-13 or CN7-6 on the paper feeder main PWB goeslow right after the cassette is installed. If not, replace the paperfeeder main PWB.

(4)The paper feederpaper feed clutch 1/2or paper feederpaper conveyingclutch does not oper-ate.

Broken clutch coil. Check for continuity across the coil. If none, replace the clutch.



Defective paper feedermain PWB. Run maintenance item U247 and check if following terminals onthe paper feeder main PWB goes low. If not, replace the paperfeeder main PWB.Paper feeder paper feed clutch 1: CN4-3Paper feeder paper feed clutch 2: CN4-1Paper feeder paper conveying clutch: CN4-5


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1-4-4 Mechanical problems


(1)No primary paper feed.

Check if the paper feeder separation roller 1or 2 is soiled with paper powd

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